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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of United States provisional patent application serial No. 60/353,628, filed Feb. 1, 2002, which is herein incorporated by reference.
FIELD OF INVENTION
[0002] This invention generally relates to optical data transmission systems. More specifically, the invention relates to improvements in synchronizing the operation of an optical pulse carver and an electroabsorption data modulator in an optical transmitter for long-haul (LH) and ultralong-haul (ULH) transmission.
BACKGROUND OF INVENTION
[0003] High bit-rate (LH and/ULH) dense wavelength-division-multiplexing (DWDM) transmission systems require reliable, compact, and economical transmitters. FIG. 1 depicts a typical transmitter 100 for ON-OFF-keying, Return-to-Zero (RZ) transmission and consists of a semiconductor distributedfeedback (DFB) laser 102 followed by a pulse carver modulator (PCM) 104 and an electroabsorption data modulator (EAM) 106 . The order of the EAM and PCM is reversible. The PCM is driven by an electronic clock 108 running at the line rate of the system (10 GHz, for example) and produces a train of RZ pulses from the DFB laser output to act as a carrier for data. A phase shifter 112 is also typically placed between the clock 108 and the PCM 104 to initialize transmitter timing. An electronic data pulse stream to be transmitted (consisting of, for example, a series of square electric pulses representing 1's and 0's of binary data D from data module 110 ) modulates the optical transmission of the EAM, and the data is encoded into an optical pulse train. The final output of the two modulators is an optically modulated data pulse train.
[0004] Two problems associated with such transmitters are maintaining the stringent requirements of the output wavelength and power stability and maintaining the correct timing between the two modulators for the pulse carving and data modulation. Temperature fluctuation in the field and the aging of the electronic devices cause the RF group delays of the drive circuits of the modulators to drift, resulting in timing misalignment. This timing misalignment increases the penalties in the data transmission and needs to be addressed for optimal performance of the optical communication systems. For example, one aspect of the penalties that may arise in system 100 is seen by inspection of the graphs shown in FIGS. 2 A- 2 D. FIG. 2A depicts a case in which the optical pulse from the PCM enters the EAM too early and leads the data pulse. In such a circumstance, a positive chirp is introduced into the data (a change in frequency Δω and as seen by the dotted line above the data and timing curves in FIG. 2A). The spectral analysis of the timing conditions of FIG. 2A is shown in FIG. 2B wherein a center frequency (CF) is flanked by asymmetrical lower sideband (LSB) and upper sideband (USB). The reverse conditions (wherein the optical pulse lags behind the data pulse is seen in FIG. 2C. In this condition, spectral analysis (as shown in FIG. 2D) reveals that the asymmetry of the upper and lower sidebands still exists, but is reversed from the previous condition. In an optimal and desired condition, the data pulse and the pulsed optical output of the PCM share a common center point with respect to time (denoted by (x) in FIGS. 2A and C). In such a condition, chirp is minimized and the spectral analysis reveals symmetrical upper and lower sideband modulation levels. The timing drift in real devices tends to be random and thus the optical data will suffer from random chirping without an active management of the timing between the PCM and EAM.
[0005] Therefore, it is desired to have an apparatus for LH and ULH DWDM transmission that is capable of synchronizing the pulse carver modulator and electroabsorption data modulator and a concomitant method for establishing such operational conditions.
SUMMARY OF THE INVENTION
[0006] The present invention provides an apparatus for the synchronization of a pulse carver modulator and electroabsorption data modulator used in an optical transmitter for optical telecommunication. It includes a first, pulse carver modulator to generate a RZ optical pulse train, a second, electroabsorption modulator to encode the data onto the optical pulse train, an optical filter to resolve upper and lower modulation sidebands of the RZ optical data, and an analyzer to measure the relative optical power of the two modulation side bands and convert the received optical power of the sidebands into a control signal for synchronizing the two modulators. The present invention also includes a voltage-controlled phase shifter to control the relative timing between the pulse carver modulator and electroabsorption modulator via the control signal and optical power splitters to tap a portion of the optical data into at least two portions.
[0007] In one embodiment of the invention, a semiconductor DFB laser is used and a Lithium Niobate amplitude modulator is used for pulse carving. A wedged etalon is used as a filter element to select the USB and LSB from the spectrum of the optical data. The filter is slightly wedged such that the thickness varies linearly along its cross-section and the transmission frequency changes accordingly. The analyzer contains two substantially identical photo-detectors to measure the optical power of the filtered USB and LSB. An electronic differential amplifier takes the signal from the two photo-detectors and produces a control signal proportional to the difference of the powers of USB and LSB. The phase shifter, in response to said control signal, adapts the temporal delay of the electronic drive of the pulse carver modulator in a manner that reduces differences between the relative power levels of said upper and lower sidebands.
[0008] The invention also includes a method for synchronizing pulses from an optical carver and a data modulator that has steps of providing a data bearing optical signal in response to a sequence of optical signal carrier pulses and data pulses, determining at least a relative signal strength of upper and lower modulation sidebands associated with the data bearing optical signal and in response to the determined relative signal strength, adapting the sequence of optical signal carrier pulses in a manner tending to reduce differences between the signal strength of the upper and lower modulation sidebands. In one embodiment, the determining step includes splitting the data bearing optical signal into a plurality of optical signal portions, passing at least two of the optical signal portions through a filter element to produce filtered optical signal portions having respective center frequencies offset from an initial center frequency of a predetermined amount and detecting a power level of each of the at least two filtered optical signal portions. The adapting step includes applying a control signal to a shifting device for adjusting an optical signal carrier pulse rate, the control signal being indicative of the differences in signal strength between the lower and upper modulation sidebands.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
[0010] [0010]FIG. 1 depicts a prior art optical transmitter for optical communication;
[0011] [0011]FIG. 2 depicts instances of temporal misalignment between the pulse carver and data modulation in FIG. 1 and the spectral consequences of such misalignments;
[0012] [0012]FIG. 3 depicts an optical transmitter in accordance with the subject invention;
[0013] [0013]FIG. 4 depicts a graph of timing misalignment vs. power differences of the USB and LSB;
[0014] [0014]FIG. 5 is a detailed view of a filter element of the system of the subject invention;
[0015] [0015]FIG. 6 depicts a series of method steps in accordance with a method of the subject invention for fabricating the filter element;
[0016] [0016]FIG. 7 depicts a series of method steps in accordance with the subject invention for synchronization of a pulse carver and a data modulator; and
[0017] [0017]FIG. 8 depicts a graph of timing offset versus bit error rate, which plots specific results of an experiment conducted with the system of the subject invention.
[0018] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.
DETAILED DESCRIPTION OF THE INVENTION
[0019] [0019]FIG. 3 depicts a system 300 for ultralong-haul dense wavelength division multiplexing (DWDM) transmission of data in an optical environment. The system 300 contains a semiconductor distributed feedback laser (DFB) 302 and a pulse carver modulator (PCM) 304 . In a preferred embodiment, the PCM 304 is a Lithium-Niobate PCM. The optical carrier frequency of the DFB laser is typically a multiple of 50 GHz as set by the industry standard. The PCM 304 is driven by an electronic clock 312 running at the line rate of the communication network and produces a train of Return-to-Zero (RZ) optical carrier pulses from the DFB laser output. An electronic data pulse stream to be transmitted (consisting of, for example, a series of square electric pulses representing 1's and 0's of binary data D from data module 310 ) modulates optical transmissions from an electroabsorption modulator (EAM) 306 , and results in the data being encoded into an optical pulse train (TX). The data module 310 and electronic clock 312 are connected such that the data rate (10 Gbits/s, for example ) is identical to the repetition rate (10 GHz, for example) of the optical pulse train produced by the PCM 304 . A phase shifter 326 temporally shifts the clock signal to the PCM 304 and hence controls the timing between the pulse carving in the PCM 304 and data modulation in the EAM 306 . Additionally, data module 310 communicates with the electronic clock 312 via control signals C. Likewise, the electronic clock 312 can send control signals to the data module 310 , thereby allowing for additional communication. For those who are skilled in the art, it should be apparent that several different configurations of the transmitter are possible, where the present invention is still applicable. Examples of such modifications are, but not limited to, replacement of the semiconductor DFB laser by a semiconductor tunable laser, the Lithium-Niobate PCM by a low-chirp EAM pulse carver, or the combination of the DFB laser and the Lithium-Niobate PCM by any low-chirp pulsed laser source, such as a mode-locked fiber laser. Moreover, the order of the PCM 304 and EAM 306 is interchangeable. However, the EAM's 306 primary task is for data modulation and its operational characteristics are its polarization insensitivity and low drive voltage requirement. Examples of suitable components are JDS Uniphase QF935/208 for the DFB, Lucent X2623C for the PCM and Oki OM5642W-30B for the EAM.
[0020] As discussed earlier, there is a direct correlation between the spectral asymmetry of the optical data pulses and the temporal misalignment between the PCM 304 and EAM 306 . The pulse and data modulation rate is 10 Gbit/s. Specifically, FIG. 4 depicts a graph 400 of timing offset in picoseconds between the PCM 304 and EAM 306 versus the normalized power difference (Δ) in the upper and lower modulation sidebands. More specifically, Δ=((power in +10 GHz sideband)−(power in −10 GHz sideband ))/(power in the carrier). It is easily seen by inspection of graph 400 that as the timing offset increases from 0, the normalized power moves into a more negative regime (and the lower sideband is smaller in intensity than the upper sideband as denoted by the solid curve in the inset graph 402 ). Similarly, as the timing offset decreases from 0, the normalized power increases and a shift in the frequency spectrum occurs resulting in the lower sideband being greater in intensity than the upper sideband (as denoted by the dashed curve in the inset graph 402 ). More specifically, the inset in FIG. 4 depicts the optical spectra (shifted by the optical carrier frequency) of the output TX of the transmitter 300 in FIG. 3 in the case when the pulse carver leads (solid curve) or lags (dashed curve) the EAM 306 by 20 ps.
[0021] The measurement of the relative powers in the upper and lower sidebands requires a filter element 316 with a spectral resolution better than roughly a third of the modulation bandwitdth. The spectral measurement of the modulation sidebands is most easily implemented using a wedged etalon as depicted in FIG. 3. It has no moving parts unlike other filter elements, such as a scanning etalon. A small fraction (˜10%) of the output signal (data-encoded optical pulse train) TX is connected to an optical splitter 314 to create a plurality of transmitted signals TX (e.g., three split signals TX). The split output signals TX are then passed through a wedged etalon filter 316 .
[0022] The details of the wedged etalon filter 316 are depicted in FIG. 5. The filter element 316 (etalon) is a fused silica substrate block 500 . The block consists of two planes, a first plane 502 and a second plane 504 . The second plane 504 is angled with respect to first plane 502 . In one example of the etalon, the angle of the second plane 504 with respect to the first plane 502 is approximately 10 arcsec. The angle is calculated such that the first order modulation sideband frequencies on either side of the center frequency can be viewed over a desired linear spacing shift along the direction of the first plane 502 . In one example of the subject invention, the angle of the etalon is produced in such a manner so as to produce a 10 GHz transmission peak shift over approximately a 2 mm linear direction along first plane 502 . The filter thickness varies linearly along its cross-section. The transmission spectrum of a wedged etalon filter is made up of a comb of periodic transmission peaks with the period of Δf=c/2nt, where c is the speed of light, n is the refractive index of the etalon material, and t is the filter thickness. Thus, different frequencies will be filtered depending on the local thickness at the location at which the light impinges. For example, only the upper side band is transmitted from a top port of the optical splitter 314 while the lower side band is filtered from a bottom port of the optical splitter 314 . The wedged etalon filter 316 is made of fused silica and designed with the thickness t o ˜2 mm at the center of the filter, corresponding to Δf=50 GHz. This is identical to the frequency spacing of the industry standard optical channel spacing (ITU grid). Consequently, the same filter can be used for all possible wavelengths used in the optical communication industry without modification of the design. The wedge angle of 10 arcsec produces a 10 GHz shift of the filter transmission peak for every 2 mm linear displacement of the light input position. Accordingly, in this example of the embodiment, the linear spacing between each of the three samples of the data-encoded optical pulse train TX is 2 mm. As an added benefit of this system 300 , it is realized that the wedged etalon filter 316 can also function as a wavelength locker. More specifically, since the etalon 316 was specifically fabricated for filtering frequencies on the ITU grid, the output intensity from the second plane 504 at the center frequency point can be monitored so as to confirm that the DFB output wavelength is that which is expected for the system.
[0023] The modulation sidebands are analyzed (i.e., amount of power in each sideband is examined) by a spectral analyzer 318 to determine the extent of misalignment and generate correction signals accordingly. The spectral analyzer 318 contains, among other components, a first detector 322 1 and a second detector 322 2 . The first detector 322 1 analyzes the strength of the lower sideband and the second detector 322 2 analyzes the strength of the upper sideband of the output data-encoded optical pulse train TX. In one example of the subject invention, the first and second detectors 322 1 and 322 2 , respectively, are P-I-N diodes that are used to detect the intensity of the lower and upper sidebands, respectively. The diodes convert the optical intensity into a lower sideband voltage signal (LSBV) and an upper sideband voltage signal (USBV). The LSBV and USBV are provided as inputs into a differential amplifier 324 to produce a differential control signal (DS). The differential control signal DS is a value that is indicative of the difference of the lower sideband and upper sideband modulation intensities. Accordingly, the greater the intensity difference between the lower and upper sidebands, the greater the relative shifting of the PCM optical pulse train from the center of the electrical data pulses in the EAM 306 ; hence, the larger the differential control signal DS.
[0024] The differential control signal DS is provided as input to a phase shifter 326 . The phase shifter 326 also receives as input, output signals from the electronic clock 312 . As such, the phase shifter 326 can adjust the temporal phase of the incoming clock signal information based upon the differential control signal DS thereby providing a temporal delay to the drive signal of PCM 304 . As a result, the optical carrier pulse train from PCM 304 is shifted in time relative to the data modulation pulses applied to the EAM. For example, in a situation such as that shown in FIG. 2A (where the optical pulse leads the data pulse), the differential control signal DS will be such that the resultant timing control signals outputted from the phase shifter 326 brings the optical pulse closer to the center of the data pulses (“x” in FIG. 2A). Similarly, in a condition where the optical pulse lags the data pulse, the differential control signal DS will be such that the resultant timing control signals from the phase shifter 326 centers the optical pulses with respect to the data pulses.
[0025] A method for producing the wedged etalon filter 316 is shown as a series of method steps 600 of FIG. 6. Specifically, the method 600 starts at step 602 and proceeds to step 604 where a fused silica substrate block is provided for further processing. The initial substrate is slightly thicker than the target thickness to account for the material loss owing to the etching process to be detailed. Other materials, including silicon, can also be used. At step 606 , the substrate is dipped into an etching solution in a time-controlled manner so as to reduce the thickness of the substrate in a graduated, linear manner. In one particular example, the substrate is silica and is dipped in an HF buffer solution of approximate concentration of 7% at an immersion rate of approximately 3 mm/min. As a result of this time-controlled dipping operation, the block substrate is altered so that two previously parallel planes (e.g., first plane 502 and pre-second plane 504 a ) are now at an angle of 10 arcsec with respect to each other. At step 608 , a reflective coating is applied to first plane 502 and second plane 504 . In particular, and in a specific example, the reflective coating is approximately 80% and the resultant spectral resolution of the filter is 2 GHz, suitable for separating the modulation side bands at ±10 GHz. The method ends at step 610 with the completed etalon filter 316 . One skilled in the art will realize that different angles and thicknesses of a given dispersion element can be formed depending upon system requirements and index of refraction of the initial substrate.
[0026] A method for synchronizing the PCM 304 and the EAM 306 is also disclosed in the subject invention and is specifically shown by the series of method steps 700 of FIG. 7. Specifically, the method starts at step 702 and proceeds to step 704 wherein samples of the data bearing optical pulse train are provided for further inspection and analysis. In one embodiment of the invention, three samples of the optical data are provided. At step 706 , the output spectral characteristics of the optical data pulses are obtained. The output spectrum of the optical data is obtained by, for example, a specially designed etalon, which is capable of filtering the operating frequency of the optical element (laser) and also separating the first order upper and lower sidebands.
[0027] At step 708 , the relative strength of the upper and lower sidebands of the output spectrum are determined. In one example, the relative strength of the upper and lower sidebands is determined by converting the output intensity of these frequencies into electrical signals. At step 710 , a correction signal is generated based upon the sideband information obtained from the determining step 708 . In one example, the electrical signals obtained by converting the intensity of the upper and lower sidebands are used as inputs to a differential amplifier to generate an output amplifier signal. At step 712 , the correction signal is provided to a timing device. In one example of the invention, the output signal generated by the operational amplifier is provided to a RF phase shifter in the system. The phase shifter device alters the timing of the generation of the optical pulse train in the PCM with respect to data pulses so as to center the optical pulses with respect to the data pulses. Successful centering the optical pulses with respect to the data pulses is observed by subsequent monitoring of the upper and lower sidebands of subsequent output data spectrums and observing smaller and smaller correction signals (eventually resulted in a zero value correction signal). The method ends at step 714 .
[0028] In support of the concepts and specific embodiments described herein, an experiment was performed to assess the validity of the subject invention. Specifically, a 64-channel, 10-Gb/s ULH system having the design, construction and operation as described herein was operated under the conditions presented herein. Additionally, the bit-error rate of one of the channels having a transmission path of over 5,000 kilometers was monitored. The result of the experiment are shown in FIG. 8 as depicted by a graph 800 . Specifically, the graph depicts timing offset (in picoseconds) versus the bit error rate (in logarithmic scale). For the desired application of the subject system, it is generally acknowledged that a bit error rate less than 10 −9 is within the accepted bit error rate for transmitting optical signals. Inspection of graph 800 readily indicates that such a bit error rate is easily maintained provided that the timing offset between the PCM and the EAM is kept within a 10 picosecond band around a center point (representing the perfect alignment of the two modulators ).
[0029] Although various embodiments that incorporate the teachings of the present invention have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings.
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Method and apparatus for synchronizing two different types of modulators in an optical transmission system includes a first modulator generating an optical pulse train, a second modulator encoding data onto the optical pulse train, an optical filter resolving upper and lower modulation sidebands of the optical data and an analyzer measuring the optical power of modulation sidebands and converting the received optical power of the sidebands into a control signal for synchronizing the two modulators. A wedged etalon is the filter element selecting the USB and LSB from the optical data spectrum. The analyzer contains photo-detectors measuring the optical power of the filtered USB and LSB and an electronic differential amplifier producing a control signal based upon photo-detector output. The phase shifter, in response to said control signal, adapts the temporal delay of the first modulator to reduce differences between the power levels of said upper and lower sidebands.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for producing 3,3',4,4'-tetramethyldiphenylmethane. More particularly, it pertains to a process for efficiently producing 3,3',4,4'-tetramethyldiphenylmethane, the intermediary raw material for 3,4,3',4'-benzophenonetetracarboxylic dianhydride which is important as the starting material for the carboxylic acid component that is the raw material for polyimide resin and as that for heat resistant high molecular compounds such as the curing agent for epoxy resins.
2. Description of the Related Arts
It has heretofore been known that 3,3',4,4'-tetramethyldiphenylmethane (hereinafter sometimes referred to as "3,3',4,4'-TMDM") is useful as the starting material to be oxidized into 3,4,3',4'-benzophenonetetracarboxylic dianhydride (hereinafter sometimes referred to as "BTDA"), but nothing has been known regarding the process for efficiently producing 3,3',4,4'-TMDM in high yield. Thus, BTDA has been produced by the process wherein two molecules of o-xylene and one molecule of acetaldehyde are subjected to condensation reaction in the presence of a large amount of sulfuric-acid catalyst to provide 1,1-bis(3,4-dimethylphenyl)ethane, which is then oxidized by nitric acid to anhydrate itself into BTDA as the product.
The above-mentioned conventional process, however, has suffered the disadvantage that relatively large amounts of isomers and high boiling substance are produced as the by-products, which are not only unusable but also responsible for decrease in the yield of the objective product in the oxidation step.
Aside from the above, o-xylene and formaldehyde are reacted in the presence of such acid catalyst as sulfuric acid or p-toluenesulfonic acid to produce tetramethyldiphenylmethane (hereinafter sometimes referred to as "TMDM"), which however, contains three types of major isomers, namely 3,3',4,4'-TMDM; 2,3,3',4'-tetramethyldiphenylmethane (hereinafter sometimes referred to as "2,3,3',4'-TMDM"); and 2,2',3,3'-tetramethyldiphenylmethane (hereinafter sometimes referred to as "2,2'3,3'-TMDM").
Having a higher melting point as compared with the other isomers, the objective 3,3',4,4'-TMDM can be separated and recovered from TMDM containing the above-mentioned three types of isomers by means of crystallization (refer to Vopr. Khim. Tekhnol., 71,112-114 (1983), USSR).
However, the aforestated conventional process alone wherein the catalyst such as sulfuric acid or p-toluenesulfonic acid is employed to produce TMDM, from which 3,3',4,4'-TMDM is separated and recovered by means of crystallization is available only in low yield of the objective 3,3',4,4'-TMDM. It is, therefore, necessary to contrive the improvement in the yield of the objective 3,3',4,4'-TMDM by improving the selectivity of reaction and the like.
SUMMARY OF THE INVENTION
An intensive research and investigation made by the present inventors on the improvement in the yield of 3,3',4,4'-TMDM produced from TMDM led to the finding that a TMDM with a relatively low content of 3,3',4,4'-TMDM is isomerized into a TMDM with a high content of 3,3',4,4'-TMDM by the use of a catalyst. The present invention has been accomplished on the basis of the foregoing finding and information.
It is a general object of the present invention to provide a novel process for producing 3,3',4,4'-TMDM in high yield from TMDM containing different isomers which is obtained by the condensation reaction of o-xylene and formaldehyde.
It is another object of the present invention to improve the yield of 3,3',4,4'-TMDM from TMDM obtained by the condensation reaction of o-xylene with formaldehyde.
It is still another object of the present invention to efficiently produce BTDA from o-xylene and formaldehyde as the starting materials.
Thus the present invention provides a process for producing 3,3',4,4'-TMDM which comprises subjecting TMDM containing at least one of 2,3,3',4'-TMDM and 2,2',3,3'-TMDM to isomerization reaction in the presence of a catalyst into
In addition, the present invention provides a process for producing BTDA which comprises the steps of subjecting TMDM as the starting material obtained by the reaction of o-xylene with formaldehyde in the presence of a catalyst to isomerization reaction into 3,3',4,4'-TMDM in the presence of a catalyst, recovering 3,3',4,4'-TMDM thus produced by separating from the resultant reaction products while reusing the residual liquid other than said 3,3',4,4'-TMDM by mixing the liquid in the above-mentioned starting material and oxidizing 3,3',4,4'-TMDM thus recovered in the presence or absence of a catalyst.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Any TMDM containing 2,3,3',4'-TMDM and/or 2,2',3,3'-TMDM may be employed as the starting material for isomerization reaction in the present invention without specific limitation to the process for producing itself. In general, the TMDM can be produced by the known process in which o-xylene and formaldehyde are subjected to condensation reaction in the presence of the conventional acid catalyst such as sulfuric acid or p-toluenesulfonic acid, which process is disclosed in the specification of U.S. Pat. No. 2,848,509, etc.
In order to prevent the formation of high boiling substances in the isomerization reaction according to the present invention, a solvent such as an aromatic hydrocarbon may be used, of which o-xylene is most desirably used as the reaction solvent for the purpose of enhancing the selectivity of the reaction.
As the isomerization catalyst to be used in the present invention, the conventional catalyst for alkylation and/or isomerization reaction may be used. Although not necessarily clear in the reaction mechanism, the isomerization reaction is presumed to take place simultaneously as an intermolecular transalkylation reaction in addition to the intramolecular isomerization reaction with the result that a large proportion of 3,3',4,4'-TMDM is produced.
The specific examples of the catalyst for isomerization reaction to be used in the present invention include Bronsted acid such as hydrofluoric acid, sulfuric acid and phosphoric acid, Fridel-Craft catalyst such as HCl-AlCl 3 and HF-BF 3 , Lewis acid such as aluminum chloride, antimony pentachloride, ferric chloride, tin chloride, titanium chloride and boron trifluoride and zeolite catalyst, among which HCl--AlCl 3 , HF--BF 3 , AlCl 3 and zeolite catalyst are preferably used.
Particularly desirable among various types of zeolite catalyst is the crystalline aluminosilicate zeolite, which is the cation-substituted type activated zeolite belonging to twelve-membered oxygen ring structure zeolite typified by Y-type zeolite.
The typical substituted cation includes hydrogen, ammonia, metallic cation and mixture thereof. Of the substituted metallic cations, rare earth element cations and alkaline earth metal cations are particularly desirable.
In the case where the catalyst of HCl--AlCl 3 , HF--BF 3 or AlCl 3 is used in the isomerization reaction, the reaction may be carried out by either of a batchwise system and a continuous flow system, whereas in the case of a zeolite being used, a continuous flow system is preferable.
The isomerization reaction can be effected under a variety of conditions, and the suitable condition may be selected according to each situation. The preferable condition of isomerization reaction, however, consists in reaction temperatures ranging from -15° C. to 300° C. and the reaction pressures in the range of 0.1 to 30 atom. A reaction temperature higher than 300° C. tends to accelerate side reactions which form high boiling substances, sometimes accompanied by the rearrangement of the methyl groups in an aromatic ring.
When TMDM is produced by the conventional process, that is, the known process in which o-xylene and formaldehyde are subjected to condensation reaction in the presence of a catalyst at a relatively low selectivity of 3,3',4,4'-TMDM, followed by the performance of the above-described isomerization reaction by the use of the resultant TMDM as the starting material, the selectivity of 3,3',4,4'-TMDM can be enhanced. Moreover, when the resultant 3,3',4,4'-TMDM is separated from the reaction products after the isomerization reaction while the residual liquid after the separation is recycled and mixed in the starting material to be isomerized and the isomerization reaction is repeated, the yield of the resultant 3,3',4,4'-TMDM is improved.
The oxidation of the 3,3',4,4'-TMDM thus obtained in the presence or absence of a catalyst affords BTDA. The oxidation may be effected by means of a known air oxidation or nitric acid oxidation and specifically exemplified by (1) air oxidation process wherein air is blown into acetic acid solvent containing 3,3',4,4'-TMDM at a high temperature and a high pressure in the presence of a catalyst of heavy metal series and (2) nitric acid oxidation process wherein oxidation is carried out in the presence of 20 to 40% by weight of aqueous solution of nitric acid at a high temperature and a high pressure.
The oxidation of the 3,3',4,4'-TMDM usually results in the formation of 3,3',4,4'-benzophenonetetracarboxylic acid (hereinafter sometimes referred to as "BTDA"), which is anhydrated by the known process to afford the objective BTDA.
As described hereinbefore, the process according to the present invention enables the improvement in the yield of 3,3',4,4'-TMDM produced from TMDM with a low 3,3',4,4'-TMDM content as well as the efficient production of more useful BTDA from the resultant 3,3'4,4'-TMDM.
The present invention will be described in more detail with reference to the following non-limitative examples, in which the substances in the oil phase were analyzed by means of gas chromatography. Example 1
In a 500 ml autoclave were placed 36 g of TMDM as the starting material for isomerization reaction having an isomer composition of 36.9% of 3,3',4,4'-TMDM; 57.4% of 2,3,3',4'-TMDM; and 5.7% of 2,2',3,3'-TMDM, 34 g of o-xylene as the solvent and 58 g of hydrofluoric acid and 3.3 g of boron trifluoride each as the catalyst to effect isomerization reaction with stirring at -4° C. and 0.8 kg/cm 2 G for one hour.
After the reaction was completed, the reaction liquid was neutralized and washed with water, and the oil phase was recovered in an amount of 68.7 g with the analytical value of 54.5% by weight of o-xylene and 35.4% by weight of TMDM.
The resultant TMDM had an isomer composition of 92.0% of 3,3',4,4'-TMDM and 8.0% of 2,3,3',4'-TMDM.
EXAMPLE 2
In a 200 ml three-neck flask equipped with a stirring rod, a thermometer and a cooler were placed 11.2 g of TMDM as the starting material for isomerization reaction having an isomer composition of 36.9% of 3,3',4,4'-TMDM; 57.4% of 2,3,3',4'-TMDM; and 5.7% of 2,2',3,3'-TMDM, 10.6 g of o-xylene as the solvent and 2.66 g of aluminum chloride anhydride as the catalyst with cooling to 0° C.
After isomerization reaction at 0° C. for 2 hours, the aluminum chloride was decomposed with water to remove itself, and the oil phase was washed with water three times and dehydrated with sodium sulfate anhydride to afford 20.8 g of the product as the oil phase.
The above-mentioned reaction liquid had a composition containing 50.8% by weight of o-xylene, 44.2% by weight of TMDM and 5.0% by weight of miscellaneous products other than the above two.
The resultant TMDM had an isomer composition of 91.8% of 3,3',4,4'-TMDM and 8.2% of 2,3,3',4'-TMDM.
EXAMPLE 3
Preparation of catalyst
The zeolite catalyst of HY, CeY and CaY type each as used in the present example were synthesized according to Example 2 in the specification of Japanese Patent Publication No. 1639/1961.
The ion exchange procedure was carried out at 90° C. for 16 hours by separately using 0.5N aqueous solution of ammonia hydrochloride, 0.5N aqueous solution of cerium chloride and 0.5N aqueous solution of calcium chloride each, followed by washing with water twice and drying at 150° C. for 2 hours.
The preliminarily dried catalyst in powder form was compression molded to form tablet, which was milled in a mortar, classified with a screen and adjusted to 10 to 42 mesh. The ammonium-substituted Y-type zeolite was calcined at 560° C. for 3 hours in a stream of nitrogen to be converted to H-type zeolite.
Isomerization reaction
With o-xylene was mixed TMDM having an isomer composition of 42.6% of 3,3',4,4'-TMDM; 53.8% of 2,3,3',4'-TMDM; and 3.6% of 2,2',3,3'-TMDM to produce o-xylene solution containing 51.4% by weight of TMDM as the starting material to be isomerized.
In a 12 ml closed-type reactor made of stainless steel were placed 6 g of the above-mentioned starting material and 2 g of the afore-said catalyst which had been dried at 300° C. for 2 hours immediately before use. Then the reactor was put in an oil bath which had been adjusted to a prescribed temperature and equipped with a shaker to carry out isomerization reaction under stirring for a predetermined time. Immediately after the reaction was completed, the reactor was taken out of the oil bath and cooled with water. Then the reaction liquid was taken out of the reactor and analyzed for composition thereof. The result is given in Table 1 for each of the above-described catalysts.
TABLE 1______________________________________(Starting material and catalyst used, andcomposition of the resultant reaction liquid)Type of Startingcatalyst, etc. material HY HY CeY CeY CeY CaY______________________________________Reaction tem- -- 110 120 120 160 180 200perature (°C.)Reaction time -- 3 3 3 3 2 3(hr)Compositon ofreaction liquid(wt %)o-xylene 48.6 48.1 49.7 48.1 49.9 52.0 49.8TMDM 51.4 43.7 39.9 43.5 31.2 23.4 36.4Other products 0 8.2 10.4 8.4 18.9 24.6 13.8Composition ofTMDM isomer(%)3,3',4,4'-TMDM 42.6 79.5 84.6 77.9 79.4 81.2 76.62,3,3',4'-TMDM 53.8 19.5 15.4 21.0 20.6 18.8 22.42,2',3,3'-TMDM 3.6 1.0 0 1.1 0 0 1.0______________________________________
EXAMPLE 4
A 30 ml catalyst-packed type continuous reactor made of stainless steel was packed was 8.0 g of the catalyst HY as prepared in the preceding Example 3, which then was dried at 300° C. for 3 hours in a stream of nitrogen.
Thereafter the starting material as prepared in Example 3 was continuously fed to the reactor to proceed with isomerization reaction at a reaction temperature of 120° C. under ordinary pressure at a weight hourly space velocity of 0.926 hr -1 .
The composition of the reaction liquid after 24 hours of reaction indicated 52.0% by weight of o-xylene, 39.3% by weight of TMD and 8.7% by weight of miscellaneous products other than the above two. The resultant TMDM had an isomer composition of 76.6% of 3,3',4,4'-TMDM, 21.7% of 2,3,3',4'-TMDM and 1.7% of 2,2',3,3'-TMDM.
EXAMPLE 5
Synthesis of TMDM
In a two liter flask equipped with a stirring rod, a thermometer and a cooler were placed 425 g (4 mol) of o-xylene and 306 g (2 mol) of 64% sulfuric acid. Then, 81 g (1 mol) of 37% aqueous solution of formaldehyde was added dropwise to the above mixture in the flask at 121° C. under reflux for 3 hours. After the completion of the addition, the mixture was stirred for one hour. The product after reaction was allowed to stand for 30 minutes for cooling and liquid separation. The oil phase thus separated was washed with water 3 times and dehydrated with sodium sulfate anhydride to afford 427 g of the reaction liquid as the oil phase (R-1).
A sample taken from the reaction liquid thus obtained was analyzed for the composition. The result was 52.5% by weight of o-xylene, 38.1% by weight of TMDM and 9.4% by weight of miscellaneous products other than the above two. The resultant TMDM had an isomer composition of 59.4% of 3,3',4,4'-TMDM, 37.4% of 2,3,3',4'-TMDM and 3.2% of 2,2',3,3'-TMDM.
The yield based on formaldehyde (hereinafter referred to as "Yield") was 72.6 mol % of TMDM and 43.1 mol % of 3,3',4,4'-TMDM.
Distillation
Of 427 g of the oil phase (R-1) after dehydration, 217 g thereof was sampled and distilled under reduced pressure. As the result, 109 g of o-xylene was recovered and 77 g of TMDM was obtained as the distillate at a boiling point of 162° C. under a pressure of 4 mmHg.
The 24 g of bottom residue (R-2) after TMDM distillation contained 16.0% by weight of TMDM having an isomer composition of 65.8% of 3,3',4,4'-TMDM and 34.2% of 2,3,3',4'-TMDM.
Separation of 3,3',4,4'-TMDM
77 g of TMDM as separated by distillation was cooled to 1° C. to crystallize 3,3',4,4'-TMDM, which was separated by filtration to afford 39 g of crude 3,3',4,4'-TMDM having a purity of 80.5% by weight. The filtrate after filtration is referred to as F-1.
The crude 3,3',4,4'-TMDM was recrystallized from 80 g of ethanol at 5° C. and the crystal thus obtained was separated by filtration. The filtrate after the filtration is referred to as F-2.
The aforementioned crystal was melted at 60° C., and ethanol therein was distilled away to provide 27 g of 3,3',4,4'-TMDM as the product having a purity of 99.3% by weight and a melting point of 39° C.
The ethanol was distilled away from the filtrate (F-2) of the recrystallization and the residue was mixed with the filtrate (F-1) of the crystallization to form mother liquor after the separation of 3,3',4,4'-TMDM. The mother liquor had an isomer composition of 37.2% of 3,3',4,4'-TMDM, 57.6% of 2,3,3',4'-TMDM and 5.2% of 2,2',3,3'-TMDM.
Isomerization reaction
In a 1000 ml three-neck flask equipped with a stirring rod, a thermometer and a cooler were introduced, as a starting material for isomerization, a mixture of 210 g of R-1 (oil phase of the reaction liquid) which was not distilled (total R-1 of 427 g minus distilled amount of 217 g), 24 g of the bottom residue (R-2), 48 g of R-3 (the mother liquor after the separation of 3,3',4,4'-TMDM) and 109 g of o-xylene recovered by distillation (material composition by weight: 56.0% of o-xylene, 33.8% of TMDM and 10.2% of others and isomer composition of TMDM: 51.4% of 3,3',4,4'-TMDM, 44.7% of 2,3,3',4'-TMDM and 3.9% of 2,2',3,3'-TMDM) and 47.7 g of aluminum chloride anhydride as the catalyst to effect reaction at 18° C. for 2 hours.
After the end of the reaction, the aluminum chloride was decomposed with water to remove itself, and the oil phase was washed with water three times and dehydrated with sodium sulfate anhydride to afford 387 g of the product as the oil phase.
The aforementioned reaction liquid had a composition by weight of 54.2% of o-xylene, 43.7% of TMDM and 2.1% of other products than the above two.
The above-mentioned TMDM had an isomer composition of 91.5% of 3,3',4,4'-TMDM and 8.5% of 2,3,3',4'-TMDM.
The overall yield of the 3,3',4,4'-TMDM was 81.1 mol % including the 3,3',4,4'-TMDM with 99.3% purity by weight which was recovered in the 3,3',4,4'-TMDM separation step of the present Example.
EXAMPLE 6
In a one liter antoclave equipped with a stirrer, a thermometer and an external heater were placed 37.5 g (0.165 mol) of the synthesized 3,3',4,4'-TMDM and 458.4 g (2.13 mol as HNO 3 ) of 30% HNO 3 . The mixture was pressurized with nitrogen gas to 1 kg/cm 2 G and heated up to 210° C. at a temperature-rise rate of 70° C./hour under stirring initiated simultaneously with the initiation of the temperature raising. After the temperature reached 210° C., the heating with stirring was continued for 3 hours followed by cooling of the autoclave to room temperature to conclude the reaction. The gas inside the autoclave was released, and to a flask was transferred the content therein, which was yellowish green liquid containing crystals. Then, the liquid was evaporated to bone dryness with an oil bath at 120° to 140° C. to afford crude BTA in the form of yellowish white powder having an acid value of 612.9 mg KOH/g at a Yield of 150.3% by weight.
To 35 g of crude BTA thus obtained were added 350 g of acetic anhydride as the solvent and 1.75 g of granular activated carbon. The mixture was heated at 100° C. with stirring for one hour, followed by filtration for removing the insolubles including the used activated carbon. The solvent was removed from the filtrate at a reduced pressure of 60 mmHg to crystallize and separate purified BTDA as the product.
The purified BTDA as obtained at a crystallization rate of 65.4% had an acid value of 691.0 mgKOH/g, a melting point of 223° C. and a Gardner color scale of No. 6 for the melt.
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There is provided a process for producing 3,3',4,4'-tetramethyldiphenylmethane which comprises subjecting tetramethyldiphenylmethane containing at least one of 2,3,3',4'-tetramethyldiphenylmethane and 2,2',3,3'-tetramethyldiphenylmethane to isomerization reaction in the presence of a catalyst to convert into 3,3',4,4'-tetramethyldiphenylmethane. According to the process of the present invention, the objective 3,3',4,4'-tetramethyldiphenylmethane is efficiently obtained from tetramethyldiphenylmethane obtainable in particular by the reaction of o-xylene with formaldehyde. The 3,3',4,4'-tetramethyldiphenylmethane thus obtained can be converted by oxidation into 3,4,3',4'-benzophenonetetracarboxylic acid dianhydride which is important as a raw material for heat-resistant high molecular compounds.
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CROSS REFERENCE TO RELATED APPLICATION
None
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
FIELD OF THE INVENTION
The invention set forth herein relates to a device for heating golf balls for purposes of increasing the distance the ball will travel when struck with a golf club.
BACKGROUND OF THE INVENTION
It is generally understood that a golf ball will travel significantly further when heated to at least 80° F. Accordingly, devices capable of heating and maintaining golf balls at such temperatures have significant practical utility for golfers in colder regions, where temperatures rarely, if ever, reach or exceed 80° F. Likewise, such devices are useful for all golfers during colder months of the year.
Several prior art devices have been proposed to enable golfers to take advantage of the aforementioned performance benefits associated with heated golf balls. These devices come in a wide array of shapes, sizes and configurations and employ a variety of means for heating golf balls disposed therein, including: chemical (U.S. Pat. Nos. 4,545,362, 5,915,373 and 5,998,771), heated air (U.S. Pat. Nos. 3,683,155, 4,420,681, 4,967,062 and 5,057,670), heated water (U.S. Pat. No. 4,049,949), conduction (U.S. Pat. No. 6,130,411), solar power (U.S. Pat. No. 5,860,415) and radiation (U.S. Pat. No. 4,155,002).
Despite the physical differences between existing golf ball heaters, however, virtually all of the devices disclosed in the above cited patents are deficient in at least one significant respect. None of these devices are equipped to portably, effectively and reliably heat and maintain golf balls within a desired temperature range, particularly over extended periods of play. For example, the heaters disclosed in U.S. Pat. Nos. 4,049,949, 4,155,002, 4,967,062 and 5,057,670 require access to a standard electrical outlet in order for balls to become heated to the desired temperature range. During play, the respective heat sources are disabled and insulation is relied upon to keep the balls heated. Thus, while these devices are equipped to heat golf balls to a desired temperature, it cannot be said that they are capable of portably and effectively maintaining a desired temperature range over an extended period of time.
Prior art heaters employing other means for heating golf balls are similarly ill-equipped and insufficient for heating balls to a specific temperature and portably, effectively and reliably maintaining balls within an a specific temperature range. U.S. Pat. No. 6,130,411 discloses a golf ball heater relying on conductance to heat golf balls to the desired temperature. In addition, this device employs elements facilitating portable heating of golf balls, temperature monitoring and automatic application of heat where the temperature falls under the desired range. Power to the heating means is automatically shut off where the temperature exceeds the desired range. The problem, however, is that the operation of the heating means is independent from the retrieval of a heated ball. That is, where the user opens the device to retrieve a ball and leaves the heater open or fails to fully close the device, the heating means will continue to operate without effectively heating and maintaining the remaining balls within the desired range. Further, the exposed heating means poses a substantial safety risk.
Therefore, it is desirable that a device exist that reliably heats golf balls to a desired temperature, monitors and maintains that temperature, yet avoids the problems and hazards associated with existing golf ball heating devices.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed at a golf ball heating device that portably, effectively and reliably heats and maintains balls within a desired temperature range. More specifically, the present invention is directed to a golf ball heater comprising a rectangular container, the interior of which is outfitted with at least one heating element and rails for holding golf balls. One end of the container includes a sliding door for retrieving a heated golf ball. On one side of the container, a control box is outfitted with circuitry to cooperatively work with sensors in the container for purposes of selectively activating the heating element(s) according to whether or not the sliding door is open or shut and whether or not the temperature inside the container is within the optimal temperature range.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an external view of the preferred embodiment of the heating container component of the present invention.
FIG. 2 is a top view of the preferred embodiment of the heating container component of the present invention.
FIG. 2 a shows the connectivity between the heating container component of the present invention and a golf cart.
FIG. 2 b shows the connectivity between the heating container component of the invention and a remote control battery pack.
FIG. 3 is an internal view of the preferred embodiment of the heating element disposed within the heating container component of the present invention.
FIG. 4 is a diagram of the electrical connections employed in the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , the preferred embodiment includes a heating box 3 , which facilitates heating and storage of any desired number of golf balls practicable. The heating box 3 is preferably, but not necessarily, rectangular in shape. Nevertheless, it should be understood that the heating box 3 can function in accordance with the present invention while taking on a multitude of shapes and/or dimensions. A sliding door 4 is located at one end of the heating box 3 . Next, a control box 2 is affixed to one surface of heating box 3 , preferably the top. The control box 2 houses control circuitry 12 and voltage regulator circuitry 11 . (See FIG. 4 ).
The heating box 3 also includes a push button lock 5 . Though not pictured, the lock 5 is equipped with any suitable means for interconnecting the lock 5 with the power supply for the thermal resistor(s) 8 supplying heat inside the box 3 . The locking mechanism of the push button lock 5 can also be electrically connected to a door open sensor 13 (see FIG. 4 ) in order to control the flow of electricity to the resistor(s) 8 . The flow is shut off when the push button lock 5 is depressed to open the sliding door. As such, where the sliding door is left open, the thermal resistors 8 are prevented from continuing to generate heat. This feature is a valuable safety feature as well.
The preferred embodiment also includes a light emitting diode (“LED”) temperature display 1 , which displays the temperature inside the heating box 3 and allows the user to easily determine when the golf balls disposed therein are at an appropriate temperature. It should be understood, however, that any practicable means for providing an audio or visual indication of the interior temperature of the box 3 would work equally as well. Alternatively, the temperature indicator 1 can be omitted, as it is not essential to the proper use and/or function of the invention.
Referring now to FIG. 2 , the top view of the preferred embodiment reveals that the LED display 1 is preferably, though not necessarily, disposed on top of the control box 2 . As seen in FIG. 2 a , power connector 6 is a male connector, designed to mate with a female connector 20 permanently mounted on a golf cart 21 and hardwired to the golf cart battery 10 .
Alternatively, as seen in FIG. 2 b , remote control battery connector 14 is also provided and is likewise a male connector suitable for interconnection with a female connector 22 on any remote control (“RC”) battery pack 23 . In this way, the heater is optionally portable for use by golfers riding suitably equipped golf carts or for use by a walking golfer using an RC battery. Nevertheless, other types of power connectors and adaptors used in any suitable configuration would also be acceptable.
Next, FIG. 3 is a side view cut away of the internal components of heating box 3 . While any practicable method of supporting golf balls in the heating box 3 would be acceptable, the preferred embodiment employs aluminum rails 7 attached in any effective manner to the interior walls of the heating box 3 . The rails are positioned with a downward slope (preferably a 2% slope) to allow golf balls to roll and be easily collected by the user. A temperature sensitive sensor 9 controls the flow of electricity to the thermal resistor(s) 8 and thereby enables the heating box 3 to maintain a consistent temperature range. The thermal resistor(s) 8 will preferably have at least a −32 degrees to 200 degrees Fahrenheit operating range and be resistant to water.
In operation, the temperature sensitive sensor 9 activates the flow of electricity to the thermal resistor(s) 8 when the ambient temperature inside heating box 3 falls below 75 degrees Fahrenheit. Likewise, the sensor 9 causes electricity to the thermal resistors 8 to be shut off when the ambient temperature inside heating box 3 reaches 85 degrees Fahrenheit. In this way, an optimal temperature range is maintained inside the heating box 3 . The circuitry 11 and 12 enabling the temperature sensitive sensor 9 to control the flow of electricity to the thermal resistor(s) 8 can be constructed from any commercially available circuitry components, and will typically be low voltage control signal wiring, typically 0V–5V.
FIG. 4 is a diagram of the electrical connections used in the preferred embodiment of the invention. Here, a golf cart battery 10 or a RC Battery 14 provides electricity of any appropriate voltage (e.g., 12V, 24V, 36V or 48V) to the voltage regulator circuitry 11 . The voltage regulator circuitry 11 is housed in the control box 2 , and, in turn, provides power to both the control circuitry 12 (also in the control box 2 ) and to the thermal resistor(s) 8 located inside the heater 3 . The control circuitry 12 monitors signals from both the temperature sensor 9 and a door open sensor 13 . Upon receiving an open door signal from door open sensor 13 , the control circuitry 12 causes the voltage regulator circuitry 11 to stop providing power to the thermal resistor(s) 8 .
Likewise, an over-temperature signal from the temperature sensor 9 causes the control circuitry 12 to turn off the thermal resistor 8 power being supplied by the voltage regulator circuitry 11 . Conversely, an under-temperature signal from the temperature sensor 9 will cause the control circuitry 12 to turn on voltage regulator circuitry 11 power to the thermal resistor(s) 8 . In the preferred embodiment, the temperature sensor 9 sends an electrical control signal to the control circuitry 12 when the ambient temperature inside the heating box 3 falls below 75 degrees Fahrenheit. In that case, the control circuitry 12 causes power to be supplied to the thermal resistor(s) from the voltage regulator circuitry 11 . When the temperature sensitive switch 9 detects an ambient temperature of at least 85 degrees Fahrenheit inside the heating box, the temperature sensitive sensor 9 sends an electrical control signal to the control circuitry 12 that causes the control circuitry 12 to turn off voltage regulator circuitry 11 power to the thermal resistor(s) 8 .
Finally, the door open sensor 13 sends an electrical control signal to the control circuitry 12 when the sliding door of the heating box 3 is opened. This causes the control circuitry 12 to turn off voltage regulator circuitry 11 power to the thermal resistor(s) 8 . The door open sensor 13 also detects whether or not the sliding door is in a closed position. Where the door is closed, the door open sensor 13 sends an electrical control signal to control circuitry 12 , which causes the control circuitry 12 to turn on voltage regulator circuitry 11 power to the thermal resistor 8 .
While the foregoing sections describe the preferred embodiment of the invention, those skilled in the art will immediately recognize that there are other ways that a device can be created to meet the objectives of the invention. The description of the preferred embodiment is therefore not in any way intended to limit the scope of the invention. Likewise, characteristics of the preferred embodiment described herein are not in any way intended to limit the claims unless the characteristic is explicitly described within the body of the claim itself. The wording of the claims of the invention and that alone defines the scope of the invention, and it is the inventor's intention to use words in the claims to express their plain and ordinary meaning from the perspective of one or ordinary skill in the art of the invention, contemplating expressly that said meaning is broader than the characteristics of the preferred embodiment described herein.
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The present invention is directed to a golf ball heater comprising a rectangular container, the interior of which is outfitted with at least one heating element and rails for holding golf balls. One end of the container includes a sliding door for retrieving a heated golf ball. On one side of the container, a control box is outfitted with circuitry to cooperatively work with sensors in the container for purposes of selectively activating the heating element(s) according to whether or not the sliding door is open or shut and whether or not the temperature inside the container is within the optimal temperature range.
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FIELD OF THE INVENTION
[0001] The present invention relates to sealing arrangements for automotive doors. More particularly, the present invention relates to ergonomic configurations for primary seal carriers that ease installation of door seals in door openings of automotive vehicles.
BACKGROUND OF THE INVENTION
[0002] Automotive vehicles are configured with an automotive body having door openings defined by inwardly facing peripheries on which doors are mounted. Most doors are pivoted on the opening and swing to close, while other doors slide and shift to close. The usual practice is to place a seal arrangement adjacent to the periphery of the opening for sealing engagement with a surface of the door which is usually in the form of a peripheral land. In order to secure the sealing arrangement to the door opening, a flange is provided over which a base portion of the seal is positioned. The flange is then crimped over the base portion of the seal to retain the seal in the door opening over the expected life of the vehicle. This crimping operation requires a crimping tool that squeezes the base portion of the sealing arrangement. The crimping tool is expensive in and of itself and requires maintenance and attention, which when combined with labor costs, add expense to the assembly of automotive vehicles.
[0003] In view of the aforementioned considerations, there is a need for an arrangement wherein door seals are mounted and retained without the use of a crimping tool.
SUMMARY OF THE INVENTION
[0004] An automotive door sealing arrangement is configured to facilitate mounting and retaining a door seal adjacent to a periphery of a door opening in an automotive vehicle without crimping of a retaining flange, wherein the seal is mounted adjacent to the door opening with a low insertion force and is retained adjacent to the door opening with a high extraction force.
[0005] In the automotive door sealing arrangement, the door seal is mounted on a flange cantilevered adjacent to the periphery of the door opening. The flange has an attached edge and a free edge, and has an inner surface facing toward the automotive body and outer surface facing away from the automotive body. The door seal comprises a U-shaped base having outer and inner portions spaced from one another and connected by a bight portion to define a slot therebetween. A collapsible sealing portion projects from the outer portion for sealing engagement with the automotive door and a flexible lip portion extends from the bight portion for covering body structure disposed adjacent to the opening in spaced relation to the flange. A resilient spacer engages and urges the outer portion of the U-shaped base away from the flange, and a retaining rib is disposed on the inner portion of the U-shaped base and extends toward the flange. The retaining rib has a first bias when engaging one of the surfaces of the flange to deflect the rib upon pushing the U-shaped base over the flange and a second bias which prevents the seal from backing out of engagement with the flange. Consequently, the U-shaped base is retained on the flange by the second bias.
[0006] In one aspect of the sealing arrangement, the surface of the rib is planar and the second bias occurs upon attempting to deflect the rib in a reverse direction.
[0007] In another aspect of the sealing arrangement, the retaining rib engages a stop surface on a sealing ramp to positively retain the retaining rib on the flange.
[0008] In still another aspect of the sealing arrangement, the retaining rib engages a bead on the flange to positively retain the retaining rib on the flange.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Various other features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
[0010] FIG. 1 is a perspective side view of an automotive vehicle showing an automotive body having a door opening therein that has a peripheral seal arrangement configured to seal with a door mounted adjacent to the opening;
[0011] FIG. 2 is an inside view of the door opening of FIG. 1 prior to installing the seal;
[0012] FIG. 3 is a perspective view of a portion of a peripheral portion of the door opening of FIG. 2 ;
[0013] FIG. 4 is a view similar to FIG. 2 but showing the seal installed.
[0014] FIG. 5 is an elevation taken through FIG. 1 showing a first embodiment of the automotive door sealing arrangement prior to mounting the sealing arrangement on a flange positioned at the periphery of the door opening;
[0015] FIG. 6 is a side elevation similar to FIG. 5 showing the sealing arrangement retained on the flange at the periphery of the door opening with the automotive door open;
[0016] FIG. 7 is a view similar to FIG. 6 but showing the automotive door closed and compressing the seal;
[0017] FIG. 8 is a view similar to FIG. 6 , but showing a second embodiment of the automotive door sealing arrangement, and
[0018] FIG. 9 is a view similar to FIGS. 5-8 but showing a third embodiment of the sealing arrangement.
DETAILED DESCRIPTION
[0019] Referring now to FIG. 1 there is shown an automotive vehicle 10 having a body 12 with an opening 14 for receiving an automotive door 18 which is mounted adjacent the opening to move between an open and closed position. The opening 14 has a peripheral portion 16 on which is mounted a sealing arrangement 20 which seals with a relatively rigid, peripheral land portion 22 on the inner surface of the door 18 . As will be more fully explained hereinafter, the sealing arrangement 20 has a compressible portion for accomplishing the seal 21 and a resilient portion which serves as a seal carrier for mounting the seal adjacent to the periphery of the door opening.
[0020] FIG. 2 is an inside view of the body frame showing a flange 30 upon which the seal 21 ( FIG. 1 ) of the sealing arrangement 20 is mounted. The flange 30 is known in the art as a B & R flange, and as is seen in FIG. 3 , is configured from welding an outer portion 31 of the body frame to an inner portion 32 . As is seen in FIG. 4 , the seal 21 is slid laterally over the flange 30 to form the sealing arrangement 20 .
[0021] Referring now to FIGS. 5 , 6 and 7 , where a first embodiment of the sealing arrangement 20 is shown in elevation, the sealing arrangement 20 has a substantially constant cross section throughout its extension while mounted at the periphery 16 of the door opening 14 shown in FIGS. 1 , 2 and 4 . As is seen in FIG. 2 , the sealing arrangement 20 relies on cooperation between vehicle body structure adjacent the door opening 14 and the seal 21 . The automotive body structure adjacent the door opening 10 includes the flange 30 , which is preferably comprised of a lamination of an outer plate 31 and an inner plate 32 , but may include as many as four plates or maybe a single plate. An area 34 behind the flange 30 provides space for interior molding for the vehicle cabin.
[0022] The seal 21 includes a compressible sealing portion 40 comprised of a pair of superimposed compressible tubes 42 and 44 , each vented to the atmosphere and pressed against the peripheral land 22 of the door 18 to seal therewith when the door is shut. The tube 44 is unitary with a U-shaped base 48 having an outer portion 50 and an inner portion 52 joined by a bight 54 to define a slot 56 . The U-shaped base 48 functions a seal carrier for the compressible sealing portion 40 . Extending inwardly from the U-shaped base 48 toward the body of the automobile 10 is a lip 57 , which lip has a rib string 58 thereon that is pulled so that the lip 57 can be made to cooperate with interior cabin structure on the inboard side of the flange 30 .
[0023] As is shown in FIG. 6 , to install the seal 21 on the periphery 16 of the door opening 14 , the seal 21 is pressed into place over the flange 30 , which flange is received in the slot 56 defined between the outer portion 50 and inner portion 52 of the U-shaped base 48 . In order to have a low insertion force, but high retention or extraction force with respect to the flange 30 , the outer portion 50 of the U-shaped base 48 has a plurality of ribs 60 which are oriented to slant back toward the bight 54 of the base, while the inner portion 52 has a retaining rib 62 and a stabilizing rib 64 which also slant back toward the bight 54 . The retaining rib 62 is triangular in cross section with a base 63 substantially wider than the tip 65 . Thus, the ribs 60 , 62 and 64 act as barbs allowing relatively easy insertion of the flange 30 into the opening 56 , but difficult extraction of the flange from the opening. The ribs 60 on the outer portion 50 of the U-shaped base 48 provide a spacer arrangement that urges the outer portion away from the flange 30 so that the retaining rib 62 and stabilizing rib 64 are urged into engagement with the flange.
[0024] FIG. 7 shows the automotive door 18 closed against the seal 40 to flatten or compress the outer and inner tubes 42 and 44 against the U-shaped base 48 forming the seal carrier, thus, sealing the door opening 14 .
[0025] As is seen in FIGS. 5-9 , the retaining rib 62 has a locking tab 66 thereon, which in the embodiment of FIGS. 5 , 6 and 7 , interacts with a ramp 70 . The ramp 70 has a ramp surface 72 and a stop surface 74 . The ramp surface 72 deflects the retaining rib 62 by bending the retaining rib back toward the inner portion 52 of the U-shaped base 48 until the retaining rib clears the ramp 70 . Thereafter, the retaining rib 62 snaps back to seat the locking tab 66 behind the stop surface 74 on the ramp 70 . When a force is applied to the seal 21 tending to remove the seal 21 from the flange 30 , there is positive engagement between the locking tab 66 and the surface 74 that prevents removal of the seal. The ramp 70 may be continuous on the flange 30 , or may be intermittent with gaps between ramp portions.
[0026] Referring now to FIG. 8 , the ramp 70 is reconfigured as a bead 70 ′ in accordance with a second embodiment of the invention. The bead 70 ′ is either continuous or in the form of short bead sections. As with the ramp 70 of FIGS. 5-7 , the bead 70 ′ has a ramp surface 72 ′ and a stop surface 74 ′ with the ramp surface 72 ′ deflecting the retaining rib 62 ′ and the stop surface 74 ′ engaging the locking tab 66 ′ to positively retain the seal 21 ′ on the flange 30 ′.
[0027] FIG. 9 discloses a third embodiment of the invention wherein a flange 30 ″ does not have the ramp 70 of FIG. 1 or bead 70 ′ of FIG. 2 , but rather retains the seal 21 ″ on the flange 30 ″ by friction between the free ends of the ribs 60 engaging the bottom surface 33 ″ of flange 30 ″ and the rib 64 and retaining rib 62 engaging the top surface 35 ″ of the flange 30 ″. Since the ribs 60 and 64 and retaining rib 62 slant back toward the bight 54 of the U-shaped base, the ribs 60 and 64 and the retaining rib 62 functioning as barbs that are forced into tighter engagement with the surfaces 33 ″ and 35 ″ in reaction to a force applied to remove the seal 21 ″ from the flange 30 ″. The insertion force for the flange 30 ″ is substantially less than the reverse force or retraction force occurring upon attempting to bend the retaining rib 62 counter to its slant.
[0028] By so configuring the automotive door sealing arrangement 22 as set forth in the embodiments of FIGS. 5-9 , it is no longer necessary to crimp the flanges 30 , 30 ′ and 30 ″ in order to retain the seal 21 in place on the flanges. Thus, assembly is eased, crimping tools are no longer necessary and assembly is ergonomically friendly.
[0029] From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention, and without departing form the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.
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A seal mounting flange projects from automotive body structure into a door opening and receives a U-shaped base portion of a seal that seals with the periphery of an automotive door. The U-shaped base portion has ribs extending therefrom that function as barbs which engage the flange or engage a ramp or bead on the flange to prevent the seal from being dislodged from the door opening. The seal includes a pair of joined tubular portions that are relatively flexible and are flattened upon closing the door to seal with the door.
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SUMMARY OF THE INVENTION
This invention is concerned with a sweeper which is a surface cleaning or surface maintenance machine and may be of the self-propelled type meaning that it has wheels which may be power-driven. The sweeper has a main brush which is generally horizontally disposed and power-driven and is positioned opposite a hopper which has a rear opening opposite the brush to receive material which is swept up and thrown forward by the brush into the hopper, normally referred to as a direct throw sweeper. Such a unit normally has a vacuum fan connected to the hopper tending to create a vacuum therein which draws air in under and around the sides of the sweeper, for example, the side skirts to hold in the dust that is created by the brush which is objectionable if it escapes from the machine.
A primary object of the invention is a sweeper of this general type which effectively provides for the loading of light material such as paper, dry leaves and the like with a minimum of alteration of the basic structure of the machine.
Another object is a machine of the above type which increases the speed of rotation of the brush when light debris is encountered so that lightweight material will be thrown farther into the hopper.
Another object is an arrangement for increasing the speed of the vacuum fan with the increase in speed of the brush to assist in drawing the lightweight material farther into the hopper.
Another object is a hydraulically operated sweeper of the above type which uses one circuit for driving the brush and vacuum fan so that their speed may be varied and another circuit for driving a side brush which is normally used to move material from alongside the sweeper into the path of the main brush with the speed of the side brush not being increased when the speed of the main brush and vacuum fan are increased.
Another object is a sweeper of the above type which does not create or have brush wear problems.
Another object is a sweeper of the above type which has a disk type side brush or gutter brush, the speed of which is not increased when the main brush and/or vacuum fan speeds are increased.
Another object is a hydraulic system for a sweeper of the above type which uses a main circuit for operating the main brush and exhaust fan and a separate circuit for the side brush.
Another object is a speed control arrangement which enables a direct throw sweeper to load light debris effectively.
Another object is a direct throw sweeper which has a speed control for the sweeping brush and vacuum fan which is constructed and arranged to give acceptable brush life with effective light debris loading.
Another object is a sweeper of the above type which may be either a low dump or a high dump unit.
Another object is a sweeper of the above type with effective light debris loading without major added components.
Another object is a sweeper of the above type which effects light debris loading at much lower costs than prior devices.
Another object is a sweeper of the above type which may be powered by a gasoline, LP or diesel engine as well as a battery powered unit.
Another object is a unit of the above type in which the main brush and side brush are hydraulically operated and the vacuum fan is driven by a belt from the engine.
Another object is a sweeper of the above type in which the main brush and vacuum fan are belt driven by the engine and the side brush is driven by an electric motor.
Another object is a sweeper of the above type which is entirely battery powered.
Another object is a unit of the above type which can operate much of the time at lower noise levels, lower emission level and lower fuel consumption.
Another object is a unit of the above type which with its high speed, brush and possibly more air movement can sweep difficult-to-sweep debris, such as long pine needles, tobacco leaves and the like, better than a normal speed brush.
Another object is a unit of the above type which, because of its high speed brush, allows for sweeping at higher travel speeds, for example, up to 10 miles per hour, where the surroundings allow it, such as patrol sweeping of parking lots which normally have only scattered light debris.
Other objects will appear from time to time in the ensuing specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a forward throw sweeper;
FIG. 2 is a schematic of a speed control;
FIG. 3 is a hydraulic circuit for the unit;
FIG. 4 is a schematic of a variant form;
FIG. 5 is a schematic of a further variant; and
FIG. 6 is a schematic of a further variant.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, a sweeper has been shown in outline generally at 10 with a frame 12 on wheels 14 and an engine, not shown, so that it is self-propelled in the usual manner. It is a rider type unit with the operator having a seat or compartment 16 and various controls 18.
A main brush 20 is disposed laterally across the unit and rotates counterclockwise in FIG. 1 so that it propels debris forwardly through an inlet opening 21 into a trash bin or hopper 22 which may be a low dump or high dump unit. A baffle 24 generally divides the hopper into a lower trash compartment 26 and an upper filter compartment 28 which has a suitable filter, diagrammatically indicated at 30, which may be of the pleated paper variety. A vacuum fan 32 of any suitable type exhausts air from the trash hopper through a suitable connection 34 which, in this case, is shown at a point remote from the inlet 21 for the hopper.
The unit is also shown with a side brush 36 often referred to as a gutter brush which is rotated so as to move trash and debris from the side to in front of the unit so that the main brush 20 will then throw the debris into the hopper.
Such a sweeper is very effective in sweeping sand and other dense and heavy debris off of a floor or other surface to be cleaned, but problems have been encountered in the past in sweeping up light debris, such as paper, dry leaves and the like. Such light debris is thrown forward, but the air resistance tends to stop such material so that it piles up near the inlet or opening 21 while the heavier material will be propelled forwardly into the front of the hopper. The result of the light material piling up in the hopper inlet is that the hopper will become blocked off before it is full or loaded.
The vacuum fan 32 is conventionally used to create a vacuum in the hopper so that the dust that is stirred up or created by the main brush 20 draws air in under the side skirts and through the hopper inlet 21 so that the dust will not escape. The dusty air is pulled through the filter 30 by the fan and then exhausted to the atmosphere.
The present invention solves the problem of loading the light debris, when it is encountered, by speeding up the operation of the main brush and/or the vacuum fan for the time that light debris is being swept so that the light debris does not block the hopper inlet. The speed of the main brush 20 is normally set for what is optimum sweeping of the heavy material, i.e. sand, consistent with maximum brush life and what will stir up a minimum of dust. Speeding up the operation of the main brush 20 and the fan 32 on occasion will fully or adequately carry the light material, such as paper, dry leaves, and the like, forwardly into the hopper and prevent the inlet 21 from being prematurely clogged. The unit thus may be characterized as a two-speed unit, a normal speed which might be characterized as low speed and a high speed for loading the light debris. In a given unit, representative values are as follows:
______________________________________ LOW SPEED HIGH SPEED______________________________________Engine 2200 RPM 2750 RPMMain Brush 415 RPM 500 RPMFan 410 CFM 510 CFM______________________________________
A representative and diagrammatic two-speed control has been shown in FIG. 2 in which a control lever 38 for the operator has a detent plate 40 with a three position cam track 42 and a pivot 44 for the lever with a push-pull cable 46 connected to the other end. The control lever is movable between "idle" and "normal" positions but must be manually raised before it can be pushed forward to "high", the pivot 44 being in a slot so that it also may be raised. The lever may be spring biased downwardly by a light spring to assist gravity as a safety to prevent the operator from inadvertently "going into high", if that is found desirable. The control cable 46 in turn operates a lever 48 on a governor 50 which is belt driven from the engine crankshaft by a belt pulley 51. Lever 48 is connected by a spring 52 to a bell crank or throttle control arm 54 on the governor which, through a throttle control link 56, is connected to a throttle control lever 58 on the carburetor 60. The arrangement in FIG. 2 is diagrammatic and is only intended to illustrate the principle.
The governor, carburetor and the linkage connecting them may be conventional and are well known to those familiar with industrial engines.
Engine governors are available which do not operate on traditional mechanical principles but instead are electronic. They normally employ a sensor which detects engine speed and converts it into a signal. This is processed into a suitable signal to supply to a servomechanism that opens and closes the throttle in response to engine speed variations, thereby maintaining a desirable engine speed. Such governors would be applicable or usable with or in this invention and are intended to fall within the scope of the present disclosure, but will not be described in detail.
The invention may also be used with a sweeper having a diesel engine which customarily has a speed governor built into its fuel pump, with a lever on the pump housing for controlling engine speed. This lever is comparable in function and operation to the lever 48 of FIG. 2 and a similar control such as that designated 40 in FIG. 2 can be applied or used with or in the invention.
The sweeper may have a conventional hydrostatic transmission in the traction drive with a variable displacement reversible piston pump coupled directly to the engine which supplies a fixed displacement hydraulic motor on the drive wheel. Such a unit is conventionally steered with travel speed controlled by a conventional heel-and-toe foot pedal. The engine is operated at full governed speed at all times with the travel speed being controlled from 0 to maximum forward and reverse by the control pedal, all of which is conventional.
In the hydraulic circuit diagram in FIG. 3, a variable displacement reversible pump 62 driven by the engine is connected by a closed loop circuit to a fixed displacement motor 63 on the rear drive wheel 14 in a conventional manner. The entire unit 64 as shown enclosed by phantom lines may be a conventional commercially available hydrostatic transmission pump unit, comprised of variable displacement reversible pump 62, charge pump 65 with associated low pressure relief valve 66, four check valves 67 and two high pressure relief valves 68. A fixed displacement pump 69 is also driven by the engine and supplies hydraulic fluid for the various other components. Fluid from pump 69 passes through a priority flow control valve 70 to be explained later, through line 71 to a main control valve unit 72 which has a first manually operated valve 74 shown in the neutral position where it supplies fluid to a second manually operated valve 76. In position 78, first valve 74 operates a hopper lift cylinder 80. Position 82 on the first valve will hold the hopper in lifted position and also pass fluid through to valve 76. When the second valve 76 is in position 84, it supplies fluid to a pair of hopper rollout cylinders 86 if the unit is a high dump system. Position 88 on the second valve reverses the rollout cylinders 86 and causes the hopper to roll back. Position 90 on the first valve sends fluid through a line 92 to a motor 94 that operates the side brush 36. Neutral position as shown on valve 74 will shut off the side brush motor.
The priority flow control valve 70 operates in a conventional manner. It serves to direct a constant flow of fluid though line 71 to side brush motor 94 regardless of excess flow from pump 69 within the limits of the device. The excess fluid is directed through line 98 to main brush motor 102 which operates main brush 20 shown in FIG. 1 and to vacuum fan motor 104 which operates vacuum fan 32 shown in FIG. 1. Thus when engine speed is increased, the speed and fluid output of pump 69 will increase. The flow through line 71 will remain constant and the increased flow will pass through line 98 and increase the speed of main brush motor 102 and vacuum fan motor 104. A selector valve 100 is in parallel with main brush motor 102 and vacuum fan motor 104. The selector valve 100 may include a solenoid operated valve 106 which, when the solenoid is operated, moves valve 106 to blocking position so that the main brush motor 102 and vacuum fan motor 104 are operated. The solenoid may be controlled, for example, by a toggle switch on the dashboard, operated by the driver, to start or stop the main brush and vacuum fan. A cooler 108 and filter 110 in the return line as well as the reservoir or sump 112 are shown and may be conventional. Two high pressure relief valves 114 may be installed for protection against excess pressure in lines 71 and 98.
The use, operation and function of the invention are as follows:
The invention has been disclosed in connection with a forward throw sweeper in which material is propelled by a brush through a rear opening in a hopper. The hopper is divided into two chambers, the lower chamber for debris and the upper chamber for a filter unit. A vacuum fan is connected to the hopper so as to create a partial vacuum therein so that dust created by the brush will be kept inside the sweeper by atmospheric air drawn in under the side skirts, etc., all of which may be conventional. Such a sweeper adequately handles heavy material, such as sand and the like. But light material such as leaves, paper, etc. resists being thrown by the brush and will pile up in the hopper inlet.
In the present arrangement, when light debris is encountered, the main brush and vacuum fan are speeded up. This gives the main brush more throw and provides more vacuum from the vacuum fan. The result is that paper and dry leaves that might otherwise clog the hopper inlet will be carried forward in the hopper.
The speed of the side brush 36 is normally set to move debris from alongside the sweeper into the path of the main brush. The speed is selected to dislodge the material in front of the side brush and move it under the main body of the sweeper but not fast enough to throw the debris completely across the path of the sweeper. It is desirable that the speed of the side brush be held constant regardless of the speed of the main brush and vacuum fan to avoid throwing debris across the path of the sweeper and outside the path of the main brush.
The operator of the sweeper may be provided with a speed control, as in FIG. 2, which allows him to operate the sweeping brush and vacuum fan at two speeds. The lower brush speed is chosen for optimum sweeping of sand, for example. This gives maximum brush life and stirs up a minimum of dust. The fan speed which is associated with this brush speed gives adequate dust control and requires a minimum of power to run the fan. This is an economical setting which will be used most of the time in normal sweeping. The higher speed setting increases the brush speed and air flow volume through the hopper to a point where the amount of light debris loaded in the hopper is acceptable. The increased brush wear and fan power consumption can be tolerated because sweeping light debris is usually a relatively small part of the total duty cycle of the sweeper.
When the brush and fan are put in the second or higher speed, however, the side brush maintains its speed because of the inclusion of the priority flow control valve in the circuit.
In the disclosed hydraulic circuit, the connections for hydraulically raising the hopper when it needs to be dumped, then rolling it out for dumping into a receptacle, are also shown. During these operations, all of the fluid in line 71 is diverted from, driving the side brush and used for the lift and dump functions.
Operating the engine at either of two speeds will not affect the operator's ability to control the travel speed of the sweeper. If the engine is running at "normal" and the sweeper is moving at a certain speed and the driver changes the engine speed to "high", the sweeper might tend to increase its speed. But the operator can maintain his previous speed by making a compensating change in the setting of the speed control pedal and continue his work using that setting. Thus, the addition of a second engine speed does not need to increase the travel speed of the sweeper.
One of the main advantages of the present invention is that it increases loading of light debris without introducing major added components, such as a compactor plate, an auxiliary blower, etc., all of which are expensive.
While an engine has been referred to, it should be understood that it may be a gasoline, LP or diesel engine. In fact, any suitable type of power drive may be used. Another approach might be to have the vacuum fan 32 driven directly by the engine, for example, through a belt with the main brush, side brush, hopper lifting and dump cylinders, etc. all operated by a hydraulic circuit. Two-speed engine control could still be used. For example in FIG. 4, an engine has been indicated generally at 116 driving a hydraulic pump 118 which may be the same as pump 62 in FIG. 3. A pulley 120 drives a belt 122 which in turn drives the vacuum fan 124. The hydraulic circuit operated by pump 118 may be the same as what is shown in FIG. 3 except that it would not include the vacuum fan motor 104.
The invention can also be applied to a sweeper in which the side brush is driven by an electric motor off of a battery. In that case, the engine which drives the main brush and vacuum fan could be operated at two speeds without affecting the speed of the side brush.
As mentioned previously, the sweeper could have its main brush and vacuum fna belt driven by the engine and a side brush driven by an electric motor. For example, as shown in FIG. 5, an engine 126 is indicated as having a belt drive 128 to a main brush 130 and a similar belt drive 132 to the vacuum fan 134 so that these may vary in speed as the engine speed varies. Variable engine speeds may be obtained by controlling the engine governor as shown in FIG. 2 herein. The side or gutter brush 142 is driven at a constant speed by an electric motor 144 which is connected to a battery 140 through a suitable switch 146.
While the invention has been referred to in connection with two speeds, it should be understood that more than two speeds might be used. In that sense, a variable range of speeds could be used although two is considered adequate.
There is another type of sweeper which is battery powered for indoor use where engines are not favored. In that type of sweeper, electric motors drive the various components. And it will be understood that this two speed arrangement for the purposes indicated could be used on such a battery operated sweeper with two speed electric motor controls applied to the main brush and vacuum fan motors.
For example, in FIG. 6, a battery 148 with a switch 150 has the motor 152 for the side brush connected in parallel with the motors 154 for the main brush and 156 for the vacuum fan. A suitable resistance 158 or the like may be placed in series with the main brush and vacuum fan motors 154 and 156 and shorted out by a switch 160. With the switch open, the resistance 158 would be in series with the main brush and vacuum fan motor so that they would run slower and would speed up when switch 160 is closed without affecting the speed of the side brush motor 152. Also, the vacuum fan has been shown as connected to the hopper at a point remote from the debris inlet which is considered an advantage since the air current created by the fan will tend to draw light material farther into the hopper. There is a line of sweepers that draw this air from directly above the sweeping brush and the two speed approach outlined above may be used on such an arrangement although it is considered more desirable to draw the air fully through the hopper in loading light debris.
Whereas the FIG. 3 form of hydraulic circuit uses a single pump with a flow divider for driving the various components so that the side or gutter brush has a constant speed and the main brush and fan have variable speeds, it should be understood that the same result may be accomplished by using more than one pump. For example, a unit might have a separate variable displacement pump for the main brush and fan with the side or gutter brush, dumping cylinders and controls, etc. being driven by a separate fixed displacement pump. But the arrangement shown in FIG. 3 is considered more desirable because a separate variable displacement pump would be more expensive.
Also, while the invention has only been shown in connection with a forward throw sweeper in FIG. 1, it should be understood that it is just as applicable to an over-the-top sweeper with a rear hopper where, even though loading light debris may not be a problem, other advantages could be obtained.
In addition, in either a forward throw or an over-the-top sweeper, the invention might be used for high speed patrol sweeping of large areas, such as in parking lots having only occasional light debris. It could also be used to sweep heavy accumulations of any debris, such as sand and the like, without slowing down as much as a sweeper with a normal speed brush. It will also be effective in sweeping fine dust, such as starch, talc and the like, better than the machine with standard air and brush speeds. Further, it will give a better polish or luster to a fine floor, if that is considered desirable. As well, the increased air flow should give better dust control in any type of sweeping operation.
Of particular advantage is the fact that the sweeper may and will be operating much, if not most, of the time at lower noise levels, lower emission levels and lower fuel consumption.
Whereas the preferred form and several variations of the invention have been shown and suggested, it should be understood that suitable additional modifications, changes, substitutions and alterations may be made without departing from the invention's fundamental theme.
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This invention is concerned with a sweeper, meaning a sweeper with a rotary main brush opposite a hopper, and increasing its ability to load light debris, such as paper, dry leaves and the like so that light debris will be propelled farther into the debris hopper. This is done by setting the speed of the main brush at a lower speed for normal operation to effectively throw what may be thought of as heavier material, such as sand, forwardly into the hopper with the speed being such that excessive wear of the brush is avoided and a higher speed of rotation being effected from time to time so that paper, dry leaves and the like, which may be considered lightweight material, are thrown farther into the hopper with the increased speed of the main brush overcoming the air resistance that normally stops such lightweight material which, at normal operation of the brush, tends to pile up in the rear of the hopper. The sweeper uses a vacuum fan to create a suction in the hopper with the vacuum fan also being speeded up with the brush speed increase which assists in loading the lightweight debris in the hopper. Since the increased speed is used for the main brush and vacuum fan only from time to time when light debris is encountered and on a limited basis, the increased brush wear and power consumption caused thereby is tolerable.
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BACKGROUND OF THE INVENTION
1. Field Of The Invention
The present invention relates to downhole oil and gas well tools and more particularly relates to a jacking apparatus that can be used in a downhole oil well environment when supported upon the free end of a length of coil tubing that is wound upon a spool at the wellhead area. Even more particularly, the present invention relates to an improved downhole oil well tool that can be used to remove objects that are stuck in the oil well by generating a lifting or jacking force through pressurized fluid applied to a piston after slips or wedges anchor the tool body to the wall of a casing so that the lifting energy is transmitted to the casing rather than solely to the coil tubing unit.
2. General Background
In the drilling and production of oil and gas wells, it is often a problem to complete a well because an object such as a downhole oil well tool or instrument has become stuck in the well. Once these objects are stuck, they often require considerable force for removal. This a is problem in restricted environments wherein the well bore is very small in diameter. Often times, a coil tubing unit can be used to reach restricted portions of a well. However, the lifting power of a coil tubing unit is somewhat restricted because of the small diameter (and small wall thickness) of coil tubing.
SUMMARY OF THE PRESENT INVENTION
The present invention provides an improved oil and gas well tool in the form of a lifting or jacking tool for retrieving articles that are stuck downhole in the well bore of an oil and gas well as defined by an elongated vertically oriented well casing.
The apparatus includes a coil tubing unit having a reel at the earth's surface with coil tubing wound thereon, and with a free end that can pay into the bore of the oil and gas well, wherein the coil tubing is a bore for conveying fluids from the earth's surface to the well bore.
A tool body provides an upper end portion that connects to the free end of the coil tubing.
The tool body provides a lower end portion that forms a connection during use with the article to be retrieved.
The tool body includes an elongated mandrel having a central longitudinal bore that communicates with the bore of the coil tubing.
Slips or wedge members are carried by the tool body for anchoring the tool body to the casing portion of the well bore.
A piston is concentrically placed about the mandrel for moving the slips between engaged and disengaged positions. A hydraulic chamber is positioned between the mandrel and the piston for moving the piston relative to the mandrel.
The slips are positioned on the tool body so that the position of the piston is fixed relative to the casing once the slips anchor the tool body to the casing of the well bore.
After the slips are anchored to the casing, the mandrel then travels upperwardly relative to the casing when fluid continually expands the chamber to move the piston. This creates a lifting force that is dependant upon hydraulic power generated at the chamber rather than by the lifting strength of the coil tubing unit.
In one embodiment, a number of stacked pistons and corresponding number of hydraulic chambers are provided so that the surface area of the chambers is enlarged to provide greater lifting.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals, and wherein:
FIG. 1 is a schematic view of the preferred embodiment of the apparatus of the present invention, and illustrating the method of the present invention;
FIG. 2A is a fragmentary elevational view of the preferred embodiment of the apparatus of the present invention shown in a released position;
FIG. 3A is a fragmentary sectional view of the preferred embodiment of the apparatus of the present invention shown in a locked position;
FIG. 2B is a fragmentary view of the preferred embodiment of the apparatus of the present invention showing the tool body in released position;
FIG. 3B is a fragmentary elevational view of the preferred embodiment of the apparatus of the present invention showing the tool body in a locked position;
FIG. 4 is a sectional fragmentary elevational view of the preferred embodiment of the apparatus of the present invention illustrating the lower end portion of the tool as attached to an article to be retrieved from the well bore.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1, 2A-3A and 2B-3B and 4 show the preferred embodiment of the apparatus of the present invention designated generally by the numeral 10. The coil tubing unit includes a reel 6 with coil tubing 7 wound up thereupon. The core tubing 7 has a free end 8 that attaches at a threaded connection for example to tool body 11. Coil tubing units 5 are commercially available devices that generally comprise the reel 6, the wound coil tubing 7, and a coil tubing free end 8 portion. The reel 6 can be trailer mounted as shown. Boom assembly 9 supports the coil tubing as it enters the wellhead W and casing C. Coil tubing 7 is commercially available and typically has a central longitudinal bore for allowing fluids to flow therethrough. Downhole oil well jacking tool 10 includes a tool body 11 having an upper end 12. The bore of Coil tubing 7 communicates with the bore 14 of tool body 11. An upper mandrel section 13 defines the upper end 12 of the tool body 11. External threads 15 provide a place for attachment of a coil tubing unit thereto and specifically for attaching the tool body 11 to the free end of the coil tubing unit.
Second mandrel section 16 has external threads 15 at the upper end portion thereof for forming a connection to the internal thread 17 of upper mandrel section 13.
Second mandrel section 16 has an enlarged lower end portion 19 with an O-ring 18 for forming a seal with the inner surface 21 of first piston 20. Piston 20 has a lower end portion that is enlarged, and which includes an annular shoulder 23 that acts as a stop for movement of piston 20 relative to lower end portion 19 of second mandrel section 16. Shoulder 22 is placed just above cylindrical annular surface 23 at the lower end portion 24 of piston 20. Lower end portion 24 of piston 20 provides an 0-ring seal 26 that forms a seal against inner surface 25 of third mandrel section 32.
Lower end portion 24 includes a transverse end face 27 that butts up against coil spring 23. A hydraulic chamber 30 is defined by the space shown in FIGS. 2A-3A for receiving pressurized fluid as shown by the curved arrow 34 via port 33. Pressurized fluid transmitted to the tool body 11 from the coil tubing is transmitted to the bore 14 and thus communicates with port 33 and chamber 31. This pressurized fluid causes the piston 20 to move away from second mandrel section 16 as shown in FIGS. 3A-3B.
Likewise, a second port 43 receives pressurized fluid from the bore 14 as shown by arrow 44 in FIG. 3A. The upper end portion 35 of third mandrel section 32 forms a threaded connection at external threads 36 with the internal threads 37 of lower end portion 19 of second mandrel section 16.
Third mandrel section 32 provides a lower end portion 38 with an O-ring seal 39 for forming a seal with second piston 30. Lower end portion 38 provides internal threads 40 that form a threaded connection with external threads 32 of fourth mandrel section 41. The two hydraulic chambers 31 and 45 thus simultaneously receive pressurized fluid from bore 14 of tool body 11. This provides twice as much force for lifting an article to be retrieved once the tool body 11 is anchored to the casing "c" using the plurality of slips 52.
The lower end portion 46 of second piston 30 has an O-ring seal 47 for forming a seal with fourth mandrel section 41. Fifth mandrel section 50 attaches to the lower end portion 48 of fourth mandrel section 41 at threaded connection 51. Below lower end portion 46 of second piston 30, a plurality of wedged slips 52 are circumferentially spaced about tool body 11. Each of the slips 52 provides teeth 54 for biting into the casing C as shown in FIG. 3B.
When the lower end 55 of piston 30 moves down responsive to an introduction of fluid under pressure into ports 33 and 43, inclined surface 56 engages the inclined surface 53 of wedge slips 52. The wedge slips 52 also engage the inclined surface 58 of annular ring 57.
Ring 57 is supported from below by coil spring 61 which bottoms upon annular flange 60. Upward movement of ring 57 is prevented beyond stop 69. The slips 52 move outwardly to engage casing "C" as shown in FIG. 3B. The ring 57 moves downwardly toward flanged portion 61, compressing spring 61.
This construction provides a smooth, even distribution of load to the plurality of slips 53 so that the wedge shaped slip members each evenly engage the casing "C" creating a load transfer surface between the plurality of slip members 52 and the casing "C". However, continued introduction of fluid under pressure into the chambers 31 and 45 causes relative movement of the plurality of mandrel sections 13, 16, 32, 41, and 50 upwardly. As the fluid enters the chambers 31, 45 each of the chambers 31, 45 expands, pushing the mandrels upwardly. This also raises the lower, threaded end 62 of the tool body 11 and the stuck article 68.
The article 68 is connected to a plurality of fingers 66 depending from tool body section 65. The fingers 66 engage a fishing neck 67. Lower end 62 forms a connection with slack joints 63, 64. As the lower end portion 62 travels upwardly, the stuck article 68 also moves upwardly. Slack joints 63, 64 are commercially available devices that allow downward motion in order to recock or reload the jacking apparatus 10. This sphere 69 seals the tool bore 14 after the fingers 66 grip neck 67. The sphere 69 can be dropped from the wellhead area via the bore of the coil tubing unit.
The following table lists the part numbers and part descriptions as used herein and in the drawings attached hereto.
______________________________________PARTS LISTPart Number Description______________________________________ 5 coil tubing unit 6 reel 7 coil tubing 8 free end 9 boom assembly10 downhole oil well jacking tool11 tool body12 upper end13 upper mandrel section14 bore15 external threads16 second mandrel section17 internal threads18 O-rings19 lower end portion20 first piston21 inner surface22 annular shoulder23 coil spring24 lower end portion25 inside annular face26 O-ring seal27 end face28 annular shoulder29 cylindrical surface30 second piston31 chamber32 third mandrel section33 port34 arrow35 upper end portion36 external threads37 internal threads38 lower end portion39 O-ring seal40 internal threads41 fourth mandrel section42 external threads43 port44 arrow45 chamber46 lower end portion47 O-ring seal48 lower end portion49 O-ring seal50 fifth mandrel section51 threaded connection52 wedge member53 inclined surface54 teeth55 lower end portion56 inclined surface57 annular ring58 annular beveled surface59 annular beveled surface60 annular flanged portion61 coil spring62 threaded end63 slack joint section64 slack joint section65 spear type grab66 fingers67 fishing neck68 stuck "fish"69 sphereC casingW wellhead______________________________________
Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
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A coil tubing supported jacking tool can be used to remove articles that are stuck in an oil and gas well casing bore. The coil tubing unit transmits pressurized fluid to the tool body. At its lower end, the tool body grips the stuck article. A piston chamber expands to set slips for anchoring the tool body to the well casing. The piston then moves upwardly away from the slips, pulling the stuck article free.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/029,541 filed Feb. 18, 2008, the disclosure of which is incorporated herein by reference.
COPYRIGHT NOTICE
[0002] This application contains material that is subject to copyright protection. Such material may be reproduced by any person exactly as it appears in the Patent and Trademark Office patent files or records. The copyright owner otherwise reserves all rights to such material.
FIELD
[0003] This application generally relates to information technology in the field of Internet broadcasting, and more particularly to media stream monitoring.
BACKGROUND
[0004] In the field of Internet broadcasting, it is often difficult for broadcasters to readily determine if a network connection is established, or, if connected, whether media content is actually being streamed. Typically, a user, such as a broadcaster, may attempt to connect to a streaming server's port and listen for a media stream to determine streaming media existence and quality. There exists a need for a more efficient system and method for media stream monitoring and analysis.
SUMMARY
[0005] A method of verifying the transmission of audio content in a media stream may comprise receiving from a server a portion of a media stream having a first audio file format, processing the media stream portion to obtain data values, and determining if any of the data values fall outside of a pre-determined range of data values. A system for verifying the transmission of audio content may comprise a computer connected to a server over a network, and the computer may be adapted to receive from the server a portion of a media stream having a first audio file format, process the media stream portion to obtain a set of data values, determine the highest absolute data value of the set and compare the highest absolute data value to a data value corresponding to audio silence.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 depicts an embodiment of a system that may be used for media stream monitoring.
[0007] FIG. 2 is a flow chart of one embodiment of a method for media stream monitoring.
[0008] FIG. 3 is a flow chart of one embodiment of a method for processing an audio sample for silence.
[0009] FIG. 4 is a flow chart of one embodiment of a method for processing an audio sample for spectral noise signatures in an embodiment of the present invention.
[0010] FIGS. 5A and 5B depict one embodiment of a screen shot of a user interface.
[0011] FIG. 6 is one embodiment of a screen shot of an interface providing access to a plurality of media streams.
[0012] FIGS. 7A and 7B depict one embodiment of a screen shot of a user interface.
[0013] FIG. 8 is one embodiment of a screen shot of a user interface.
DETAILED DESCRIPTION
[0014] A system and method for monitoring and analyzing one or more media streams is described. As shown in FIG. 1 , a monitoring server 10 may be provided to monitor and analyze one or more streaming servers for media streams. In the embodiment of FIG. 1 , streaming servers 12 , 14 , and 16 may each provide one or more media streams. In one embodiment, the media streams may be Internet-based music streams, such as those provided by Internet radio stations. Those skilled in the art will recognize that the media streams may comprise audio, video, data or text, or various combinations thereof. A user may use a user computer 18 or other device (such as a laptop, cell phone, PDA or portable electronic device) to access the media streams transmitted by streaming servers 12 , 14 , and 16 . Those skilled in the art will also recognize that the system and method may be used with networks other than the Internet, and that the server arrangement of FIG. 1 is exemplary. Those skilled in the art will further recognize that Web servers or other suitable streaming media computers may be used, as well, and that a PC may just as easily be used in place of a monitoring server 10 .
[0015] Referring to the embodiment of FIG. 1 and FIG. 6 , an interface 100 may be displayed on user computer 18 to provide the user with access a plurality of media streams, through links to the URL of the media stream. In the embodiment of FIG. 6 , the user interface 100 may include a web page that provides links to various media streams. For example and not by way of limitation, streaming server 12 may provide an Internet-based music stream, named Al's Music Mart, that comprises a variety of music from the 80 s to today. The user interface 100 may provide a link 102 to the Al's Music Mart stream. A user may click on the Al's Music Mart link 102 in order to connect the user's computer 18 to streaming server 12 . Similarly, an Alternative link 104 may be provided to allow the user to connect the user's computer 18 to streaming server 14 in order to receive and listen to an alt-rock music stream. Other links may be provided for access other media streams, such as an Americana NewGrass link 106 that may connect computer 18 to streaming server 16 .
[0016] A broadcaster of media streams, such as a radio station broadcasting via the Internet, may also access the media streams that it broadcasts in the same way that the users may. For example, the broadcaster of the Al's Music Mart stream may access streaming server 12 as would a user. As is known, the broadcaster may thereby verify that streaming server 12 is actually streaming content, and that the streamed content has the expected quality. As noted above, however, that method of monitoring and analyzing media streams is inefficient, particularly if the broadcaster provides multiple media streams from multiple streaming servers. In contrast, the system and method described herein may allow a broadcaster to self-monitor and analyze its own media streams much more efficiently.
[0017] Referring to FIGS. 1-2 , one embodiment of a method of media stream monitoring may include determining the media stream type based on the URL of the media stream as indicated at 20 . That may be accomplished, for example, by determining from the streaming server the MIME type of the media stream. Alternatively, the media stream type may be determined by issuing a request to the streaming server asking for “content type” HTTP headers. A stream type may include but is not limited to Microsoft's Media Services (MMS) and Real Time Streaming Protocol (RTSP). A monitoring server 10 may initiate a connection with one of streaming servers 12 , 14 or 16 ports using a Transmission Control Protocol (TCP) connection as indicated at 22 . Those skilled in the art will recognize that other protocols, such as User Datagram Protocol (UDP), may also be used. If a connection is not made with a streaming server (decision box 24 ), a connection may be initiated again as indicated at 34 . If a connection is still not made (decision box 36 ), an error message may be logged that the connection cannot be made as indicated at 38 . If a connection is made (decision box 24 or 36 ), the monitoring server 10 may attempt to receive or download one or more samples or portions of a media stream (such as music audio content) as indicated at 26 . For example, the monitoring server may receive a two-second portion of the media stream. If no data can be received (decision box 28 ), an error message may be logged that it was not possible to download any data as indicated at 40 . If a sample of the media stream is received (decision box 28 ), the samples may be converted to a preferred file format, including but not limited to WAV file format as indicated at 30 . Those skilled in the art will recognize that the file format may be uncompressed, lossless, lossy or otherwise suitable for processing. The WAV samples may be processed as indicated at 32 .
[0018] Referring now to FIG. 3 , the media sample (in this example, an audio sample) may be processed to determine if it is silent or near silent. The sample may be opened and a numeric data value may be obtained for the samples after skipping over any headers as indicated at 52 . The data values may represent volume level, for example, or indicate the presence (or lack thereof) of video or other content. For media streams that include audio, the left and right audio channels may be checked for silence or near silence, as defined to be a numeric data value above a set threshold or outside a selected range, as indicated at 54 . If the samples are found to be at or near silence (decision box 56 ), an error message may be logged as indicated at 58 . If the sample is found to not be silent or near silent (decision box 56 ), checking for silence may be stopped as indicated at 60 . In one embodiment, the media stream may be processed to obtain Pulse Code Modulation (PCM) data values. Such values may, for audio samples, may indicate volume. For example, the range for silence may be designated as a PCM data value range of −50 to 50, where complete silence is a value of 0. If PCM data values of the processed media stream sample fall outside that range, that may serve as an indication that the media stream actually contains media content. Those skilled in the art will recognize that other ranges may be selected above the data value for complete silence or a value for complete silence may be selected.
[0019] In one example, if an Internet radio station makes a streaming connection with a server, but the media stream packets contain no audio or other intended content, monitoring server obtains a sample of the media stream and processes it to obtain PCM data values that indicate audio volume. If the PCM values are at or near silence (i.e., at or near a PCM data value of 0), or otherwise fall within a designated range for silence (e.g., between −50 and 50), the monitoring server may be able to detect if the media stream sample (and inferentially the rest of the media stream) contains audio content. If no audio content is detected (e.g., the PCM data values are within the designated range for silence), then the monitoring server may send an alert or notification, such as an email, to the Internet radio station operator.
[0020] Referring to FIG. 4 , a sample may be analyzed for spectral noise signatures. In one embodiment, the sample may be broken down into multiple bands as indicated at 64 . The content of each band may be analyzed for spectral noise signatures as indicated at 66 . For example, PCM values could be used to detect certain tones. Those skilled in the art will recognize that PCM or other data values may pertain to the frequency and/or amplitude of audio or other content.
[0021] In another embodiment, a video sample may be processed to check if Artist and Title data at least partially matches. In addition, a video or audio sample, or a combination thereof, may be processed to determine if copyright warning information or a particular watermark is attached. In some embodiments, a video sample may be broken down into component video to analyze whether a live video signature, a blank screen, or all noise is present. Those skilled in the art will recognize that PCM values may be used for that purpose. A component video may be captured and saved for later human review of the component video if, for example, a blank screen or all noise was determined to be present.
[0022] Referring now to FIGS. 5A and 5B , in some embodiments, a user interface 108 may be provided to manage a plurality of media streams being monitored using the system and method described herein. Those skilled in the art will recognize that a server may provide more than one media stream, and that various media streams may pertain to various radio markets. Radio markets may be categorized by demographics, location, interests, and the like. In one embodiment, the user interface may be web-based and may be used to assign streaming to users and keep track of errors, such as errors in connecting to the stream or silence-related errors. When Static Streams button 90 is selected, a listing of all static streams (i.e., streams from a static IP address) being monitored may appear in user interface 108 . A Shortname column 70 may provide an abbreviated name for each media stream. A URL column 72 may provide the URL for each media stream. A repeatsilencewaming column 74 may provide either a 1 (true) or a 0 (false), where a 1 means that an email or other type of notification will be sent to a user every time the system detects silence, and a 0 means an email or other type of notification will be sent to a user only the first time the system detects silence. A Markets column 78 may provide one or more user names and email addresses for users in a market that are assigned to the stream, for the system to use for sending notifications. Such users may be, for example, the radio station from which the stream originates, and/or the radio stations in markets served by the stream. An options column 80 may provide a Show button 81 for showing the users and email addresses and what markets each stream is in. An Edit button 83 may be provided for editing that user information, and a Destroy button 85 may be provided for removing the stream information. Of course, other functions may be provided in an options column 80 . A similar display may be provided when a user selects the Dynamic Streams button 94 .
[0023] When the Server button 92 is selected, a screen such as that shown in FIG. 8 may appear with a listing of one or more streaming servers. A streaming server may be identified by its IP address in IP column 120 , while a new streaming server may be added by clicking the New Server button 128 . Information about a particular streaming server may be displayed by clicking the Show button 122 , edited with the Edit button 124 , or deleted from the system with the Destroy button 126 .
[0024] Referring now to FIG. 5A , FIG. 5B , FIG. 7A , FIG. 7B , and FIG. 8 , when the Markets button 96 is selected, the screen shown in FIGS. 7A and 7B may appear listing all users utilizing the system. The name of a user may appear in the Name column 118 , one or more email addresses assigned to the user may appear in the Email To column 98 , while the email address where notifications from the system originate may be provided in the Email From column 110 . A Silence column 111 may have a 1 to set the system to check for silence, and have a 0 to set the system to not check for silence. A Connectivity column 112 may provide a 1 to set the system to check for connectivity and a 0 if the system is not set to check for connectivity. A Connectcount column 114 may provide the number of connectivity errors that need to occur before a notification is sent to a user. A Server column 116 may provide one or more streaming servers assigned to a user. A Show button 130 may display details of a user, an Edit button 132 may allow a user's information to be edited, while a Destroy button 134 may allow a user to be deleted from the system. When the Login button 82 is selected, a user may login to interface 108 to access and edit the information contained therein. When the Logout button 84 is selected, a user may log out of interface 108 . When the Signup button 84 is selected, a new user may sign up to have access to the user interface. As noted above, when the Dynamic Streams button 94 is selected, a screen (not shown) may appear listing all dynamic streams being monitored, i.e. streams whose URLs are subject to change. Dynamic URLs may be used to prevent listeners from directly linking to a URL and force them to use a particular media player in order to listen (or view, or otherwise access, as the case may be) to the stream.
[0025] Although the foregoing specific details describe certain embodiments of this invention, persons having ordinary skill in the art will recognize that various changes may be made in the details of this invention without departing from the spirit and scope of the invention as defined in the appended claims. Therefore, it should be understood that this invention is not to be limited to the specific details shown and described herein.
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A method of verifying the transmission of audio content in a media stream may comprise receiving from a server a portion of a media stream having a first audio file format, processing the media stream portion to obtain data values, and determining if any of the data values fall outside of a pre-determined range of data values. A system for verifying the transmission of audio content may comprise a computer connected to a server over a network, and the computer may be adapted to receive from the server a portion of a media stream having a first audio file format, process the media stream portion to obtain a set of data values, determine the highest absolute data value of the set and compare the highest absolute data value to a data value corresponding to audio silence.
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THE INVENTION
The present invention is directed generally to electromagnetic interference (EMI) gaskets and, more specifically, to electronic gaskets for preventing the passage of electromagnetic signals of higher than a given frequency. Even more specifically, the present invention is directed to an EMI gasket, which operates satisfactorily in an interface between an edge of a sheet metal panel and a reasonably flat surface, against which the sheet metal panel abuts.
BACKGROUND
Although various companies have made forms of EMI shielding gaskets secured with double-sided tape or having clips that are used for parallel (2 flat) surface applications, the applicant does not know of any instance where such EMI gasketing material operates between the edge of a sheet metal panel and a flat surface area which is no more (in the width direction) than double the dimension of the sheet metal panel thickness.
It is, therefore, an object of the present invention to provide an improved EMI gasket for use between a sheet metal panel edge and a limited space flat surface.
Other objects and advantages of the present invention will be apparent from a reading of the specification and appended claims in conjunction with the drawings, wherein:
FIG. 1 is a cutaway drawing of a printed circuit card holding box using the present invention between a door or cover to the box and the box itself;
FIG. 2 is a detailed drawing illustrating a side view representative of the conditions shown in FIG. 1;
FIG. 3 is a front or inside view of a plurality of gasket fingers of the type illustrated in FIG. 2;
FIG. 4 shows in slightly more detail the portion of the finger extending over the sheet metal edge and its positioning and movement limiting tab;
FIG. 5 illustrates a second embodiment of the gasket fingers utilizing the sheet metal panel as a force base rather than a turned over edge of the panel as previously shown in FIG. 2;
FIG. 6 shows a variation of the finger as compared to FIG. 2 using the same portion of the panel as a force base; and
FIG. 7 illustrates a fourth embodiment of the inventive concept utilizing double-sided tape to secure and position the fingers relative the gasketed sheet metal panel edge.
DETAILED DESCRIPTION
In FIG. 1, a panel rack or box, generally designated as 10, is shown with a top card guide portion 12, a backplane 14, a lower card guide portion 16 and a side panel 18. In addition, there is a sheet metal panel door or access cover, generally designated as 20, having a corner area 22 and a sheet metal panel lip edge 24. Cover 20 has a similar sheet metal panel lip on the lower portion of the drawing and designated as 26. Situated on the sheet metal panel lip edge 24 are a plurality of openings, designated as 28, and a plurality of gasket fingers, two of which are designated as 30 and 32. A flat edge of top portion 12 is designated as 34, and a similar portion of bottom 16 is designated as 35. Portions 34 and 35 constitute the reasonably flat surface against which the butt edge of sheet metal portions 24 and 26 must respectively abut. As will be realized, the "flat" is merely close to being flat since typically sheet metal is "formed" by bending flat sheets of material and the bending causes internal stresses. The fingers, such 30 and 32, provide the gasket interface between areas 24 and 34, while fingers such as 36 and 37, provide a similar gasketing function between panel portions 26 and 35. As illustrated in the lower portion of FIG. 1, a connecting bridge is designated as 38. This connecting bridge may be used for easing the installation of the fingers as a set, and for maintaining proper spacing of the fingers in some embodiments of the inventive application. Within the box 10, there is room for a plurality of cards, one cutaway card is designated as 40 and is connected into a electrical plug receptacle 42. A handle 44 is shown which is used as a means to facilitate both the installation and removal of the card by providing forces to the card as to make electrical contact with the contacts within receptacle 40, or to ease the removal of the card from the friction pressure of these contacts. A handle, similar to that of 44, may be used on the upper portion of the box and the card 40 (if necessary), to equalize the pressures applied to the card 40.
In FIG. 2, numbers as appropriate to those shown in FIG. 1 are used where possible. In addition, a second handle 46 is illustrated to insert the card 40. The finger 30 is shown as having a tab 48 inserted into opening 28 and the finger 30 has a first surface 50 and a second surface 52 forming a U-shaped enclosure of the edge of panel 24. A third surface 54 and a fourth surface 56 form a generally V-shaped section of the finger situated substantially at right angles to the U-shaped portion previously defined. The V-shaped portion comprising surfaces 54 and 56 provide a pressure away from the base of cover 20 and in a direction parallel to the surface of panel lip 24 toward the flat surface 34 of panel 12.
In FIG. 3, the panel lip 24 is shown with a plurality of fingers such as 75, 77, and 79, each interconnected with a web of material designated as 81. The material 81 would correspond to that shown and designated as 38 in FIG. 1. On finger 75, a bend area designated as 83 is shown which corresponds to the bend between portions 54 and 56 of the finger of FIG. 2. The bend area 85 corresponds to the bend between surfaces 52 and 54 of FIG. 2 and define the junction between the V and the U-shaped portions of the finger means.
In FIG. 4, an outside view of the surface of panel 24 of FIG. 2 is illustrated in more detail with the surface 50 being bent over the outside of panel lip 24 and the tab 48 being inserted into opening 28 for restricting the amount of vertical and horizontal movement of the spring due to forces generated by the V-shaped portion comprising surfaces 54 and 56.
In FIG. 5, a sheet metal section 90 has an opening 92 and an opening 94 with a right angle section 96. A contact finger embodying the concepts of the present invention has a first surface 98, and a second surface 100 wherein these two surfaces define a V-shaped section. Third and fourth surfaces 102 and 104 are designated which form a U-shaped portion and enclose an edge of panel 90, as well as being connected to one end of V-shaped portion comprising surfaces 98 and 100. An extension of surface 98 hooks through opening 92 to establish a base for a force in the direction of an arrow 106, which is substantially parallel to the panel surface of panel 90. This is the direction that the U-shaped portion having a contact surface 108 is urged. Surface 108 would be making contact against a surface, such as the flat surface 34 of FIG. 1.
FIG. 6 is similar to FIG. 5, except that the surface 98 has a tab situated slightly differently so that it coacts with a recess or an opening 110 in the portion 96 of the panel, rather than in the side portion 90 as shown in FIG. 5. This still provides a base for exerting a force in the direction 106 as previously indicated, so that the surface 108 can make contact with a flat abutting surface.
FIG. 7 shows a version of the finger where the finger comprises portions 120 and 122, constituting the V-shaped force providing portion of the finger, while portions 124 and 126 provide the U-shaped portion, a surface 128 provides the contact area, and a piece of double-sided tape 130 provides attachment to the base for supplying a force in the direction of arrow 132. As drawn, this is the relaxed position where no force is provided. A dash line area with legs, designated as 120' and 122', shows the clip in a mounted position, where the force, shown as 132, is exerted to maintain a contact pressure between surface 128 and a surface, such as 34 in FIG. 1.
As will be realized, the material used in constructing the fingers must be a resilient material which can be deformed, whereby it will assume a given normal form, but it can also be temporarily deformed to maintain a good electrical contact when compressed by low stress deforming forces, such as when the cover 20 is attached to the remaining portion of box 10 of FIG. 1. One such material is beryllium copper. Another material that would perform satisfactorily is phospher bronze.
For the purpose of defining the shape of the spring-like member in the claims, relative angles have been used. As an example of terminology only and not to be considered as restrictive, the spring of FIG. 6 may be considered to have first, second, third and fourth surfaces 98, 100, 102 and 104, respectively. Although the portions 98 and 100 form an acute angle therebetween, the single piece of metal that is used to form this resultant product would typically be placed in a bending device and the formerly straight or flat piece of metal is bent to an angle of between 110 and 170 degrees to form this acute angle. The piece of metal is then bent in the opposite direction and thus may be said to be bent in a negative angle of between -20 and -70 degrees to form the obtuse angle between portions 100 and 102. Finally, to form the portion which encloses the lip of the sheet metal 90, the portion 104 is bent, relative to the previously straight portion 180 degrees with respect to the surface 102. As may be appreciated by those skilled in the art, a negative angle as defined with respect to bending a sheet of flat metal can be positive bends in one direction of bending and reverse angle or negative bends in the opposite direction.
OPERATION
Although the operation of the present invention should be self-evident from the previous information, it may be summarized as a resilient clip which in a preferred embodiment contains spacing material, such as shown in FIG. 1 as interconnecting material 38, and FIG. 3 as interconnecting material 81 which is used both for spacing of the fingers and for ease of installation. The clips contain a force providing V-shaped portion connected to a sheet metal lip edge engaging U-shaped portion with locating tabs, such as 48 of FIG. 2, on the U-shaped portion. This locating tab interacts with an opening, such as 28 of FIG. 1 or FIG. 2, to keep the force from the V-shaped portion from extending the U-shaped portion out beyond a given amount above the edge of the sheet metal panel, such as 24 of either FIG. 1 or FIG. 2. When the panel, such as 20 of FIG. 1, is attached to the main box 10 of FIG. 1, the U-shaped portions are forced back towards the edge of panel lips 24 and 26, during which time electrical contact is maintained between the cover 20 and the box 10. The spacing between the various fingers, such as 32 and 34, is such that signal frequencies of lower than a given frequency cannot pass through the opening. Although the contact fingers should operate and maintain their position as described thus far and as illustrated in FIG. 2, various additional embodiments are illustrated in FIGS. 5 through 7 with provisions for attaching the V-shaped portion at a base support extremity to prevent excessive movement of the finger with respect to the panel edge, shown as 90 in FIGS. 5 and 6.
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The present invention uses a plurality of spaced contact fingers to provide EMI (electromagnetic interference) shielding at the gap junction between the edge of a sheet metal panel and its butt interface with a narrow flat surface. Each of the fingers comprises a U-shaped portion enclosing the sheet metal panel edge and a V-shaped portion situated substantially at right angles to the U-shaped portion and urging the U-shaped portion in an outwardly direction so as to provide contact between the sheet metal panel and the flat surface to which it is interfacing.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/905,565, filed Mar. 7, 2007, which is hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates generally to metalloprotease inhibiting compounds containing a heterocyclic moiety, and more particularly to MMP-13 inhibiting compounds with a modified benzoxazine moiety.
BACKGROUND OF THE INVENTION
Matrix metalloproteinases (MMPs) and aggrecanases (ADAMTS=a disintegrin and metalloproteinase with thrombospondin motif) are a family of structurally related zinc-containing enzymes that have been reported to mediate the breakdown of connective tissue in normal physiological processes such as embryonic development, reproduction, and tissue remodelling. Over-expression of MMPs and aggrecanases or an imbalance between extracellular matrix synthesis and degradation has been suggested as factors in inflammatory, malignant and degenerative disease processes. MMPs and aggrecanases are, therefore, targets for therapeutic inhibitors in several inflammatory, malignant and degenerative diseases such as rheumatoid arthritis, osteoarthritis, osteoporosis, periodontitis, multiple sclerosis, gingivitis, corneal epidermal and gastric ulceration, atherosclerosis, neointimal proliferation (which leads to restenosis and ischemic heart failure) and tumor metastasis.
The ADAMTSs are a group of proteases that are encoded in 19 ADAMTS genes in humans. The ADAMTSs are extracellular, multidomain enzymes whose functions include collagen processing, cleavage of the matrix proteoglycans, inhibition of angiogenesis and blood coagulation homoeostasis ( Biochem. J. 2005, 386, 15-27 ; Arthritis Res. Ther. 2005, 7, 160-169; Curr. Med. Chem. Anti - Inflammatory Anti - Allergy Agents 2005, 4, 251-264).
The mammalian MMP family has been reported to include at least 20 enzymes ( Chem. Rev. 1999, 99, 2735-2776). Collagenase-3 (MMP-13) is among three collagenases that have been identified. Based on identification of domain structures for individual members of the MMP family, it has been determined that the catalytic domain of the MMPs contains two zinc atoms; one of these zinc atoms performs a catalytic function and is coordinated with three histidines contained within the conserved amino acid sequence of the catalytic domain. MMP-13 is over-expressed in rheumatoid arthritis, osteoarthritis, abdominal aortic aneurysm, breast carcinoma, squamous cell carcinomas of the head and neck, and vulvar squamous cell carcinoma. The principal substrates of MMP-13 are fibrillar collagens (types I, II, III) and gelatins, proteoglycans, cytokines and other components of ECM (extracellular matrix).
The activation of the MMPs involves the removal of a propeptide, which features an unpaired cysteine residue complexed with the catalytic zinc (II) ion. X-ray crystal structures of the complex between MMP-3 catalytic domain and TIMP-1 and MMP-14 catalytic domain and TIMP-2 also reveal ligation of the catalytic zinc (II) ion by the thiol of a cysteine residue. The difficulty in developing effective MMP inhibiting compounds comprises several factors, including choice of selective versus broad-spectrum MMP inhibitors and rendering such compounds bioavailable via an oral route of administration.
MMP-3 (stromelysin-1; transin-1) is another member of the MMP family ( FASEB J. 1991, 5, 2145-2154). Human MMP-3 was initially isolated from cultured human synoviocytes. It is also expressed by chondrocytes and has been localized in OA cartilage and synovial tissues ( Am. J. Pathol. 1989, 135, 1055-64).
MMP-3 is produced by basal keratinocytes in a variety of chronic ulcers. MMP-3 mRNA and Protein were detected in basal keratinocytes adjacent to but distal from the wound edge in what probably represents the sites of proliferating epidermis. MMP-3 may thus prevent the epidermis from healing ( J. Clin. Invest. 1994, 94, 79-88).
MMP-3 serum protein levels are significantly elevated in patients with early and long-term rheumatoid arthritis ( Arthritis Rheum. 2000, 43, 852-8) and in osteoarthritis patients ( Clin. Orthop. Relat. Res. 2004, 428, 272-85) as well as in other inflammatory diseases like systemic lupus erythematosis and ankylosing spondylitis ( Rheumatology 2006, 45, 414-20).
MMP-3 acts on components of the ECM as aggrecan, fibronectin, gelatin, laminin, elastin, fibrillin and others and on collagens of type III, IV, V, VII, IX, X ( Clin. Orthop. Relat. Res. 2004, 428, 272-85). On collagens of type II and IX, MMP-3 exhibits telopeptidase activity ( Arthritis Res. 2001, 3, 107-13; Clin. Orthop. Relat. Res. 2004, 427, S118-22). MMP-3 can activate other MMP family members such as MMP-1, MMP-7, MMP-8, MMP-9 and MMP-13 ( Ann. Rheum. Dis. 2001, 60 Suppl 3:iii62-7).
MMP-3 is involved in the regulation of cytokines and chemokines by releasing TGFβ1 from the ECM, activating TNFα, inactivating IL-1β and releasing IGF ( Nat. Rev. Immunol. 2004, 4, 617-29). A potential role for MMP-3 in the regulation of macrophage infiltration is based on the ability of the enzyme to convert active MCP species into antagonistic peptides ( Blood 2002, 100, 1160-7).
MMP-8 (collagenase-2; neutrophil collagenase; EC 3.4.24.34) is another member of the MMP family ( Biochemistry 1990, 29, 10628-34). Human MMP-8 was initially located in human neutrophils ( Biochemistry 1990, 29, 10620-7). It is also expressed by macrophages, human mucosal keratinocytes, bronchial epithelial cells, ginigival fibroblasts, resident synovial and articular chondrodrocytes mainly in the course of inflammatory conditions ( Cytokine & Growth Factor Rev. 2006, 17, 217-23).
The activity of MMP-8 is tightly regulated and mostly limited to the sites of inflammation. MMP-8 is expressed and stored as an inactive pro-enzyme in the granules of the neutrophils. Only after the activation of the neutrophils by proinflammatory mediators, MMP-8 is released and activated to exert its function.
MMP-8 plays a key role in the migration of immune cells to the sites of inflammation. MMP-8 degrades components of the extracellular matrix (ECM) such as collagen type I, II, III, VII, X, cartilage aggrecan, laminin-5, nidogen, fibronectin, proteoglycans and tenascin, thereby facilitating the cells migration through the ECM barrier. MMP-8 also influences the biological activity of its substrates. Through proteolytic processing of the chemokines IL-8, GCP-2, ENA-78, MMP-8 increases the chemokines ability to activate the infiltrating immune cells. While MMP-8 inactivates the serine protease inhibitor alpha-1 antitrypsin through its cleavage ( Eur. J. Biochem. 2003, 270, 3739-49; PloS One 2007, 3, 1-10; Cytokine & Growth Factor Rev. 2006, 17, 217-23).
MMP-8 has been implicated in the pathogenesis of several chronic inflammatory diseases characterized by the excessive influx and activation of neutrophils, including cystic fibrosis ( Am. J. Resprir. Critic. Care Med 1994, 150, 818-22), rheumatoid arthritis ( Clin. Chim. Acta 1996, 129-43), chronic periodontal disease ( Annals Med. 2006, 38, 306-321) and chronic wounds ( J. Surg. Res. 1999, 81, 189-195).
In osteoarthritis patients, MMP-8 protein expression is significantly elevated in inflamed human articular cartilage in the knee and ankle joints ( Lab Invest. 1996, 74, 232-40; J. Biol. Chem. 1996, 271, 11023-6).
The levels of activated MMP-8 in BALF is an indicator of the disease severity and correlates with the airway obstruction in patients with asthma, COPD, pulmonary emphysema and bronchiectasis ( Lab Invest. 2002, 82, 1535-45; Am. J. Respir. Crit. Care Med. 1999, 159, 1985-91; Respir. Med. 2005, 99, 703-10; J. Pathol. 2001, 194, 232-38).
SUMMARY OF THE INVENTION
The present invention relates to a new class of heterocyclic moiety containing pharmaceutical agents which inhibits metalloproteases. In particular, the present invention provides a new class of metalloprotease inhibiting compounds that exhibit potent inhibiting activity towards metalloproteases, in particular towards MMP-13.
The present invention provides a new classes of heterocyclic metalloprotease compounds, which is represented by the following general formula:
wherein all variables in the preceding Formulas (I) are as defined hereinbelow.
The heterocyclic metalloprotease inhibiting compounds of the present invention may be used in the treatment of metalloprotease mediated diseases, such as rheumatoid arthritis, osteoarthritis, abdominal aortic aneurysm, cancer (e.g. but not limited to melanoma, gastric carcinoma or non-small cell lung carcinoma), inflammation, atherosclerosis, multiple sclerosis, chronic obstructive pulmonary disease, ocular diseases (e.g. but not limited to ocular inflammation, glaucoma, retinopathy of prematurity, macular degeneration with the wet type preferred and corneal neovascularization), neurologic diseases, psychiatric diseases, thrombosis, bacterial infection, Parkinson's disease, fatigue, tremor, diabetic retinopathy, vascular diseases of the retina, aging, dementia, cardiomyopathy, renal tubular impairment, diabetes, psychosis, dyskinesia, pigmentary abnormalities, deafness, inflammatory and fibrotic syndromes, intestinal bowel syndrome, allergies, Alzheimers disease, arterial plaque formation, oncology, periodontal, viral infection, stroke, atherosclerosis, cardiovascular disease, reperfusion injury, trauma, chemical exposure or oxidative damage to tissues, chronic wound healing, wound healing, hemorrhoid, skin beautifying, pain, inflammatory pain, bone pain and joint pain, acne, acute alcoholic hepatitis, acute inflammation, acute pancreatitis, acute respiratory distress syndrome, adult respiratory disease, airflow obstruction, airway hyperresponsiveness, alcoholic liver disease, allograft rejections, angiogenesis, angiogenic ocular disease, arthritis, asthma, atopic dermatitis, bronchiectasis, bronchiolitis, bronchiolitis obliterans, burn therapy, cardiac and renal reperfusion injury, celiac disease, cerebral and cardiac ischemia, CNS tumors, CNS vasculitis, colds, contusions, cor pulmonae, cough, Crohn's disease, chronic bronchitis, chronic inflammation, chronic pancreatitis, chronic sinusitis, crystal induced arthritis, cystic fibrosis, delayed type hypersensitivity reaction, duodenal ulcers, dyspnea, early transplantation rejection, emphysema, encephalitis, endotoxic shock, esophagitis, gastric ulcers, gingivitis, glomerulonephritis, glossitis, gout, graft vs. host reaction, gram negative sepsis, granulocytic ehrlichiosis, hepatitis viruses, herpes, herpes viruses, HIV, hypercapnea, hyperinflation, hyperoxia-induced inflammation, hypoxia, hypersensitivity, hypoxemia, inflammatory bowel disease, interstitial pneumonitis, ischemia reperfusion injury, kaposi's sarcoma associated virus, liver fibrosis, lupus, malaria, meningitis, multi-organ dysfunction, necrotizing enterocolitis, osteoporosis, chronic periodontitis, periodontitis, peritonitis associated with continuos ambulatory peritoneal dialysis (CAPD), pre-term labor, polymyositis, post surgical trauma, pruritis, psoriasis, psoriatic arthritis, pulmatory fibrosis, pulmatory hypertension, renal reperfusion injury, respiratory viruses, restinosis, right ventricular hypertrophy, sarcoidosis, septic shock, small airway disease, sprains, strains, subarachnoid hemorrhage, surgical lung volume reduction, thrombosis, toxic shock syndrome, transplant reperfusion injury, traumatic brain injury, ulcerative colitis, vasculitis, ventilation-perfusion mismatching, and wheeze.
In particular, the heterocyclic metalloprotease inhibiting compounds of the present invention may be used in the treatment of MMP-13, MMP-8 and MMP-3 mediated degenerative diseases characterized by excessive extracellular matrix degradation and/or remodelling, such as cancer, and chronic inflammatory diseases such as arthritis, rheumatoid arthritis, osteoarthritis, atherosclerosis, abdominal aortic aneurysm, inflammation, multiple sclerosis, parkinsons disease, chronic obstructive pulmonary disease and pain, such as inflammatory pain, bone pain and joint pain.
The present invention also provides heterocyclic metalloprotease inhibiting compounds that are useful as active ingredients in pharmaceutical compositions for treatment or prevention of metalloprotease—especially MMP-13—mediated diseases. The present invention also contemplates use of such compounds in pharmaceutical compositions for oral or parenteral administration, comprising one or more of the heterocyclic metalloprotease inhibiting compounds disclosed herein.
The present invention further provides methods of inhibiting metalloproteases, by administering formulations, including, but not limited to, oral, rectal, topical, intravenous, parenteral (including, but not limited to, intramuscular, intravenous), ocular (ophthalmic), transdermal, inhalative (including, but not limited to, pulmonary, aerosol inhalation), nasal, sublingual, subcutaneous or intraarticular formulations, comprising the heterocyclic metalloprotease inhibiting compounds by standard methods known in medical practice, for the treatment of diseases or symptoms arising from or associated with metalloprotease, especially MMP-13, including prophylactic and therapeutic treatment. Although the most suitable route in any given case will depend on the nature and severity of the conditions being treated and on the nature of the active ingredient. The compounds from this invention are conveniently presented in unit dosage form and prepared by any of the methods well-known in the art of pharmacy.
The heterocyclic metalloprotease inhibiting compounds of the present invention may be used in combination with a disease modifying antirheumatic drug, a nonsteroidal anti-inflammatory drug, a COX-2 selective inhibitor, a COX-1 inhibitor, an immunosuppressive, a steroid, a biological response modifier, a viscosupplement, a pain reducing drug or other anti-inflammatory agents or therapeutics useful for the treatment of chemokines mediated diseases.
DETAILED DESCRIPTION OF THE INVENTION
One aspect of the invention relates to a compound having Formula (I):
wherein:
R 4 in each occurrence is independently selected from R 10 , hydrogen, alkyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl, halo, haloalkyl, CF 3 , (C 0 -C 6 )-alkyl-COR 10 , (C 0 -C 6 )-alkyl-OR 10 , (C 0 -C 6 )-alkyl-NR 10 R 11 , (C 0 -C 6 )-alkyl-NO 2 , (C 0 -C 6 )-alkyl-CN, (C 0 -C 6 )-alkyl-S(O) y OR 10 , (C 0 -C 6 )-alkyl-S(O) y NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 CONR 11 SO 2 R 30 , (C 0 -C 6 )-alkyl-S(O) x R 10 , (C 0 -C 6 )-alkyl-OC(O)R 10 , (C 0 -C 6 )-alkyl-OC(O)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(═NR 10 )NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 C(═NR 11 )NR 10 R 11 , (C 0 -C 6 )-alkyl-C(O)OR 10 , (C 0 -C 6 )-alkyl-C(O)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(O)NR 10 SO 2 R 11 , (C 0 -C 6 )-alkyl-C(O)—NR 11 —CN, O—(C 0 -C 6 )-alkyl-C(O)NR 10 R 11 , S(O) x —(C 0 -C 6 )-alkyl-C(O)OR 10 , S(O) x —(C 0 -C 6 )-alkyl-C(O)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(O)NR 10 —(C 0 -C 6 )-alkyl-NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 —C(O)R 10 , (C 0 -C 6 )-alkyl-NR 10 —C(O)OR 10 , (C 0 -C 6 )-alkyl-NR 10 —C(O)—NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 —S(O) y NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 —S(O) y R 10 , O—(C 0 -C 6 )-alkyl-aryl and O—(C 0 -C 6 )-alkyl-heteroaryl,
wherein each R 4 group is optionally substituted one or more times, or
wherein each R 4 group is optionally substituted by one or more R 14 groups;
R 8 is selected from R 10 or optionally R 8 and X 1 when taken together with the nitrogen and sp 2 -carbon atom to which they are attached complete a 5- to 8-membered unsaturated or partially unsaturated heterocycle optionally containing additional heteroatoms selected from O, S(O) x , N or NR 50 and which is optionally substituted one or more times;
R 9 in each occurrence is independently selected from R 10 , hydrogen, alkyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl, halo, CHF 2 , CF 3 , OR 10 , SR 10 , COOR 10 , CH(CH 3 )CO 2 H, (C 0 -C 6 )-alkyl-COR 10 , (C 0 -C 6 )-alkyl-OR 10 , (C 0 -C 6 )-alkyl-NR 10 R 11 , (C 0 -C 6 )-alkyl-NO 2 , (C 0 -C 6 )-alkyl-CN, (C 0 -C 6 )-alkyl-S(O) y OR 10 , (C 0 -C 6 )-alkyl-P(O) 2 OH, (C 0 -C 6 )-alkyl-S(O) y NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 CONR 11 SO 2 R 30 , (C 0 -C 6 )-alkyl-S(O) y R 10 , (C 0 -C 6 )-alkyl-OC(O)R 10 , (C 0 -C 6 )-alkyl-OC(O)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(═NR 10 )NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 C(═NR 11 )NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 C(═N—CN)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(═N—CN)NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 C(═N—NO 2 )NR 10 R 11 , (C 0 -C 6 )-alkyl-C(═N—NO 2 )NR 10 R 11 , (C 0 -C 6 )-alkyl-C(O)OR 10 , (C 0 -C 6 )-alkyl-C(O)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(O)NR 10 SO 2 R 11 , C(O)NR 10 —(C 0 -C 6 )-alkyl-heteroaryl, C(O)NR 10 —(C 0 -C 6 )-alkyl-aryl, S(O) 2 NR 10 —(C 0 -C 6 )-alkyl-aryl, S(O) 2 NR 10 —(C 0 -C 6 )-alkyl-heteroaryl, S(O) 2 NR 10 -alkyl, S(O) 2 —(C 0 -C 6 )-alkyl-aryl, S(O) 2 —(C 0 -C 6 )-alkyl-heteroaryl, (C 0 -C 6 )-alkyl-C(O)—NR 11 —CN, O—(C 0 -C 6 )-alkyl-C(O)NR 10 R 11 , S(O), —(C 0 -C 6 )-alkyl-C(O)OR 10 , S(O), —(C 0 -C 6 )-alkyl-C(O)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(O)NR 10 —(C 0 -C 6 )-alkyl-NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 —C(O)R 10 , (C 0 -C 6 )-alkyl-NR 10 —C(O)OR 10 , (C 0 -C 6 )-alkyl-NR 10 —C(O)—NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 —S(O) y NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 —S(O) y R 11 , O—(C 0 -C 6 )-alkyl-aryl and O—(C 0 -C 6 )-alkyl-heteroaryl, wherein each R 9 group is optionally one or more times substituted;
R 10 and R 11 in each occurrence are independently selected from hydrogen, alkyl, cycloalkyl, cycloalkylalkyl, heterocycloalkyl, fluoroalkyl, heterocycloalkylalkyl, haloalkyl, alkenyl, alkynyl, aryl, heteroaryl, arylalkyl, heteroarylalkyl and aminoalkyl, wherein alkyl, cycloalkyl, cycloalkylalkyl, heterocycloalkyl, fluoroalkyl, heterocycloalkylalkyl, alkenyl, alkynyl, aryl, heteroaryl, arylalkyl, heteroarylalkyl and aminoalkyl are optionally substituted one or more times, or R 10 and R 11 when taken together with the nitrogen to which they are attached complete a 3- to 8-membered ring containing carbon atoms and optionally containing a heteroatom selected from O, S(O) x , or NR 50 and which is optionally substituted one or more times;
R 14 is independently selected from hydrogen, alkyl, arylalkyl, cycloalkylalkyl, heteroarylalkyl, heterocyclylalkyl and halo, wherein alkyl, arylalkyl, cycloalkylalkyl, heteroarylalkyl and heterocyclylalkyl are optionally substituted one or more times;
R 17 is selected from R 9 , alkenyl, alkynyl, bicycloalkyl, heterobicycloalkyl, spiroalkyl, spiroheteroalkyl, cycloalkyl fused aryl, heterocycloalkyl fused aryl, cycloalkyl fused heteroaryl, heterocycloalkyl fused heteroaryl or a bicyclic or tricyclic fused ring system, wherein at least one ring is partially saturated, and
wherein each R 17 group is optionally substituted one or more times, or
wherein each R 17 group is optionally substituted one or more R 9 groups;
R 30 is selected from alkyl and (C 0 -C 6 )-alkyl-aryl, wherein alkyl and aryl are optionally substituted;
R 50 in each occurrence is independently selected from hydrogen, alkyl, aryl, heteroaryl, C(O)R 80 , C(O)NR 80 R 81 , SO 2 R 80 and SO 2 NR 80 R 81 , wherein alkyl, aryl, and heteroaryl are optionally substituted one or more times;
R 80 and R 81 in each occurrence are independently selected from hydrogen, alkyl, cycloalkyl, cycloalkylalkyl, heterocycloalkyl, fluoroalkyl, heterocycloalkylalkyl, haloalkyl, alkenyl, alkynyl, aryl, heteroaryl, arylalkyl, heteroarylalkyl and aminoalkyl, wherein alkyl, cycloalkyl, cycloalkylalkyl, heterocycloalkyl, fluoroalkyl, heterocycloalkylalkyl, alkenyl, alkynyl, aryl, heteroaryl, arylalkyl, heteroarylalkyl and aminoalkyl are optionally substituted, or R 80 and R 81 when taken together with the nitrogen to which they are attached complete a 3- to 8-membered ring containing carbon atoms and optionally a heteroatom selected from O, S(O) x , NH, and N(alkyl) and which is optionally substituted one or more times;
L c is selected from a single bond or an acyclic, straight or branched, saturated or unsaturated hydrocarbon chain having 1 to 10 carbon atoms, optionally containing 1 to 3 groups independently selected from —S—, —O—, NR 10 —, —NR 10 CO—, —CONR 10 —, —S(O) x —, —SO 2 NR 10 —, —NR 10 SO 2 —, NR 10 SO 2 NR 10 —, —NR 10 CONR 10 —, —OC(O)NR 10 —, —NR 10 C(O)O—, which replace single carbon atoms, which in case that more than two carbon atoms are replaced are not adjacent, and wherein the hydrocarbon chain is optionally substituted one or more times;
L d is selected from a single bond or a straight or branched, saturated or unsaturated hydrocarbon chain having 1 to 10 carbon atoms, optionally containing 1 to 3 groups independently selected from —O—, —NR 10 —, —S(O) x —, —NR 10 C(X 1 )—, —C(X 1 )NR 10 —, —SO 2 NR 10 —, —NR 10 SO 2 —, —O—SO 2 —, —SO 2 —O—, —NR 10 SO 2 NR 10 —, —NR 10 C(X 1 )NR 10 —, —OC(X 1 )NR 10 —, —NR 10 C(X 1 )O—, —OC(X 1 )—, —C(X 1 )O—, -Q 2 -, —NR 10 -Q 2 -, -Q 2 -NR 10 —, —C(X 1 )-Q 2 -, -Q 2 -C(X 1 )—, —O-Q 2 -, —S(O) x -Q 2 -, and -Q 2 -S(O) x — which replace single carbon atoms, which in case that more than two carbon atoms are replaced are not adjacent, and wherein the hydrocarbon chain is optionally substituted one or more times;
Q 1 is a 4- to 8-membered ring selected from cycloalkyl, heterocycloalkyl, bicycloalkyl, heterobicycloalkyl or a 5- or 6-membered ring selected from aryl and heteroaryl, wherein cycloalkyl, heterocycloalkyl, bicycloalkyl, heterobicycloalkyl, aryl and heteroaryl are optionally substituted one or more times by R 4 and optionally a substituent of Q 1 is linked with L d to complete a 3- to 8-membered ring containing carbon atoms and optionally heteroatoms selected from O, S(O) x , —NH, and —N(alkyl) wherein this new ring is optionally substituted one or more times;
Q 2 is independently selected from an aromatic, partially aromatic or non-aromatic cyclic, bicyclic or multicyclic system containing 0 to 8 heteroatoms selected from N, O and S(O) x , which is optionally substituted one or more times with R 4 and wherein the cycles are optionally spiro fused and optionally a substituent of Q 2 is linked with L d to complete a 3- to 8-membered ring containing carbon atoms and optionally heteroatoms selected from O, S(O) x , —NH, and —N(alkyl) wherein this new ring is optionally substituted one or more times;
X 1 is independently selected from S, NR 10 , NOR 10 , N—CN, NCOR 10 , N—NO 2 , and N—SO 2 R 10 ;
Y is selected from O, S(O) x , CR 10 R 11 , and NR 10 ;
Z 1 is independently selected from C, S, S═O, PR 10 and P—OR 10 ;
w is independently selected from 0 to 3;
x is independently selected from 0 to 2;
y is selected from 1 and 2; and
N-oxides, pharmaceutically acceptable salts, prodrugs, formulations, polymorphs, racemic mixtures and stereoisomers thereof.
In one embodiment, in conjunction with any above or below embodiments, Q 2 selected from:
wherein:
R 22 is selected from hydrogen, hydroxy, halo, alkyl, cycloalkyl, alkoxy, alkenyl, alkynyl, NO 2 , NR 10 R 11 , CN, SR 10 , SSR 10 , PO 3 R 10 , NR 10 NR 10 R 11 , NR 10 N═CR 10 R 11 , NR 10 SO 2 R 11 , C(O)OR 10 , C(O)NR 10 R 11 , SO 2 R 10 , SO 2 NR 10 R 11 , and fluoroalkyl, wherein alkyl, cycloalkyl, alkoxy, alkenyl, alkynyl, and fluoroalkyl are optionally substituted one or more times;
R 13 is selected from hydrogen, hydroxy, halo, alkyl, cycloalkyl, alkoxy, alkenyl, alkynyl, NO 2 , NR 10 R 11 , CN, SR 10 , SSR 10 , PO 3 R 10 , NR 10 NR 10 R 11 , NR 10 N═CR 10 R 11 , NR 10 SO 2 R 11 , C(O)OR 10 , and fluoroalkyl, wherein alkyl, cycloalkyl, alkoxy, alkenyl, alkynyl, and fluoroalkyl are optionally substituted one or more times;
R 51 is independently selected from hydrogen, alkyl, aryl, heteroaryl, arylalkyl, cycloalkylalkyl, heteroarylalkyl and haloalkyl, wherein alkyl, aryl, heteroaryl, arylalkyl, cycloalkylalkyl, heteroarylalkyl and haloalkyl are optionally substituted one or more times; and
K 1 is O, S(O) x , or NR 51 .
In one embodiment, in conjunction with any above or below embodiments, the compound is:
wherein:
L, M and T are independently selected from CR 9 and N.
In one embodiment, in conjunction with any above or below embodiments, the compound is selected from:
wherein:
L c is selected from —SO 2 NR 10 —, —S(O) x —, S(O) 2 O—, —C(O)O—, —C(O)NR 10 —, —NR 10 —, —NR 10 SO 2 —, —OC(O)—, —OC(O)NR 10 , NR 10 C(O)—, —NR 10 CO 2 —, —NR 10 C(O)NR 10 —, —NR 10 C(═NR 10 )—, and —O—.
In one embodiment, in conjunction with any above or below embodiments, the compound of claim 4 selected from:
In one embodiment, in conjunction with any above or below embodiments, R 17 is selected from:
wherein:
R is selected from C(O)NR 10 R 11 , COR 10 , SO 2 NR 10 R 11 , SO 2 R 10 , CONHCH 3 and CON(CH 3 ) 2 , wherein C(O)NR 10 R 11 , COR 10 , SO 2 NR 10 R 11 , SO 2 R 10 , CONHCH 3 and CON(CH 3 ) 2 are optionally substituted one or more times;
R 5 in each occurrence is independently selected from hydrogen, alkyl, C(O)NR 10 R 11 , aryl, arylalkyl, SO 2 NR 10 R 11 and C(O)OR 10 , wherein alkyl, aryl and arylalkyl are optionally substituted one or more times;
R 6 is independently selected from R 9 , alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, bicycloalkyl, heterobicycloalkyl, spiroalkyl, spiroheteroalkyl, aryl, heteroaryl, C(O)OR 10 , CH(CH 3 )CO 2 H, (C 0 -C 6 )-alkyl-COR 10 , (C 0 -C 6 )-alkyl-OR 10 , (C 0 -C 6 )-alkyl-NR 10 R 11 , (C 0 -C 6 )-alkyl-NO 2 , (C 0 -C 6 )-alkyl-CN, (C 0 -C 6 )-alkyl-S(O) y OR 10 , (C 0 -C 6 )-alkyl-P(O) 2 OH, (C 0 -C 6 )-alkyl-S(O) y NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 CONR 11 SO 2 R 30 , (C 0 -C 6 )-alkyl-S(O) x R 10 , (C 0 -C 6 )-alkyl-OC(O)R 10 , (C 0 -C 6 )-alkyl-OC(O)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(═NR 10 )NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 C(═NR 11 )NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 C(═N—CN)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(═N—CN)NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 C(═N—NO 2 )NR 10 R 11 , (C 0 -C 6 )-alkyl-C(═N—NO 2 )NR 10 R 11 , (C 0 -C 6 )-alkyl-C(O)OR 10 , (C 0 -C 6 )-alkyl-C(O)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(O)NR 10 SO 2 R 11 , C(O)NR 10 —(C 0 -C 6 )-alkyl-heteroaryl, C(O)NR 10 —(C 0 -C 6 )-alkyl-aryl, S(O) 2 NR 10 —(C 0 -C 6 )-alkyl-aryl, S(O) 2 NR 10 —(C 0 -C 6 )-alkyl-heteroaryl, S(O) 2 NR 10 -alkyl, S(O) 2 —(C 0 -C 6 )-alkyl-aryl, S(O) 2 —(C 0 -C 6 )-alkyl-heteroaryl, (C 0 -C 6 )-alkyl-C(O)—NR 11 —CN, O—(C 0 -C 6 )-alkyl-C(O)NR 10 R 11 , S(O), —(C 0 -C 6 )-alkyl-C(O)OR 10 , S(O) x —(C 0 -C 6 )-alkyl-C(O)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(O)NR 10 —(C 0 -C 6 )-alkyl-NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 —C(O)R 10 , (C 0 -C 6 )-alkyl-NR 10 —C(O)OR 10 , (C 0 -C 6 )-alkyl-NR 10 —C(O)—NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 —S(O) y NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 —S(O) y R 11 , O—(C 0 -C 6 )-alkyl-aryl and O—(C 0 -C 6 )-alkyl-heteroaryl,
wherein each R 6 group is optionally substituted one or more times, or
wherein each R 6 group is optionally substituted by one or more R 14 groups;
R 7 is independently selected from hydrogen, alkyl, cycloalkyl, halo, R 4 and NR 10 R 11 , wherein alkyl and cycloalkyl are optionally substituted one or more times, or optionally two R 7 groups together at the same carbon atom form ═O, ═S or ═NR 10 ;
R 15 is independently selected from hydrogen, alkyl, cycloalkyl, C(O)R 10 , C(O)NR 10 R 11 and haloalkyl, wherein alkyl, cycloalkyl, and haloalkyl are optionally substituted one or more times;
B 1 is selected from NR 10 , O and S(O) x ;
D 4 , G 4 , L 4 , M 4 , and T 4 , are independently selected from CR 6 and N;
E is independently selected from a bond, CR 10 R 11 , O, NR 5 , S, S═O, S(═O) 2 , C(═O), N(R 10 )(C═O), (C═O)N(R 10 ), N(R 10 )S(═O) 2 , S(═O) 2 N(R 10 ), C═N—OR 11 ,
—C(R 10 R 11 )C(R 10 R 11 )—, —CH 2 —W 1 — and
U is independently selected from C(R 5 R 10 ), NR 5 , O, S, S═O and S(═O) 2 ;
W 1 is independently selected from O, NR 5 , S, S═O, S(═O) 2 , N(R 10 )(C═O), N(R 10 )S(═O) 2 and S(═O) 2 N(R 10 );
Z is a 4- to 8-membered ring consisting of cycloalkyl, heterocycloalkyl or a 5- or 6-membered ring selected from aryl and heteroaryl, wherein cycloalkyl, heterocycloalkyl, aryl and heteroaryl are optionally substituted one or more times;
g and h are independently selected from 0-2; and
r is selected from 1-4.
In one embodiment, in conjunction with any above or below embodiments, R 17 is selected from:
and wherein
R 9 is selected from hydrogen, fluoro, halo, CN, alkyl, CO 2 H,
In one embodiment, in conjunction with any above or below embodiments, the compound is selected from:
In one embodiment, in conjunction with any above or below embodiments, R 4 is substituted 0, 1 or 2 times.
In one embodiment, in conjunction with any above or below embodiments, R 4 is substituted by 0, 1 or 2 R 14 groups.
In one embodiment, in conjunction with any above or below embodiments, R 6 group is substituted 0, 1 or 2 times.
In one embodiment, in conjunction with any above or below embodiments, R 6 group is substituted by 0, 1 or 2 R 14 groups;
In one embodiment, in conjunction with any above or below embodiments, R 7 is independently selected from hydrogen, alkyl, cycloalkyl, halo, R 4 and NR 10 R 11 , wherein alkyl and cycloalkyl are optionally substituted one or more times, or optionally two R 7 groups together at the same carbon atom form ═O, ═S or ═NR 10 ;
In one embodiment, in conjunction with any above or below embodiments, R 8 is R 10 .
In one embodiment, in conjunction with any above or below embodiments, R 8 and X 1 when taken together with the nitrogen and sp 2 -carbon atom to which they are attached complete a 5- to 8-membered unsaturated or partially unsaturated heterocycle optionally containing additional heteroatoms selected from O, S(O) x , N or NR 50 and which is substituted 0, 1 or 2 times.
In one embodiment, in conjunction with any above or below embodiments, one R 9 is selected from R 10 , alkyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl, halo, CHF 2 , CF 3 , OR 10 , SR 10 , COOR 10 , CH(CH 3 )CO 2 H, (C 0 -C 6 )-alkyl-COR 10 , (C 0 -C 6 )-alkyl-OR 10 , (C 0 -C 6 )-alkyl-NR 10 R 11 , (C 0 -C 6 )-alkyl-NO 2 , (C 0 -C 6 )-alkyl-CN, (C 0 -C 6 )-alkyl-S(O) y OR 10 , (C 0 -C 6 )-alkyl-P(O) 2 OH, (C 0 -C 6 )-alkyl-S(O) y NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 CONR 11 SO 2 R 30 , (C 0 -C 6 )-alkyl-S(O) x R 10 , (C 0 -C 6 )-alkyl-OC(O)R 10 , (C 0 -C 6 )-alkyl-OC(O)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(═NR 10 )NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 C(═NR 11 )NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 C(═N—CN)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(═N—CN)NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 C(═N—NO 2 )NR 10 R 11 , (C 0 -C 6 )-alkyl-C(═N—NO 2 )NR 10 R 11 , (C 0 -C 6 )-alkyl-C(O)OR 10 , (C 0 -C 6 )-alkyl-C(O)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(O)NR 10 SO 2 R 11 , C(O)NR 10 —(C 0 -C 6 )-alkyl-heteroaryl, C(O)NR 10 —(C 0 -C 6 )-alkyl-aryl, S(O) 2 NR 10 —(C 0 -C 6 )-alkyl-aryl, S(O) 2 NR 10 —(C 0 -C 6 )-alkyl-heteroaryl, S(O) 2 NR 10 -alkyl, S(O) 2 —(C 0 -C 6 )-alkyl-aryl, S(O) 2 —(C 0 -C 6 )-alkyl-heteroaryl, (C 0 -C 6 )-alkyl-C(O)—NR 11 —CN, O—(C 0 -C 6 )-alkyl-C(O)NR 10 R 11 , S(O) x —(C 0 -C 6 )-alkyl-C(O)OR 10 , S(O) x -(C 0 -C 6 )-alkyl-C(O)NR 10 R 11 , (C 0 -C 6 )-alkyl-C(O)NR 10 —(C 0 -C 6 )-alkyl-NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 —C(O)R 10 , (C 0 -C 6 )-alkyl-NR 10 —C(O)OR 10 , (C 0 -C 6 )-alkyl-NR 10 —C(O)—NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 —S(O) y NR 10 R 11 , (C 0 -C 6 )-alkyl-NR 10 —S(O) y R 11 , O—(C 0 -C 6 )-alkyl-aryl and O—(C 0 -C 6 )-alkyl-heteroaryl, wherein each R 9 group is substituted 0, 1 or 2 times; and the remaining R 9 groups are hydrogen.
In one embodiment, in conjunction with any above or below embodiments, R 9 is H.
In one embodiment, in conjunction with any above or below embodiments, R 17 is selected from R 9 , alkenyl, alkynyl, bicycloalkyl, heterobicycloalkyl, spiroalkyl, spiroheteroalkyl, cycloalkyl fused aryl, heterocycloalkyl fused aryl, cycloalkyl fused heteroaryl, heterocycloalkyl fused heteroaryl or a bicyclic or tricyclic fused ring system, wherein at least one ring is partially saturated, and wherein each R 17 group is substituted 0, 1 or 2 times and 0 or 1 R 9 groups.
In one embodiment, in conjunction with any above or below embodiments, R 30 is selected from alkyl and (C 0 -C 6 )-alkyl-aryl, wherein alkyl and aryl are optionally substituted 0, 1 or 2 times.
In one embodiment, in conjunction with any above or below embodiments, one R 9 is sR 50 in each occurrence is independently selected from hydrogen, alkyl, aryl, heteroaryl, C(O)R 80 , C(O)NR 80 R 81 , SO 2 R 80 and SO 2 NR 80 R 81 , wherein alkyl, aryl, and heteroaryl are substituted 0, 1 or 2 times.
In one embodiment, in conjunction with any above or below embodiments, R 80 and R 81 in each occurrence are independently selected from hydrogen, alkyl, cycloalkyl, cycloalkylalkyl, heterocycloalkyl, fluoroalkyl, heterocycloalkylalkyl, haloalkyl, alkenyl, alkynyl, aryl, heteroaryl, arylalkyl, heteroarylalkyl and aminoalkyl, wherein alkyl, cycloalkyl, cycloalkylalkyl, heterocycloalkyl, fluoroalkyl, heterocycloalkylalkyl, alkenyl, alkynyl, aryl, heteroaryl, arylalkyl, heteroarylalkyl and aminoalkyl are optionally substituted 0, 1 or 2 times, or R 80 and R 81 when taken together with the nitrogen to which they are attached complete a 3- to 8-membered ring containing carbon atoms and optionally a heteroatom selected from O, S(O) x , NH, and N(alkyl) and which is optionally substituted 0, 1 or 2 times.
In one embodiment, in conjunction with any above or below embodiments, L c is selected from a single bond or an acyclic, straight or branched, saturated or unsaturated hydrocarbon chain having 1 to 10 carbon atoms, optionally containing 1 to 3 groups independently selected from —S—, —O—, NR 10 —, —NR 10 CO—, —CONR 10 —, —S(O) x —, —SO 2 NR 10 —, —NR 10 SO 2 —, NR 10 SO 2 NR 0 —, —NR 10 CONR 10 —, —OC(O)NR 10 —, —NR 10 C(O)O—, which replace single carbon atoms, which in case that more than two carbon atoms are replaced are not adjacent, and wherein the hydrocarbon chain is optionally substituted one or more times;
In one embodiment, in conjunction with any above or below embodiments, L c is absent.
In one embodiment, in conjunction with any above or below embodiments, L c is selected from —CONH— and —NHCO—.
In one embodiment, in conjunction with any above or below embodiments, L d is selected from a single bond or a straight or branched, saturated or unsaturated hydrocarbon chain having 1 to 10 carbon atoms, optionally containing 1, 2 or 3 groups independently selected from —O—, —NR 10 —, —S(O) x —, —NR 10 C(X 1 )—, —C(X 1 )NR 10 —, —SO 2 NR 10 —, —NR 10 SO 2 —, —O—SO 2 —, —SO 2 —O—, —NR 10 SO 2 NR 10 —, —NR 10 C(X 1 )NR 10 —, —OC(X 1 )NR 10 —, —NR 10 C(X 1 )O—, —OC(X 1 )—, —C(X 1 )O—, -Q 2 -, —NR 10 -Q 2 -, -Q 2 -NR 10 —, —C(X 1 )-Q 2 -, -Q 2 -C(X 1 )—, —O-Q 2 -, —S(O) x -Q 2 -, and -Q 2 -S(O)X— which replace single carbon atoms, which in case that more than two carbon atoms are replaced are not adjacent, and wherein the hydrocarbon chain is substituted 0, 1, 2 or 3 times;
In one embodiment, in conjunction with any above or below embodiments, L d is selected from —CH 2 NHCO— and —CH 2 CONH—.
In one embodiment, in conjunction with any above or below embodiments, L d is —CH 2 NHCO—.
In one embodiment, in conjunction with any above or below embodiments, Q 1 is a 4-, 5-, 6-, 7- or 8-membered ring selected from cycloalkyl, heterocycloalkyl, bicycloalkyl, heterobicycloalkyl or a 5- or 6-membered ring selected from aryl and heteroaryl, wherein cycloalkyl, heterocycloalkyl, bicycloalkyl, heterobicycloalkyl, aryl and heteroaryl are substituted by 0, 1 or 2 R 4 groups and optionally a substituent of Q 1 is linked with L d to complete a 3- to 8-membered ring containing carbon atoms and optionally heteroatoms selected from O, S(O) x , —NH, and —N(alkyl) wherein this new ring is optionally substituted one or more times.
In one embodiment, in conjunction with any above or below embodiments, Q 1 is phenyl.
In one embodiment, in conjunction with any above or below embodiments, Q 1 is pyridyl.
In one embodiment, in conjunction with any above or below embodiments, Q 2 is [fill in];
In one embodiment, in conjunction with any above or below embodiments, X 1 is O.
In one embodiment, in conjunction with any above or below embodiments, Y is O.
In one embodiment, in conjunction with any above or below embodiments, Z 1 is independently selected from C, S, S═O, PR 10 and P—OR 10 .
Another aspect of the invention relates to a method of inhibiting a metalloprotease enzyme, comprising administering a compound selected from any of the above or below embodiments.
In another embodiment, in conjunction with any above or below embodiments, the metalloprotease is selected from MMP-3, MMP-8, and MMP-13.
In another embodiment, in conjunction with any above or below embodiments, the metalloprotease is MMP-13.
Another aspect of the invention relates to a method of treating a metalloprotease mediated disease, comprising administering to a subject in need of such treatment an effective amount of a compound selected from any of the above or below embodiments.
In another embodiment, in conjunction with any above or below embodiments, the disease is rheumatoid arthritis.
In another embodiment, in conjunction with any above or below embodiments, the disease is osteoarthritis.
In another embodiment, in conjunction with any above or below embodiments, the disease is inflammation.
In another embodiment, in conjunction with any above or below embodiments, the disease is atherosclerosis.
In another embodiment, in conjunction with any above or below embodiments, the disease is multiple sclerosis.
In another embodiment, in conjunction with any above or below embodiments, the disease is selected from: rheumatoid arthritis, osteoarthritis, abdominal aortic aneurysm, cancer (e.g. but not limited to melanoma, gastric carcinoma or non-small cell lung carcinoma), inflammation, atherosclerosis, chronic obstructive pulmonary disease, ocular diseases (e.g. but not limited to ocular inflammation, glaucoma, retinopathy of prematurity, macular degeneration with the wet type preferred and corneal neovascularization), neurologic diseases, psychiatric diseases, thrombosis, bacterial infection, Parkinson's disease, fatigue, tremor, diabetic retinopathy, vascular diseases of the retina, aging, dementia, cardiomyopathy, renal tubular impairment, diabetes, psychosis, dyskinesia, pigmentary abnormalities, deafness, inflammatory and fibrotic syndromes, intestinal bowel syndrome, allergies, Alzheimers disease, arterial plaque formation, oncology, periodontal, viral infection, stroke, atherosclerosis, cardiovascular disease, reperfusion injury, trauma, chemical exposure or oxidative damage to tissues, wound healing, hemorrhoid, skin beautifying, pain, inflammatory pain, bone pain and joint pain, acne, acute alcoholic hepatitis, acute inflammation, acute pancreatitis, acute respiratory distress syndrome, adult respiratory disease, airflow obstruction, airway hyperresponsiveness, alcoholic liver disease, allograft rejections, angiogenesis, angiogenic ocular disease, arthritis, asthma, atopic dermatitis, bronchiectasis, bronchiolitis, bronchiolitis obliterans, burn therapy, cardiac and renal reperfusion injury, celiac disease, cerebral and cardiac ischemia, CNS tumors, CNS vasculitis, colds, contusions, cor pulmonae, cough, Crohn's disease, chronic bronchitis, chronic inflammation, chronic pancreatitis, chronic sinusitis, crystal induced arthritis, cystic fibrosis, delayed type hypersensitivity reaction, duodenal ulcers, dyspnea, early transplantation rejection, emphysema, encephalitis, endotoxic shock, esophagitis, gastric ulcers, gingivitis, glomerulonephritis, glossitis, gout, graft vs. host reaction, gram negative sepsis, granulocytic ehrlichiosis, hepatitis viruses, herpes, herpes viruses, HIV, hypercapnea, hyperinflation, hyperoxia-induced inflammation, hypoxia, hypersensitivity, hypoxemia, inflammatory bowel disease, interstitial pneumonitis, ischemia reperfusion injury, kaposi's sarcoma associated virus, lupus, malaria, meningitis, multi-organ dysfunction, necrotizing enterocolitis, osteoporosis, chronic periodontitis, periodontitis, peritonitis associated with continuos ambulatory peritoneal dialysis (CAPD), pre-term labor, polymyositis, post surgical trauma, pruritis, psoriasis, psoriatic arthritis, pulmatory fibrosis, pulmatory hypertension, renal reperfusion injury, respiratory viruses, restinosis, right ventricular hypertrophy, sarcoidosis, septic shock, small airway disease, sprains, strains, subarachnoid hemorrhage, surgical lung volume reduction, thrombosis, toxic shock syndrome, transplant reperfusion injury, traumatic brain injury, ulcerative colitis, vasculitis, ventilation-perfusion mismatching, and wheeze.
Another aspect of the invention relates to a pharmaceutical composition comprising:
A) an effective amount of a compound according to any of the above or below embodiments;
B) a pharmaceutically acceptable carrier; and
C) a drug, agent or therapeutic selected from: (a) a disease modifying antirheumatic drug; (b) a nonsteroidal anti-inflammatory drug; (c) a COX-2 selective inhibitor; (d) a COX-1 inhibitor; (e) an immunosuppressive; (f) a steroid; (g) a biological response modifier; (h) a viscosupplement; (i) a pain reducing drug; and (j) a small molecule inhibitor of pro-inflammatory cytokine production.
Another aspect of the invention relates to the use of a compound according to any of the above or below embodiments in the manufacture of a medicament for treating a metalloprotease mediated disease.
Another aspect of the invention relates to the use of a compound according to any of the above or below embodiments in conjunction with a drug, agent or therapeutic selected from: (a) a disease modifying antirheumatic drug; (b) a nonsteroidal anti-inflammatory drug; (c) a COX-2 selective inhibitor; (d) a COX-1 inhibitor; (e) an immunosuppressive; (f) a steroid; (g) a biological response modifier; (h) a viscosupplement; (i) a pain reducing drug; and (j) a small molecule inhibitor of pro-inflammatory cytokine production, in the manufacture of a medicament for treating a metalloprotease mediated disease.
The terms “alkyl” or “alk”, as used herein alone or as part of another group, denote optionally substituted, straight and branched chain saturated hydrocarbon groups, preferably having 1 to 10 carbons in the normal chain, most preferably lower alkyl groups. Exemplary unsubstituted such groups include methyl, ethyl, propyl, isopropyl, n-butyl, t-butyl, isobutyl, pentyl, hexyl, isohexyl, heptyl, 4,4-dimethylpentyl, octyl, 2,2,4-trimethylpentyl, nonyl, decyl, undecyl, dodecyl and the like. Exemplary substituents may include, but are not limited to, one or more of the following groups: halo, alkoxy, alkylthio, alkenyl, alkynyl, aryl (e.g., to form a benzyl group), cycloalkyl, cycloalkenyl, hydroxy or protected hydroxy, carboxyl (—COOH), alkyloxycarbonyl, alkylcarbonyloxy, alkylcarbonyl, carbamoyl (NH 2 —CO—), substituted carbamoyl ((R 10 )(R 11 )N—CO— wherein R 10 or R 11 are as defined below, except that at least one of R 10 or R 11 is not hydrogen), amino, heterocyclo, mono- or dialkylamino, or thiol (—SH).
The terms “lower alk” or “lower alkyl” as used herein, denote such optionally substituted groups as described above for alkyl having 1 to 4 carbon atoms in the normal chain.
The term “alkoxy” denotes an alkyl group as described above bonded through an oxygen linkage (—O—).
The term “alkenyl”, as used herein alone or as part of another group, denotes optionally substituted, straight and branched chain hydrocarbon groups containing at least one carbon to carbon double bond in the chain, and preferably having 2 to 10 carbons in the normal chain. Exemplary unsubstituted such groups include ethenyl, propenyl, isobutenyl, butenyl, pentenyl, hexenyl, heptenyl, octenyl, nonenyl, decenyl, and the like. Exemplary substituents may include, but are not limited to, one or more of the following groups: halo, alkoxy, alkylthio, alkyl, alkynyl, aryl, cycloalkyl, cycloalkenyl, hydroxy or protected hydroxy, carboxyl (—COOH), alkyloxycarbonyl, alkylcarbonyloxy, alkylcarbonyl, carbamoyl (NH 2 —CO—), substituted carbamoyl ((R 10 )(R 11 )N—CO— wherein R 10 or R 11 are as defined below, except that at least one of R 10 or R 11 is not hydrogen), amino, heterocyclo, mono- or dialkylamino, or thiol (—SH).
The term “alkynyl”, as used herein alone or as part of another group, denotes optionally substituted, straight and branched chain hydrocarbon groups containing at least one carbon to carbon triple bond in the chain, and preferably having 2 to 10 carbons in the normal chain. Exemplary unsubstituted such groups include, but are not limited to, ethynyl, propynyl, butynyl, pentynyl, hexynyl, heptynyl, octynyl, nonynyl, decynyl, and the like. Exemplary substituents may include, but are not limited to, one or more of the following groups: halo, alkoxy, alkylthio, alkyl, alkenyl, aryl, cycloalkyl, cycloalkenyl, hydroxy or protected hydroxy, carboxyl (—COOH), alkyloxycarbonyl, alkylcarbonyloxy, alkylcarbonyl, carbamoyl (NH 2 —CO—), substituted carbamoyl ((R 10 )(R 11 )N—CO— wherein R 10 or R 11 are as defined below, except that at least one of R 10 or R 11 is not hydrogen), amino, heterocyclo, mono- or dialkylamino, or thiol (—SH).
The term “cycloalkyl”, as used herein alone or as part of another group, denotes optionally substituted, saturated cyclic hydrocarbon ring systems, desirably containing one ring with 3 to 9 carbons. Exemplary unsubstituted such groups include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclodecyl, and cyclododecyl. Exemplary substituents include, but are not limited to, one or more alkyl groups as described above, or one or more groups described above as alkyl substituents.
The term “bicycloalkyl”, as used herein alone or as part of another group, denotes optionally substituted, saturated cyclic bridged hydrocarbon ring systems, desirably containing 2 or 3 rings and 3 to 9 carbons per ring. Exemplary unsubstituted such groups include, but are not limited to, adamantyl, bicyclo[2.2.2]octane, bicyclo[2.2.1]heptane and cubane. Exemplary substituents include, but are not limited to, one or more alkyl groups as described above, or one or more groups described above as alkyl substituents.
The term “spiroalkyl”, as used herein alone or as part of another group, denotes optionally substituted, saturated hydrocarbon ring systems, wherein two rings of 3 to 9 carbons per ring are bridged via one carbon atom. Exemplary unsubstituted such groups include, but are not limited to, spiro[3.5]nonane, spiro[4.5]decane or spiro[2.5]octane. Exemplary substituents include, but are not limited to, one or more alkyl groups as described above, or one or more groups described above as alkyl substituents.
The term “spiroheteroalkyl”, as used herein alone or as part of another group, denotes optionally substituted, saturated hydrocarbon ring systems, wherein two rings of 3 to 9 carbons per ring are bridged via one carbon atom and at least one carbon atom is replaced by a heteroatom independently selected from N, O and S. The nitrogen and sulfur heteroatoms may optionally be oxidized. Exemplary unsubstituted such groups include, but are not limited to, 1,3-diaza-spiro[4.5]decane-2,4-dione. Exemplary substituents include, but are not limited to, one or more alkyl groups as described above, or one or more groups described above as alkyl substituents.
The terms “ar” or “aryl”, as used herein alone or as part of another group, denote optionally substituted, homocyclic aromatic groups, preferably containing 1 or 2 rings and 6 to 12 ring carbons. Exemplary unsubstituted such groups include, but are not limited to, phenyl, biphenyl, and naphthyl. Exemplary substituents include, but are not limited to, one or more nitro groups, alkyl groups as described above or groups described above as alkyl substituents.
The term “heterocycle” or “heterocyclic system” denotes a heterocyclyl, heterocyclenyl, or heteroaryl group as described herein, which contains carbon atoms and from 1 to 4 heteroatoms independently selected from N, O and S and including any bicyclic or tricyclic group in which any of the above-defined heterocyclic rings is fused to one or more heterocycle, aryl or cycloalkyl groups. The nitrogen and sulfur heteroatoms may optionally be oxidized. The heterocyclic ring may be attached to its pendant group at any heteroatom or carbon atom which results in a stable structure. The heterocyclic rings described herein may be substituted on carbon or on a nitrogen atom.
Examples of heterocycles include, but are not limited to, 1H-indazole, 2-pyrrolidonyl, 2H,6H-1,5,2-dithiazinyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazole, 4H-quinolizinyl, 6H-1,2,5-thiadiazinyl, acridinyl, azocinyl, benzimidazolyl, benzofuranyl, benzothiofuranyl, benzothiophenyl, benzoxazolinyl, benzoxazolyl, benzthiazolyl, benztriazolyl, benztetrazolyl, benzisoxazolyl, benzisothiazolyl, benzimidazalonyl, carbazolyl, 4aH-carbazolyl, b-carbolinyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, 2H,6H-1,5,2-dithiazinyl, dihydrofuro[2,3-b]tetrahydrofuran, furanyl, furazanyl, imidazolidinyl, imidazolinyl, imidazolyl, 1H-indazolyl, indolenyl, indolinyl, indolizinyl, indolyl, isatinoyl, isobenzofuranyl, isochromanyl, isoindazolyl, isoindolinyl, isoindolyl, isoquinolinyl, isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxadiazolyl, 1,2,3-oxadiazolyl, 1,2,4-oxadiazolyl, 1,2,5-oxadiazolyl, 1,3,4-oxadiazolyl, oxazolidinyl, oxazolyl, oxazolidinylperimidinyl, oxindolyl, phenanthridinyl, phenanthrolinyl, phenarsazinyl, phenazinyl, phenothiazinyl, phenoxathiinyl, phenoxazinyl, phthalazinyl, piperazinyl, piperidinyl, pteridinyl, piperidonyl, 4-piperidonyl, pteridinyl, purinyl, pyranyl, pyrazinyl, pyrazolidinyl, pyrazolinyl, pyrazolyl, pyridazinyl, pyridooxazole, pyridoimidazole, pyridothiazole, pyridinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, 4H-quinolizinyl, quinoxalinyl, quinuclidinyl, carbolinyl, tetrahydrofuranyl, tetrahydroisoquinolinyl, tetrahydroquinolinyl, tetrazolyl, 6H-1,2,5-thiadiazinyl, 1,2,3-thiadiazolyl, 1,2,4-thiadiazolyl, 1,2,5-thiadiazolyl, 1,3,4-thiadiazolyl, thianthrenyl, thiazolyl, thienyl, thienothiazolyl, thienooxazolyl, thienoimidazolyl, thiophenyl, triazinyl, 1,2,3-triazolyl, 1,2,4-triazolyl, 1,2,5-triazolyl, 1,3,4-triazolyl, xanthenyl.
Further examples of heterocycles include, but not are not limited to, “heterobicycloalkyl” groups such as 7-oxa-bicyclo[2.2.1]heptane, 7-aza-bicyclo[2.2.1]heptane, and 1-aza-bicyclo[2.2.2]octane.
“Heterocyclenyl” denotes a non-aromatic monocyclic or multicyclic hydrocarbon ring system of about 3 to about 10 atoms, desirably about 4 to about 8 atoms, in which one or more of the carbon atoms in the ring system is/are hetero element(s) other than carbon, for example nitrogen, oxygen or sulfur atoms, and which contains at least one carbon-carbon double bond or carbon-nitrogen double bond. Ring sizes of rings of the ring system may include 5 to 6 ring atoms. The designation of the aza, oxa or thia as a prefix before heterocyclenyl define that at least a nitrogen, oxygen or sulfur atom is present respectively as a ring atom. The heterocyclenyl may be optionally substituted by one or more substituents as defined herein. The nitrogen or sulphur atom of the heterocyclenyl may also be optionally oxidized to the corresponding N-oxide, S-oxide or S,S-dioxide. “Heterocyclenyl” as used herein includes by way of example and not limitation those described in Paquette, Leo A.; “Principles of Modern Heterocyclic Chemistry” (W. A. Benjamin, New York, 1968), particularly Chapters 1, 3, 4, 6, 7, and 9; “The Chemistry of Heterocyclic Compounds, A series of Monographs” (John Wiley & Sons, New York, 1950 to present), in particular Volumes 13, 14, 16, 19, and 28; and “J. Am. Chem. Soc.”, 82:5566 (1960), the contents all of which are incorporated by reference herein. Exemplary monocyclic azaheterocyclenyl groups include, but are not limited to, 1,2,3,4-tetrahydrohydropyridine, 1,2-dihydropyridyl, 1,4-dihydropyridyl, 1,2,3,6-tetrahydropyridine, 1,4,5,6-tetrahydropyrimidine, 2-pyrrolinyl, 3-pyrrolinyl, 2-imidazolinyl, 2-pyrazolinyl, and the like. Exemplary oxaheterocyclenyl groups include, but are not limited to, 3,4-dihydro-2H-pyran, dihydrofuranyl, and fluorodihydrofuranyl. An exemplary multicyclic oxaheterocyclenyl group is 7-oxabicyclo[2.2.1]heptenyl.
“Heterocyclyl,” or “heterocycloalkyl,” denotes a non-aromatic saturated monocyclic or multicyclic ring system of about 3 to about 10 carbon atoms, desirably 4 to 8 carbon atoms, in which one or more of the carbon atoms in the ring system is/are hetero element(s) other than carbon, for example nitrogen, oxygen or sulfur. Ring sizes of rings of the ring system may include 5 to 6 ring atoms. The designation of the aza, oxa or thia as a prefix before heterocyclyl define that at least a nitrogen, oxygen or sulfur atom is present respectively as a ring atom. The heterocyclyl may be optionally substituted by one or more substituents which may be the same or different, and are as defined herein. The nitrogen or sulphur atom of the heterocyclyl may also be optionally oxidized to the corresponding N-oxide, S-oxide or S,S-dioxide.
“Heterocyclyl” as used herein includes by way of example and not limitation those described in Paquette, Leo A.; “Principles of Modern Heterocyclic Chemistry” (W. A. Benjamin, New York, 1968), particularly Chapters 1, 3, 4, 6, 7, and 9; “The Chemistry of Heterocyclic Compounds, A series of Monographs” (John Wiley & Sons, New York, 1950 to present), in particular Volumes 13, 14, 16, 19, and 28; and “J. Am. Chem. Soc.”, 82:5566 (1960). Exemplary monocyclic heterocyclyl rings include, but are not limited to, piperidyl, pyrrolidinyl, piperazinyl, morpholinyl, thiomorpholinyl, thiazolidinyl, 1,3-dioxolanyl, 1,4-dioxanyl, tetrahydrofuranyl, tetrahydrothiophenyl, tetrahydrothiopyranyl, and the like.
“Heteroaryl” denotes an aromatic monocyclic or multicyclic ring system of about 5 to about 10 atoms, in which one or more of the atoms in the ring system is/are hetero element(s) other than carbon, for example nitrogen, oxygen or sulfur. Ring sizes of rings of the ring system include 5 to 6 ring atoms. The “heteroaryl” may also be substituted by one or more substituents which may be the same or different, and are as defined herein. The designation of the aza, oxa or thia as a prefix before heteroaryl define that at least a nitrogen, oxygen or sulfur atom is present respectively as a ring atom. A nitrogen atom of a heteroaryl may be optionally oxidized to the corresponding N-oxide. Heteroaryl as used herein includes by way of example and not limitation those described in Paquette, Leo A.; “Principles of Modern Heterocyclic Chemistry” (W. A. Benjamin, New York, 1968), particularly Chapters 1, 3, 4, 6, 7, and 9; “The Chemistry of Heterocyclic Compounds, A series of Monographs” (John Wiley & Sons, New York, 1950 to present), in particular Volumes 13, 14, 16, 19, and 28; and “J. Am. Chem. Soc.”, 82:5566 (1960). Exemplary heteroaryl and substituted heteroaryl groups include, but are not limited to, pyrazinyl, thienyl, isothiazolyl, oxazolyl, pyrazolyl, furazanyl, pyrrolyl, 1,2,4-thiadiazolyl, pyridazinyl, quinoxalinyl, phthalazinyl, imidazo[1,2-a]pyridine, imidazo[2,1-b]thiazolyl, benzofurazanyl, azaindolyl, benzimidazolyl, benzothienyl, thienopyridyl, thienopyrimidyl, pyrrolopyridyl, imidazopyridyl, benzoazaindole, 1,2,3-triazinyl, 1,2,4-triazinyl, 1,3,5-triazinyl, benzthiazolyl, dioxolyl, furanyl, imidazolyl, indolyl, indolizinyl, isoxazolyl, isoquinolinyl, isothiazolyl, oxadiazolyl, oxazinyl, oxiranyl, piperazinyl, piperidinyl, pyranyl, pyrazinyl, pyridazinyl, pyrazolyl, pyridyl, pyrimidinyl, pyrrolyl, pyrrolidinyl, quinazolinyl, quinolinyl, tetrazinyl, tetrazolyl, 1,3,4-thiadiazolyl, 1,2,3-thiadiazolyl, 1,2,4-thiadiazolyl, 1,2,5-thiadiazolyl, thiatriazolyl, thiazinyl, thiazolyl, thienyl, 5-thioxo-1,2,4-diazolyl, thiomorpholino, thiophenyl, thiopyranyl, triazolyl and triazolonyl.
The phrase “fused” means, that the group, mentioned before “fused” is connected via two adjacent atoms to the ring system mentioned after “fused” to form a bicyclic system. For example, “heterocycloalkyl fused aryl” includes, but is not limited to, 2,3-dihydro-benzo[1,4]dioxine, 4H-benzo[1,4]oxazin-3-one, 3H-Benzooxazol-2-one and 3,4-dihydro-2H-benzo [f][1,4]oxazepin-5-one.
The term “amino” denotes the radical —NH 2 wherein one or both of the hydrogen atoms may be replaced by an optionally substituted hydrocarbon group. Exemplary amino groups include, but are not limited to, n-butylamino, tert-butylamino, methylpropylamino and ethyldimethylamino.
The term “cycloalkylalkyl” denotes a cycloalkyl-alkyl group wherein a cycloalkyl as described above is bonded through an alkyl, as defined above. Cycloalkylalkyl groups may contain a lower alkyl moiety. Exemplary cycloalkylalkyl groups include, but are not limited to, cyclopropylmethyl, cyclopentylmethyl, cyclohexylmethyl, cyclopropylethyl, cyclopentylethyl, cyclohexylpropyl, cyclopropylpropyl, cyclopentylpropyl, and cyclohexylpropyl.
The term “arylalkyl” denotes an aryl group as described above bonded through an alkyl, as defined above.
The term “heteroarylalkyl” denotes a heteroaryl group as described above bonded through an alkyl, as defined above.
The term “heterocyclylalkyl,” or “heterocycloalkylalkyl,” denotes a heterocyclyl group as described above bonded through an alkyl, as defined above.
The terms “halogen”, “halo”, or “hal”, as used herein alone or as part of another group, denote chlorine, bromine, fluorine, and iodine.
The term “haloalkyl” denotes a halo group as described above bonded though an alkyl, as defined above. Fluoroalkyl is an exemplary group.
The term “aminoalkyl” denotes an amino group as defined above bonded through an alkyl, as defined above.
The phrase “bicyclic fused ring system wherein at least one ring is partially saturated” denotes an 8- to 13-membered fused bicyclic ring group in which at least one of the rings is non-aromatic. The ring group has carbon atoms and optionally 1-4 heteroatoms independently selected from N, O and S. The nitrogen and sulfur heteroatoms may optionally be oxidized. Illustrative examples include, but are not limited to, indanyl, tetrahydronaphthyl, tetrahydroquinolyl and benzocycloheptyl.
The phrase “tricyclic fused ring system wherein at least one ring is partially saturated” denotes a 9- to 18-membered fused tricyclic ring group in which at least one of the rings is non-aromatic. The ring group has carbon atoms and optionally 1-7 heteroatoms independently selected from N, O and S. The nitrogen and sulfur heteroatoms may optionally, be oxidized. Illustrative examples include, but are not limited to, fluorene, 10,11-dihydro-5H-dibenzo[a,d]cycloheptene and 2,2a,7,7a-tetrahydro-1H-cyclobuta[a]indene.
The phrase “cyclic” denotes to a saturated, partially unsaturated or unsaturated ring group with one ring. The ring group has carbon atoms and optionally 1-10 heteroatoms independently selected from N, O and S. The nitrogen and sulfur heteroatoms may optionally be oxidized. Illustrative examples include, but are not limited to, cyclobutane, cyclohexene, morpholine, tetrahydrofurane, benzene, thiophene, imidazole.
The phrase “biyclic” denotes to a saturated, partially unsaturated or unsaturated ring group with two ring. The ring group has carbon atoms and optionally 1-10 heteroatoms independently selected from N, O and S. The nitrogen and sulfur heteroatoms may optionally be oxidized. The rings may be annulated or otherwise connected, e.g. via a spiro connectivity. Illustrative examples include, but are not limited to, indane, tetrahydronaphthalin, tetrahydroquinoline, benzocycloheptane, and 1,3-diaza-spiro[4.5]decane-2,4-dione.
The phrase “multicyclic” denotes to a saturated, partially unsaturated or unsaturated ring group with at least three rings. The ring group has carbon atoms and optionally 1-10 heteroatoms independently selected from N, O and S. The nitrogen and sulfur heteroatoms may optionally be oxidized. The rings may be annulated or otherwise connected, e.g. via a spiro connectivity. Illustrative examples include, but are not limited to, fluorene, adamantyl, bicyclo[2.2.2]octane, bicyclo[2.2.1]heptane, cubane, 10,11-dihydro-5H-dibenzo[a,d]cycloheptene, 2,2a,7,7a-tetrahydro-1H-cyclobuta[a]indene, 5,6,7,8-tetrahydro-benzo[4,5]thieno[2,3-d]pyrimidine, 11-oxa-3,5-diaza-tricyclo[6.2.1.0 2,7 ]undeca-2(7),3,5-triene, 3,5-diaza-tricyclo[6.2.2.0 2,7 ]dodeca-2(7),3-dien-6-one.
The term “pharmaceutically acceptable salts” refers to derivatives of the disclosed compounds wherein the parent compound is modified by making acid or base salts thereof. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of basic residues such as amines; alkali or organic salts of acidic residues such as carboxylic acids; and the like. Examples therefore may be, but are not limited to, sodium, potassium, choline, lysine, arginine or N-methyl-glucamine salts, and the like.
The pharmaceutically acceptable salts include the conventional non-toxic salts or the quaternary ammonium salts of the parent compound formed, for example, from non-toxic inorganic or organic acids. For example, such conventional non-toxic salts include those derived from inorganic acids such as, but not limited to, hydrochloric, hydrobromic, sulfuric, sulfamic, phosphoric, nitric and the like; and the salts prepared from organic acids such as, but not limited to, acetic, propionic, succinic, glycolic, stearic, lactic, malic, tartaric, citric, ascorbic, pamoic, maleic, hydroxymaleic, phenylacetic, glutamic, benzoic, salicylic, sulfanilic, 2-acetoxybenzoic, fumaric, toluenesulfonic, methanesulfonic, ethane disulfonic, oxalic, isethionic, and the like.
The pharmaceutically acceptable salts of the present invention can be synthesized from the parent compound which contains a basic or acidic moiety by conventional chemical methods. Generally, such salts can be prepared by reacting the free acid or base forms of these compounds with a stoichiometric amount of the appropriate base or acid in water or in an organic solvent, or in a mixture of the two. Organic solvents include, but are not limited to, nonaqueous media like ethers, ethyl acetate, ethanol, isopropanol, or acetonitrile. Lists of suitable salts are found in Remington's Pharmaceutical Sciences, 18th ed., Mack Publishing Company, Easton, Pa., 1990, p. 1445, the disclosure of which is hereby incorporated by reference.
The phrase “pharmaceutically acceptable” denotes those compounds, materials, compositions, and/or dosage forms which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of human beings and animals without excessive toxicity, irritation, allergic response, or other problem or complication commensurate with a reasonable benefit/risk ratio.
The phrase “pharmaceutically acceptable carrier” denotes media generally accepted in the art for the delivery of biologically active agents to mammals, e.g., humans. Such carriers are generally formulated according to a number of factors well within the purview of those of ordinary skill in the art to determine and account for. These include, without limitation: the type and nature of the active agent being formulated; the subject to which the agent-containing composition is to be administered; the intended route of administration of the composition; and, the therapeutic indication being targeted. Pharmaceutically acceptable carriers include both aqueous and non-aqueous liquid media, as well as a variety of solid and semi-solid dosage forms. Such carriers can include a number of different ingredients and additives in addition to the active agent, such additional ingredients being included in the formulation for a variety of reasons, e.g., stabilization of the active agent, well known to those of ordinary skill in the art. Non-limiting examples of a pharmaceutically acceptable carrier are hyaluronic acid and salts thereof, and microspheres (including, but not limited to poly(D,L)-lactide-co-glycolic acid copolymer (PLGA), poly(L-lactic acid) (PLA), poly(caprolactone (PCL) and bovine serum albumin (BSA)). Descriptions of suitable pharmaceutically acceptable carriers, and factors involved in their selection, are found in a variety of readily available sources, e.g., Remington's Pharmaceutical Sciences, 17th ed., Mack Publishing Company, Easton, Pa., 1985, the contents of which are incorporated herein by reference.
Pharmaceutically acceptable carriers particularly suitable for use in conjunction with tablets include, for example, inert diluents, such as celluloses, calcium or sodium carbonate, lactose, calcium or sodium phosphate; disintegrating agents, such as croscarmellose sodium, cross-linked povidone, maize starch, or alginic acid; binding agents, such as povidone, starch, gelatin or acacia; and lubricating agents, such as magnesium stearate, stearic acid or talc. Tablets may be uncoated or may be coated by known techniques including microencapsulation to delay disintegration and adsorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate alone or with a wax may be employed.
Formulations for oral use may be also presented as hard gelatin capsules where the active ingredient is mixed with an inert solid diluent, for example celluloses, lactose, calcium phosphate or kaolin, or as soft gelatin capsules wherein the active ingredient is mixed with non-aqueous or oil medium, such as glycerin, propylene glycol, polyethylene glycol, peanut oil, liquid paraffin or olive oil.
The compositions of the invention may also be formulated as suspensions including a compound of the present invention in admixture with at least one pharmaceutically acceptable excipient suitable for the manufacture of a suspension. In yet another embodiment, pharmaceutical compositions of the invention may be formulated as dispersible powders and granules suitable for preparation of a suspension by the addition of suitable excipients.
Carriers suitable for use in connection with suspensions include suspending agents, such as sodium carboxymethylcellulose, methylcellulose, hydroxypropyl methylcelluose, sodium alginate, polyvinylpyrrolidone, gum tragacanth, gum acacia, dispersing or wetting agents such as a naturally occurring phosphatide (e.g., lecithin), a condensation product of an alkylene oxide with a fatty acid (e.g., polyoxyethylene stearate), a condensation product of ethylene oxide with a long chain aliphatic alcohol (e.g., heptadecaethyleneoxycethanol), a condensation product of ethylene oxide with a partial ester derived from a fatty acid and a hexitol anhydride (e.g., polyoxyethylene sorbitan monooleate); and thickening agents, such as carbomer, beeswax, hard paraffin or cetyl alcohol. The suspensions may also contain one or more preservatives such as acetic acid, methyl and/or n-propyl p-hydroxy-benzoate; one or more coloring agents; one or more flavoring agents; and one or more sweetening agents such as sucrose or saccharin.
Cyclodextrins may be added as aqueous solubility enhancers. Preferred cyclodextrins include hydroxypropyl, hydroxyethyl, glucosyl, maltosyl and maltotriosyl derivatives of α-, β-, and γ-cyclodextrin. The amount of solubility enhancer employed will depend on the amount of the compound of the present invention in the composition.
The term “formulation” denotes a product comprising the active ingredient(s) and the inert ingredient(s) that make up the carrier, as well as any product which results, directly or indirectly, from combination, complexation or aggregation of any two or more of the ingredients, or from dissociation of one or more of the ingredients, or from other types of reactions or interactions of one or more of the ingredients. Accordingly, the pharmaceutical formulations of the present invention encompass any composition made by admixing a compound of the present invention and a pharmaceutical carrier.
The term “N-oxide” denotes compounds that can be obtained in a known manner by reacting a compound of the present invention including a nitrogen atom (such as in a pyridyl group) with hydrogen peroxide or a peracid, such as 3-chloroperoxy-benzoic acid, in an inert solvent, such as dichloromethane, at a temperature between about −10° C. to 80° C., desirably about 0° C.
The term “polymorph” denotes a form of a chemical compound in a particular crystalline arrangement. Certain polymorphs may exhibit enhanced thermodynamic stability and may be more suitable than other polymorphic forms for inclusion in pharmaceutical formulations.
The compounds of the invention can contain one or more chiral centers and/or double bonds and, therefore, exist as stereoisomers, such as double-bond isomers (i.e., geometric isomers), enantiomers, or diastereomers. According to the invention, the chemical structures depicted herein, and therefore the compounds of the invention, encompass all of the corresponding enantiomers and stereoisomers, that is, both the stereomerically pure form (e.g., geometrically pure, enantiomerically pure, or diastereomerically pure) and enantiomeric and stereoisomeric mixtures.
The term “racemic mixture” denotes a mixture that is about 50% of one enantiomer and about 50% of the corresponding enantiomer relative to all chiral centers in the molecule. Thus, the invention encompasses all enantiomerically-pure, enantiomerically-enriched, and racemic mixtures of compounds of Formula (I).
Enantiomeric and stereoisomeric mixtures of compounds of the invention can be resolved into their component enantiomers or stereoisomers by well-known methods. Examples include, but are not limited to, the formation of chiral salts and the use of chiral or high performance liquid chromatography “HPLC” and the formation and crystallization of chiral salts. See, e.g., Jacques, J., et al., Enantiomers, Racemates and Resolutions (Wiley-Interscience, New York, 1981); Wilen, S. H., et al., Tetrahedron 33:2725 (1977); Eliel, E. L., Stereochemistry of Carbon Compounds (McGraw-Hill, NY, 1962); Wilen, S. H., Tables of Resolving Agents and Optical Resolutions p. 268 (E. L. Eliel, Ed., Univ. of Notre Dame Press, Notre Dame, Ind., 1972); Stereochemistry of Organic Compounds, Ernest L. Eliel, Samuel H. Wilen and Lewis N. Manda (1994 John Wiley & Sons, Inc.), and Stereoselective Synthesis A Practical Approach, Mihaly Nogradi (1995 VCH Publishers, Inc., NY, N.Y.). Enantiomers and stereoisomers can also be obtained from stereomerically- or enantiomerically-pure intermediates, reagents, and catalysts by well-known asymmetric synthetic methods.
“Substituted” is intended to indicate that one or more hydrogens on the atom indicated in the expression using “substituted” is replaced with a selection from the indicated group(s), provided that the indicated atom's normal valency is not exceeded, and that the substitution results in a stable compound. When a substituent is keto (i.e., ═O) group, then two hydrogens on the atom are replaced. Furthermore two hydrogens on the atom can be replaced to form a thiocarbonyl (i.e., ═S) or ═N—NO 2 , ═N—CN, ═N—H, ═N—(C 1 -C 4 )alkyl, ═N—OH, ═N—O(C 1 -C 4 )alkyl, ═N—CO(C 1 -C 4 )alkyl, and ═N—SO 2 (C 1 -C 4 )alkyl.
Unless moieties of a compound of the present invention are defined as being unsubstituted, the moieties of the compound may be substituted. In addition to any substituents provided above, the moieties of the compounds of the present invention may be optionally substituted with one or more groups independently selected from:
B(OH) 2 ;
B(O—(C 1 -C)alkyl) 2 ;
C 1 -C 4 alkyl;
C 2 -C 4 alkenyl;
C 2 -C 4 alkynyl;
CF 3 ;
halo;
OH;
O—(C 1 -C 4 alkyl);
OCH 2 F;
OCHF 2 ;
OCF 3 ;
ONO 2 ;
OC(O)—(C 1 -C 4 alkyl);
OC(O)—(C 1 -C 4 alkyl);
OC(O)NH—(C 1 -C 4 alkyl);
OC(O)N(C 1 -C 4 alkyl) 2 ;
OC(S)NH—(C 1 -C 4 alkyl);
OC(S)N(C 1 -C 4 alkyl) 2 ;
SH;
S—(C 1 -C 4 alkyl);
S(O)—(C 1 -C 4 alkyl);
S(O) 2 —(C 1 -C 4 alkyl);
SC(O)—(C 1 -C 4 alkyl);
SC(O)O—(C 1 -C 4 alkyl);
NH 2 ;
N(H)—(C 1 -C 4 alkyl);
N(C 1 -C 4 alkyl) 2 ;
N(H)C(O)—(C 1 -C 4 alkyl);
N(CH 3 )C(O)—(C 1 -C 4 alkyl);
N(H)C(O)—CF 3 ;
N(CH 3 )C(O)—CF 3 ;
N(H)C(S)—(C 1 -C 4 alkyl);
N(CH 3 )C(S)—(C 1 -C 4 alkyl);
N(H)S(O) 2 —(C 1 -C 4 alkyl);
N(H)C(O)NH 2 ;
N(H)C(O)NH—(C 1 -C 4 alkyl);
N(CH 3 )C(O)NH—(C 1 -C 4 alkyl);
N(H)C(O)N(C 1 -C 4 alkyl) 2 ;
N(CH 3 )C(O)N(C 1 -C 4 alkyl) 2 ;
N(H)S(O) 2 NH 2 );
N(H)S(O) 2 NH—(C 1 -C 4 alkyl);
N(CH 3 )S(O) 2 NH—(C 1 -C 4 alkyl);
N(H)S(O) 2 N(C 1 -C 4 alkyl) 2 ;
N(CH 3 )S(O) 2 N(C 1 -C 4 alkyl) 2 ;
N(H)C(O)O—(C 1 -C 4 alkyl);
N(CH 3 )C(O)O—(C 1 -C 4 alkyl);
N(H)S(O) 2 O—(C 1 -C 4 alkyl);
N(CH 3 )S(O) 2 O—(C 1 -C 4 alkyl);
N(CH 3 )C(S)NH—(C 1 -C 4 alkyl);
N(CH 3 )C(S)N(C 1 -C 4 alkyl) 2 ;
N(CH 3 )C(S)O—(C 1 -C 4 alkyl);
N(H)C(S)NH 2 ;
NO 2 ;
CO 2 H;
CO 2 —(C 1 -C 4 alkyl);
C(O)N(H)OH;
C(O)N(CH 3 )OH:
C(O)N(CH 3 )OH;
C(O)N(CH 3 )O—(C 1 -C 4 alkyl);
C(O)N(H)—(C 1 -C 4 alkyl);
C(O)N(C 1 -C 4 alkyl) 2 ;
C(S)N(H)—(C 1 -C 4 alkyl);
C(S)N(C 1 -C 4 alkyl) 2 ;
C(NH)N(H)—(C 1 -C 4 alkyl);
C(NH)N(C 1 -C 4 alkyl) 2 ;
C(NCH 3 )N(H)—(C 1 -C 4 alkyl);
C(NCH 3 )N(C 1 -C 4 alkyl) 2 ;
C(O)—(C 1 -C 4 alkyl);
C(NH)—(C 1 -C 4 alkyl);
C(NCH 3 )—(C 1 -C 4 alkyl);
C(NOH)—(C 1 -C 4 alkyl);
C(NOCH 3 )—(C 1 -C 4 alkyl);
CN;
CHO;
CH 2 OH;
CH 2 O—(C 1 -C 4 alkyl);
CH 2 NH 2 ;
CH 2 N(H)—(C 1 -C 4 alkyl);
CH 2 N(C 1 -C 4 alkyl) 2 ;
aryl;
heteroaryl;
cycloalkyl; and
heterocyclyl.
In some cases, a ring substituent may be shown as being connected to the ring by a bond extending from the center of the ring. The number of such substituents present on a ring is indicated in subscript by a number. Moreover, the substituent may be present on any available ring atom, the available ring atom being any ring atom which bears a hydrogen which the ring substituent may replace. For illustrative purposes, if variable R X were defined as being:
this would indicate a cyclohexyl ring bearing five R X substituents. The R X substituents may be bonded to any available ring atom. For example, among the configurations encompassed by this are configurations such as:
These configurations are illustrative and are not meant to limit the scope of the invention in any way.
When cyclic ring systems are illustrated with cycles or fragment of cycles in the formula, it is meant that the bridge atom connecting the cyclic ring systems with an the substituent (e.g. another ring) can be a carbon or nitrogen atom. For illustrative purposes, if the fragment Q X were defined as being a ring, wherein two adjacent atoms are substituted to form an additional 6-membered ring:
this would indicate that e.g. the following structures are possible:
Biological Activity
The inhibiting activity towards different metalloproteases of the heterocyclic metalloprotease inhibiting compounds of the present invention may be measured using any suitable assay known in the art. A standard in vitro assay for measuring the metalloprotease inhibiting activity is described in Examples 1700 to 1704.
The heterocyclic metalloprotease inhibiting compounds of the invention have an MMP-13 inhibition activity (IC 50 MMP-13) ranging from below 0.1 nM to about 20 μM, and typically, from about 1 nM to about 1 μM. Heterocyclic metalloprotease inhibiting compounds of the invention desirably have an MMP inhibition activity ranging from below 0.2 nM to about 20 nM. Examples of heterocyclic metalloprotease inhibiting compounds of the invention that have an MMP-13 activity lower than 100 nM are Example 1, 1/1 and 1/4. An Examples ranging from 100 nM to 20 μM is Example 1/2.
The synthesis of metalloprotease inhibiting compounds of the invention and their biological activity assay are described in the following examples which are not intended to be limiting in any way.
General
Suitable cyclic systems Q 2 in Formula (I) can be prepared as described previously in our company, e.g. WO2006/128184 or US2007/0155738. They can be coupled e.g. via the standard EDCI/HOAt/base procedure to the amine building blocks described below.
EXAMPLES AND METHODS
All reagents and solvents were obtained from commercial sources and used without further purification. Proton spectra ( 1 H-NMR) were recorded on a 250 MHz NMR spectrometer in deuterated solvents. Purification by column chromatography was performed using silica gel, grade 60, 0.06-0.2 mm (chromatography) or silica gel, grade 60, 0.04-0.063 mm (flash chromatography) and suitable organic solvents as indicated in specific examples. Preparative thin layer chromatography was carried out on silica gel plates with UV detection.
Preparative Examples are directed to intermediate compounds useful in preparing the compounds of the present invention.
Preparative Example 1
Step A
To a solution of the starting material (380 mg) (synthesis as described in WO2006/128184) in dry THF was added Lawesson's reagent (660 mg) and the mixture was stirred for 4 h and then concentrated. The remaining residue was dissolved in EtOAc, washed subsequently with 10% aqueous citric acid, saturated aqueous NaHCO 3 and brine, dried (MgSO 4 ), filtered, concentrated and purified by chromatography (silica, cyclohexane/EtOAc 85:15 to 8:2) to afford the title compound as a colourless solid (312 mg, 78%). [MNa] + =317.
Preparative Example 1a
Following a similar procedure as described in the Preparative Example 1, except using the educt indicated in Table I.1 below, the following compound was prepared.
TABLE I.1
Prep. Ex. #
educt
product
yield
1a
87% [MH] + = 244/46
Preparative Example 2
Step A
To an ice cooled solution of the title compound from Preparative Example 9 (100 mg) in dry MeOH were added di-tert-butyl dicarbonate (300 mg) and NiCl 2 .6H 2 O (20 mg), followed by the careful portionwise addition of NaBH 4 (120 mg). The resulting black mixture was stirred for 10 min at 0-5° C. (ice bath), then the ice bath was removed and stirring at room temperature was continued for 2 h. Then diethylenetriamine was added and the mixture was concentrated to dryness. The remaining residue was suspended in EtOAc, washed subsequently with 10% aqueous citric acid, saturated aqueous NaHCO 3 and brine, dried (MgSO 4 ), filtered, concentrated and purified by flash chromatography (CH 2 Cl 2 /MeOH 95:5 to 9:1) to afford the title compound as a colourless solid. [MNa] + =324.
Step B
The title compound from the Step A above was stirred in a 4M solution of HCl in 1,4-dioxane (10 mL) at room temperature for 4 h and then concentrated to afford the title compound (79 mg, 66% over two steps) as a colourless solid. [M-NH 2 C] + =186, [M-Cl] + =203.
Preparative Example 2a
Following a similar procedure as described in the Preparative Example 2, Step A, except using the educt indicated in Table I.2 below, the following compound was prepared.
TABLE I.2
Prep. Ex. #
educt
product
yield
2a
n.d. [MH] + = 324
Preparative Example 3
Step A
The title compound from Preparative Example 1a (387 mg), 2-aminoethyldimethylacetal (850 mg) in dry methanol (30 mL) was added t butylperoxide (1 mL) and the mixture was stirred for 2 h at room temperature. Then a aqueous solution of sodium sulfite was added and the mixture was concentrated, diluted with ethyl acetate and washed with 1% citric acid and brine. The organic phase was separated, dried, concentrated and used without further purification. [MH] + =315/317
Step B
The title compound from the Step A above was stirred in 3N HCl (20 mL) and isopropanol (60 mL) under reflux for 2 h, evaporated and diluted with water, filtered and dried to afford the title compound (228 mg, 57% over two steps) as an off-white solid, which was used without further purification
Preparative Examples 4a to 4e
Following a similar procedure as described in the Preparative Example 2, Step B except using the educt indicated in Table I.4 below, the following compounds were prepared.
TABLE I.4
Prep. Ex. #
educt
product
yield
4a
quant. [M-Cl] + = 220
4b
quant. [M-Cl] + = 194
4c
quant. [M-Cl] + = 200
4d
quant. [M-Cl] + = 194
4e
n.d. [M-Cl] + = 202
Preparative Example 5
Step A
The title compound from the Preparative Example 1 (123 mg) was treated as described in Monatsh. Chem. 1989, 120, 81-84 to afford the title compound as a colourless solid (120 mg, 89%). [MNa] + =342.
Preparative Example 6
Step A
A suspension of the title compound from Preparative Example 1 (48 mg), cyanamide (80 mg), NEt 3 (20 μL) in dry MeOH (10 mL) was stirred at 60° C. overnight, evaporated, absorbed on silica and purified by flash chromatography (cyclohexane/ethyl acetate 6:4) to give the title compound (41 mg) as a colorless solid. [MNa] + =325.
Preparative Example 7
Step A
A suspension of the title compound from Preparative Example 1 (81 mg), HONH 2 .HCl (60 mg), NEt 3 (100 μL) in dry MeOH (10 mL) was stirred at room temperature overnight, evaporated, diluted with EtOAc and washed with water and brine, dried and evaporated to give the title compound (90 mg, quant.) as a colourless solid. [MNa] + =316.
Preparative Example 8
Step A
A solution of title compound the from Preparative Example 1a above (164 mg) and formylhydrazine (50 mg) in butanol was heated under microwave irradiation to 160° C. for 3 h, absorbed on silica and purified by flash chromatography (silica, CH 2 Cl 2 /methanol 98:2 to 95:5) to afford the title compound as a colourless solid (129 mg, 76%). [MH] + =252/54.
Preparative Example 9
Step A
A mixture of the title compound from the Preparative Example 8 (125 mg), Zn(CN) 2 (44 mg) and Pd(PPh 3 ) 4 (40 mg) in dry DMF (10 mL) was degassed and heated at 85° C. under an argon atmosphere overnight. The mixture was concentrated, diluted with 1N HCl, sonificated, filtered and washed with water, few methanol and then pentane to afford the title compound (100 mg, quant.) as a colourless solid. [MH] + =199.
Examples 9a
Following a similar procedure as described in the Example 9 except using bromide indicated in Table II.9 below, the following compound was prepared.
TABLE II.3
Prep. Ex. #
educt
product
yield
9a
n.d. [MH] + = 198
Example 1
Step, A
To a solution of the acid derivative (38 mg) (synthesis described in WO2006/128184), the amine from the Preparative Example 2, Step B above (25 mg), EDCI (˜2 eq.) and HOAt (1 eq.) in DMF (10 mL) was added N-methylmorpholine (30 μL). The mixture was stirred overnight and then concentrated. The remaining residue was suspended in 10% aqueous citric acid and the residue was filtered to afford the title compound as a yellow solid, which was used without further purification in the next step. [MNa] + =643.
Step B
The intermediate from Step A above was stirred in formic acid for 4 h and then evaporated. The remaining residue was suspended in 10% aqueous citric acid and the residue was filtered to afford the title compound as a yellow solid (37 mg, 75% over two steps). [MH] + =565.
Examples 1/1 to 1/3
Following a similar procedure as described in the Example 3 except using the amines and acids indicated in Table II.1 below, the following compounds were prepared.
TABLE II.1
Ex. #
amine, acid
product
yield
1/1
4% [MH] + = 557
1/2
78% [MH] + = 582
1/3
46% [MH] + = 564
Examples 2/1 to 2/8
If one were to follow a similar procedure as described in the Example 1 except using the amines and acids indicated in Table II.2 below, the following compounds could be prepared.
TABLE II.2
Ex. #
amine, acid
product
2/1
2/2
2/3
2/4
2/5
2/6
2/7
2/8
Examples 3/1 to 3/6
If one were to follow a similar procedure as described in the Example 1, Step A except using the amines and acids indicated in Table II.3 below, the following compounds could be prepared.
TABLE II.3
Ex. #
amine, acid
product
3/1
3/2
3/3
3/4
3/5
3/6
Examples 4/1 to 4/6
If one were to follow a similar procedure as described in the Example 314 in US2007/0155738, except using the ester indicated in Table II.4 below, the following compounds could be prepared.
TABLE II.4
Ex. #
ester
4/1
4/2
4/3
4/4
4/5
4/6
Ex. #
product
4/1
4/2
4/3
4/4
4/5
4/6
Example 1700
Assay for Determining MMP-13 Inhibition
The typical assay for MMP-13 activity is carried out in assay buffer comprised of 50 mM Tris, pH 7.5, 150 mM NaCl, 5 mM CaCl 2 and 0.05% Brij-35. Different concentrations of tested compounds are prepared in assay buffer in 50 μL aliquots. 10 μL of a 50 nM stock solution of catalytic domain of MMP-13 enzyme (produced by Alantos or commercially available from Invitek (Berlin), Cat.# 30100812) is added to the compound solution. The mixture of enzyme and compound in assay buffer is thoroughly mixed and incubated for 10 min at room temperature. Upon the completion of incubation, the assay is started by addition of 40 μL of a 12.5 μM stock solution of MMP-13 fluorescent substrate (Calbiochem, Cat. No. 444235). The time-dependent increase in fluorescence is measured at the 320 nm excitation and 390 nm emission by automatic plate multireader. The IC 50 values are calculated from the initial reaction rates.
Example 1701
Assay for Determining MMP-3 Inhibition
The typical assay for MMP-3 activity is carried out in assay buffer comprised of 50 mM MES, pH 6.0, 10 mM CaCl 2 and 0.05% Brij-35. Different concentrations of tested compounds are prepared in assay buffer in 50 μL aliquots. 10 μL of a 100 nM stock solution of the catalytic domain of MMP-3 enzyme (Biomol, Cat. No. SE-109) is added to the compound solution. The mixture of enzyme and compound in assay buffer is thoroughly mixed and incubated for 10 min at room temperature. Upon the completion of incubation, the assay is started by addition of 40 μL of a 12.5 μM stock solution of NFF-3 fluorescent substrate (Calbiochem, Cat. No. 480455). The time-dependent increase in fluorescence is measured at the 330 nm excitation and 390 nm emission by an automatic plate multireader. The IC 50 values are calculated from the initial reaction rates.
Example 1702
Assay for Determining MMP-8 Inhibition
The typical assay for MMP-8 activity is carried out in assay buffer comprised of 50 mM Tris, pH 7.5, 150 mM NaCl, 5 mM CaCl 2 and 0.05% Brij-35. Different concentrations of tested compounds are prepared in assay buffer in 50 μL aliquots. 10 μL of a 50 nM stock solution of activated MMP-8 enzyme (Calbiochem, Cat. No. 444229) is added to the compound solution. The mixture of enzyme and compound in assay buffer is thoroughly mixed and incubated for 10 min at 37° C. Upon the completion of incubation, the assay is started by addition of 40 μL of a 10 μM stock solution of OmniMMP fluorescent substrate (Biomol, Cat. No. P-126). The time-dependent increase in fluorescence is measured at the 320 nm excitation and 390 nm emission by an automatic plate multireader at 37° C. The IC 50 values are calculated from the initial reaction rates.
Example 1703
Assay for Determining MMP-12 Inhibition
The typical assay for MMP-12 activity is carried out in assay buffer comprised of 50 mM Tris, pH 7.5, 150 mM NaCl, 5 mM CaCl 2 and 0.05% Brij-35. Different concentrations of tested compounds are prepared in assay buffer in 50 μL aliquots. 10 μL of a 50 nM stock solution of the catalytic domain of MMP-12 enzyme (Biomol, Cat. No. SE-138) is added to the compound solution. The mixture of enzyme and compound in assay buffer is thoroughly mixed and incubated for 10 min at room temperature. Upon the completion of incubation, the assay is started by addition of 40 μL of a 12.5 μM stock solution of OmniMMP fluorescent substrate (Biomol, Cat. No. P-126). The time-dependent increase in fluorescence is measured at the 320 nm excitation and 390 nm emission by automatic plate multireader at 37° C. The IC 50 values are calculated from the initial reaction rates.
Example 1704
Assay for Determining Aggrecanase-1 Inhibition
The typical assay for aggrecanase-1 activity is carried out in assay buffer comprised of 50 mM Tris, pH 7.5, 150 mM NaCl, 5 mM CaCl 2 and 0.05% Brij-35. Different concentrations of tested compounds are prepared in assay buffer in 50 μL aliquots. 10 μL of a 75 nM stock solution of aggrecanase-1 (Invitek) is added to the compound solution. The mixture of enzyme and compound in assay buffer is thoroughly mixed. The reaction is started by addition of 40 μL of a 250 nM stock solution of aggrecan-IGD substrate (Invitek) and incubation at 37° C. for exact 15 min. The reaction is stopped by addition of EDTA and the samples are analysed by using aggrecanase ELISA (Invitek, InviLISA, Cat. No. 30510111) according to the protocol of the supplier. Shortly: 100 μL of each proteolytic reaction are incubated in a pre-coated micro plate for 90 min at room temperature. After 3 times washing, antibody-peroxidase conjugate is added for 90 min at room temperature. After 5 times washing, the plate is incubated with TMB solution for 3 min at room temperature. The peroxidase reaction is stopped with sulfurous acid and the absorbance is red at 450 nm. The IC 50 values are calculated from the absorbance signal corresponding to residual aggrecanase activity.
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The present invention relates generally to pharmaceutical agents containing a heterocyclic moiety, and in particular, to heterocyclic metalloprotease inhibiting compounds. More particularly, the present invention provides a new class of heterocyclic MMP-13 inhibiting compounds with a modified benzoxazine moiety, that exhibit an increased potency and selectivity in relation to currently known MMP-13 inhibitors.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. application Ser. No. 13/274,763 filed Oct. 17, 2011, now pending, which is a continuation-in-part of U.S. application Ser. No. 13/006,316 filed Jan. 13, 2011, now U.S. Pat. No. 8,701,261. The entire contents of each of the aforementioned applications are incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates to improved systems and methods for hanging or standing shelving units for a number of applications including without limitation support units for building heating, ventilation, and air conditioning (“HVAC”) systems and components, as well as suspended shelving units for holding, for example, children's games and toys, closet organizers with hangers and shelves, adjustable pipe hangers with preset means to ensure proper drainage pitch, for storage space in a garage or workshop, storage shelves over a garage door, and as a hanging unit for audio/visual equipment.
DESCRIPTION OF RELATED ART
[0003] Interior spaces of homes and other buildings are typically provided with areas for storage and storage solutions which are not adequate for the storage needed in the home or building. Hangers for mounting HVAC units, hanging pipes, and storing other items in a building are known in the prior art. More specifically, by way of example, U.S. PreGrant Publication No. 2007/0145222 to Rausch discloses a method and device for a hanging apparatus that is used to support ductwork, pipes, wiring, conduit and the like from support beams such as I-Joists.
[0004] U.S. Pat. No. 7,596,962 to Karamanos discloses, prior to installation into a HVAC system a fully-functional zone-control unit which also includes a pair of caps which seal the ends of the piping assemblies, and a pressure gauge for sensing pressurization of the piping assemblies and coil which the caps seal. A pressure gauge permits testing to insure that the piping assemblies and coil are leak free.
[0005] U.S. Pat. No. 7,261,256 to Pattie, et al. discloses a variable-duct support assembly for mounting a duct. The variable-duct support assembly includes rails having a groove which has a pair of support brackets for supporting ducts. The support brackets are coupled to one or more flexible bands for clamping the duct between the support brackets and the flexible bands.
[0006] U.S. Pat. No. 7,083,151 to Rapp discloses a laterally-reinforced duct saddle for hanging a length of horizontal flexible duct from a supporting structure. The duct saddle includes a generally flat, elongated blank adapted for bending around and receiving a portion of the flexible duct.
[0007] U.S. Pat. No. 6,866,579 to Pilger discloses a boot hanger mounting bracket assembly formed of a sturdy yet bendable material so that it can be configured and adjusted on-site. Once configured, the boot hanger mounting bracket assembly is secured to the building structure by securing a pair of boot hanger arms to the ceiling joists, wall studs or other support structure to provide a positive inexpensive way to mount the duct components.
[0008] U.S. Pat. No. 6,719,247 to Botting discloses a hanger for seating a flexible duct. The hanger has one end that can be attached to a support structure, such as a beam or joist, and a second end with a cradle for receiving a duct that can be freely seated in the cradle.
[0009] U.S. Pat. No. 5,741,030 to Moore, et al. discloses an air duct starting collar having integral clips used for installation in a planar surface of an air duct. A flange of the device permits variance in hole size, and roughness of the hole's edge.
SUMMARY
[0010] In one aspect, an apparatus is provided for a hanging shelving unit having at least one arm adapted to be attached at its top end to a steel beam, wood rafter, wood joist, wood beam, or ceiling, a bar adapted to be slidably coupled to the arm having a first horizontally extending arm located at the bottom of the bar to form a J bar, clearance openings located in the arm and in the J bar for receiving fasteners for attaching the arm to the J bar to raise or lower the first horizontally extending arm to provide for storage at different heights, a first extension member removably coupled to the first vertically displaced horizontally extending arm, and wherein the first extension member has a length that provides for storage space of different widths and is adapted to be removably attached to a first vertically displaced horizontally extending arm on an opposing J bar.
[0011] In another aspect, an apparatus is provided for a standing shelving unit having at least one leg adapted to be attached at its bottom end to a steel beam, wood rafter, wood joist, or wood beam, a bar adapted to be slidably coupled to the leg having a first horizontally extending arm located at the top of the bar to form a L bar, clearance openings located in the leg and in the L bar for receiving fasteners for attaching the leg to the L bar to raise or lower the first horizontally extending arm to provide for storage at different heights, a first extension member removably coupled to the first vertically displaced horizontally extending arm, and wherein the first extension member has a length that provides for storage space of different widths and is adapted to be removably attached to a first vertically displaced horizontally extending arm on an opposing L bar.
[0012] In yet another aspect, a method for hanging the adjustable shelving unit is provided.
[0013] In a further aspect, a method for securing the standing adjustable shelving unit is provided.
[0014] One advantage of the present development resides in the versatility of the shelving unit which provides for a variety of widths and heights to provide a hanging or standing shelving unit that can be used for a number of applications including building heating, ventilation, and air conditioning (“HVAC”) systems, a shelving unit for holding children's games and toys, as a closet organizer with hangers and shelves, for storage space in a garage or workshop, storage shelves over a garage door, and as an audio/visual equipment hanging unit.
[0015] Another advantage of the present development is the ability to easily adjust the height of the hanging or standing unit.
[0016] Still another advantage of the present development is the ability to easily add additional shelves to the unit and to adjust the height to accommodate what needs to be stored.
[0017] Other benefits and advantages of the present disclosure will become apparent to those skilled in the art upon a reading and understanding of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention.
[0019] FIG. 1 is a side view of the rear left and rear right hanging arms of the support unit, the front left and front right hanging arms not being shown, where the hanging arms consist of upper paddle arms attached at their upper ends to separate support members and at their lower ends to a J shaped bar having an upper horizontal extension for receiving a telescoping connecting member for supporting an HVAC unit and a telescoping lower horizontal extension for receiving a telescoping extension for supporting an emergency drain pan; and
[0020] FIG. 2 is a side view of the rear left and rear right hanging arms of the support unit, the front left and front right hanging arms not being shown, where the hanging arms consist of upper paddle arms which are turned ninety degrees and are attached at their upper ends to a common support member, and at their lower ends to “J” shaped bars having an upper horizontal extension for receiving an AC unit and a lower horizontal extension for receiving an emergency drain pan.
[0021] FIG. 3 is a front perspective view of a second embodiment support unit, having front and rear, left and right hanging arms, where the hanging arms consist of a means of attachment at their upper ends to a support member or the ceiling, and at their lower ends to “J” shaped bars having a horizontal extension for holding various items, including HVAC units, clothes, toys, games, television and audio visual equipment, and the like.
[0022] FIG. 4A is a fully retracted side view of the embodiment appearing in FIG. 3 , having rear left and rear right hanging arms of the support unit, the front left and front right hanging arms not being shown, where the hanging arms consist of an attachment section and are attached at their upper ends to a common support member, and at their lower ends to “J” shaped bars having a horizontal extension for receiving an AC unit and a drain pan support member for receiving an emergency drain pan.
[0023] FIG. 4B is a fully expanded side view of the embodiment of FIG. 4A , having rear left and rear right hanging arms of the support unit, the front left and front right hanging arms not being shown, where the hanging arms consist of an attachment section and are attached at their upper ends to a common support member, and at their lower ends to “J” shaped bars having a horizontal extension for receiving an AC unit and a drain pan support member for receiving an emergency drain pan.
[0024] FIG. 4C is a fully retracted side view of the support member appearing in FIGS. 4A and 4B .
[0025] FIG. 4D is a fully expanded side view of the support member appearing in FIGS. 4A-4C .
[0026] FIG. 5 is an exploded side view of the support unit embodiment appearing in FIGS. 3 , 4 A and 4 B.
[0027] FIG. 6 is a side view of a third embodiment support unit, having front and rear, left and right hanging arms, where the hanging arms consist of a means of attachment at their upper ends to a support member or the ceiling, and at their lower ends to “J” shaped bars having a horizontal extension for holding various items, and a plurality of the shelves and hanging bars for holding various items, including HVAC units, clothes, toys, games, and the like.
[0028] FIG. 7 is a side view of a forth embodiment support unit, having front and rear, left and right hanging arms, where the hanging arms consist of a means of attachment at their upper ends to a support member or the ceiling, at their lower ends to “J” shaped bars having a horizontal extension for holding various items such as DVD players, blue ray players, cable boxes, and the like, and an upper shelf having a horizontal extension for holding a television unit.
[0029] FIG. 8 is a side view of a fifth embodiment support unit, having front and rear, left and right hanging arms, where the hanging arms consist of a means of attachment at their upper ends to a support member, ceiling, or closet system, at their lower ends to “J” shaped bars having a horizontal extension and adjustable shelves for holding various items such as clothes, toys, games, and the like.
[0030] FIG. 9 is a front perspective view of a sixth embodiment support unit for hanging over a garage door, having front and rear, left and right hanging arms, where the hanging arms consist of a means of attachment at their upper ends to a support member or ceiling, at their lower ends to “J” shaped bars having a horizontal extension and a plurality of supports for holding various items such as tools, yard equipment, and the like.
[0031] FIG. 10A is a fully expanded front view of the support unit, having front right and front left standing legs, the rear right and rear left standing legs not being shown, where the standing legs consist of an attachment section and are attached at their lower ends to a common support member, and at their upper ends to bars at right angles having a horizontal extension.
[0032] FIG. 10B is a fully retracted front view of the support unit embodiment appearing in FIG. 10A .
[0033] FIG. 10C is a partially expanded side view of the support unit embodiment of FIGS. 10A and 10B , having front right and rear right standing legs and a right center support member, the front left and rear left standing legs and the left center support member not being shown, where the standing legs consist of an attachment section and are attached at their lower ends to a common support member, at their upper ends to bars at right angles having a horizontal extension, and center support members attached to and connecting the bars of the front right and rear right standing legs and the bars of the front left and rear left standing legs.
[0034] FIG. 10D is a fully retracted side view of the support unit embodiment appearing in FIG. 10C .
[0035] FIG. 11A is an exploded front view of the support unit embodiment appearing in FIGS. 10A-10D .
[0036] FIG. 11B is an exploded side view of the support member appearing in FIGS. 10A-10D .
[0037] FIG. 12 is an isometric view of a support unit similar to the embodiment appearing in FIGS. 10A-10D and 11 A- 11 B except the corner joint is a tee joint in this embodiment.
[0038] FIG. 13 is an enlarged exploded view of one of the lower legs in FIG. 12 with a first alternative embodiment base plate.
[0039] FIG. 14 is an enlarged exploded view of one of the lower legs in FIG. 12 with a second alternative embodiment base plate.
[0040] FIG. 15 is an isometric view of a further alternative embodiment of a support unit similar to the embodiment appearing in FIGS. 12 wherein the base plates are omitted.
[0041] FIG. 16 is a front perspective view of an alternative embodiment support unit, having left and right hanging arms, where the hanging arms consist of a means of attachment at their upper ends to a support member or the ceiling, and at their lower ends to “U” shaped bar having an attachment mechanism for holding various items, including HVAC units, television and audio visual equipment, hanging storage units, pot racks, and the like.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] Referring to FIGS. 1 and 2 the support unit embodiment disclosed is composed of four upper arms adapted to be connected to four “J” shaped bars where each J shaped bar has an upper horizontal extension for receiving an HVAC unit and a lower horizontal extension for receiving an emergency drain pan. The upper arms and the J bars are composed of square metal tubing precut to size and fabricated to shape. The upper arms and the J bars have drilled or punched openings located on centers which are between one and two inches for adjustability. The upper arms are sized to telescope into and out of the J bars to provide for different height adjustments.
[0043] Each J bar has two horizontal arms where the upper horizontal arm is used to provide support for an HVAC unit and the lower horizontal arm is used to provide support for an emergency drain pan. Each horizontal arm is sized to telescope into a connecting sleeve and the horizontal arms and connection sleeves have openings for receiving ringed clevis pins or nuts and bolts to lock the two together. Extension members of various lengths are available which telescope into the coupling sleeves for adjusting the width between the left and right J bars to the width of the HVAC unit which is to be supported by the air handler support unit. The extension members and the coupling sleeves each have openings which are spaced apart by between one and two inches, more or less for receiving ringed clevis pins or nuts and bolts to lock the two together for different dimension applications.
[0044] The paddle arms each have at their upper ends a flat plate which is adapted to be located next to a wood support member and has openings which are provided to receive bolts or screws which are used to attach the paddle arm to a wood support member such as a wood rafter, joist or beam.
[0045] In another embodiment the flat plate at the upper ends of the paddle arms is adapted to receive at least one C clamp which is used to attach the paddle arms to steel beams.
[0046] The air handler support unit disclosed telescopes both horizontally and vertically to accommodate units having various heights and widths. The spacing between the front and rear paddle arms is varied to accommodate the length of the HVAC unit. The support unit bottom shelf may be outfitted with two “H” hangers to receive the telescoping emergency drain pan horizontal arm, which can be relocated to the upper shelf to help in removing internal parts of each unit. The entire support unit disclosed is adjustable to receive HVAC units of different heights, widths and lengths.
[0047] Referring to FIG. 1 , there is disclosed a side view of the rear left hanging arm 10 and rear right hanging arm 12 of the air handler support unit, the front left and front right hanging arms not shown, where each hanging arm consists of an upper paddle arm 14 and a “J” bar 16 at its lower end. In this embodiment each of the hanging arms, the left and right rear hanging arms and the left and right front hanging arms are similar in all aspects and, therefore, the detailed description of the rear left hanging arm which follows applies to each of the other hanging arms.
[0048] Upper paddle arm 14 is a square tube composed of steel and having a length of about twenty four inches, more or less. The top of the paddle arm 14 is welded to a flat plate 18 having a length of about eight inches, a width of about three inches and a thickness of about one-eighth of an inch, more or less. The flat plate 18 has two columns of openings 20 , (see FIG. 2 ), which are sized for receiving screws or bolts for attaching the paddle arm 14 to a wood support member such as a wood rafter, joist or beam. In the embodiment of FIG. 1 the upper paddle arms are attached to separate wood rafters, joists or rafters.
[0049] The paddle arm 14 has a first plurality of openings 24 located at spaced apart intervals (e.g., on two inch centers) which are parallel to the width of the flat plate, and a second plurality of openings 26 , (see FIG. 2 ), located at spaced apart intervals (e.g., on two inch centers) which are transverse to the width of the flat plate and are located between the first plurality of openings 24 . The paddle arm 14 which is a square tube composed of steel with an outside dimension of between one-half of an inch and one inch, more or less, telescopes into the J bar 16 . The J bar 16 is a square tube composed of steel with an inside dimension which makes a sliding fit with the outside dimension of paddle arm 14 and has a length of about twenty two and one-half inches, more or less. Located at the bottom of the J bar 16 are two horizontally extending arms 28 , 30 which are welded to the J bar 16 and are vertically displaced from each other by a distance of about five inches, more or less. Each arm 28 , 30 is a square tube with a width that is similar to the width of the tube 14 , is made of steel, has a length of about two inches, more or less, and telescopes into connecting sleeves 32 , 34 . The J bar 16 and horizontal arms 28 , 30 have clearance openings for receiving ringed Clevis pins or nuts and bolts for attaching the J bar 16 to the paddle arm 14 and the arms 28 , 30 to connecting sleeves 32 , 34 . Connecting sleeves 32 , 34 each have a length of about fourteen inches, more or less.
[0050] Referring to FIG. 2 , there is disclosed a side view of the rear left and rear right hanging arms of the support unit, the front left and front right hanging arms not shown, where the support unit of FIG. 2 differs from FIG. 1 only in that the upper paddle arms of the hanging arms are turned ninety degrees and are attached at their upper ends to a common support member rather than to separate support members such as a wood rafter, joist or beam 36 with bolts or screws.
[0051] Each J bar telescopes over and is adjustably attached to a paddle arm which allows for different height adjustments from twenty six inches to forty inches in two inch increments. Connecting sleeves 32 , 34 on opposing horizontally extending arms 32 , 34 of the J bars telescope around horizontal extension members 38 for different width adjustments of between twenty eight inches and forty inches in two inch increments.
[0052] Referring now to FIGS. 3 , 4 A- 4 B, and 5 there appears a second embodiment of the support unit 100 having four hanging arms 102 and where each hanging arm 102 consists of an upper arm 104 and a “J” bar 106 at its lower end. The upper arms 104 are a square tube composed of steel or another metal/metal alloy and the top of the upper arms 104 having a first plurality of openings 108 on the front and rear of upper arms 104 , three openings in the preferred embodiment, which are sized for receiving screws, bolts, or the like for attaching the upper arms 104 to hang the support unit 100 to a steel beam, wood rafter, wood joist, wood beam, ceiling, or the like. If the first plurality of openings 108 does not align with the desired support member the upper arms 104 may be rotated ninety degrees to align with the desired support member for attachment using a screw, bolt, or the like. Alternatively, the arms 104 may have a plurality of openings 109 on the left and right of the upper arms 104 , three openings in the preferred embodiment, offset from the first plurality of openings 108 which are sized for receiving screws, bolts, or the like for attaching the upper arms 104 to hang the support unit 100 to a steel beam, wood rafter, wood joist, wood beam, ceiling, or the like.
[0053] In the present embodiment, a second plurality of openings 130 of the upper arms 104 are located at spaced apart intervals (e.g., on two inch centers) on the front and rear of the square tube, and a third plurality of openings 136 , are located at spaced apart intervals (e.g., on two inch centers) on the left and right side of the square tube offset from the second plurality of openings 130 . The second and third plurality of openings 130 and 136 , respectively, are located at a desired interval for the intended use of the support unit 100 . The upper arms 104 telescope into the J bars 106 . The J bars 106 may be square tubes composed, for example, of steel or other metal or metal alloy with an inside dimension which makes a sliding fit with the outside dimension of the upper arms 104 . Located at the bottom of each J bar 106 is a horizontally extending arm 110 which may be integral with the vertical portion of the J bar bent to form the horizontally extending portion 110 of the J bar 106 . Alternatively, the horizontal arms 110 may be separately formed and attached, e.g., by welding the horizontally extending arms 110 to the bottom of the upper portion of the J bars 106 . The arms 110 may be square tubes with the same width as the width of the vertically extending portion of the J bars 106 .
[0054] The extension members 112 are telescopically received within the arms 110 . The J bars 106 and horizontal arms 110 have one or more clearance openings 114 for receiving fasteners 116 for securing the J bars and the telescopically received arms 104 and extension members 112 in fixed position. The fasteners 116 may be, for example, pins, Clevis pins, thumb screws, nuts and bolts, or the like for attaching the J bars 106 to the arms 104 and the horizontally extending arms 110 to the extension members 112 . Depending on the means used to secure the extension members 112 inside of the horizontally extending arms 110 , the extension members 112 may include a plurality of openings 132 evenly spaced apart along the member 112 . In the preferred exemplary embodiment the extension members 112 enable the support unit 100 to expand from approximately 32 inches wide to approximately 48 inches wide although other dimensions are contemplated. The extension members 112 are secured inside of the horizontally extending arms 110 via fasteners 116 which pass through the clearance openings 114 and into one of the plurality of openings 132 to secure the unit 100 at the desired width.
[0055] One or more support members 118 may optionally be attached to the horizontal arms 110 . The support members 118 are attached to the arms 110 using coupling sleeves or hooks 120 . The coupling hook 120 at a first end of the support member 118 attaches to one horizontally extending arm 110 and the coupling hook 120 at a second end of the support member 118 attaches to a parallel horizontal arm 110 . The support members 118 provide additional support for items that are being stored on the support unit 100 . The support members 118 may be square tubes composed, for example, of steel or other metal or metal alloy with a dimension to hold the weight of the item selected for supporting. The coupling hooks 120 may be welded to the ends of the support members 118 and may be made of a sheet of steel or other metal or metal alloy which is bent to create three sides which slip over the square tubes of the horizontal arms 110 . The inside dimension of the coupling hooks 120 makes a sliding fit with the outside dimension of the horizontal arms 110 .
[0056] In an alternative embodiment, the support members 118 may include two arms (not shown) where the first arms (not shown) telescope into the second arms (not shown) to increase and decrease the width between the horizontal arms 110 of the support unit 100 . The first and second arms (not shown) each having a coupling hook 120 attached at the outside end for securing to the horizontal arms 110 . The first and second arms may be square tubes composed of a metal or metal alloy (e.g., steel) with the inside dimension of the first arm making a sliding fit with the outside dimension of the second arm at their inside ends.
[0057] As best seen in FIGS. 3 , 4 A- 4 D and 5 an optional pan support 122 having a lower pan 124 and “J” bars 126 . The “J” bars 126 have hooks 128 on the upper end for securing the pan support 122 to the arms 110 of the support unit 100 and are secured at the lower end to the pan 124 . In the exemplary embodiment, the pan 124 may be used to catch water from an HVAC unit that is not working properly.
[0058] Referring now to FIG. 6 , there appears a further embodiment support unit 200 which may be used as a suspended shelving unit. The unit 200 may advantageously be used for holding children's games and toys, however, myriad of other uses are contemplated. The support unit 200 may be hung, for example, from the ceiling of a child's bedroom or playroom to provide additional storage for toys, games, stuffed animals, and the like. The support unit 200 includes four hanging arms 202 , where each hanging arm 202 consists of an upper arm 204 and a “J” bar 206 telescopically receiving the upper arm 204 at its lower end. The upper arms 204 may be a square tube and may be composed of steel or another metal or metal alloy. The top of the upper arm 204 having a first plurality of openings 208 , which are sized for receiving screws, bolts, or the like for attaching the upper arms 204 to hang the support unit 200 to a steel beam, wood rafter, wood joist, wood beam, ceiling, or the like.
[0059] In the present embodiment, the first plurality of openings 208 of the upper arms 204 are located at spaced apart intervals (e.g., on two inch centers) on the front and rear of the square tube, and a second plurality of openings 209 , are located at spaced apart intervals (e.g., on two inch centers) on the left and right side of the square tube offset from the first plurality of openings 208 . The first and second plurality of openings 208 and 209 , respectively, are located at a desired interval for the intended use of the support unit 200 . The upper arms 204 telescope into the J bar 206 to raise and lower the height of the support unit 200 . The J bar 206 may be a square tube composed of a metal or metal alloy (e.g., steel) with an inside dimension which makes a sliding fit with the outside dimension of the upper arms 204 .
[0060] Located at the bottom of the J bar 206 is one horizontally extending arm 210 which may be integral with the vertical portion of the J bar and bent to form the horizontally extending portion 210 of the J bar 206 . Alternatively, the horizontal arms 210 may be separately formed and attached, e.g., by welding the horizontally extending arms 210 to the bottom of the upper portion of the J bars 206 . The arms 210 may be square tubes with the same width as the width of the vertically extending portion of the J bars 206 . One or more additional horizontally extending arms 220 are located on the vertical portion of the J bar 206 above the horizontally extending arm 210 and are welded to the J bar 206 . Each arm 220 is a square tube with a width the same as the width of the horizontally extending arm 210 . The arms 220 may alternately be attached to the J bar 206 using coupling sleeves, the coupling sleeve may slide over the vertical portion of the J bar 206 and may be secured to the J bar 206 via a fastener. The extension member 212 telescopes into the arm 210 and each of the extension members 222 telescope into the corresponding and aligned arms 220 . The J bar 206 and horizontal arms 210 and 220 have clearance openings 214 for receiving fasteners 216 for securing the J bars 206 to the arms 204 and the telescopically received extension members 212 and 222 to the arms 210 and 220 , respectively, in a fixed position. The fasteners 216 may be, for example, pins, Clevis pins, thumb screws, nuts and bolts, or the like for attaching the J bars 206 to the arms 204 and the extension members 212 and 222 to the arms 210 and 220 .
[0061] Referring now to FIG. 7 , there appears yet another embodiment support unit 300 which may advantageously be used as a hanging support unit for audio and/or video equipment, such as televisions and related audio and visual equipment. The support unit 300 includes four hanging arms 302 , where each hanging arm 302 consists of an upper arm 304 and a “J” bar 306 at its lower end. The upper arms 304 are square tubes composed of metal or metal alloy (e.g., steel). The top of the upper arm 304 has a first plurality of openings 308 , which are sized for receiving screws, bolts, or the like for attaching the upper arms 304 to hang the support unit to a steel beam, wood rafter, wood joist, wood beam, ceiling, or the like. For attachment to a finished ceiling, an attachment plate 324 may be secured to the top of each upper arm 304 . The attachment plate 324 has a plurality of openings 326 , four openings in the preferred exemplary embodiment, which are sized for receiving screws, bolts, or the like for attaching the upper arms 304 to a joist in the ceiling or anchoring the upper arms 304 into the drywall.
[0062] The upper arms 304 and horizontally extending arms 310 are of the type described above with reference to FIGS. 3-6 . The upper arms 304 are telescopically received into the J bars 306 . The J bars 306 are of the type described above with reference to FIGS. 3-6 . Located at the bottom of the J bar 306 are two horizontally extending arms 310 and 320 . The arms 310 may be integral with the vertical portion of the J bar and bent to form the horizontally extending portions 310 of the J bar 306 , while the horizontal arms 320 may be separately formed and attached, e.g., by welding the horizontally extending arms 320 to the vertical portion of the J bars 306 at a desired separation above the horizontally extending arms 310 . Alternatively, the horizontal arms 310 may be separately formed and attached, e.g., by welding the horizontally extending arms 310 to the bottom of the vertical portion of the J bars 306 . The extension members 312 and 322 are telescopically received within the arms 310 and 320 , respectively, to obtain the desired separation between opposing J bars 306 . The extension members 312 and 322 are of the type described above with reference to FIGS. 3-6 .
[0063] The shelf created by arms 310 and extension members 312 may be used to hold audio and visual equipment, such as cable boxes, DVD players, game consoles, and the like. The shelf created by arms 320 and extension members 322 may be used to suspend a television from the ceiling at a desired height rather than mounting it onto a wall or supported on a stand. Although the illustrated embodiment shows two horizontal shelves, it will be recognized that additional supports may be inserted to provide additional support for the television and audio and visual components.
[0064] Referring now to FIG. 8 , there appears another embodiment support unit 400 which may advantageously be used as a closet organizer with hangers and shelves. The support unit 400 includes four hanging arms 402 where each hanging arm 402 consists of an upper arm 404 and a “J” bar 406 at its lower end. The upper arms 404 are a square tube composed of a metal or metal alloy, such as steel. The top of the upper arm 404 having a first plurality of openings 408 , which are sized for receiving screws, bolts, or the like for attaching the upper arms 404 to hang the support unit 400 to a steel beam, wood rafter, wood joist, wood beam, ceiling, or the like. For attachment to a finished ceiling, an attachment plate not shown may be secured to the top of each upper arm 404 . The attachment plates may have a plurality of openings not shown, which are sized for receiving screws, bolts, or the like for attaching the upper arms 404 to a joist in the ceiling or anchoring the upper arms 404 into the ceiling drywall.
[0065] The upper arms 404 and horizontally extending arms 410 are of the type described above with reference to FIGS. 3-7 . The upper arms 404 telescope into the J bar 406 . The J bar 406 is of the type described above with reference to FIGS. 3-7 . Located at the bottom of the J bar 406 are a plurality of horizontally extending arms, there are three horizontally extending arms in the preferred embodiment 410 , 418 , and 422 . Although the illustrated embodiment shows three horizontal arms, it will be recognized that arms may be removed or additional arms may be added to provide more or less shelves for the shelving unit 400 . The horizontally extending arm 410 may be integral with the vertical portion of the J bar and bent to form the horizontally extending portion 410 of the J bar 406 , while the arms 418 and 422 may be secured onto the J bar 406 at a desired separation above the arm 410 using coupling sleeves 420 . The coupling sleeves 420 may be secured to the J bar 406 using fasteners 416 , e.g., pins, Clevis pins, nuts and bolts, or the like. Alternatively, the arms 410 , 418 and 422 may be separately formed and attached, e.g. via welding, at fixed positions on the J bars 406 .
[0066] The extension member 412 telescopes into arm 410 and is slidably adjustable to obtain the desired separation between opposing J bars 406 . The extension member 412 is of the type described above with reference to FIGS. 3-7 . The arms 418 and 422 may come in a variety of sizes to correspond to the sizes of the arms 410 and extension member 412 . In one alternative embodiment, the arms 418 and 422 may be segmented, including an extension member in the center of the segmented arms 418 and 422 which telescopes into the arms 418 and 422 to allow for adjustment of the arms 418 and 422 in the same manner as arm 410 . In another alternative embodiment, the arms 418 and 422 may be comprised of two telescopic segments.
[0067] The shelves created by arm 410 and extension member 412 , and arms 418 , and 422 may advantageously be used as closet shelves for clothes, shoes, sheets, towels, and any other items stored in a closet and may include transversely-extending rods for clothing and other items on clothes hangers. Additional arms may be added to provide additional shelves and rods for alternative closet storages shelving arrangements.
[0068] Referring now to FIG. 9 , there appears yet another embodiment of the support unit 500 which may be used to provide storage shelves in the empty space found over a garage door. The support unit 500 may be sized to fit between the rails 524 for a garage door 526 and above the garage door 526 when it is in the open position to provide additional storage in the space above the garage door. The support unit 500 includes four hanging arms 502 and where each hanging arm 502 consists of an upper arm 504 and a “J” bar 506 at its lower end. The upper arms 504 may be a square tube composed of steel or another metal or metal alloy. The top of the upper arm 504 includes a first plurality of openings 508 , which are sized for receiving screws, bolts, or the like for attaching the upper arms 504 to hang the support unit 500 to a steel beam, wood rafter, wood joist, wood beam, ceiling, or the like. For attachment to a finished ceiling, an attachment plate not shown may be secured to the top of each upper arm 504 . The attachment plate may have a plurality of openings not shown, which are sized for receiving screws, bolts, or the like for attaching the upper arms 504 to a joist in the ceiling or anchoring the upper arms 504 into the drywall.
[0069] The upper arms 504 and horizontally extending arms 510 are of the type described above with reference to FIGS. 3-8 . The upper arms 504 telescope into the J bar 506 and are secured using fasteners 516 , e.g., pins, Clevis pins, nuts and bolts, or the like. The J bar 506 is of the type described above with reference to FIGS. 3-8 . The arms 510 may be integral with the vertical portion of the J bar and bent to form the horizontally extending arms 510 of the J bar 506 . Alternatively, the horizontal arms 510 may be separately formed and attached, e.g., by welding the horizontally extending arms 510 to the bottom of the vertical portion of the J bars 506 . The extension member 512 is telescopically received within the arm 510 to obtain the desired separation between opposing J bars 506 . The extension member 512 is of the type described above with reference to FIGS. 3-8 .
[0070] Additional support for items to be stored above the garage door 526 is provided by a plurality of support members 518 , in the preferred embodiment there are four additional support members. Although the illustrated embodiment shows four support members, it will be recognized that support members may be removed or added to provide the desired amount of support for items stored on the unit 500 . The support members 518 are secured onto the arms 510 at a desired separation using coupling hooks 520 . The coupling hooks 520 at the first end of the support member 518 are secured to the arms 510 at a desired point and the coupling hooks 520 at the second end of the support member 518 are secured to a parallel arm 510 the same distance from the curve of the J bar 506 . In alternative embodiments fasteners, such as pins, Clevis pins, nuts and bolts, or the like may be used to secure the support members 518 to the arms 510 . In another alternative embodiment, the support members 518 may be comprised of two telescopic segments. The support members 518 and coupling hooks 520 may be of the type described above with reference to FIGS. 3 , 4 A- 4 B, and 5 .
[0071] The shelves created by arm 510 and extension member 512 , and support members 518 are used to create additional storage in the space above an open garage door.
[0072] Referring now to FIGS. 10A-10D , 11 A- 11 B, and 12 , there appears yet another embodiment support unit 600 having four legs 602 and where each leg 602 consists of a lower leg 604 and an “L” bar 606 at its upper end. The lower legs 604 may be square tubes composed of a metal or metal alloy, such as steel. An attachment plate 608 may be secured to the bottom of each lower leg 604 , e.g., via welding. The attachment plates 608 have a plurality of openings 610 , four openings in the preferred exemplary embodiment, which are sized for receiving screws, bolts, or the like for attaching the lower legs 604 to the top of a steel or wood beam, floor joist, floor or the like 612 .
[0073] In the present embodiment, the lower legs 604 may have a plurality of openings 614 located at spaced apart intervals (e.g., on two inch centers) on the front and rear of the square tube, and a second plurality of openings 640 , are located in the preferred exemplary embodiment at spaced apart intervals (e.g., on two inch centers) on the left and right side of the square tube between the plurality of openings 614 . The plurality of openings 614 and second plurality of openings 640 may be located at any desired interval based on the intended use of the support unit 600 .
[0074] The lower legs 604 telescope into the L bars 606 . The L bars 606 are square tubes composed of metal or metal alloy with an inside dimension which makes a sliding fit with the outside dimension of the lower legs 604 . The L bars 606 have clearance openings 620 for receiving fasteners 622 , such as pins, Clevis pins, thumb screws, nuts and bolts, or the like which align with the plurality of openings 614 and 640 in the lower legs 604 for attaching the L bars 606 to the lower legs 604 . Located at the top of each L bar 606 is a horizontally extending arm 616 which is attached to the upright portion to form the L bars 606 . The L bars 606 may be formed by welding the horizontally extending arms 616 to the top of the upper portion of the L bars 606 or alternatively may be formed by bending a single length of tubing as described above. The arms 616 are square tubes with the same width as the width of the top of the L bars 606 and may be made of steel or another metal or metal alloy. The arms 616 of the front right and front left L bars 606 and the arms 616 of the rear right and rear left L bars 606 are connected using extension members 618 . The extension members 618 telescope into the horizontally extending arms 616 . The arms 616 have clearance openings 624 for receiving fasteners, such as pins, Clevis pins, thumb screws, nuts and bolts, or the like for attaching the horizontally extending arms 616 to the extension members 618 . Depending on the means used to secure the extension members 618 inside of the horizontally extending arms 616 , the extension members 618 may include a plurality of openings 638 evenly spaced apart along the extension members 618 . In the preferred exemplary embodiment the extension members 618 enable the support unit 600 to expand from approximately two feet two inches to approximately three feet two inches although other dimensions are contemplated.
[0075] One or more support members 626 may optionally be attached to the horizontal arms 616 . The support members 626 are attached using coupling hooks 630 . The coupling hooks 630 are attached at a first end of the support member 626 to a front horizontally extending arm 616 and at a second end of the support member 626 to the corresponding rear horizontally extending arm 616 . The support members 626 and coupling hooks 630 may be of the type described above with reference to FIGS. 3 , 4 A- 4 B, and 5 . The support members 626 provide additional support for the items to be stored on the support unit 600 .
[0076] The support members 626 can be a set length or extendable. If the support members 626 are to be extendable they may include a first arm 632 and a second arm 634 . The first and second arms 632 and 634 , respectively, are square tubes made of metal or metal alloy, such as steel. The first arms 632 are preferably the same width as the width of the L bars 606 . The second arms 634 are telescopically received within the first arms 632 . The first and second arms 632 and 634 may have clearance openings 636 for receiving a fastener for securing the arms 632 and 634 at a defined width, such as a pin e.g., a Clevis pin, thumb screw, nut and bolt, or the like for attaching the first arms 632 to the second arms 634 . Depending on the means used to secure the second arm 634 inside of the first arm 632 , the second arms 634 may include a plurality of openings (not shown) evenly spaced apart along the second arms 634 to provide a plurality of sizing options. In the preferred exemplary embodiment the support members 626 may expand from two feet eight inches to four feet, although other dimensions are contemplated.
[0077] When the support unit 600 is used for an HVAC system an optional pan (not shown) may be placed under the horizontally extending arms 616 and the support members 626 and/or on the top of base support structure 612 to catch any water that may be expelled if the HVAC system is not working properly.
[0078] As best seen in FIG. 13 , an alternative attachment mechanism 700 is shown. The embodiment 700 can be used as an alternative support member with any of the stand embodiments described above, including the embodiment 600 appearing in FIG. 12 , as well as the stands appearing in FIGS. 10A-D and 11 A-B, wherein the base plate is replaced with a generally oval or circular attachment foot 702 that is attached to the bottom of each lower leg 604 . The attachment feet 702 may be made of steel or other metal and include a cross member 704 secured inside a frame 706 . The frame 706 and cross member 704 may be secured, e.g. via welding. The cross member may have an attachment post 708 having at least one set of corresponding holes 710 for securing the lower leg 604 to the foot 702 via a fastener 712 , e.g., a pin, a Clevis pin, thumb screw, nut and bolt, or the like. The frame 706 may be formed of the same tubular stock material used for the L bars 606 . The cross member 704 and post 708 may be formed of a similar tubular stock material used for the L bars 606 in a smaller size to allow the lower leg 604 to fit over the post 708 thereby securing the support unit to the attachment mechanisms 700 . The embodiment of FIG. 13 is especially advantageous for use in supporting an HVAC condensing unit on a flat roof, e.g., having rubber or other flat roofing material while eliminating sharp corners, thus minimizing the likelihood that the base member will puncture or damage the roof membrane.
[0079] Another alternative embodiment 800 , also advantageous for use on a flat roof, appears in FIG. 14 . The embodiment 800 is as described above by way of reference to the embodiment 700 appearing in FIG. 13 , but wherein alternative attachment feet 802 to be secured to the bottom of each lower leg 604 are generally rectangular or square. The attachment feet 802 may be formed of a steel or other metal and have a cross member 804 secured inside a frame 806 . The frame 806 and cross member 804 may be secured, e.g. via welding. The cross member may have an attachment post 808 having at least one set of corresponding holes 810 for securing the lower leg 604 to the foot 802 via a fastener 812 , e.g., a pin, a Clevis pin, thumb screw, nut and bolt, or the like. The frame 806 may be formed of the same tubular stock material used for the L bars 606 . The cross member 804 and post 808 may be formed of a similar tubular stock material used for the L bars 606 in a smaller size to allow the lower leg 604 to fit over the post 808 thereby securing the support unit to the attachment mechanisms 800 .
[0080] As best seen in FIG. 15 , another alternative embodiment 900 of the support unit is shown. The support unit embodiment 900 is similar to the embodiment 600 appearing in FIG. 12 , but is adapted for the attachment of the lower legs 604 directly to the desired attachment surface, for example using a fastener (not shown) such as a pin, a Clevis pin, thumb screw, nut and bolt, or the like. The fastener may be received within one or more of the plurality of openings 614 and the second plurality of openings 640 and secured to the attachment surface. Alternatively, the fasteners may be omitted and the unit 900 may rest directly on the support surface.
[0081] Referring now to FIG. 16 , there appears a further embodiment support unit 950 having upper hanging arms 952 and 954 which each mate with an end of a “U” bar 956 . The hanging arm 952 mates with a first end 958 of the U bar 956 and hanging arm 954 mates with a second end 960 of the U bar 956 . The hanging arms 952 and 954 are square tubes composed of steel or another metal/metal alloy and having a first plurality of openings 962 on the front and rear of the hanging arms 952 and 954 , which are sized for receiving screws, bolts, or the like for attaching the hanging arms 952 , 954 to hang the support unit 950 to a steel beam, wood rafter, wood joist, wood beam, ceiling, or the like at a first end and to secure the hanging arms 952 and 954 to the U bar 956 at a second end. If the first plurality of openings 962 does not align with the desired support member the hanging arms 952 and 954 may be rotated ninety degrees to align with the desired support member for attachment using a screw, bolt, or the like. Alternatively, the arms 952 and 954 may have a second plurality of openings 964 , as shown in FIG. 16 , offset from the first plurality of openings 962 which are sized for receiving screws, bolts, or the like for attaching the hanging arms 952 and 954 to hang the support unit 950 to a steel beam, wood rafter, wood joist, wood beam, ceiling, or the like and to secure the hanging arms 952 and 954 to the U bar 956 at a second end. The hanging arms 952 are secured to the U bar 956 via fasteners 970 , for example, pins, Clevis pins, thumb screws, nuts and bolts, or the like.
[0082] In the present embodiment, the first plurality of openings 962 are located at spaced apart intervals (e.g., on two inch centers) on the front and rear of the square tube, and the second plurality of openings 964 , are located at spaced apart intervals (e.g., on two inch centers on the left and right side of the square tube offset from the first plurality of openings 962 . The first and second plurality of openings 962 and 964 , respectively, are located at a desired interval for the intended use of the support unit 950 . The hanging arms 952 and 954 telescope into the U bar 956 . The U bar 956 may be a square tube bent into a U shape and composed, for example, of steel or other metal or metal alloy with an inside dimension which makes a sliding fit with the outside dimension of the hanging arms 952 and 954 .
[0083] Located at the bottom of the U bar 956 is an attachment opening 966 for attaching a rotating support member 968 , such as a fastener, bracket, or the like, for securing a HVAC unit, television and audio visual equipment, hanging storage units, pot racks, and the like to the support unit 950 . The rotating support member 968 is secured to the U bar 956 via a fastener 972 , for example, pins, Clevis pins, thumb screws, nuts and bolts, or the like, which enables the support member 968 to rotate 360 degrees about the fastener 972 .
[0084] The invention has been described with reference to the preferred embodiments. Modifications and alterations will occur to others upon a reading and understanding of the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
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The present disclosure relates to shelving systems and methods that are adaptable to a number of applications, including building heating, ventilation, and air conditioning (“HVAC”) systems, shelving units for holding children's games and toys, closet organizers with hangers and shelves, storage systems in a garage or workshop, storage shelves over a garage door, and as a shelving unit for audio and visual equipment. The shelving unit includes a means for attachment to an overhead member, such as a steel beam, wood rafter, wood joist, wood beam, or ceiling, a generally J or L shaped bar, the ability to raise or lower the J or L shaped bar to provide for storage at different heights, an extension member removably coupled to the J or L bar, and wherein the extension member has a length that provides for storage space of different widths. In another aspect, an inverted shelving stand is provided. In still a further aspect, a U shaped swiveling hanging unit is provided.
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CONTRACTUAL ORIGIN OF THE INVENTION
The United States Government has rights in this invention under contract No. DE-AC02-83H10093 between the U.S. Department of Energy and the Solar Energy Research Institute, a division of the Midwest Research Institute.
FIELD OF THE INVENTION
The invention pertains to a multiple layered, single structure of several light emitting diodes (LEDs) of varying band gaps. This structure is at least a two-terminal device with tunnel junction, and made by first growing thin films of alternative p- and n-doped materials of a low band gap and finishing with the step of growing thin films of alternating p-and n-doped materials of a high band gap.
BACKGROUND OF THE INVENTION
Because of their size and low power requirements, semiconductor light-emitting diodes occupy a large role as components in visual display systems, and there is increasing demand for components for new and improved visual display systems which will exhibit greater capabilities without having to add additional components or elements to the visual display systems.
In some display systems, a number of ways of fabricating arrays containing components that emit light of the same wavelength are known. One such article appears in the October 1967 issue of IEEE Transactions on Electron Devices, Vol. ED-14, No. 10, wherein there is described the fabrication of integrated arrays of electroluminescant diodes.
U.S. Pat. No. 3,611,069 discloses a method for making arrays of gallium arsenide phosphide diodes for use in alphanumeric light displays.
As the level of expertise in the fabrication and deployment of visual displays rose, demand for multiple color displays as an extension of this technological area surfaced with increasing intensity. It then became apparent that an obvious method for obtaining different colors could be achieved by adding additional diodes to the array; however, a drawback in the use of additional diodes resided in the disadvantage of having to add to the number of component or element positions in the array, and thereby, create further complexity and difficulty in the fabrication process.
U.S. Pat. No. 3,611,069 pertains to providing devices of multiple-layered semiconductive regions of differing conductivity forming light-emitting PN junctions at the interface of two different conductivity-type regions. In this multiple-junction structure, each diode junction ;can be independently addressed to achieve independent color control. Thus, properly doped gallium aluminum phosphide can be made to luminesce either green or rod, and by the superposition of red and green emitting junctions, yellow emission may be created.
However, the technology known to date is not known to make available, spatially uniform visual displays of more than one color using a two-terminal multi-wavelength LED device with tunnel junction, wherein two or more colors are emitted from the same device.
SUMMARY OF THE INVENTION
It is a general object of the present invention to provide LED visual displays of more than one color.
A further object of the invention is to provide LED visual displays that are spatially uniform displays of more than one color.
A yet further object of the invention is to provide LED visual displays that are spatially uniform displays of more than one color emitted from the same device.
A still further object of the invention is to provide LED visual displays that are spatially uniform displays of more than one color emitted from the same device, wherein said device is a two-terminal device with tunnel junction.
In general, the multiple wavelength light emitting diode of the invention comprises a multiple layered, single structure of several LED's of varying band gaps, and is made by depositing thin films of alternating p-doped and n-doped materials, wherein the lowest band gap material is deposited first and the highest band gap material is deposited last. Electrical connections are then structured in place so that all of the n-p junctions can be collectively energized to emit simultaneously the corresponding wavelengths or colors. The device of the invention may be utilized to provide the three primary colors or emit them simultaneously to produce white light.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified schematic of a monochromator for detecting emissions of wavelengths.
FIG. 2 is a simplified schematic of a generic tandem cell of GaAs/GaInP having a tunnel junction of GaAs or GaInP n+ and GaAs p+.
FIG. 3 is a simplified schematic of another hetero structure of a tandem cell useful in the invention.
FIG. 4 is a scan showing emission of two different wavelengths for the diode of FIG. 5.
FIG. 5 is a schematic cross-section of a GaInP 2 /GaAs tandem structure contemplated by the invention.
DETAILED DESCRIPTION OF THE INVENTION
A multi-wavelength diode is made by interconnecting two or more single diodes with one or more tunnel junctions or interconnects. Emission is then obtained by forward biasing the entire device. The primary requirements include individual diodes that are designed as they would be if used individually, an appropriate stacking order in which the highest band gap material is on the emitting face of the device, and transparent tunnel junctions or interconnects. The transparency of the tunnel junction or interconnect is at least as important as a very low contact resistivity since absorption in this layer will prevent emission of the long wavelength device, while resistance in this layer will increase the voltage required to energize the device. The requirements on this tunnel junction are far less stringent than for the high-efficiency solar cell described below.
As an example of the multi-wavelength LED we have used a monolithic, tandem solar cell. This device has been optimized for efficient conversion of sunlight to electricity, rather than conversion of electricity to sunlight. Nevertheless, it demonstrates the operation of the invention. The device was grown in a vertical, air-cooled reactor at one atmosphere using organometallic chemical vapor deposition (OMCVD). The group III source gases were trimethylindium, trimethylgallium, and trimethyaluminum; the group V source gases were arsine and phosphine. The dopant sources were diethylzinc and hydrogen selenide. The arsine and phosphine were purified on-line by passing them over a gettering compound. The optoelectronic properties and phototvoltaic quality of the materials listed above are complex and coupled functions of the growth temperature Tg, the V/III ratio, composition, dopant type and concentration, and substrate quality. Generally, however, the cascade device is grown at Tg=700° C. The phosphides are grown with V/III=30 and a growth rate of 80-100 nm/minute; the arsenides, with V/III=35 and a growth rate of 120-150 nm/minute, with the exception the GaAs tunnel diode is grown at a rate of 40 nm/minute.
The absorbers of both subcells are doped with Zn to a level of (1-4)×10 17 cm -3 . The emitters and window layers are doped with Se at about 10 18 cm -3 . Both layers of the GaAs tunnel diode are heavily doped at concentrations approaching 10 19 cm -3 . Tunnel diodes grown under conditions simulating the fabrication of a full cascade device have a series resistance of 10 31 3 -10 -2 cm 2 , and are relatively stable at 700° C. for at least 30-40 minutes.
The front and back contacts of these devices were electroplated gold. Because of the high dopant concentration in both the GaAs substrate and the top GaAs contacting layer (not shown in the FIG. 5), no thermal annealing of either contact is required. The front contact is defined by photolithography and obscures approximately 5% of the total cell area. The cell perimeter is also defined by photolithography and a mesa etch that uses a sequential combination of concentrated hydrochloric acid and an ammonia perioxide:water solution. The ammonia/peroxide solution is also used to remove the GaAs contacting layer between the gold grid fingers. The antireflection coating (ARC) is a double layer of evaporated ZnS and MgF 2 , with thicknesses of 60 and 120 nm, respectively.
The emission of light of two wavelengths from this device was observed with a system as shown in FIG. 1. A modulated voltage was applied in addition to a DC forward-biasing voltage. The emission was analyzed by placing the device at the entrance of a monochromator and a silicon photo-detector at the exit of the same monochromator. A lock-in amplifier, tuned to the wavelength of the modulation, was used to enhance the sensitivity of the detection. FIG. 4 shows a scan having emission at two different wavelengths for the diode of FIG. 5, which shows a cross-section of a GnInP 2 /GaAs tandem structure of the invention. The higher energy peak, observed at an energy of 1.89 eV, corresponds to the emission obtained from a single-junction diode fabricated from Ga 0 .5 In 0 .5 P. The lower energy peak, observed at an energy of 1.4 eV, corresponds to the emission obtained from a single-junction diode fabricated from GaAs.
Other hetero structures having a tunnel junction, and which are equally operable in the context of the invention are shown in FIG. 2, which is a schematic of a generic tandem cell of GaAs./GaInP having a tunnel junction of GaAs or GaInPn + and GaAsp + , and FIG. 3, which is a schematic of another hetero structure of a tandem cell of the invention.
The invention, in adding multiple layers to arrive at several LED's of varying band gaps that are combined into one structure permit two or more colors to be emitted in spatially uniform displays from the same device.
It is to be understood that the foregoing method for providing an LED visual display that is a spatially uniform display of more than one color emitted from the same device, wherein said device is a two-terminal device with tunnel junction is given by way of illustration only and is not meant to limit the method of making these structures. It should also be appreciated that the number of layers need not be limited to those illustrated herein, but can be altered to achieve a multiplicity of spatially uniform displays of more than one color emitted from the same device.
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A multiple wavelength LED having a monolithic cascade cell structure comprising at least two p-n junctions, wherein each of said at least two p-n junctions have substantially different band gaps, and electrical connector means by which said at least two p-n junctions may be collectively energized; and wherein said diode comprises a tunnel junction or interconnect.
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REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. application Ser. No. 12/316,354, filed Dec. 11, 2008, which claims priority to European Patent Application No. 07024889.3, filed Jan. 1, 2008.
FIELD
The invention relates to an evaluation method for determining a power reduction due to aging of at least one photovoltaic module at constant radiation intensity by measuring an electrical variable that may vary after a while such as cell current, cell voltage and/or cell power without additional sensors for measuring the radiation intensity.
The power of solar cells or of photovoltaic modules is subject to aging. The loss of efficiency ranges from 10% to 20% over a period of time of 20 years.
For mounting, solar cells are combined into modules, so-called solar or photovoltaic modules or solar panels. After 20 years, a solar module only has 90% to 80% of the power indicated.
DESCRIPTION OF THE PRIOR ART
From a study “Pratt R. G. et al: “Power of a 4 kW amorphous-silicon alloy photovoltaic array at Oakland Community College, Auburn Hills, Mich.” XP010750513” it is known to record the efficiency and the energy output of the plant over a short period of time. It appears from the study that the mere comparison of e.g., the energy output in the same month of e.g., two consecutive years does not allow inference on the aging of the PV modules since the values characterizing the energy output such as radiation intensity and temperature differ too much.
Methods are known, which are based on artificially accelerated aging tests. These tests are only performed for certain conditions such as temperature and irradiation and are thus usually allocated safety factors. Hence, the efficiency a manufacturer guarantees after a certain time is usually less than the actual efficiency drop. For such tests, additional sensors are moreover utilized for sensing for example the temperature or radiation intensity.
In practice, the power drop of the solar module is very difficult to follow over time. It is difficult to locate whether the power drop is within the limits indicated by the manufacturer since certain general conditions are needed for this purpose such as a certain outside temperature, precise sensors or calibratable radiation sensors and the like.
SUMMARY
It is the object of the invention to find a method of the type mentioned herein above by means of which a long-term power reduction of solar modules in an installed solar plant can be readily determined with high accuracy.
This object is solved by the following method steps:
fixing at least one class k, which is comparable on a year-to-year basis, within which a daily power curve or portions of the daily power curve of the photovoltaic module can be compared to each other on the basis of the radiation intensity and the outside temperature to be expected as well as of the radiation time, said class k corresponding to a defined time range,
measuring energy output values Ek,n that can be compared on a year-to-year basis from a comparable power curve Pk,n (t) by the variable delivered by the photovoltaic generator so that energy differences will be determined on the basis of the classes k, n being the respective year,
indicating a power reduction of the photovoltaic module with respect to one or more previous years of the energy output value Ek,n immediately delivered by the photovoltaic module by calculating the difference from the energy outputs Ek,l of the comparable years i,
data of comparable days having a comparable power curve P(t) of the photovoltaic module are being observed over several years.
Further advantageous implementations of the invention are characterized in the dependent claims.
Thanks to the measurement method of the invention, it is possible to determine very precisely a long-term power reduction without the need of additional sensors.
The invention relies on the observation that comparable days in terms of radiation intensity and temperature of the solar plant can be found over several years, these days allowing a reliable statement with regards to power reduction thanks to their comparability. In order to ensure comparability in terms of solar radiation, it is possible to compare over the years days in which a power curve P(t) is almost identical for example. Since the radiation intensity and the radiation time fluctuate in the course of a year, the year is divided in several periods, i.e., in several classes k. k may for example be equal to 52 so that the comparison may be made weekly. The actual comparison then only occurs within one class k over the years n.
Accordingly, the invention relies on the idea consisting in observing the energy output of the solar plant over several years. Actual data are compared with the values in previous years. This allows locating in which way the energy output decreases over the years.
In every year, the days must be found at which the energy output of the solar plant is comparable with values of previous years in order to be capable of making a reliable statement in terms of power reduction.
Accordingly, for each year n, there may be a maximum of k energy values. These energy values can be compared to the energy values of a previous year, for example to those of the previous year or of the first year. The difference between the energy values is for example a measure of the power reduction. This difference can be normalized. The energy amount of the previous year may serve as a standard.
Accordingly, the invention allows observing over the years power reduction within one class. Thanks to this accurate measurement, a solar plant can thus be connected for a longer time to a grid without maintenance works. It is also possible to locate early increased power reduction so that photovoltaic modules can be exchanged in time.
To measure the energy output, a variable of the generator such as the generator current, the generator voltage or the generator power can be measured.
In an advantageous embodiment of the measurement method of the invention, there are provided at least two classes k, which are distributed over the year and within which the daily power curves or the portion of the daily power curve are comparable on the basis of the radiation intensity and the outside temperature as well as of the radiation time. This allows for taking into consideration the seasonal fluctuations of the radiation intensity and of the outside temperature as well as of the irradiation time to be expected.
Sensing or filing a daily curve of the power P of the generator as well as of the energy output E of the photovoltaic generator of the day is particularly advantageous, a day power curve P(t) being determined, the course of which is comparable to at least one day curve Pk,n(t) from previous years. Accordingly, a measurement of the day curve of the power of the solar generator P(t) as well as of the daily energy output Etag, i.e., of the two variables is advantageous. These values can be recorded and filed in a data bank, for example by means of a data logger. Within each class k, one day power curve Pk,n(t) the course of which is comparable to the day power curves Pk,i(t) from previous years can be determined for each year n. This also means that at most k energy output values Ek,n are determined for each year, said energy output values being compared to the energy output values Ek,l of the previous years i, for example the first year values Ek, 1 so that at the most k values are determined for the energy differences .DELTA.Ek,n. At least one of these energy differences .DELTA.Ek,n related to an energy output value Ek,i of a previous year, for example of the first year Ek, 1 is used to indicate the power reduction of the solar generator.
Accordingly, within each class, one day or one measurement period is determined the power curve P(t) and the energy output E of which is comparable to measurements performed in earlier days.
It is advantageous that a number ktmax of day classes kj is formed. The day classes correspond to time periods that are associated with fixed time intervals and that are distributed over the daily sunshine period to be expected. This comparison then occurs between measurement intervals comprising both the same k and kj classes. One class may also be a class having a same pair of coefficients (k, kj) or a same tuple. In the variant widened to include the day classes, there is a maximum of k*kj energy values E((k,kj),n), which are compared to the energy values of the previous years. Differences and averages can be calculated here.
In an advantageous embodiment of the invention, comparable days are determined within one class in two steps at most, namely by calculating and evaluating the first derivation Pk′(t) of the function Pk(t).
The first derivation Pk′(t) of the data host Pk(t) is hereby calculated and it is checked whether certain limit values have been respected. If these limit values are exceeded or not reached, it can be assumed that this day was cloudless.
Alternatively, the first derivation Pk′(t) is calculated and evaluated by testing a curve area included therein for fixed limit values. In a first step, the first derivation Pk′(t) then enters an evaluation method which yields values that are not allowed to exceed or fall short of imposed limit values.
Using a plausibility criterion, it can be clearly determined in a second step whether the day is really cloudless. One plausibility criterion may for example be measurement data from the data host Pk(t) lying within tolerance bands such as a tolerance band for a certain region or a tolerance band for summer days and one for winter days. This means that this plausibility criterion is applied to the data host P(t) for example.
An alternative plausibility criterion is applied to the energy output Ek,tag. The energy output Ek,tag is not allowed to fall short of an imposed limit value either.
As an alternative or in addition thereto zero crossings of the first derivation Pk′(t) are advantageously evaluated in another implementation. A day is clearly cloudless if there is only one zero crossing. This evaluation method can be performed in only one step.
It is further sensible to impose limit values in the first year and to verify these limit values in the following years.
In another advantageous developed implementation of the method of the invention there is provided that at least one average value .DELTA.Emittel is calculated from the k energy difference values .DELTA.Ek,n for the year n as a measure for power reduction. By calculating the average, it is possible to make a very precise statement about the aging condition of the solar cells. The advantage of this way of proceeding is that quotients or percentage values obtained thereby, meaning daily and weekly values, can be averaged both for the k and for the kj classes. One thus obtains a very wide statistical basis, which ensures good accuracy of the values.
A particular benefit is obtained if a daily power curve is determined, which substantially comprises a daily power maximum. This case occurs if the day is cloudless. In this variant of the invention, only energy values from measurement periods are compared in which there was no shadow. Shadowing can be recognized with the methods mentioned herein above.
In this variant, time periods of shadow are recognized by evaluating the change in luminosity occasioned by passing clouds. In principle, one locates the change in luminosity by calculating the derivation of the power generated by the solar plant with respect to time. High values of such a derivation are evaluated by an evaluation algorithm which calculates whether the time range of the measurement was influenced by clouds. An effect of benefit is obtained by implementing an evaluation standard through fix or adaptive threshold values. An evaluation standard with amount averages, quadratic averages or other values can be utilized. An advantage is obtained if a time range with shadowing is recognized by comparing the amount of power or energy generated in the time range with a comparative value. If there are significant negative differences, there were shadows. Such a comparative value can be generated from a model of radiation on a cloudless day. A comparative value can also be calculated from the radiation values of previous days, in particular if these corresponding time intervals were recognized to be cloudless. An effect of benefit is obtained if a comparative value is calculated from values of previous years that have been stored.
An exemplary embodiment will be described in closer detail with reference to the drawings, additional developed implementations of the invention and advantages thereof being described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
In said drawings:
FIG. 1 a shows a matrix for several years 1 through n as well as several classes 1 through k showing energy outputs,
FIG. 1 b shows a matrix comparable to that of FIG. 1 a , this matrix now showing the energy differences,
FIG. 2 a shows a measured curve of the power P of a photovoltaic generator for a cloudless day,
FIG. 2 b shows a schematic course of the curve shown in FIG. 2 a,
FIG. 2 c shows the course of the first derivation for the function shown in FIG. 2 b,
FIG. 3 a shows a measured gradient of the power P of the photovoltaic generator for a day with passing clouds, is FIG. 3 b shows a schematic curve of the power shown in FIG. 3 a for the day with passing clouds,
FIG. 3 c shows the course of the first derivation for the function shown in FIG. 3 b,
FIG. 4 a shows the measured course of the power P of the photovoltaic generator for a cloudy day,
FIG. 4 b shows the schematic curve of the power P for this day with overcast sky,
FIG. 4 c shows the curve of the first derivation for the function shown in FIG. 4 b.
DETAILED DESCRIPTION
FIG. 1 a illustrates a matrix with energy output data for several years 1 through n, which are indicated in the matrix lines as well as for several classes 1 through k, which are indicated in the columns. The formulae below the matrix indicate the energy differences for each class k and for the respective year n. For each year n, one then has k energy values E.sub.k,n. These energy values passing clouds can then be compared to the energy values E.sub.k,l of the year before i, of any previous year or of the first year. The difference .DELTA.E.sub.k,n=E.sub.k,i−E.sub.k,n is taken to measure the power reduction. This difference can be normalized. The energy output of the year before i can for example serve as a standard so that the power reduction can be expressed by .DELTA.E.sub.k,n/E.sub.k,i=(E.sub.k,i−E.sub.k,n)/E.sub,k,l As a result, a power reduction of the photovoltaic modules can be observed within one class over several years.
Accordingly, in FIG. 1 a , .DELTA.E.sub. 1 ,n through .DELTA.E.sub.k,n signify energy differences for each class. .DELTA.E*.sub.l,n means normalized energy differences for each class; this will be explained in closer detail later.
In accordance with the invention, the method is based on the measurement or on the acquisition of the daily curve of the power of the solar generator P(t) as well as on a daily energy output Etag. These data can be stored in a data bank.
Distributed over the year, there are several classes k. Two classes k are required though. This is beneficial in order to take into account a seasonal radiation intensity as well as a seasonal dependent outside temperature.
Within each class k, a power curve Pk,n(t) is determined for each year n, said curve having a course that is comparable with the daily power curves Pk,l of previous years i.
I.e., for each year, a maximum number k of energy output values E.sub.k,n are ascertained, which are compared to the energy output values E.sub.k,l of the previous years, for example with the energy output values E.sub.k,l, so that a maximum number k of values is determined for the energy differences .DELTA.E.sub.k,n.
At least one of these energy differences .DELTA.E.sub.k,n related to an energy output value Esub.k,l of a previous year i, for example of the first year value E.sub.k,l, is used to indicate the power reduction of the photovoltaic generator.
Preferably, the energy outputs are related to one day. I.e., within each class one ascertains a day the power curve P(t) and the energy output E of which are comparable with measurements performed in earlier days. For each year n, one then has k energy values E.sub.k,n, which relate to one day. These daily energy values E.sub.k,n can then be compared with the daily energy values E.sub.k,n−1 of the year before or with the energy values E.sub.k,l of the first year or of any year.
In FIG. 1 b there is shown another matrix which includes the energy differences for several years 1 through n as well as for all classes 1 through k. Below the matrix, there is shown a measurement graph showing the energy differences .DELTA.E related to the years 1 through n.
From these variables, mean values from all the k energy differences .DELTA.(E.sub.k,n) can be acquired for one year n, namely with the formula:
. DELTA.Emittel,n= 1 km= 1 k.DELTA.Em,n##EQU 00001##
For normalized energy differences, the above mentioned formula takes the following form:
DELTA.Emittel,n*= 1 km= 1 k.DELTA.Em,n*##EQU 00002##
Then, the values .DELTA.E.sub.mittel,n or .DELTA.E*.sub.mittel,n indicate a yearly average value for power reduction of the photovoltaic generator in the respective year n.
It is also possible to consider quadratic averages or an average to the power of p, i.e., .DELTA.(E.sub.k,n).sup.p or .DELTA.(E.sub.(k,kj),n).sup.p. As a result, a significant change in the values is possible through which the ageing process of the cells can be normalized. An effect of benefit is obtained if p is a constant comprised between 2 and 6. Herein after, location is described for comparable days.
The FIGS. 2 a , 3 a and 4 a show different daily power curves P(t) for different weather conditions. In FIG. 2 a , the measured power curve is based on a cloudless day. In FIG. 3 a , a measured curve of the power P of the solar generator is shown as a function of the time for a day with passing clouds, the sun irradiating periodically the photovoltaic generator through holes in said clouds. In FIG. 4 a , the measured curve of the power P of the solar generator relates to a very cloudy day or to a day with constant weak solar radiation.
As shown in FIG. 2 a , the radiation power of the sun increases at sunrise. About noon, it reaches its maximum peak. Toward sunset, the radiation falls toward zero again. FIG. 2 a accordingly illustrates the measured curve of the power P of a photovoltaic generator or of one or more photovoltaic modules as a function of time t for a cloudless day. As can be seen from the curve, there is only one daily maximum with respect to power P. There is no power break due to passing clouds.
In FIG. 3 a it can be seen that there are strong power fluctuations. The intensity of the radiation of the photovoltaic modules, which has changed because of the passing clouds, can be seen clearly.
If a day generates a curve as shown in FIG. 4 a , the day is for example cloudy or rainy and the solar radiation quite low. Typically, this may be a winter day.
Accordingly, the FIGS. 2 a , 3 a and 4 a show typical measured power curves
P(t) for days with different weather conditions, these being in discrete form, i.e., they constitute effective measured variables. For simplicity's sake, these functions are shown schematically or as continuous functions in the FIGS. 2 b , 3 b and 4 b . The discrete measurement data can also be transformed into continuous functions through appropriate interpolation methods.
Preferably, in a first step, the first derivation P′(t) of the power curve P(t) is formed and evaluated for each day, as shown in the FIGS. 2 c , 3 c and 4 c.
FIG. 2 b shows the cloudless, sunny day. A plurality of measurement results are filed in a data bank over the day.
These results are shown in the curve through measurement points on the curve. The curve has a day maximum peak, which is typically about noon. The area below the curves corresponds to the curve integral or to the energy.
FIG. 3 b schematically shows the power curve for passing clouds. A kind of harmonics, which are generated by the periodical shadowing through the clouds, are superimposed on a basic curve, which corresponds to the curve in FIG. 2 b.
In order to be capable of determining a power reduction of the solar module with very high accuracy, data having a comparable power curve P(t) of the photovoltaic module or of the solar plant are preferably observed over several years. As they are comparable, it is possible to make a reliable statement with respect to power reduction of the photovoltaic module. In principle, completely cloudy days as illustrated in FIG. 4 a or 4 b or days with passing clouds as shown in the FIG. 3 a or 3 b are in principle suited for comparison. A comparison with cloudless days is however preferred, i.e., a curve as shown in FIG. 2 a or 2 b is compared year by year.
The measurement method preferably uses the power curve P(t) as well as the energy output E that corresponds to the area enclosed by the curve. This area is hatched in the FIGS. 2 b , 3 b and 4 b . Both are evaluated. Through this measurement method, additional information such as outside temperature or radiation data is not needed. Sensors are not needed either since the power data are measured from the variable of the photovoltaic module that has been delivered. A voltage, a current or both can be measured. It is also possible to directly measure the power.
The FIGS. 2 c through 4 c show the first derivation P′(t) of the functions shown in the FIGS. 2 b through 4 b.
FIG. 4 b shows an example for the curve of the power of the photovoltaic generator as a function of time (t) for a day with overcast sky. In FIG. 4 c , there is for example shown the associated first derivation with respect to time. As opposed to a cloudless day, the maximum power Pmax can however be significantly less.
In a first step, the function P′(t) is formed.
The first derivation P′(t) can be evaluated in different ways. The evaluation clearly indicates whether the day is cloudless or not, as shown in FIG. 3 c.
In a second step, one then analyzes and makes certain whether a cloudless day has indeed been found. For this purpose, the power curve P(t) or its first derivation P′(t) is evaluated. Preferably, two evaluation steps are utilized in order to reliably acquire a comparable cloudless day.
In one of the steps, the first derivation P′(t) is evaluated. For this purpose, there are two possibilities of evaluating the first derivation P′(t). A first possibility is based on the fact that the evaluation method is based on analyzing a maximum for P′(t). If, as shown in FIG. 2 c , the maximum value P′max is for example below an imposed limit (upper dashed line) or if the minimum value P′min is above an imposed limit P′min (lower dashed line), it is supposed that the day is cloudless.
As shown in FIG. 3 c , the first derivation of the power curve for a day with passing clouds has a much higher maximum value P′max but also a much lower minimum value P′min than the first derivation of the power curve for a cloudless day shown in FIG. 2 c . In the FIGS. 2 c , 3 c and 4 c , the upper limit P′max and the lower limit P′min are also shown as dashed lines. Such limit values can also be defined for certain regions. This is possible because average radiation values are known in principle for all the regions in a country. Since radiation values are not only known for regions but also e.g., for certain cities, fine-tuning is possible. These limit values are advantageously acquired and fixed for e.g., a cloudless day in the first year the plant is in operation. Then, verification is performed in the course of the years. Thus, even long-term climatic changes in a region due to climate change can be taken into consideration.
As shown in FIG. 4 c , the values of the first derivation of the power curve for an overcast day are also below or above the imposed limits. Another criterion can be readily used to undoubtedly and automatically locate a cloudless day. This is advantageous because a completely cloudy day yields a daily power curve P(t) that is similar to that of a cloudless day.
A second possibility of evaluating the first derivation P′(t) is described herein after. In this variant of the evaluation method, P′(t) is also formed from the power curve P(t) for each day.
For each day, the integral is for example determined
I= 1 Tag . intg . Tag( P′ ( t ) t )2 t##EQU 00003##
If the value I acquired lies below a maximum allowable limit l_max so that I<l_max, it can be assumed that the day is cloudless and this day can be included in calculating the power reduction. This limit is obtained from typical radiation values and depends for example on the geographical situation. The corresponding day is then fixed according to the same pattern as in the previous example of the evaluation method of P′(t).
The integral I is a measure for the area included in the first derivation P′(t). A comparison between the FIGS. 2 c and 4 c clearly shows that the area enclosed by the curve is significantly smaller on a cloudy day. This area is determined by the integral I. This means, if I<l_max, the day may also be cloudy. Therefore, it is appropriate to perform an additional evaluation step.
In another possibility of evaluating the first derivation P′(t), only the zero crossings of the P′(t) are taken into consideration. If the day is for example cloudless, the number of zero crossings of the curve P(t) is equal to 1. This zero crossing takes place at the time of power maximum, as shown in FIG. 2 c . If more than one zero crossing is located, as is illustrated in FIG. 3 c , it can be assumed that the day is not cloudless.
Herein after, the second step of evaluating the power curve P(t) is described in closer detail.
Since in the first step it is at first only supposed that the day is cloudless or not, this must be confirmed in a second step.
There are different variants to achieve this. The first possibility is to evaluate the daily power curve P(t) in the second step.
The first method for evaluating the daily power curve P(t) consists in determining the daily energy output Etag and in comparing it with an imposed minimum value. If the daily energy output Etag exceeds this minimum value, it is certain that the day is cloudless.
The second evaluation method in the second step consists in evaluating the extreme values of the power curve P(t). For this purpose, an absolute value of the power Pabs is acquired from the host of data P(t) measured within one day. It may for example be the maximum value Pmax of the power P(t) for the day observed or also an average of several power maxima. If this value Pabs lies within a tolerance band ranging from Pabs_min to Pabs_max, then it may well be a relatively cloudless day. Indirectly one also considers the radiation intensity and the duration without the need for an additional sensor.
This method can be even further improved by using the measurement or the measurement values of the temperature of the modules and/or of the outside temperature.
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A method for determining a power reduction due to ageing of a photovoltaic module includes measuring a variable associated with a performance of the module in one or more time periods within a given year, each time period defining a class, and constructing curves of discrete values, each power curve constructed from the measured electric variable at a plurality of times of a day within each class, and the curves constructed for a plurality of years. The method includes determining energy values based on the constructed curves for at least one class for each of the plurality of years, and determining a power reduction of the photovoltaic module with respect to one or several previous years by calculating a difference between the energy output values of a given class in a particular year and the energy output values of the given class in a year previous to the particular year.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/304,070, filed Nov. 23, 2011, which claims the benefit of U.S. Provisional Patent Application No. 61/416,610, filed Nov. 23, 2010, which are hereby incorporated by reference herein in their entireties.
REFERENCE REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
SEQUENTIAL LISTING
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to a scanning acoustic microscope with an inverted transducer and bubbler functionality for inspecting a part.
[0006] 2. Description of the Background of the Invention
[0007] U.S. Pat. No. 7,584,664 is entitled “acoustic micro imaging device having at least one balanced linear motor assembly.” U.S. Pat. No. 7,522,780 is entitled “frequency domain processing of scanning acoustic imaging signals.” U.S. Pat. No. 7,395,713 is entitled “tray-fed scanning microscope system and method primarily for immobilizing parts during inspection.” U.S. Pat. No. 7,000,475 is entitled “acoustic micro imaging method and apparatus for capturing 4D acoustic reflection virtual samples.” U.S. Pat. No. 6,981,417 is entitled “scanning acoustic micro imaging method and apparatus for non-rectangular bounded files.” U.S. Pat. No. 6,895,820 is entitled “acoustic micro imaging method and apparatus for capturing 4D acoustic reflection virtual samples.” U.S. Pat. No. 6,890,302 is entitled “frequency domain processing of scanning acoustic imaging signals.” U.S. Pat. No. 6,880,387 is entitled “acoustic micro imaging method providing improved information derivation and visualization.” U.S. Pat. No. 6,460,414 is entitled “automated acoustic micro imaging system and method.” U.S. Pat. No. 6,357,136 is entitled “scanning acoustic microscope system and method for handling small parts.” U.S. Pat. No. 5,684,252 is entitled “method and apparatus for ultrasonic inspection of electronic components.” U.S. Pat. No. 5,600,068 is entitled “controlled-immersion inspection.” U.S. Pat. No. 4,866,986 is entitled “method and system for dual phase scanning acoustic microscopy.” U.S. Pat. No. 4,781,067 is entitled “balanced scanning mechanism.” U.S. Pat. No. 4,518,992 is entitled “acoustic imaging system and method.” U.S. Patent Application Pub. No. 20090095086 is entitled “scanning acoustic microscope with a profilometer function.” U.S. Provisional Application Ser. No. 61/362,131 is entitled “acoustic micro imaging device with a scan while loading feature.” The contents of all of the aforementioned patents, publications and applications are incorporated by reference into this application as if fully set forth herein.
SUMMARY OF THE INVENTION
[0008] According to one aspect, a scanning acoustic microscope includes a transducer mounted in a cup below a particular elevation capable of producing ultrasonic energy, and a coupling fluid source disposed below the particular elevation, which is configured to introduce coupling fluid into the cup. Ultrasonic energy is directed upwardly through coupling fluid disposed between and contacting the transducer and a first surface of a part to be inspected. The part is disposed at the particular elevation and a second surface of the part is not contacted by coupling fluid during testing.
[0009] According to another aspect, a scanning acoustic microscope includes a transducer mounted in a cup below a particular elevation, and a coupling fluid source disposed below the particular elevation, which is configured to introduce coupling fluid into the cup. The scanning acoustic microscope also includes a pump connected to the cup for pressurizing the coupling fluid before it enters the cup. The scanning acoustic microscope further includes a controller operable to control the transducer and the coupling fluid source during testing such that ultrasonic energy is directed upwardly through coupling fluid disposed between and contacting the transducer and a first surface of a part to be tested. The part is disposed at the particular elevation and a second surface of the part is not contacted by coupling fluid during testing.
[0010] According to yet another aspect, a method of scanning a part using a scanning acoustic microscope includes the steps of mounting a transducer mounted in a cup below a particular elevation and disposing a coupling fluid source at the particular elevation. The coupling fluid source is configured to introduce coupling fluid into the cup. The method also includes the step of providing a controller for controlling the transducer and the coupling fluid source during testing such that ultrasonic energy is directed upwardly through coupling fluid disposed between and contacting the transducer and a bottom surface of the part to be inspected. The part is disposed at the particular elevation and an upper surface of the part is not contacted by coupling fluid during testing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Various examples objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
[0012] FIG. 1A is a top view of a tray of parts that is designed to support various large microelectronic samples for transport through a scanning acoustic microscope illustrated in the remaining figures;
[0013] FIG. 1B is a side view, partly in cross section, of a portion of an embodiment of a scanning acoustic microscope having an inverted transducer and a bubbler functionality;
[0014] FIG. 2 is a combined diagrammatic view and block diagram showing the transport of coupling fluid through the microscope of FIG. 1B ; and
[0015] FIG. 3 is a block diagram showing the electrical connections of the microscope of FIG. 1B .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] 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 with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiment illustrated. It should be further understood that the title of this section of this specification, namely, “Detailed Description of the Preferred Embodiments” relates to a requirement of the United States Patent Office, and does not imply, nor should be inferred to limit the subject matter disclosed herein.
[0017] In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular.
[0018] The description in this document concerns a scanning acoustic microscope having an inverted transducer and a bubbler feature. It is the applicants' intention to preserve the ability to claim a device that includes an inverted transducer and a bubbler feature in combination with none, any, some or all of the other acoustic microscopy features disclosed in the patents and other information incorporated by reference into this document as if fully set forth herein as noted in the background of the invention section.
[0019] FIG. 1A is a top view of a tray 10 that is designed to support a number of large microelectronic samples for transport through a scanning acoustic microscope having an inverted transducer and a bubbler feature. In the illustrated embodiment, tray 10 includes four part support areas 12 , 14 , 16 and 18 that are defined by ledges 20 , 22 , 24 and 26 . A suitable target such as, for example, a microelectronic sample part 36 (shown in FIG. 1B ) can be supported on the ledges 20 - 26 within the support areas 12 - 18 of the tray 10 .
[0020] FIG. 1B is a side, partial cross sectional view of a portion of an embodiment of a scanning acoustic microscope 28 having an inverted transducer and a bubbler functionality. Scanning acoustic microscope 28 includes a waterproof ultrasonic transducer 30 that is designed to emit pulses of ultrasonic energy along axis 32 towards an underside 34 of a sample part 36 that, in use, is generally opposite to the force of gravity. An outer portion of sample part 36 rests on one of the ledges 20 - 26 defining one of the part support areas 12 - 18 in tray 10 . Transducer 30 is connected to suitable control circuitry (not shown) via line 38 .
[0021] In the illustrated embodiment of the invention, transducer 30 is secured to a bottom surface of a spray cup 40 by, for example, a threaded connection. A water inlet tube 42 is inserted through a side aperture in spray cup 40 with sufficient pressure to allow water (or any other suitable coupling fluid) to fully immerse the transducer 30 inside of spray cup 40 and then travel upwards in a laminar flow (so that bubbles or entrained air do not form in the flow, at lease until the water deflects off the part) and contact the underside 34 of sample part 36 . One aspect of the invention is that, for example, the water pressure is sufficiently high to cause a water flow to cover the distance between the end of the spray cup 40 and the underside 34 of the sample part 36 without blowing the part 36 off of the tray 10 if the water pressure were too high. As discussed in greater detail hereinafter, the appropriate water pressure for a given application can be determined by visual inspection and then set and thereafter automatically applied for subsequent acoustic microscopic inspection of trays of parts as they are moved into and then out of the scanning acoustic microscope 28 . Furthermore, it is may be preferable (depending upon, among other things, coupling fluid supply pressure) that a gap be maintained between the sample part 36 and the spray cup 40 to prevent water pressure from becoming too high such that the water pressure causes the part to be lifted off of the tray 10 .
[0022] In addition, the sample part 36 may have a critical and non-critical side wherein the critical side cannot get wet. To prevent water from seeping up around the ledges 20 - 26 during the inspection of the non-critical side, a fan or air knife can be used to blow air toward the critical side of the sample part 36 . The fan or air knife is preferably located above the tray 10 and scanning microscope 28 and may be of sufficient capacity to generate a stream of air that covers the entire tray 10 . Alternatively, the fan or air knife may cover only a single part 36 or portion of a part, for example the edges(s) of a part 36 , as desired. The fan or knife blower may also be used to maintain the sample part 36 in place if the pressure of the water flow increases.
[0023] Another feature of the invention disclosed herein involves the utilization of a drain saucer 43 that, in an exemplary embodiment of the invention, is connected to an outer and lower external surface of spray cup 40 . The drain saucer 43 includes a raised outer rim 44 that is sufficiently wide to be able to capture all of the water emitted from the spray cup as it splashes off of the sample part 36 and the tray 10 and falls back towards the drain saucer 43 due to the force of gravity. A drain tube 46 is inserted in an aperture formed in a bottom portion of drain saucer 43 that is shaped so that all water caught by the drain saucer 43 is directed towards the drain tube 46 .
[0024] FIG. 2 is a schematic diagram showing the transport of water through the scanning acoustic microscope 28 . An inlet pump 48 draws water from reservoir 50 via tube 52 , pressurizes the water to a suitable level, and then provides the pressurized water to spray cup 40 via tube 42 . A drain pump 54 draws water from the drain saucer 43 via drain tube 46 and then provides the collected water back to reservoir 50 via tube 56 .
[0025] FIG. 3 is a schematic diagram showing the electrical connections of the scanning acoustic microscope 28 . The transducer assembly 58 includes, in the illustrated embodiment, the transducer 30 , the spray cup 40 and the drain saucer 43 shown in FIG. 1B . Electrical signals between, to, and from the transducer 30 to the controller 60 pass along line 38 . Controller is electrically connected to x, y, z stage drivers 62 via line 64 so that the x, y, z stage drives can cause transducer assembly 58 to be moved in operative relation with respect to the tray 10 by means of actuators 66 to allow for non-destructive testing of the samples on tray 10 to take place. For example, this action can cause transducer 10 to be moved in an x-y raster scan of each sample.
[0026] Controller 60 also is electrically connected to pumps 48 and 54 via lines 68 and 70 . The pumps 48 and 54 are turned on and off as needed for non-destructive testing purposes of samples disposed on the tray 10 . Information about the scanning process and the scan results are caused to be shown on the display 74 by controller 60 . For example, both time domain and frequency domain images of a particular sample can be appropriately color coded and then shown to an operator for analysis. Controller 60 is electrically connected to a memory 72 so that, if desired, data for scans can be stored for later analysis or retrieved therefrom and transmitted to others via suitable transport (e.g., email or a memory stick).
INDUSTRIAL APPLICABILITY
[0027] Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention and to teach the best mode of carrying out same. The exclusive rights to all modifications which come within the scope of the appended claims are reserved.
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A scanning acoustic microscope includes a transducer mounted in a cup below a particular elevation capable of producing ultrasonic energy and a coupling fluid source disposed below the particular elevation, which is configured to introduce coupling fluid into the cup. Ultrasonic energy is directed upwardly through coupling fluid disposed between and contacting the transducer and a first surface of a part to be inspected. The part is disposed at the particular elevation such that a second surface of the part is not contacted by coupling fluid during testing.
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TECHNICAL FIELD
[0001] The present invention relates to a strainer wall structure (referred to as a passive filtration apparatus) for filtering foreign substances, settlings, etc., generated upon occurrence of failures or accidents of an apparatus requiring a water circulation system, and more particularly, to a strainer wall structure used to remove foreign substances from a fluid suctioned into a pipe and a re-circulation pump when the re-circulation pump goes through an operation of an emergency core cooling system (ECCS) when a pipe failure occurs in a nuclear power plant.
BACKGROUND ART
[0002] A nuclear reactor of a nuclear power plant is surrounded by a safety vessel formed of concrete and steel, which is referred to as a containment, in which a coolant circulates to maintain a proper temperature. In addition, the nuclear reactor includes an ECCS for cooling the nuclear reactor upon occurrence of failures or accidents.
[0003] The ECCS must be operated upon occurrence of accidents such as coolant leakage, etc., to cool the nuclear reactor for 30 days with no external interference. The ECCS is a system for collecting coolant discharged and water sprinkled upon a pipe failure into a sump disposed at the lowermost part in the containment, sprinkling the water from an upper part of the containment using the re-circulation pump to cool the containment, and circulating some of the water through a nuclear reactor cooling system to remove remaining heat of the nuclear reactor using a remaining heat removing pump.
[0004] When coolant leakage occurs due to damage to a pipe, etc., in a primary system of the nuclear power plant, foreign substances such as lagging materials, coating materials, latent foreign substances, etc., are generated due to discharge of a coolant. In addition, the discharged coolant and water sprinkled from a sprinkler system of the containment move all foreign substances to a re-circulation sump disposed at a lower end of the containment of the nuclear reactor. Therefore, in order for the foreign substances not to decrease performance of the ECCS, a filtration apparatus is provided in front of an introduction part of a suction pipe guided to an emergency cooling pump.
[0005] When a high temperature and high pressure pipe is broken, foreign substances such as fragments of lagging materials, coating materials, etc., are generated and moved toward the sump, and the filtration apparatus functions to filter the foreign substances moved to the sump and supply the filtered water into the re-circulation pump, without interfering with the operation of the re-circulation pump.
[0006] The filtration apparatus ensures that the foreign substances generated due to accidents can be filtered and the water can appropriately pass therethrough. In this case, a pressure drop due to the foreign substances must be guaranteed not to exceed an allowable critical value.
[0007] A conventional filter screen used in a pressurized water reactor type nuclear power plant has a small screen surface only, and the screen surface is mainly formed of flat grid segments. Thus, when the screen surface is contaminated with fiber settlings, a pressure drop at the screen may be largely increased to an unallowable level.
[0008] However, the filtration apparatus having a single surface may be easily deformed by a high pressure, and a small effective filtration area per a unit volume may decrease filtration efficiency. In order to solve the problem, while the number of filtration apparatus may be increased, their installation cost is high, which causes economical problems. Therefore, a filtration apparatus capable of increasing a filtration area per unit volume is still needed.
Technical Problem
[0009] In order to solve the foregoing and/or other problems, it is an aspect of the present invention to provide a strainer wall structure, a filtration method using the same, and a method of fabricating the same that are capable of providing a substantially larger effective filtration area in the same length and width, substantially reducing foreign substances covering a suction surface and a flow resistance of the foreign substances, and reducing a pressure drop at a cooling water pass corresponding thereto.
[0010] It is another aspect of the present invention to provide a strainer wall structure, a filtration method using the same, and a method of fabricating the same in which maintenance and installation thereof can be easily performed, and manufacturing and installation costs can be reduced to solve economical problems in exchange and installation thereof.
Technical Solution
[0011] The foregoing and/or other aspects of the present invention may be achieved by providing a strainer wall structure including an inlet side through which cooling water is introduced and an outlet side through which the cooling water is discharged, including: a body having an opening in a direction of the inlet side, closed side surfaces, and an outlet port disposed at one of the closed side surfaces; a filter screen inserted into the opening and formed of a punched plate having a plurality of filter holes; and a modular cassette apparatus including a plurality of first filter plates inserted into the body, each having a plurality of first grooves, and formed by bending the punched plate; and a plurality of second filter plates each having a plurality of second groves inserted into the first grooves, and formed by bending the punched plate, so that the plurality of first filter plates disposed in one direction are perpendicularly assembled to the plurality of second filter plates to form a grid structure.
[0012] The grid structure and the filter screen may define suction pockets.
[0013] Each of the first filter plates and the second filter plates may have a dual wall structure to form a discharge cap disposed therein.
[0014] In the modular cassette apparatus, the width of the first grooves may be equal to the thickness of the second filter plates, and the width of the second grooves may be equal to the thickness of the first filter plates, so that the first filter plates are press-fitted into the second filter plates.
[0015] When the cooling water is suctioned into the suction pockets, the cooling water may be surrounded by five surfaces constituted by the first filter plates, the second filter plates and the filter screens.
[0016] The filter holes may have a diameter of 1 to 3 mm.
[0017] The strainer wall structure may further include a fixing frame coupled to the opening by connection members to fix the modular cassette apparatus into the body.
[0018] At least two surfaces of the outer surfaces of the body may have openings, the filter screens may be inserted into the openings, respectively, the modular cassette apparatus may be installed at the filter screens, respectively, and the fixing frames may be coupled to the outer peripheries of the openings, respectively.
[0019] The connection members may be pins, screws, rivets, or bolts.
[0020] The body may further include L-shaped steel at corners thereof.
[0021] The strainer wall structure may further include fixing plates installed in the body to fix the modular cassette apparatus in a direction of the outlet side.
[0022] Another aspect of the present invention may be achieved by providing a filtration method using a strainer wall structure including: installing a body in a passage through which cooling water flows; inserting a filter screen formed of a punched plate into an opening of the body; forming a modular cassette apparatus including a plurality of first filter plates inserted into the body, each having a dual layer structure and a plurality of first grooves, and formed by bending the punched plate; and a plurality of second filter plates each having a dual layer structure and a plurality of second groves inserted into the first grooves, and formed by bending the punched plate, so that the plurality of first filter plates disposed in one direction are perpendicularly assembled to the plurality of second filter plates to form a plurality of suction pockets in a grid structure; inserting the modular cassette apparatus into the filter screen; coupling fixing frames to an outer periphery of the opening of the body to fix the modular cassette apparatus into the body; introducing the cooling water into an inlet side to be suctioned into the plurality of suction pockets; and passing the cooling water suctioned into the suction pockets through the dual wall, which forms the suction pockets, or the filter screen, and discharging the filtered cooling water through an outlet port.
[0023] The body may include two openings, in inserting the filter screen, the filter screens may be inserted into the openings, respectively, in inserting the modular cassette apparatus, the modular cassette apparatus may be installed in the filter screens, respectively, and in fixing the modular cassette apparatus, the fixing frames may be fixed to corners of the openings, respectively.
[0024] In suctioning and discharging the cooling water, the cooling water suctioned into the suction pockets may pass through the filter screen to be discharged to the outlet side, or pass through the dual wall to be introduced into the discharge cap and then pass through the filter screen to be discharged to the outlet side.
[0025] Still another aspect of the present invention may be achieved by providing a method of fabricating a strainer wall structure including: forming a punched plate with a large area having a plurality of filter holes, and cutting the punched plate to form a plurality of rectangular holes in a matrix; cutting the punched plate with a large area along a line between the adjacent rectangular holes arranged in a longitudinal direction thereof to fabricate a first base plate, and bending the first base plate twice with respect to a first centerline thereof to form a first filter plate having a dual wall structure and a plurality of first grooves; cutting the punched plate with a large area to cut the rectangular holes arranged in a longitudinal direction thereof to divide them into halves to form a second base plate, and bending the second base plate twice with respect to a second centerline thereof to form a second filter plate having a dual wall structure and a plurality of second grooves; inserting the first grooves and the second grooves into each other to perpendicularly assemble the first filter plates to the second filter plates to form a modular cassette apparatus having a grid structure; inserting the modular cassette apparatus into the body; and coupling fixing frames to an opening of the body using connection members to fix the modular cassette apparatus into the body.
[0026] The method may further include, before inserting the modular cassette apparatus, inserting filter screens formed of the punched plates into the body.
[0027] The method punched plate may be cut by a laser to form the rectangular holes.
[0028] According to a strainer wall structure of the present invention, it is possible to provide a substantially larger effective filtration area in the same length and width. Therefore, a flow resistance of settlings and foreign substances covering a suction surface can be substantially reduced. In addition, a pressure drop generated along the strainer wall structure can be reduced depending on reduction in flow resistance.
[0029] Further, since the strainer wall structure of the present invention is fabricated by assembling a filter screen having a punched plate, a first filter plate and a second filter plate, without welding, it is possible to easily perform maintenance and installation thereof. Furthermore, since a plurality of first filter plates and second filter plates are vertically arranged, a load pressure can be distributed to increase structural integrity.
DESCRIPTION OF DRAWINGS
[0030] The above and other aspects and advantages of the present invention will become apparent and more readily appreciated from the following description of exemplary embodiments, taken in conjunction with the accompanying drawings of which:
[0031] FIG. 1 is a perspective view of a strainer wall structure in accordance with an exemplary embodiment of the present invention;
[0032] FIG. 2 is a front view of a strainer wall structure in accordance with an exemplary embodiment of the present invention;
[0033] FIG. 3 is a side view of a strainer wall structure in accordance with an exemplary embodiment of the present invention;
[0034] FIG. 4 is an exploded perspective view of a strainer wall structure in accordance with an exemplary embodiment of the present invention;
[0035] FIG. 5 is a perspective view of a body in accordance with an exemplary embodiment of the present invention;
[0036] FIG. 6 is a front view of a body in accordance with an exemplary embodiment of the present invention when seen from an open side;
[0037] FIG. 7 is a perspective view of a filter screen in accordance with an exemplary embodiment of the present invention;
[0038] FIG. 8 is a perspective view of a first filter plate in accordance with an exemplary embodiment of the present invention when seen from an inlet side;
[0039] FIG. 9 is a perspective view of the first filter plate in accordance with an exemplary embodiment of the present invention when seen from an outlet side;
[0040] FIG. 10 is a plan view of FIG. 9 ;
[0041] FIG. 11 is a perspective view of a second filter plate in accordance with an exemplary embodiment of the present invention when seen from an inlet side;
[0042] FIG. 12 is a perspective view of the second filter plate in accordance with an exemplary embodiment of the present invention when seen from an outlet side;
[0043] FIG. 13 is a side view of FIG. 12 ;
[0044] FIG. 14 is a perspective view of a modular cassette apparatus in accordance with an exemplary embodiment of the present invention;
[0045] FIG. 15 is a perspective view of a filter screen into which the modular cassette apparatus in accordance with an exemplary embodiment of the present invention is inserted;
[0046] FIG. 16 is an enlarged view of a suction pocket in accordance with an exemplary embodiment of the present invention;
[0047] FIG. 17 is a cross-sectional view taken along line A-A′ of FIG. 16 ;
[0048] FIG. 18 is a cross-sectional view taken along line B-B′ of FIG. 16 ;
[0049] FIG. 19 is a cross-sectional view taken along line C-C′ of FIG. 16 ;
[0050] FIG. 20 is a flowchart of a filtration method using a strainer wall structure in accordance with an exemplary embodiment of the present invention;
[0051] FIG. 21 is a flowchart of a method of fabricating a strainer wall structure in accordance with an exemplary embodiment of the present invention;
[0052] FIG. 22 is a cross-sectional view showing a method of fabricating a first filter plate and a second filter plate in accordance with an exemplary embodiment of the present invention; and
[0053] FIG. 23 is a perspective view of another embodiment of the present invention including a plurality of strainer wall structures.
[0054]
[0000]
*Description of Major Reference Numerals*
10: Strainer wall structure
20: Filter hole
30: Inlet side
40: Outlet side
50: Large punched plate
60: Rectangular hole
70: First base plate
71: First centerline
80: Second base plate
81: Second centerline
100: Body
110: Opening
120: Closed surface
130: L-shaped steel
140: Outlet port
150: Fixed plate
200: Filter screen
210: Filter screen plate
220: Outer periphery plate
300: First filter plate
310: First groove
320: Dual wall of first filter plate
330: Discharge cap of first
400: Second filter plate
filter plate
410: Second groove
420: Dual wall of second filter plate
430: Discharge cap of second
500: Fixed frame
filter plate
510: Connection member
520: First coupling member
521: Second coupling member
600: Modular cassette apparatus
610: Suction pocket
700: Discharge space
D: Diameter of filter hole
L F1 : Length of first filter plate
H F1 : Height of first filter plate
t f1 : Thickness of first filter plate
I g1 : Interval of first grooves
W g1 : Width of first groove
H g1 : Depth of first groove
L f2 : Length of second filter plate
H f2 : Height of second filter plate
t f2 : Thickness of second filter plate
I g2 : Interval of second grooves
W g2 : Width of second groove
H g2 : Depth of second groove
DETAILED DESCRIPTION
[0055] Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0056] FIG. 1 is a perspective view of a strainer wall structure in accordance with an exemplary embodiment of the present invention, FIG. 2 is a front view of a strainer wall structure in accordance with an exemplary embodiment of the present invention, and FIG. 3 is a side view of a strainer wall structure in accordance with an exemplary embodiment of the present invention.
[0057] As shown in FIG. 1 , a strainer wall structure 10 of the present invention is fixedly installed at a passage through which cooling water flows. The cooling water flows into an inlet side 30 of the strainer wall structure 10 to be discharged through an outlet port 140 . While two inlet sides 30 are provided as shown in FIG. 1 , one or more inlet sides may be provided.
[0058] A filter screen 200 is inserted into a body 100 having openings 110 formed at the inlet sides 30 and closed side surfaces 120 .
[0059] In addition, a modular cassette apparatus 600 , in which a first filter plate 300 and a second filter plate 400 having a dual wall ( 320 , 320 ) structure formed of punched plates are assembled in a grid structure, is inserted into the filter screen 200 .
[0060] As shown in FIG. 2 , the modular cassette apparatus 600 having a grid structure and the filter screen 200 (see FIG. 4 ) are installed in the body 100 . In addition, the first filter plate 300 , the second filter plate 400 and the filter screen 200 constituting the modular cassette apparatus 600 are formed of punched plates each having a plurality of filter holes 20 .
[0061] The diameter D of the filter hole 20 is designed to be 2.5 mm in this embodiment, and is preferably 1 to 3 mm in consideration of an installation position of the filtration apparatus or the size of foreign substances.
[0062] As shown in FIG. 3 , the outlet port 140 is installed at a lower end of one side surface of the body 100 to discharge cooling water. While not seen from the exterior, referring a partially cut view of FIG. 3 , it will be appreciated that two modular cassette apparatus 600 in which the first filter plate 300 and the second filter plate 400 are assembled are inserted in the body 200 together with the filter screens 200 , respectively. In addition, a discharge space 700 is provided between the two filter screens 200 .
[0063] FIG. 4 is an exploded perspective view of a strainer wall structure in accordance with an exemplary embodiment of the present invention.
[0064] As shown in FIG. 4 , a fixing frame 500 is coupled to an outer periphery of an opening 110 of the body 100 by a connection member 510 to fix the modular cassette apparatus 600 .
[0065] The strainer wall structure 10 is fabricated by assembling the respective components, without welding the components, to each other. In particular, the modular cassette apparatus 600 having a grid structure formed of a plurality of suction pockets 610 is assembled by inserting the first filter plate 300 and the second filter plate 400 into first grooves 310 and second grooves 410 , respectively, without welding or separate coupling means.
[0066] Side surfaces of the body 100 are formed of closed surfaces 120 , and the outlet port 140 is installed at one side surface. The opening 110 is formed in a direction of the inlet side 30 to introduce the cooling water into the opening 110 . In this embodiment, two inlet sides 30 are installed to form the body 110 having openings 110 at both sides thereof.
[0067] Two filter screens 200 are inserted into the body 100 through the inlet sides 30 , respectively. While FIG. 4 shows one side only, the filter screen 200 , the modular cassette apparatus 600 and the fixed frame 500 are assembled through the opening 110 of the body 100 at the other inlet side 30 .
[0068] In this embodiment, the filter screen 200 is formed of stainless steel, and a filter screen plate 210 and the outer periphery plate 220 are formed of punched plates having a plurality of filter holes 20 . In addition, the filter screen 200 is surrounded by four outer periphery plates 200 having lengths corresponding to the heights H f1 and H f2 of the first filter plate 300 and the second filter plate 400 .
[0069] Each modular cassette apparatus 600 is inserted into each filter screen 200 . Since they are also assembled by insertion thereof, there is no need for welding or coupling members. First, the plurality of first filter plates 300 are disposed at the filter screen 200 at predetermined intervals. In this embodiment, seven first filter plates 300 are disposed. Each of the first filter plates 300 has first grooves 310 formed at predetermined intervals. As shown in FIG. 4 , the first grooves 310 are formed in a direction of the inlet side 30 . The interval of the first grooves 310 is designed within a range of substantially 80 to 150 mm, and 110 mm in this embodiment.
[0070] In addition, the second filter plates 400 cooperate with and are perpendicularly assembled to the first filter plates 300 to form a grid structure. The second filter plates 400 are also formed of punched plates having a plurality of filter holes 20 , each of which is formed of a dual wall 420 . The second grooves 410 of the second filter plate 400 are coupled and assembled to the first grooves 310 of the first filter plate 300 . Meanwhile, the second grooves 410 of the second filter plate 400 are formed in a direction of an outlet side. An interval Ig 2 of the first grooves 310 is designed within a range of substantially 80 to 150 mm, and 100 mm in this embodiment.
[0071] As shown in FIG. 4 , the seven first filter plates 300 and the eight second filter plates 400 corresponding thereto are assembled to each other by perpendicularly fitting the first grooves 310 to the second grooves 410 to form the modular cassette apparatus 600 having a grid structure. Specifically, the thickness t f1 of the first filter plate 300 is equal to the width W g2 of the second groove 410 (designed as 30 mm in this embodiment, t f1 =W g2 ), and the thickness t f2 of the second filter plate 400 is equal to the width W g1 of the first groove 310 (designed as 30 mm in this embodiment, t f2 =W g1 ). In addition, the depth H g1 of the first groove 310 is equal to a distance of the height H f2 of the second filter plate 400 minus the depth H g2 of the second groove 410 (H g1 =H f2 −H g2 ). Further, the depth H g2 of the second groove 410 is equal to a distance of the height H f1 of the first filter plate 300 minus the depth H g1 of the first groove 310 (H g2 =H f1 −H g1 ). Therefore, the first grooves and the second grooves are perpendicularly engaged to form a grid structure.
[0072] As described in this embodiment, the seven first filter plates 300 and the eight second filter plates 400 are assembled to form the modular cassette apparatus 600 having a grid structure. The modular cassette apparatus 600 includes a plurality of suction pockets 610 , and in this embodiment, 72 suction pockets. The suction pockets 610 are opened in a direction of the inlet side 30 , surrounded by the filter screen 200 at the outlet side 40 , and surrounded by the dual wall 320 of the first filter plate 300 and the dual wall 420 of the second filter plate 400 at the remaining four surfaces. Therefore, the cooling water introduced into the suction pocket 610 is filtered through the filter holes 20 formed at the five surfaces to be introduced into the discharge space 700 .
[0073] After the modular cassette apparatus 600 are assembled to the filter screens 200 inserted into the two openings 110 of the body, respectively, the fixed frame 500 is coupled to an outer periphery of the opening 110 by connection members 510 (fixing pins, in this embodiment) to fix the modular cassette apparatus 600 (while FIG. 4 shows an insertion operation through one opening, the other opening is also assembled in the same manner). The connection members 520 may be pins, screws, rivets, bolts, etc.
[0074] FIG. 5 is a perspective view of a body in accordance with an exemplary embodiment of the present invention, and FIG. 6 is a front view of a body in accordance with an exemplary embodiment of the present invention when seen from an open side.
[0075] As shown in FIG. 5 , side surfaces of the body 100 are provided as closed surfaces, and the inlet side 30 is provided as an opening 110 . Fixed plates 150 are installed in the body to fix the filter screen 200 in a direction of the outlet side 40 .
[0076] Eight fixed plates 150 are installed at inner corners in the body. As shown in FIG. 6 , when the cooling water is introduced into the suction pocket 610 , since the body 100 receives a high pressure, an L-shaped steel 130 may be welded to the outer periphery to reinforce the body. In this embodiment, the L-shaped steel 130 is coupled to a center part of the side surface to maintain the shape of the body even under a high pressure.
[0077] It will be appreciated that the hollow outlet port 140 is installed at a lower end of one side surface of the body and is reinforced by the L-shaped steel 130 at the corners and the center part of the closed surface 120 . In addition, as shown in a partially cut view, the fixed plates 150 are installed in the body. When the two filter screens 200 are inserted through the opening 110 , the discharge space 700 is formed between the two filter screens 200 (i.e., between the two fixed plates 150 ).
[0078] FIG. 7 is a perspective view of a filter screen in accordance with an exemplary embodiment of the present invention.
[0079] The filter screen plate 210 formed of a punched plate and the outer periphery thereof are surrounded by outer periphery plates 220 having a predetermined height. The diameter D of the filter holes 20 of the punched plate is 1 to 3 mm, which is designed as 2.5 mm in this embodiment. The diameter D of the filter holes 20 is designed in consideration of the size, etc., of foreign substances generated in the containment and arriving at the filtration apparatus upon accidents. The height of the outer periphery plates 220 is equal to the height of the first filter plate 300 and the second filter plate 400 (145 mm in this embodiment).
[0080] FIG. 8 is a perspective view of a first filter plate in accordance with an exemplary embodiment of the present invention when seen from an inlet side, FIG. 9 is a perspective view of the first filter plate in accordance with an exemplary embodiment of the present invention when seen from an outlet side, and FIG. 10 is a plan view of FIG. 9 .
[0081] As shown in FIG. 8 , the first filter plate 300 is formed of a punched plate and includes a plurality of first grooves 310 . The first grooves 310 are formed in a direction of the inlet side 30 . In this embodiment, the first filter plate 300 has eight first grooves 310 . A dual wall 320 formed of a punched plate forms an outer surface of the suction pocket 610 . In addition, the cooling water passes through the dual wall 320 to be introduced into a discharge cap 330 . A flow direction of the cooling water is shown by arrows.
[0082] As shown in FIG. 9 , the first filter plate 300 is formed of a dual wall 320 structure, and includes the discharge cap 330 . The cooling water is filtered through the dual wall 320 formed of a punched plate and introduced into the discharge cap 330 to be discharged through the filter screen plate 210 . A flow direction of the cooling water is shown by arrows.
[0083] The second filter plates 400 are perpendicularly inserted into the first grooves 310 to assemble the first filter plates 300 to the second filter plates 400 .
[0084] As shown in FIG. 10 , in a specific embodiment, eight first grooves 310 are disposed at an interval I g1 of 110 mm. The width W g1 of the first grooves 310 is 30 mm, the depth H g1 is 72.5 mm, and the thickness t f1 is 30 mm. In addition, the diameter D of the filter holes 20 may be 1 to 3 mm. A flow direction of the cooling water is shown by arrows.
[0085] However, it will be appreciated that limitations to these specific numbers are described for the illustrative purpose only, and thus, should not affect determination of the scope of the present invention due to the specific numbers while maintaining the technical sprit and equivalency of the present invention.
[0086] FIG. 11 is a perspective view of a second filter plate in accordance with an exemplary embodiment of the present invention when seen from an inlet side, FIG. 12 is a perspective view of the second filter plate in accordance with an exemplary embodiment of the present invention when seen from an outlet side, and FIG. 13 is a side view of FIG. 12 .
[0087] As shown in FIGS. 11 and 12 , the second filter plate 400 is formed of a punched plate having a plurality of filter holes 20 . In addition, the second filter plate 400 has a dual wall 420 structure and includes the discharge cap 430 therein. It will be appreciated that the seven second grooves 410 are formed in a direction of the outlet side 40 . The seven first filter plates 300 are inserted into the second grooves 410 , respectively, so that the seven first filter plates 300 are perpendicularly assembled to the eight filter plates 400 to form the modular cassette apparatus 600 having a grid structure. The thickness t f2 of the second filter plates 400 is designed as 30 mm equal to that of the first filter plates 300 , which must be equal to the width W g1 of the first grooves 310 of the first filter plates 300 (t f2 =W g1 ). A flow direction of the cooling water is shown by arrows.
[0088] As shown in FIG. 13 , since the interval I g2 of the second grooves 410 of the second filter plate 400 is designed as 130 mm and the width W g2 of the second grooves 410 is equal to the thickness t f1 of the first filter plate 300 (30 mm in this embodiment), the first filter plates 300 can be inserted into the second grooves 410 , respectively. In addition, two modular cassette apparatus 600 , in which the seven first filter plates 300 are perpendicularly assembled to the eight second filter plates 400 , respectively, are inserted into the filter screen 200 . A flow direction of the cooling water is shown by arrows. The cooling water passes through the dual wall 420 to be introduced into the discharge cap 430 , and the introduced cooling water passes through the filter screen plate 210 to be discharged to the outlet side 40 . Further, the fixed frames 500 are installed at corners of the opening 110 by the connection members 510 to fix the modular cassette apparatus 600 .
[0089] FIG. 14 is a perspective view of a modular cassette apparatus in accordance with an exemplary embodiment of the present invention, and FIG. 15 is a perspective view of a filter screen into which the modular cassette apparatus in accordance with an exemplary embodiment of the present invention is inserted.
[0090] As shown in FIG. 14 , since the thickness t f1 of the first filter plates 300 is equal to the width W g2 of the second grooves 410 , the first filter plates 300 are inserted into the seven second grooves 410 , respectively. In addition, since the thickness t f2 of the second filter plates 400 is equal to the width W g1 of the first grooves 310 , the second filter plates 400 are inserted into the eight first grooves 310 to be assembled thereto. The modular cassette apparatus 600 includes a plurality of suction pockets 610 (72 suction pockets 610 in this embodiment). The cooling water in the inlet side 30 is suctioned into the suction pockets 610 . A flow direction of the cooling water is shown by arrows. The cooling water in the inlet side 30 is suctioned into the suction pockets 610 and then filtered to be discharged to the outlet side 40 .
[0091] As shown in FIG. 15 , the cooling water is suctioned into the suction pockets 610 from the inlet side 30 to be filtered by the first filter plates 300 , the second filter plates 400 and the filter screen plate 210 and then discharged to the outlet side 40 . The filter screens 200 into which the modular cassette apparatus 600 are inserted are inserted into the openings 110 of the body 100 , respectively.
[0092] FIG. 16 is an enlarged view of a suction pocket in accordance with an exemplary embodiment of the present invention, FIG. 17 is a cross-sectional view taken along line A-A′ of FIG. 16 , FIG. 18 is a cross-sectional view taken along line B-B′ of FIG. 16 , and FIG. 19 is a cross-sectional view taken along line C-C′ of FIG. 16 .
[0093] As shown in FIG. 16 , the cooling water is introduced through the inlet side 30 to be suctioned into the suction pockets 610 . Side surfaces of each suction pocket 610 are constituted by the dual walls 320 and 420 of the first filter plate 300 and the second filter plate 400 , and the filter screen plate 210 is installed at the outlet side 40 . Therefore, the cooling water introduced into the suction pockets 610 is surrounded by five surfaces. All of the five surfaces are formed of punched plates. Therefore, a filtration area per unit volume can be increased.
[0094] Specifically, the introduced cooling water may pass through the dual wall 320 or 420 of the first filter plate 300 or the second filter plate 400 constituting the side surfaces of the suction pockets 610 , or pass through the filter screen plate 210 . The cooling water passing through the first filter plates 300 or the second filter plates 400 is introduced into the discharge caps 330 and 430 , and the cooling water introduced into the discharge caps 330 and 430 passes through the filtered screen plates 210 to be introduced into the discharge space 700 and then discharged to the outlet port 140 . In addition, the cooling water passing through the filter screen plate 210 is introduced into the discharge space 700 to be discharged to the outlet port 140 .
[0095] As show in FIG. 17 , the cooling water is suctioned into the suction pockets 610 from the inlet side 30 . Then, the suctioned cooling water may be directly discharged to the outlet side 40 through the filter screen plate 210 . In addition, the cooling water passes through the dual wall 420 of the second filter plate 400 to be introduced into the discharge cap 430 . The cooling water introduced into the discharge cap 430 passes through the filter screen plate 210 to be discharged to the outlet side 40 .
[0096] In this embodiment, since the two modular cassette apparatus 600 are symmetrically provided, the cooling water discharged to the outlet side is in the discharge space 700 .
[0097] As shown in FIG. 18 , the cooling water is suctioned into the suction pockets 610 . Then, the suctioned cooling water may be immediately discharged to the outlet side 40 through the filter screen plate 210 . In addition, the cooling water passes through the dual walls 320 of the first filter plates 300 to be introduced into the discharge caps 330 . The cooling water introduced into the discharge cap 330 passes through the filter screen plate 210 to be discharged to the outlet side 40 .
[0098] In FIG. 19 , {circumflex over (x)} means a direction that the cooling water flows through the figure, and a flow direction of the cooling water is shown by arrows.
[0099] As shown in FIG. 19 , the cooling water introduced into the suction pockets 620 is introduced into the discharge caps 330 and 430 through the dual walls 320 and 420 of the first filter plates 300 and the second filter plates, which are formed of punched plates. The cooling water introduced into the discharge caps 330 and 430 is filtered again by the filter screen plate 210 to be discharged to the outlet side 40 . The cooling water discharged to the outlet side 40 is introduced into the discharge space between the two filter screens 200 to be discharged through the outlet port 140 installed at the body 100 .
[0100] <Filtration Method Using Strainer Wall Structure>
[0101] Hereinafter, a filtration method using a strainer wall structure 10 of the present invention will be described. FIG. 20 is a flowchart of a filtration method using a strainer wall structure in accordance with an exemplary embodiment of the present invention.
[0102] First, a body 100 is fixed to a passage through which cooling water flows (S 10 ). As described above, the body 100 includes openings 110 in a direction of an inlet side 30 , closed side surfaces 120 , and an outlet port 140 at one of the closed side surfaces 120 .
[0103] Then, filter screens 200 are inserted into the openings 110 of the body 110 (S 200 ). In this embodiment, two openings 110 are provided. Therefore, the filter screens 200 are inserted into the openings 110 , respectively. Each of the filter screens 200 includes a filter screen plate 210 formed of a punched plate, and an outer periphery plate 220 formed of a punched plate similar to the filter screen plate 210 and surrounding an outer periphery of the filter screen plate 210 . The filter screen 200 is fixed by fixing plates 150 in the body 100 at an outlet side 40 , and a discharge space 700 is formed in the body 100 between the two filter screens 200 .
[0104] Next, a modular cassette apparatus 600 including a plurality of suction pockets 610 formed by perpendicularly assembling seven first filter plates 300 each having eight first grooves 310 and eight second filter plates 400 each having seven second grooves 410 is provided (S 30 ). Each of the first filter plates 300 is formed of a punched plate having a plurality of filter holes 20 and has a dual wall 320 structure to form a discharge cap 330 therein. The first grooves 310 are formed in a direction of the inlet side 30 .
[0105] Each of the second filter plates 400 is also formed of a punched plate having a plurality of filter holes 20 and has a dual wall 420 structure to form a discharge cap 430 therein. The second grooves 410 are formed in a direction of the outlet side 40 . Therefore, the first filter plates 300 and the second filter plates 400 are perpendicularly assembled by the first grooves 310 and the second grooves 410 to form a grid structure of modular cassette apparatus 600 including a plurality of suction pockets 610 . Two modular cassette apparatus 600 are installed in the two filter screens 200 .
[0106] Next, the modular cassette apparatus 600 are inserted and assembled into the filter screens 200 (S 40 ). In this embodiment, since two inlet sides 30 are provided, the modular cassette apparatus 600 are assembled to the filter screens 200 inserted into the inlet sides 30 .
[0107] Fixing frames 500 are coupled to an outer periphery of the opening 110 by connection members 510 to fix the modular cassette apparatus 600 (S 50 ). The connection members 510 may be pins, screws, rivets, or bolts. The fixing frames 500 are installed at corners of the opening 110 of the body 100 . Therefore, the first filter plates 300 , the second filter plates 400 and the filter screens 200 form the strainer wall structure 10 by being assembled each other without welding.
[0108] Next, the cooling water is introduced into the suction pockets 610 (S 60 ). The introduced cooling water passes through the filter holes 20 of the first filter plates 300 , the second filter plates 400 and the filter screen plates 210 , which are formed of punched plates, to be filtered and introduced into the discharge space 700 . Then, the filtered cooling water is discharged through the outlet port 140 (S 70 ).
[0109] Method of Fabricating Strainer Wall Structure
[0110] Hereinafter, a method of fabricating a strainer wall surface 10 of the present invention will be described. FIG. 21 is a flowchart of a method of fabricating a strainer wall structure in accordance with an exemplary embodiment of the present invention, and FIG. 22 is a cross-sectional view showing a method of fabricating a first filter plate and a second filter plate in accordance with an exemplary embodiment of the present invention.
[0111] First, a plate (stainless steel in this embodiment) having a certain thickness (preferably, about 2 mm) is punched to form a plurality of filter holes 20 (having a diameter of 1 to 3 mm in this embodiment) (S 100 ). Then, the punched plate 50 having a large area is cut to form a plurality of rectangular holes, which will be formed as first grooves 310 or second grooves 410 of first filter plates 300 and second filter plates 400 (S 200 ).
[0112] As shown in FIG. 22 , the rectangular holes 60 are formed to be aligned in a matrix. The rectangular holes 60 may be formed by cutting the punched plate 50 using a laser beam. Then, the punched plate 50 having the plurality of rectangular holes 60 is cut. Two kinds of cutting methods are provided. The first filter plates 300 may be fabricated or the second filter plates 400 may be fabricated depending on the cutting methods.
[0113] Specifically, in order to fabricate the first filter plates 300 , as shown in an upper part of FIG. 22 , the punched plate 50 having the plurality of rectangular holes 60 is cut along a line between adjacent rectangular holes 60 arranged in a longitudinal direction thereof. Therefore, the punched plate 50 is cut to form first base plates 70 each having a row of rectangular holes 60 . Next, each of the first base plates 70 is bent twice with respect to a first centerline 71 of the rectangular holes 60 to fabricate first filter plate 300 (S 300 ).
[0114] In addition, in order to fabricate the second filter plates 400 , as shown in a lower part of FIG. 22 , the punched plate 50 having the plurality of rectangular holes 60 is cut to cross the rectangular holes arranged in a longitudinal direction thereof to divide them into halves. Therefore, second base plates 80 having grooves symmetrically disposed at both sides are fabricated. Then, each of the second base plates 80 is bent twice with respect to a second centerline 81 to form the second filter plate 400 (S 400 ). That is, the first filter plate 300 and the second filter plate 400 are fabricated by forming the rectangular holes 60 in the punched plate 50 with a large area using a laser beam, cutting the punched plate 50 through the above two methods, and bending the cut first base plate 70 or the second base plate 80 twice with respect to the first centerline 71 or the second centerline 81 , with no welding.
[0115] As described above, the plurality of first grooves 310 and second grooves 410 are formed in the first filter plates 300 and the second filter plates 400 . The first and second filter plates 300 and 400 are perpendicularly assembled to form the modular cassette apparatus 600 having a grid structure (S 500 ).
[0116] Next, the filter screen 200 is inserted into the body 100 , the modular cassette apparatus 600 is inserted into the filter screen 200 , and then, the fixing frame 500 is coupled to the body 100 , fabricating the strainer wall structure 10 (S 600 ).
[0117] Another Embodiment of Strainer Wall Structure
[0118] Hereinafter, another embodiment of the present invention will be described. FIG. 23 is a perspective view of another embodiment of the present invention including a plurality of strainer wall structures.
[0119] As shown in FIG. 23 , two strainer wall structures 10 are coupled by coupling members 520 and 521 . In this embodiment, while the two strainer wall structures 10 are coupled, three or more strainer wall structures may be coupled according to embodiments.
[0120] The strainer wall structure 10 has the same constitution as described above. That is, the structure 10 includes a body 100 having fixing plates 150 disposed therein, two filter screens 210 inserted into the body 100 , modular cassette apparatus 600 in which first and second filter plates 300 and 400 are assembled, and fixing frames 500 . As shown in FIG. 23 , the fixing frames 500 of the strainer wall structure 10 are coupled by first coupling members 520 , and the first coupling members 520 are coupled by second coupling members 521 to couple the two strainer wall structures 10 .
[0121] The above coupling method has been for illustrative purposes only, and other methods of coupling a plurality of strainer wall structures may fall into the scope of the present invention, not limited to the above embodiment.
[0122] The foregoing description concerns an exemplary embodiment of the invention, is intended to be illustrative, and should not be construed as limiting the invention. The present teachings can be readily applied to other types of devices and apparatus. Many alternatives, modifications, and variations within the scope and spirit of the present invention will be apparent to those skilled in the art.
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A strainer wall structure that removes foreign substances from a fluid suctioned into a pipe and a re-circulation pump that is part of an emergency core cooling system (ECCS). The strainer wall structure has an inlet side and an outlet side through which cooling water is introduced and discharged, respectively, and includes a body having an opening in a direction of the inlet side, closed side surfaces, and an outlet port disposed at one of the closed side surfaces. The strainer includes a punched plate filter screen inserted into the opening. A modular cassette apparatus including grooved first filter plates is inserted into the body, and second filter plates having second grooves is inserted into the first grooves.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and method for the assembly of surgical instruments, especially endoscopic or laparoscopic surgical instruments. More particularly, the invention relates to the assembly of a cartridge assembly to a handle assembly.
2. Background of the Related Prior Art
When manufacturing surgical instruments it is often necessary to connect a handle assembly to active elements which assist the surgeon in performing a particular task during a surgical procedure. Examples of these active elements include forceps, retractors, staplers, clip appliers and the like.
Typically, these active elements are either completely enclosed or partially enclosed within a housing (or cartridge). The housing may be relatively short in length and used during conventional invasive surgical procedures or the housing may be elongated and adapted for use during endoscopic or laparoscopic surgical procedures.
In laparoscopic procedures surgery is performed in the interior of the abdomen through a small incision. In endoscopic procedures surgery is performed in any hollow viscus of the body through narrow endoscopic tubes inserted through small entrance wounds in the skin. Laparoscopic and endoscopic procedures generally require that any instrumentation inserted into the body be sealed, i.e., provisions must be made to ensure that gases do not enter or exit the body through the laparoscopic or endoscopic incision as, for example, in surgical procedures in which the surgical region is insufflated.
Heretofore, when manufacturing the above-mentioned surgical instruments, the housing is typically connected to the handle assembly by manually opening or separating a portion of the handle assembly, inserting a portion of the housing into the handle assembly and resealing the handle assembly. As a result of the manual separating and resealing of the handle assembly, the assembly time, costs and defect rate associated with the production of these types of surgical instruments are relatively high.
Therefore, a need exists for an apparatus which increases the efficiency of the manufacturing process for producing surgical instruments by decreasing the assembly time, defect rate and, ultimately, costs associated with producing the instruments.
SUMMARY OF THE INVENTION
The present invention relates to a surgical instrument which comprises housing means and active element means for performing a function during surgical procedures, frame means having element actuating means for actuating the active element means and receiving means for reception of at least a portion of the housing means, and means for releasably connecting the housing means to the frame means such that the active element means is operatively connected to the element actuating means. Preferably, the connecting means comprises a locking member adaptable for positioning about the housing means adjacent the frame means, the locking member includes at least one locking tab spatially positioned at a proximal end thereof which engages with a corresponding locking channel positioned adjacent the receiving means.
Generally, the housing means includes an array of surgical fasteners, such as clips. The active element means includes jaw means positioned at a distal end of the housing, means for individually advancing the surgical fasteners into a position within the jaw means, and means for closing said jaw means. The frame means includes fastener advancing actuating means for actuating the fastener advancing means and jaw closing actuating means for actuating the jaw closing means.
In an alternate embodiment, an apparatus for releasably connecting endoscopic means to handle means is provided such that at least a portion of the endoscopic means is removably maintained within the handle means and active elements within the endoscopic means are operatively connected to the handle means. The apparatus comprises a locking member rotatably, slidably positioned adjacent a proximal end of the endoscopic means, and includes at least one locking tab positioned at a proximal end portion of the locking member which engages a corresponding locking channel positioned adjacent a distal end portion of the handle means.
The present invention also relates to a method for manufacturing surgical instruments which comprises inserting at least a portion of a proximal end of an endoscopic housing into a corresponding opening having at least one keyway positioned at least partially around the perimeter of the opening at a distal end of a handle assembly, positioning connecting means having at least one tab positioned at proximal end thereof adjacent the proximal end of the housing, positioning the at least one tab into engagement with the at least one keyway and rotating the connecting means such that the proximal end portion of the housing is releasably, rotatably maintained within the handle assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described hereinbelow with reference to the drawings wherein:
FIG. 1 is a perspective view of a surgical clip applier having a cartridge assembly attached to a handle assembly with the connecting member of the present invention;
FIG. 2 is a perspective view with parts separated of a portion of the surgical clip applier of FIG. 1, illustrating the interconnection between a cartridge assembly, a pistol grip handle assembly and the connecting member of the present invention;
FIG. 3 is a cross-sectional view of a portion of the handle section of FIG. 1, illustrating the operative connections between the cartridge assembly and the handle section;
FIG. 4 is a cross-sectional view from above of the operative connections between the cartridge assembly and the handle assembly of FIG. 3;
FIG. 5 is a perspective view of a portion of the instrument of FIG. 1, illustrating the connecting member in the attaching position;
FIG. 6 is a partial cross-sectional view of the instrument of FIG. 1, taken along line 6--6 of FIG. 5;
FIG. 7 is a partial cross-sectional view taken along line 7--7 of FIG. 6, illustrating the locking connection between the connecting member and the handle assembly;
FIG. 8 is a perspective view of a portion of the instrument of FIG. 1, illustrating the connecting member in a locked position;
FIG. 9 is a partial cross-sectional view of the instrument of FIG. 1, taken along line 9--9 of FIG. 8 and illustrating the locked connecting member conforming to the ornamental features of the handle assembly;
FIG. 10 is a partial cross-sectional view of the instrument of FIG. 1, taken along line 10--10 of FIG. 9 and illustrating the tab displaced from the keyway approximately 90°;
FIG. 11 is a partial cross-sectional view of the instrument of FIG. 1, taken along line 11--11 of FIG. 10 and illustrating a blocking member which limits the rotational movement of the connecting member;
FIG. 12 is a perspective view of a surgical clip applier having a cartridge assembly connected to a palm grip handle assembly;
FIG. 13 is a perspective view with parts separated of a portion of the instrument of FIG. 12, illustrating an alternate embodiment for the connecting member of the present invention;
FIG. 14 is a side elevational view of a portion of the connecting member of FIG. 13;
FIG. 15 is a perspective view of a portion of the instrument of FIG. 12, illustrating the segmented connecting member of the alternate embodiment of the present invention secured about the handle assembly and the cartridge assembly;
FIG. 16 is a partial cross-sectional view of a portion of the instrument of FIG. 12, taken along line 16--16 of FIG. 15;
FIG. 17 is a perspective view of a portion of the instrument of FIG. 12, illustrating a rotatable collar positioned over the connecting member of the present invention; and
FIG. 18 is a cross-sectional view of the surgical clip applier taken along line 18--18 of FIG. 17, illustrating the orientation of the collar about the segmented connecting member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment of the present invention will be described with reference to surgical clip appliers whose structure and function are described in, commonly assigned, U.S. Pat. Nos. 5,084,057 and 5,100,420 to Green et. al. both of which are incorporated herein by reference. Though, it should be noted that the present invention is adaptable for use in various surgical instrument having a handle assembly connected to a housing or cartridge. The exemplary clip appliers described herein are substantially identical, therefore like elements will have the same reference numerals.
Referring to FIG. 1, one embodiment in which a cartridge or housing is secured to a handle assembly is shown. The surgical clip applier 10 shown includes pistol grip handle section or frame 12 and housing or endoscopic sector 14 similar to the clip applier described in U.S. Pat. No. 5,084,057 mentioned above. The connecting member 16 of the present invention is provided to engage a corresponding opening in handle section 12 and maintain at least a portion of the proximal end of housing 14 within handle section 12.
Referring now to FIG. 2, housing 14 includes the same structure and functions in the same manner as the endoscopic section of the apparatus described in U.S. Pat. Nos. 5,084,057 and 5,100,420 previously mentioned. Included in this exemplary housing is crimping channel 18 and clip pusher 20. Crimping channel 18 is provided to close a pair of flexible opposing jaws 22, shown in FIG. 1, positioned at the distal end of housing 14, while clip pusher 20 is provided to individually advance surgical clips between the jaws. As described in the above mentioned patents, the surgical clips are advanced from a longitudinal array of clips.
Handle section 12 includes element actuating members such as handle 24 and trigger 26 which are operatively connected to the active elements within housing 14, namely the proximal end portion 28 of crimping channel 18 and the proximal end portion 30 of clip pusher 20, respectively. As shown in FIGS. 3 and 4, the proximal end portion 30 of clip pusher 20 is operatively connected to trigger 26 via pusher tube 32 (i.e., the first transmission system) and pusher release lever 34. Thus, when trigger 26 is proximally advanced toward the handle, pusher release lever 34 causes catch 36 of pusher leaf spring 38 to disengage from aperture 40 of pusher tube 32 thereby releasing pusher tube 32. The fastener advancing mechanism according to the present invention includes, trigger 26, release lever 34, catch 36 and leaf spring 38. When released, pusher tube 32 moves distally, under the action of mainspring 42, causing clip pusher 20 to advance the next clip in the clip array between the jaws. As shown in FIG. 4, the proximal end portion 30 of clip pusher 20 is configured to engage distal opening 44 in pusher tube 32 and remain rotatably maintained therein. Similarly, the proximal end portion 28 of crimping channel 18 is operatively connected to handle 24 via channel tube 46 (i.e., the second transmission system) and channel links 48 and 50. Thus, when handle 24 is proximally advanced toward instrument body or hand grip 52 of handle section 12, channel links 48 and 50 cause channel tube 46 and crimping channel 18 to move distally. Distal motion of crimping channel 18 causes the jaws of housing 14 to close. As shown in FIG. 4, the proximal end portion 28 of crimping channel 18 is configured to engage distal opening 54 in channel tube 46 and remains rotatably maintained therein. The operative connections of housing 14 to handle section 12 are further described in U.S. Pat. No. 5,084,057 mentioned above.
Referring again to FIG. 2, the distal end portion 56 of handle section 12 is provided with opening 58 to receive crimping channel 18, clip pusher 20, the proximal end portion 60 of housing 14 and collar 62 of connecting member 16. This configuration removes the need to separate the handle section to allow insertion of the proximal portion of housing 14, which, as noted above, is commonly performed within the prior art. Keyways 64 are spatially positioned on the perimeter of opening 58, as shown, and are provided to receive tabs 66 positioned at the proximal end portion of connecting member 16 so as to facilitate the connection of housing 14 to handle section 12.
In operation, connecting member 16 is initially positioned at the proximal end of housing 14, distal to collar 62. The proximal end portion 60 of housing 14 is then inserted into opening 58 so that crimping channel 18 operatively connects to handle 24 and clip pusher 20 operatively connects to trigger 26, as described above. In addition to being operatively connected to handle 24 and trigger 26, the proximal end portion 28 of crimping channel 18 and the proximal end portion 30 of clip pusher 20 are, preferably, arranged within handle section 12 so as not to inhibit or limit rotational movement of housing 14 with respect to handle section 12.
Once housing 14 is positioned within handle section 12 to the point where collar 62 of connecting member 16 is received within opening 58, tabs 66 of connecting member 16 are aligned with keyways 64 and moved proximally to slide through keyways 64 into engagement with channel 68 of handle section 12, as shown in FIGS. 5-7.
Referring now to FIGS. 8-11, connecting member 16 is rotated so that tabs 66 create a friction fit with the interior surface 70 of channel 68, thereby locking (or coupling) connecting member 16 to handle section 12. When the connecting member is locked to handle section 12 as described above, collar 62 is maintained within handle section 12, thus securing housing 14 to handle section 12. In addition, the forces exerted on collar 62 when closing the jaws in housing 14, are transferred and distributed to handle section 12 through connecting member 16.
Preferably, tabs 66 are positioned on connecting member 16 in such a manner that when connecting member 16 is rotated 90° nose 72 of connecting member 16 conforms with the ornamental features of handle section 12, as shown in FIGS. 8 and 9. As a result, tabs 66 will be displaced from keyways 64 approximately 90°, as shown in FIG. 10. Blocking member 74 may also be positioned within channel 68 to limit rotational movement of tabs 66 a predetermined number of degrees, preferably 90° as shown in FIG. 11, so as to ensure that the nose conforms with the ornamental features of handle section 12.
Referring now to FIG. 12, another embodiment in which a cartridge or housing is secured to a handle assembly is shown. The surgical clip applier 80 shown has a palm grip handle section 82 and a housing 14 similar to that described in U.S. Pat. No. 5,100,420 mentioned above. Similar to the above mentioned embodiment, handle section 82 includes handle 84 and release button 86 which are operatively connected to the active elements within housing 14, namely, the proximal end portion 28 of crimping channel 18 and the proximal end portion 30 of clip pusher 20, respectively.
Referring to FIGS. 13 and 14, nose 88 of handle section 82 is preferably divided into two segments 88a and 88b which comprise the connecting member for the palm grip embodiment. Nose segment 88a is formed into or secured to the distal end portion 90 of handle section 82, as shown. Nose segment 88b, shown in FIGS. 14 and 15, is substantially identical to nose section 88a, although mirror images of each other, and is separated from handle section 82. Nose 88 and distal end portion 90 of handle section 82 are provided with opening 92 which receives the proximal end portion 60 of housing 14.
To connect housing 14 to handle section 82, the proximal end portion 60 of housing 14 is initially inserted into opening 92 of nose 88 and handle section 82, so that the proximal end portion 28 of crimping channel 18 is operatively connected to handle 84 and the proximal end portion 30 of clip pusher 20 is operatively connected to release button 86. As previously mentioned, the operative connections between handle section 82 and housing 14 are described in U.S. Pat. No. 5,100,420. In addition to being operatively connected to handle 84 and release button 86, the proximal end portion 28 of crimping channel 18 and the proximal end portion 30 of clip pusher 20 are, preferably, arranged so as not to inhibit or limit rotational movement of the housing 14 with respect to handle section 82. In this configuration, collar 62 is positioned within channel 94 in nose segments 88a and 88b, shown in FIGS. 14 and 16. Channel 94 in combination with collar 62 secure housing 14 to handle section 82 and allow for rotational movement of housing 14 with respect to handle section 82. As noted, crimping channel 18 and clip pusher 20 are operatively connected within handle section 82 in such a manner that rotational movement of housing 14 is not interfered with.
Referring now to FIGS. 13-16, once the proximal end portion 60 of housing 14 is positioned within handle section 82, nose segment 88b is positioned about housing 14 and the distal end portion 90 of handle section 82 adjacent nose segment 88a. When positioned about nose segment 88a and housing 82, channel 96 of nose segment 88b engages support collar 98 of handle section 12. In addition, collar 62 engages channel 94 as described above. Nose segment 88b is then secured to nose segment 88a by adhesives, sonic welds or the like.
Referring now to FIGS. 17 and 18, rotational collar 100 may also be provided to facilitate rotational movement of housing 14. Rotational collar 100 is configured to slide along housing 14 towards nose 88 sufficiently to enclose the nose therein. The distal end of collar 100 may be secured to housing 14 by friction fit, adhesives or the like.
It will be understood that various modifications can be made to the embodiments of the present invention herein disclosed without departing from the spirit and scope thereof. For example, various sizes of the instrument are contemplated, as well as various types of construction materials. Also, various modifications may be made in the configuration of the parts. Therefore, the above description should not be construed as limiting the invention but merely as exemplifications of preferred embodiments thereof. Those skilled in the art will envision other modifications within the scope and spirit of the present invention as defined by the claims appended hereto.
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The present invention relates to surgical instruments having a housing or elongated cartridge, a frame and an apparatus for releasably connecting the housing to the frame. Typically, the housing has active elements which perform a particular function during a surgical procedure, such as forceps, graspers, clip appliers or staplers. The frame includes an actuating system for actuating the active elements, such as a pivotal handle or a release lever.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a National Stage of International patent application PCT/EP2008/065049, filed on Nov. 6, 2008, which claims priority to foreign French patent application No. FR 07 07860, filed on Nov. 9, 2007, the disclosures of which are incorporated by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to the streamlined tractor ropes used on a ship to pull a submersible body cast off at sea and the systems for hauling the latter onboard and stowing same, on the drum of a winch for example. It more particularly relates to the tractor ropes streamlined by means of articulated scales.
BACKGROUND OF THE INVENTION
The context of the invention is that of a naval vessel intended to deploy a towed submersible object. In such a context, in the non-operational phase, the submersible body is stored onboard the vessel and the tractor or towing rope is wound on the drum of a winch. Conversely, in the operational phase, the submersible body is submerged behind the boat and pulled by the latter by means of the tractor rope, the rope itself being immersed apart from the end that remains linked to the winch.
In such a context, it is useful to reduce the drag of the tractor rope when the latter is immersed. To do this, it is known to use a streamlined rope and in particular a rope streamlined by means of fairings, or scales, such as that illustrated by FIG. 1 . This scale comprises an elongate element, hydrodynamic, for example, in the form of a fin, presenting on a thick internal edge a tubular duct into which passes the rope and a thin external edge allowing a less turbulent flow of the water about the rope. The set of scales totally or partially covers the rope.
In normal operation, the scales are mounted to move about the rope and joined to rotate relative to each other. This way, the rotation of one scale leads to a rotation of the adjacent scales and, step by step, of all of the scales.
This means that, both when the rope is deployed in the water and when it is wound on the drum, the scales are all oriented in the same way and any change of orientation of one of the scales will bit by bit affect all the scales streamlining the rope. Thus, when the rope is deployed at sea, the scales are naturally oriented in the direction of the current generated by the pulling force exerted by the movement of the vessel. In the same way, when the rope is wound onto the drum of the winch, as the rope rises, all the scales adopt one and the same orientation relative to the drum, as illustrated by FIG. 2 , an orientation that makes it possible to wind the rope by maintaining the scales parallel to each other turn-by-turn.
However, it is often the case that, during the life of the rope, the link between certain scales is broken and that one or more scales is/are partially damaged. In this case, with the link between scales being broken in certain places, it is possible that one or more scales will no longer be aligned with the whole. It is then in particular possible that, when the rope is wound onto the drum of the winch, one or more scales will be badly oriented relative to the drum and that they will then not adopt a position conforming to the arrangement presented in FIG. 2 , an arrangement in which all the scales situated at the same level on the drum are parallel to each other. One or more scales can thus, for example, be lying down in a configuration such as that illustrated by FIG. 4 . The consequence of such a positioning is to hamper the winding of the tractor rope and often, as illustrated by the figure, to lead to the breaking of the badly-positioned scale.
SUMMARY OF THE INVENTION
One aim of the invention is to propose a solution to ensure a correct positioning and alignment, according to a given orientation, of the scales that streamline a rope, in particular a tractor rope, so as to enable it to be automatically wound onto the drum of a winch without risk of damaging the scales and this regardless of the state of integrity of these scales, in particular the state of integrity of the means that joins each scale to its neighbours rotation-wise.
To this end, the subject of the invention is a device for ensuring the orientation in a fixed direction of an object threaded on a rope, moving rotation-wise about said rope and joined to said rope translation-wise, said object having the form of a cylinder of length L, presenting a transversal section of height H and comprising a longitudinal duct having the form of a cylinder of revolution, located at the level of its widest base, by which it is threaded onto the rope. The device according to the invention is characterized in that it comprises a rear face through which leaves the rope, a bevelled front face, through which enters the rope, and a cavity of a length at least equal to the length of the object to be oriented. Said cavity presents an axis of symmetry and comprises an opening extending over its entire length, the edge of which is formed by two symmetrical half-edges, the profiles of which firstly follow two counter-rotational and coaxial helical curves, the axis of symmetry of which is the same as the axis of symmetry of the cavity. Each helical half-edge performs a rotation of around 180° about the axis of symmetry from a point of the edge of the opening common to both half-edges and situated at the level of the front face of the device. The profiles of the half-edges then follow two parallel straight segments spaced apart so that the width of the opening ensures the appropriately oriented guidance of the object until the device is paid out by maintaining the desired orientation.
In one particular embodiment of the device according to the invention, the cavity presents a wall constructed by effecting an excavation of the material forming the device along an axis that is the same as the axis of symmetry of the cavity, the excavation being done by a sweep of the section of the device by a surface corresponding to the section, in transverse cross-section, of the object, the angular opening of the sweep being defined, for the section passing through a given transverse plane, by the intersections of the half-edges with this plane.
In a particular embodiment, that can be associated with the preceding one, the device according to the invention also comprises a fixing arm making it possible to position it so as to ensure the desired orientation of the object to be oriented after its passage into the device.
According to a variant of the preceding embodiment, the fixing arm is configured to enable the movement rotation-wise in a horizontal plane of the device.
According to another variant that can be combined with the preceding one, the fixing arm forms an elastic plate making it possible to control the pressure force exerted on the rope on its passage into the device.
In an embodiment, that can be combined with the preceding ones, the device according to the invention comprises means for imposing, on the object to be oriented, an input orientation avoiding contact of the object with the point of the front face of the device.
In an embodiment, that can be combined with the preceding ones, the device according to the invention also comprises means for positioning the axis of the rope along the axis of symmetry of the cavity.
According to a variant of this embodiment, the means for positioning the axis of the rope comprise a grooved rolling bearing arranged at the rear of the bevelled front face.
In an embodiment, that can be combined with the preceding ones, the device according to the invention also comprises means for limiting the pressure force exerted on the rope on its passage into the device, these means being placed at the level of the area where the rope comes into contact with the wall of the cavity.
Another subject of the invention is an application of the device to the turning of the scales forming the streamlining of a rope for pulling a submersible body by a ship, said device being implemented to ensure the automatic orientation of the scales of the rope in an orientation allowing the rope to be wound onto the drum of a winch.
Another subject of the invention is a distribution system for a rope for pulling a submersible body by a ship, comprising a scale turning device as described above, mounted at the head of the system via the fixing arm.
Another subject of the invention is a variant of the preceding distribution system, in which the turning device is fixed to the system by means enabling the device to rotate in a vertical plane.
Advantageously, the device according to the invention can be developed for scales or various and more or less complex forms built on the model of a cylinder whose transverse cross section presents a thin and more or less hydrodynamic profile.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristics and advantages of the invention will be better appreciated from the description that follows, a description that explains the invention through a particular embodiment taken as a non-limiting example and which is based on the appended figures, which represent:
FIGS. 1 to 4 , illustrations relating to the problem posed by the automatic winding of a scaled rope onto a winch;
FIGS. 5 and 6 and 7 , overall views of the device according to the invention, in a version adapted to the automatic winding of a scaled rope onto a winch;
FIGS. 8 and 9- a to 9 - i , illustrations of the principle of operation of the device according to the invention;
FIGS. 10 and 11 , illustrations of an exemplary implementation of the device according to the invention on a winch distribution head.
DETAILED DESCRIPTION
Interest is first of all focussed on FIGS. 1 to 4 which clearly illustrate the technical problem resolved by the invention. This illustration is given through the particular example of an electric tractor rope intended to provide the link between a submersible body and the ship transporting it, when the submersible body is immersed in the wake of the ship.
As illustrated by FIG. 1 , the handling, in other words the casting off and recovery of the immersed body (not represented in the figure) is performed by means of a tractor rope 11 wound at rest on the drum 12 of a winch. When the submersible body is operational, that is, when it is immersed being towed by the ship, the tractor rope 11 is paid out from the drum to a certain length, so as to enable the positioning of the submersible body at a certain depth and at a certain distance from the ship, and to enable it to be towed. In this situation, the rope is itself immersed over all or part of its length so that it produces in its wake a water drag generating turbulences, and efforts are made to limit the drag by equipping the rope with fairings 13 , also called scales.
A scale 13 appears as an elongate element, relatively flat, having the general appearance of a dorsal fin. The scales are arranged on the rope so as to form a continuous, or discontinuous, sheathing, and articulated and moving rotation-wise about the rope. They can also, as illustrated by the cross-sectional view of FIG. 2 , be linked to each other to rotate about the axis of the rope so as to present a substantially continuous edge 14 along the axis of the rope.
This dual mobility enables both each scale 13 to follow the movements of the rope 11 in the water, movements due, for example, to the changes of heading of the pulling ship, and adopt an orientation enabling it to oppose the weakest resistance to the current provoked by the displacement of the rope in the water. The axial link that exists between each scale and its neighbours also makes it possible to limit the difference (the deviation) that can exist between a scale 13 and the scales 131 and 132 immediately adjacent, while allowing a certain deviation, as illustrated by FIG. 2 . This way, when a rotation movement about the rope is imparted on a scale 13 , the latter takes with it in its movement the adjacent scales 131 and 132 . Consequently, a high-amplitude orientation movement can be imparted on all of the sheathing formed by the juxtaposition of the scales along the rope. The duly-constituted sheathing therefore presents the appearance of a succession of fin segments, each oriented so that the sheathing presents overall the weakest possible drag given the movements imparted on the rope.
In the exemplary embodiment described here, the role of the sheathing formed by the scales 13 is to reduce the wake turbulences produced by the movement of the rope in the water, when the latter is dropped into the water and pulled by the ship. Consequently, its component scales assume a specific form which confers on them a hydrodynamic nature such as that represented in FIG. 2 . From a general descriptive point of view, each scale appears as a cylindrical object 21 of length L, of which the base section, the section 24 , substantially describes a symmetrical NACA profile presenting a thin edge 22 and a wide edge 23 . The cylinder 21 described in this way comprises in its thickest part 23 a longitudinal duct 25 in the form of a cylinder of revolution, the diameter of which is substantially equal to that of the rope 11 . The link means between the immediately adjacent scales 26 and 27 , means not represented in FIG. 2 , are, moreover, located at the level of the ends of the duct 25 .
From a more general point of view, the device according to the invention can be configured to be adapted to various forms of scales, provided that the latter appear as a cylindrical object 21 of length L, of height h and comprising on one of its edges a longitudinal duct 25 in the form of a cylinder of revolution, the diameter of which is substantially equal to that of the rope. This object can, for example, be a rectangular parallelepipedal of length L and of section s that is sufficient to house the longitudinal duct 25 on one of the edges of the parallelepidedal. The axis of the longitudinal duct is here parallel to the longitudinal axis passing through the centre of symmetry of the scale and distant from the latter.
When the submersible body is not deployed at sea, it is installed on the supporting ship while the tractor rope is wound onto the drum 12 of the winch used to manoeuvre it. To facilitate the correct automatic positioning of the rope on the surface of the winch as it is wound on, the surface of the drum can, for example, comprise, as illustrated by FIG. 3 , a helical grooving 31 in the turns of which the rope 11 is positioned.
Thus, in as much as the correct initial orientation of the rope with respect to the drum of the winch is assured, an orientation for which the free edges of the scales are not in contact with the drum, and because the scales are linked to each other, the distribution is, in normal circumstances, advantageously facilitated. After winding, the tractor rope is thus, as illustrated by FIG. 3 , correctly positioned on the drum, that is, with its scales oriented substantially perpendicularly. There is therefore no risk of damage to the scales which are intrinsically relatively fragile.
On the other hand, if one or more scales have been damaged during the phase of implementation of the submersible body, during which the rope is deployed at sea, and if the damage undergone affects their link with the adjacent scales, a correct initial positioning of the rope is not sufficient to guarantee that the complete automatic winding of the rope onto the drum of the winch will proceed correctly. Situations of the type of that illustrated by FIG. 4 may then be encountered, in which a scale 41 which is free to rotate with respect to its neighbours, because of the breaking of the means (an axial guide with end-stops for example) which provide this link, is positioned flat on the drum, so that on subsequent turns it is flattened by the rope and generally broken. In the absence of additional means, the only way of avoiding such a consequence is to manually check the state of the scales while the rope is being wound and manually position the scales that have become separated from their neighbours. Such an intervention has the major drawback of making the winding operation lengthy and, above all, not very automatic.
Consideration is now given to FIGS. 5 to 7 which overall show the device according to the invention.
FIG. 5 proposes a global representation of the device in its normal orientation. As can be seen in this figure, the device according to the invention takes the form of a solid object 51 comprising a cavity 52 presenting an axis of symmetry of revolution indicated by the broken line 59 in the figure. This cavity itself presents a longitudinal opening 53 which applies a limitation to the wall of the cavity represented by the outline 54 (i.e., the edge) of the opening. Because of its characteristic geometry, the edge 54 of the opening 53 defines, in addition to the form of the opening, a bevelled front face 55 and a rear face 56 . The device according to the invention moreover presents any external form, capable of housing the cavity described previously. For example, it has an overall form of a cylinder of revolution, as in the illustration of FIG. 4 , for example.
Concerning an object that allows a determined orientation of the tractor rope, the device according to the invention is also arranged so as to be able to be placed in proximity to the drum of the winch with a constant orientation enabling it to ensure its scale orientation function. To this end, it is designed to be able to receive a fixing arm 57 , or any other similar means.
The turned position view of FIG. 6 shows the device according to the invention with the opening 53 directed upward. It thus shows the characteristic profile of the edge of the opening 53 , and the bevelled profile of the front face 55 .
According to the invention, the edge of the opening 53 can be defined as the meeting of two curved half-edges 61 and 62 , the profiles of which follow two counter-rotational and coaxial helical curves, the axis of symmetry of which is the same as the axis 59 of the cavity. Each helical half-edge performs a rotation of around 180° from a point 63 of the edge of the opening common to both half-edges and situated at the level of the front face of the device.
The angle of rotation is in practice defined by the width of the profile of the scale in transverse cross-section, the scales, and therefore the rope on which they are mounted, being seen, as illustrated by FIG. 7 , to enter into the device through its front face 55 , presenting a widely spread opening, and to leave the device through its rear face presenting a narrower opening, oriented in the desired direction, of a form substantially identical to that of the surface 24 of the scale in transverse cross-section and of size substantially equal apart from a functional play. Beyond this angle of rotation, each half-edge is extended towards the rear of the device by a straight segment 510 or 511 defining a constant opening making it possible to guide the scale to its exit from the device.
Using such a device, it is therefore advantageously possible to automatically position a scale according to a possible orientation, regardless of the orientation taken by the latter on entering the device. As it moves through the device according to the invention, the scale, moved by the pulling force exerted on the rope to which it is joined translation-wise, is automatically guided rotation-wise from its original orientation to its final orientation which corresponds to the desired orientation.
FIG. 7 moreover shows the device according to the invention mounted on the distribution system 71 of the winch, a guidance system whose known role is to variably position the rope so that the latter forms tightly-adjacent turns occupying the entire surface of the drum after winding.
In a first simple embodiment, the device according to the invention is essentially characterized by the particular profile of the edge 54 of the opening 53 , as described in the above. In this first embodiment, the form of the wall of the cavity 53 is not specifically imposed, provided that the dimensions of the cavity allow the scales to pass through, in other words, provided that the section of the cavity is sufficient over its entire length to allow the passage of a scale being presented by its section with any orientation. In such a configuration, the cavity can, for example, have the form of the cavity 52 defined by a cylinder of revolution, the axis of revolution of which is the same as the axis 59 and presenting an opening 53 with an edge 54 such as that defined previously. The only constraint attached to the production of this cavity lies in the fact that the internal diameter of the cylinder of revolution on which it is constructed be of a size slightly less than the height h of the scale. This way, the guidance of the scale from any orientation to the desired orientation is performed solely by the edge of the opening 53 , an edge on which the scale bears via its free edge 22 (see FIG. 2 ) as it passes through the device, a passage that it performs under the action of the pulling force exerted by the rewinding of the rope. In the plainest version of this embodiment, the device according to the invention can even take the form of a rail in the form of a double helix on which the scale bears and which guides it to the desired orientation.
In a preferred embodiment, the device according to the invention is not reduced to a simple guidance rail, but, on the contrary, a solid object presenting a cavity 52 , of which the internal wall is exploited. In this embodiment, the device presents an additional characteristic associated with the form of the wall limiting the cavity 52 . According to this preferred embodiment, the wall of the cavity 52 is constructed by effecting an excavation of the material forming the device along an axis that is the same as the axis 59 , the excavation being done by a sweep of the section of the device by a surface corresponding to the section of the scale 13 , the angular opening of the sweep being defined for the section passing though a given point of the axis of symmetry 59 by the position of the half-edges 61 and 62 defining the opening 53 at the level of this point. In other words, the wall of the cavity, comprising the meeting of the two half-walls 64 and 65 , is constructed by effecting an excavation of the material forming the device along an axis that is the same as the axis of symmetry 59 of the cavity 52 , the excavation being done by a sweep of the section of the device by a surface corresponding to the section 24 of the scale 21 , the angular opening of the sweep being defined, for the section passing through a given transverse plane, by the intersections of the half-edges 61 and 62 with this plane. This embodiment is illustrated by FIGS. 8 and 9- a to 9 - i.
FIG. 8 , in conjunction with FIGS. 9 - a to 9 - i , show the form of the excavation through transverse cross-sections at various points. FIGS. 9 - a to 9 - i respectively correspond to the cross-sections A-A to I-I mentioned in FIG. 8 . The cross-section A-A substantially corresponds to a transverse view of the device from the front face (cross-section at the level of the point 63 of FIG. 6 ), whereas the cross-sections B-B to G-G correspond to intermediate cross-sections at points for which the surface of the wall of the cavity 52 is opened out, as described in the preceding section, following the helical profile of the edge 54 of the opening 53 . The cavity is thus produced, in a known manner, by changing from an excavation effected on an angular opening 91 of 360° (cross-section A-A), by different intermediate opening values 92 , to an excavation effected on an angular opening 93 that closely follows the transverse cross-sectional profile of the scale (cross-section G-G). Then, the cavity ends (cross-section H-H) in a final guidance duct 94 having substantially the form and the dimensions of the profile of the scale which opens out onto the rear face of the device (cross-section I-I).
In this preferred embodiment, the device according to the invention, although more complex to produce, presents the advantage of making it possible to assure the turning, and consequently bring in to the desired orientation, not only of the scales that are no longer linked rotation-wise to their neighbours but also those which, having been partially broken, no longer present a height h that is sufficient to allow them to bear on the edge 54 of the device to perform their reorientation. The guidance of such a scale is then provided by the internal wall of the cavity itself.
Whatever the embodiment envisaged, in particular the preferred embodiment described previously, the device according to the invention is designed and arranged relative to the winch so that the rope passes through it by being positioned substantially along the axis of symmetry 59 , indicated by the asterisk 95 in FIGS. 9 - a to 9 - i and by a horizontal broken line in FIG. 8 . To this end, the device according to the invention can comprise additional rope guidance means, placed in the area 66 where the rope 11 comes into contact with the wall of the cavity. In the configuration presented as a non-limiting example of embodiment, these additional means comprise a grooved rolling bearing 96 . This rolling bearing is mounted on the rear part of the device, in an area situated behind the turning area of the scales (see cross-section drawings G-G to I-I). These means are furthermore arranged on the device so that, when the rope rests at the bottom of the groove 97 of the rolling bearing 96 , the axis of the rope is the same, at least in the area of contact, as the axis of symmetry 59 of the device. This way, the rope can be positioned relative to a fixed point of reference of the device.
Whatever the embodiment envisaged, it is also possible to add to the device according to the invention means (see FIG. 5 or 6 ) making it possible to prevent a scale from being presented at the input of the device with an orientation in a direction bringing into direct contact the face 24 of the scale with the junction point 63 of the two half-edges 61 and 62 which constitutes the front point of the device. In practice, in such a case, however infrequent, the scale abuts on the end 63 of the device and because of this is incapable of sliding without stress along one or other of the half-edges to engage in the device. The means making it possible to overcome the consequences of such an eventuality have the characteristic of presenting to a scale located in the envisaged situation, a thin surface with rounded edges which, when it comes into contact with the top edge of the scale, imparts on the latter a slight rotation movement which prevents the front contact of the face 24 of the scale with the point 63 of the device.
As precisely illustrated by FIGS. 5 and 6 , the means 58 can, for example, consist of a short rod in the form of a beak or spur of oval section positioned at the level of the point of the device (i.e. of the point 63 ) vertically or at a small angle from the vertical. However, any other object making it possible to separate the scale from the undesirable orientation before the latter engages in the device can be envisaged.
Consideration is now given to FIGS. 10 and 11 .
FIG. 10 illustrates an exemplary implementation of the device according to the invention. In this application, the device according to the invention is mounted on the distribution system of the winch, on the drum of which the rope 12 is wound (represented without its scales in the figure). The distribution system comprises means of guiding the rope mounted on a carriage 1001 that moves along an axis 1002 parallel to the axis 15 of the drum of the winch. In this exemplary implementation, the scale turning device according to the invention is placed at the head of the distribution system, to which it is fixed via the fixing arm 57 described previously. The fixing arm takes the form of an elastic plate which here advantageously serves as a damper making it possible to control and limit the pressure force applied to the rope by the device according to the invention. Alternatively, it can also be of rigid structure, the damping then being provided by another means placed on the device according to the invention at the level of the point of contact of this device with the rope and associated, for example, with the groove rolling bearing 96 . The two solutions can, moreover, naturally be combined in one and the same embodiment of the device.
In order to ensure correct operation of the assembly, regardless of the direction of orientation of the rope and the position of the distribution system on the axis 1002 , the fixing arm of the device according to the invention, which on its own ensures the rotation of the device in a horizontal plane, is itself fixed to the distribution system by means also enabling the device according to the invention to follow the rotation movements in a vertical plane. Thus, whatever the stresses resulting from the distribution of the rope, the device according to the invention has a certain freedom of positioning which favours its optimum orientation with respect to the axis of the rope. These means can, for example, consist, as illustrated by FIG. 11 , of a part 1101 comprising a horizontal central part 1102 , on which is fixed the fixing arm 57 of the device according to the invention, and two lateral extensions arranged to enable an articulated fixing of the part 1101 to the moving carriage 1001 , enabling the central part, and therefore the device according to the invention, to move rotation-wise about a horizontal axis 1103 . The duly fixed device according to the invention 51 advantageously benefits from a mobility rotation-wise about a vertical axis 1104 and a horizontal axis 1103 , a mobility that makes it possible to lessen all the mechanical stresses that can be imposed on it at a given instant because of its orientation relative to the axis of the rope.
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The present invention relates to a means for mutually aligning the scales of a rope streamlined by means of scales articulated to rotate about its axis, the alignment being necessary to enable such a rope to be wound onto the drum of a winch. It mainly consists of a device presenting a bevelled front face and comprising a cavity extending from front to rear, inside which passes the rope before it is wound. The cavity presents a longitudinal opening with two lateral edges, each edge following, from front to back, a profile in helical form, the two helices being coaxial to each other and with the axis of symmetry of the cavity. The wall of the cavity is also configured so as to follow the cross-sectional profile of the scale all along its path in the device. The device is arranged relative to the drum on which the rope is wound so that, given the length of the edges of the opening, regardless of the orientation of a scale on entering the device, the latter, on exiting, assumes the desired orientation, in the alignment of the adjacent scales. The invention applies notably to the systems for handling tractor ropes streamlined by means of scales, used on a ship to pull a submersible body cast off at sea.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is related to our copending application Ser. No. 608,127, filed Aug. 27, 1975.
BACKGROUND OF THE INVENTION
The present invention relates to a flame-retardant carpet and a process for the preparation thereof.
When carpeting is conventionally manufactured, the fibers or pile are tufted on a relatively pliable primary backing which may be manufactured from any suitable materials such as jute or a man-made fiber such as polypropylene. The nonwear side of the backing is then coated with a bonding material of any suitable type such as latex. The latex serves to satisfactorily hold the fibers in place so that they cannot be pulled free from the primary backing and also to bond the primary backing to the secondary backing. In the past, clay has been added to the latex as a filler to reduce the cost of the bonding compound. The secondary backing, which may also be jute or artifical fiber, strengthens the carpet and ensures that the bonding material does not come into contact with the floor upon which the carpet is laid.
U.S. Pat. No. 3,418,267, granted Dec. 24, 1968, relates to flame-resistant polyamides and process thereof. The patent discloses that polyamide resin is made flame-retardant by incorporating therein from 5 to 20 percent by weight of an organic halide, e.g., chlorinated biphenyl, which is reactive with the resin only at its pyrolysis temperature and from 3 to 15 percent by weight of an oxide of tin, lead, copper, iron, zinc, or antimony.
U.S. Pat. No. 3,663,345, granted May 16, 1972, discloses a fire-retardant carpet in which the pile fibers are fixed to the primary backing by a compound comprising a latex binding material combined with an aluminum hydrate.
U.S. Pat. No. 3,719,547, granted Mar. 6, 1973, describes a flame-retardant pile fabric. A fibrous layer composed of combustible filaments or fibers extends from the top surface of a fibrous backing to present a pile surface. A coating of a film-forming halogen-containing polymer and a water-insoluble organo-phosphorus compound is applied to and confined essentially to the top surface of the backing. Where the backing is made of a thermoplastic material, a coating of the halogen-containing polymer may be used without the organo-phosphorus compound.
Although these patents are a major contribution to this art, investigations have been undertaken to produce carpeting that is significantly more flame-retardant than the carpets disclosed in the prior art.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a process for rendering pile carpets flame-retardant without impairing their aesthetic properties. Another object of this invention is to provide pile carpets having flame-retardant properties which are prepared from polyester and polyamide fibers. It is a further object of this invention to provide a process which eliminates the necessity for applying the flame-retardant composition as a separate step in the process of preparing pile carpets.
In summary, the process of the present invention is an improvement over known processes for producing a pile carpet having a relatively pliable primary backing through which polyamide or polyester fibers are tufted. The improvement comprises incorporating in said fibers from 0.05 to 15 percent by weight of a compound selected from the group consisting of antimony oxide and zinc borate, and bonding said fibers to said backing with a bonding substance comprising a latex material selected from the group consisting of vinyl chloride and vinylidene chloride polymers and copolymers, and a hydrate material selected from the group consisting of aluminum hydroxide, hydrated aluminum oxide and hydrated aluminum silicates such as kaolite, dickite, nacrite and endellite, the ratio by weight of said latex material to said hydrate material being from 1:2 to 1:4.5.
The present invention provides a flame-retardant carpet which retains its aesthetic properties and is significantly more flame-retardant than prior art carpets. We postulate that this improvement involves a synergistic interaction between the several elements of the present invention. In one preferred embodiment, the present invention provides a flame-retardant pile carpet having a relatively pliable primary backing and a tufted surface, said surface being comprised of fibers selected from the group consisting of polyester and polyamide fibers having incorporated therein from 0.05 to 15 percent by weight of a compound selected from the group consisting of antimony oxide and zinc borate, said fibers being bonded to said backing with a bonding substance comprising a latex material selected from the group consisting of vinyl chloride and vinylidene chloride polymers and copolymers, and a hydrate material selected from the group consisting of aluminum hydroxide and hydrated aluminum oxide, the ratio by weight of said latex material to said hydrate material being within the range 1:2 to 1:4.5.
The term "flame-retardant carpet" is used herein to mean that the carpet burns very slowly in a confined area when exposed in air to a direct flame or its equivalent. The preferred method of testing for flame-retardant properties may be referred to as the "Critical Radiant Flux Test" described in a report entitled NBSIR 75-950 Proposed Criteria for Use of the Critical Radiant Flux Test Method, which report is available from the National Bureau of Standards, U.S. Department of Commerce.
The test apparatus comprises a gas fired refractory radiant panel inclined at a 30° angle over the exposed portion of a horizontally mounted test specimen. The specimen surface is 3-9 inches below the lower edge of the radiant panel. The radiant panel and an adjustable height specimen transport system are enclosed in an asbestos mill board sheathed chamber with provision for a free flow of draft-free air to simulate natural burning conditions. There is a glass viewing window in the front face of the chamber. Below the window is a door which can be opened to facilitate placement and removal of the test specimen. In the examples herein, the test conditions selected involve a 30° panel angle, a panel temperature of 525° C., and the distance from panel to sample is 5.5 inches. In order to carry out our tests under extremely rigorous conditions, the carpet is burned over a 50 oz./yd. 2 hair jute pad. Distance burned (cm.) is recorded and critical energy is determined in terms of flux watts/cm. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred polyamides which are useful in the improved flame-retardant carpets of the present invention include polycaprolactam (6 nylon), the polyamides which are derived from the condensation of a dicarboxylic acid with a diamine, such as polyhexamethylene adipamide (66 nylon) and polyhexamethylene sebacamide (610 nylon), and copolymers thereof. The preferred polyesters are the linear terephthalate polyesters, i.e., polyesters of a glycol containing from 2 to 20 carbon atoms and a dicarboxylic acid component containing at least about 75% terephthalic acid. The remainder, if any, of the dicarboxylic acid component may be any suitable dicarboxylic acid such as sebacic acid, adipic acid, isophthalic acid, sulfonyl-4,4'-dibenzoic acid, or 2,8-dibenzofuran-dicarboxylic acid. The glycols may contain more than two carbon atoms in the chain, e.g., diethylene glycol, butylene glycol, decamethylene glycol, and bis-1,4-(hydroxymethyl)cyclohexane. Examples of linear terephthalate polyesters which may be employed include poly(ethylene terephthalate), poly(butylene terephthalate), poly(ethylene terephthalate/5-chloroisophthalate) (85/15), poly(ethylene terephthalate/5-[sodium sulfo]isophthalate) (97/3), poly(cyclohexane-1,4-dimethylene terephthalate), and poly(cyclohexane-1,4-dimethylene terephthalate/hexahydroterephthalate) (75/25).
The primary carpet backing is made from any suitable material. It may be a conventional woven jute construction. Also, the backing may be made of a nonwoven fibrous mass made of cellulosic or noncellulosic material including nylon, polyester, and polyolefin. Other fabric backing structures likewise can be used.
A preferred ethylene-vinyl chloride copolymer latex for use in the present invention is a known composition which is commercially available. For example, it may be purchased under the trademark POLVIN 2500 from Monsanto Company. A typical process for preparing stable ethylene/vinyl chloride copolymer latices is disclosed in U.S. Pat. No. 3,399,157, granted Aug. 27, 1968.
A preferred vinylidene chloride-vinyl chloride copolymer latex may be purchased under the trademark GEON 652 from B. F. Goodrich Chemical Company. Patents relating to preparation of vinylidene chloride copolymer latices include U.S. Pat. Nos. 3,297,613; 3,297,666; 3,317,450; and 3,962,170.
A preferred vinylidene chloride polymer latex is available from Dow Chemical Company as DOW Experimental Latex XD-8600.03. Preferred vinyl chloride latices are available from B. F. Goodrich Chemical Company under the trademark GEON 575X43 and GEON 577. Several patents have recently issued relating to flame and smoke retardant vinyl chloride and vinylidene chloride polymer compositions including U.S. Pat. Nos. 3,880,802; 3,883,480; 3,883,482; 3,914,201; and 3,922,248.
In the preferred latex-hydrate bonding composition of the present invention, it has been found that an aluminum hydrate will produce the desired result in a very satisfactory manner if proper material ratios are used. It has been determined that if either aluminum hydroxide or hydrated aluminum oxide is used, a bonding composition having a latex to hydrate weight ratio within the range 1:2 to 1:4.5 will produce an excellent fire retardant carpet. More preferably, a latex to hydrate weight ratio within the range 1:2 to 1:4 is used.
As to the manner of introducing the aforesaid antimony oxide or zinc borate into the polyester or polyamide fiber, it may be added to the polymer at the time of polymerization, or it may be blended with the polymer pellets. The concentration of the metal compound in the polymer is preferably 0.05 to 15 percent by weight; more preferably 0.1 to 12 percent.
In the following examples, parts and percentages employed are by weight unless otherwise indicated.
EXAMPLE 1
A reactor equipped with a heater and stirrer was charged with a mixture of 1,520 parts of e-caprolactam and 80 parts of aminocaproic acid. The mixture was then flushed with nitrogen and was stirred and heated to 255° C. over a 1 hour period at atmospheric pressure to produce a polymerization reaction. The heating and stirring was continued at atmospheric pressure under a nitrogen sweep for an additional 4 hours in order to complete the polymerization. Nitrogen was then admitted to the reactor and a small pressure was maintained while the polymer was extruded from the reactor in the form of a polymer ribbon. The polymer ribbon was subsequently cooled, pelletized, washed and then dried. The polymer was a white solid having a relative viscosity of about 50 to 60 as determined at a concentration of 11 grams of polymer in 100 ml. of 90 percent formic acid at 25° C. (ASTM D-789-62T).
The polymer pellets were blended with about 2.4 percent of finely divided antimony oxide (Sb 2 O 3 ) in a conventional blender and melt extruded under pressure of 1,5000 psig to a 70-orifice spinnerette to produce a fiber having about 3,600 denier. The fiber was collected, drawn at about 3.2 times the extruded length, and textured with a steam jet to produce yarn suitable for use in carpet. This yarn will hereinafter be called Yarn A. A control yarn containing no antimony oxide was prepared in the same manner as described above. This yarn will hereinafter be called Yarn B.
The yarns were then two-plied by twisting two ends together with a 1.5 S twist. The yarns were tufted into a level lop 20 oz./yd. 2 carpet at about 8.0 stitch rate. A relatively pliable nonwoven polypropylene fabric was used as the primary backing. Tufting was carried out on a conventional tufting machine operated to give a pile having a height of 5/32 to 7/32 inch.
About 8 parts of a 50 percent emulsion of a 25/75 ethylene-vinyl chloride copolymer latex was mixed with 8 parts of hydrated aluminum oxide to form a binding composition. On a dry basis, the latex-hydrate weight ratio of the binding composition was 1:2. The mixture was then applied onto the fabric described in the preceding paragraph by conventional means at the rate of 32 oz./yd. 2 of carpet on a dry basis. With the dilution described, the penetration of the mixture past the backing and into the tufts of the fabric was less than 1/16 inch so that the aesthetic properties of the pile carpet was not impaired. The carpeting was backed with a secondary jute backing and then passed through an oven at about 125° C. to cure the latex on the carpet. The following table compares the carpets made from Yarn A and Yarn B with respect to the distance burned and the critical energy necessary to propagate the flame as measured by the above-described Critical Radiant Flux Test.
______________________________________ Distance Critical Energy,Carpet System Burned (cm.) Watts/cm..sup.2______________________________________Made with Yarn A 43 0.455Made with Yarn B 62 0.235______________________________________
Clearly, the carpet made with Yarn A was significantly more flame-retardant than the carpet made with Yarn B.
EXAMPLE 2
Control carpets were also prepared from Yarn A and Yarn B in accordance with Example 1 except that a conventional styrene-butadiene rubber (SBR) latex was used instead of ethylene-vinyl chloride copolymer (EVC) latex of the present invention. The following table compares the resulting carpets with the carpets made in Example 1, using the above-described Critical Radiant Flux Test. In these tests, the standard deviation (σ) of the distance burned was about 1.7 cm. so that a difference of 5 cm. is highly significant.
______________________________________Carpet System Distance Critical Energy,Fiber Latex Burned (cm.) Watts/cm..sup.2______________________________________Yarn B SBR Greater than 91 Less than 0.130Yarn A SBR 57 0.273Yarn B EVC 62 0.235Yarn A EVC 43 0.455______________________________________
These data show that for optimum flame retardancy, it is critical to use both Yarn A (containing antimony oxide) and the ethylene-vinyl chloride copolymer latex in accordance with the present invention.
In additional comparative tests, it was shown that the use of aluminum hydroxide or hydrated aluminum oxide is also a critical element of the present invention. For example, a conventional carpet containing calcium carbonate as filler instead of hydrated aluminum oxide was completely burned in the above-described Critical Radiant Flux Test.
EXAMPLE 3
A flame-retardant carpet was prepared by the procedure of Example 1 except that the latex used was a vinyl chloride-vinylidene chloride copolymer latex sold by B. F. Goodrich Chemical Company under the trademark GEON 652, and the polymer pellets were blended with about 0.9 percent of the antimony oxide (Sb 2 O 3 ). The resulting carpet was tested in accordance with the above-described Critical Radiant Flux Test with the following results:
______________________________________Distance Critical Energy,Burned (cm.) Watts/cm..sup.2______________________________________34 0.614______________________________________
These results show that the flame-retardancy of the carpet was significantly better than that of the carpet of Example 1.
EXAMPLE 4
A flame-retardant carpet was prepared by the procedure of Example 3 except that instead of blending antimony oxide with the dried polymer, antimony oxide was added to the polymer pellets during the drying operation, i.e., while being dried, the polymer pellets were tumbled with an emulsion of antimony oxide (Sb 2 O 5 ) in amount sufficient to provide 0.5 percent antimony oxide based on the dry weight of the polymer. The resulting carpet was tested in accordance with the above-described Critical Radiant Flux Test with the following results:
______________________________________Distance Critical Energy,Burned (cm.) Watts/cm..sup.2______________________________________40 0.500______________________________________
These results show that the flame-retardancy of the carpet compared favorably with that of carpet of Example 1.
EXAMPLE 5
A flame-retardant carpet was prepared by the procedure of Example 4 except that instead of using the vinyl chloride-vinylidene chloride copolymer latex of Example 3, a vinylidene chloride polymer latex was used. A suitable latex is available from Dow Chemical Company as DOW Experimental Latex XD-8600.03. The resulting carpet was tested in accordance with the above-described Critical Radiant Flux Test with the following results:
______________________________________Distance Critical Energy,Burned (cm.) Watts/cm..sup.2______________________________________44 0.440______________________________________
These results show that the flame-retardancy of the carpet was not significantly different from that of the carpet of Example 1.
EXAMPLE 6
A flame-retardant carpet was prepared by the procedure of Example 4 except that instead of using the vinyl chloride-vinylidene chloride copolymer latex of Example 3, a vinyl chloride copolymer latex sold by B. F. Goodrich Chemical Company under the trademark GEON 351 was used. The resulting carpet was tested in accordance with the above-described Critical Radiant Flux Test with the following results:
______________________________________Distance Critical Energy,Burned (cm.) Watts/cm..sup.2______________________________________35.5 0.586______________________________________
These results shown that the flame-retardancy of the carpet was significantly improved over that of the carpet of Example 1.
EXAMPLE 7
A flame-retardant carpet was prepared by the procedure of Example 1 except that instead of blending the polymer pellets with antimony oxide, the pellets were blended with about 2 percent of finely divided zinc borate hydrate (2 ZnO.3 B 2 O 3 .3.5 H 2 O). The resulting carpet was tested in accordance with the above-described Critical Radiant Flux Test with the following results:
______________________________________Distance Critical Energy,Burned (cm.) Watts/cm..sup.2______________________________________39 0.519______________________________________
These results show that the flame-retardancy of the carpet was significantly better than that of the carpet of Example 1. Similar improved results were obtained when zinc borate was used and the ethylene-vinyl chloride copolymer latex of Example 1 was replaced with a vinyl chloride-vinylidene chloride copolymer latex sold by B. F. Goodrich Chemical Company under the trademark GEON 652, or a vinyl chloride copolymer latex sold under the trademark GEON 351.
EXAMPLE 8
A flame-retardant carpet was prepared by the procedure of Example 7 except that the latex used was a phosphate-ester-plasticized vinyl chloride latex sold by B. F. Goodrich Chemical Company under the trademark GEON 577. The resulting carpet was tested in accordance with the above-described Critical Radiant Flux Test with the following results:
______________________________________Distance Critical Energy,Burned (cm.) Watts/cm..sup.2______________________________________59 0.257______________________________________
These relatively poor results were very surprising in view of the excellent results obtained in Example 7. Apparently, it is not desirable to use a phosphate-ester-plasticized vinyl chloride latex in the process of the present invention. This is particularly pertinent in view of U.S. Pat. No. 3,719,547 to Martin et al. on Flame Retardant Pile Fabric.
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A flame-retardant pile carpet having a relatively pliable primary backing and a tufted surface, said surface being comprised of fibers selected from the group consisting of polyester and polyamide fibers having incorporated therein from 0.05 to 15 percent by weight of a compound selected from the group consisting of antimony oxide and zinc borate, said fibers being bonded to said backing with a bonding substance comprising a latex material and a hydrate material, said latex material being selected from the group consisting of polymers and copolymers of vinyl chloride and vinylidene chloride, and said hydrate material being selected from the group consisting of aluminum hydroxide and hydrated aluminum oxide, the ratio by weight of said latex material to said hydrate material being within the range 1:2 to 1:4.5.
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REFERENCE TO RELATED APPLICATIONS
The subject matter in this application is related to the subject matter in U.S. patent application Ser. No. 11/153,112, filed Jun. 15, 2005, entitled “ORBITAL TRANSMISSION WITH GEARED OVERDRIVE”, now U.S. Pat. No. 7,475,617, issued Jan. 13, 2009. The aforementioned application is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to the field of automotive transmissions. More particularly, the invention pertains to an automotive transmission with orbital gearing and a variable sun gear control.
2. Description of Related Art
Known conventional transmissions use the vehicle's engine as the primary control for making changes in vehicle speed.
The manual transmission uses a clutch to change the gear ratio, with the engine being completely disconnected from the transmission momentarily during each level of gear change, and also with the engine being quickly revved up to fairly high rpm during each level change.
The standard automatic transmission uses a torque converter to avoid the complete disconnect of the engine between levels of gear ratio change, but the inefficiency of the torque converter causes considerable slippage between engine and transmission output, particularly during initial start-up and lower speeds when as much as 50% of the engine torque may be lost. This type of transmission blends engine and transmission better than the manual, but the engine still must be revved to higher rpm during each level of multiple gear change. Also, even during engine idle when the vehicle is stationary, the automatic transmission creates a constant loss of efficiency through hydraulic losses occurring in the torque converter.
The conventional acceleration rates for engine rpm during the revving for each gearing level in both manual and automatic transmissions is often between 1000-2000 rpm/sec, and this rapid acceleration of the engine's internal parts (crank shaft, pistons, valve cams) can result in a 20-25% loss in efficiency.
There have been many different forms of automatic infinitely-variable transmissions (“IVT”), in which usable torque is supplied to the drive wheels of the automotive vehicle through a continuum of constantly variable speeds. The IVT is distinguished from the continuously-variable transmission (“CVT”), in which vehicle speed is continuously changed throughout several successively-increasing speed and torque output levels. However, until recently, no IVT or CVT has been developed that is capable of successfully handling a full range of torque and engine sizes from a very small vehicle through a large commercial truck. Torvec, Inc., the assignee of the present invention, has recently successfully tested an IVT that can be readily sized to cover this entire range of engine size and torque requirements. Also, this recently tested IVT was specifically designed for propelling not only large SUVs (sport utility vehicles) but also small trucks and school busses. One of the latest designs of the Torvec IVT is disclosed in U.S. Pat. No. 6,748,817 entitled “Transmission with Minimal Orbiter”.
Torvec IVT's have been progressively improved during an extensive period of product testing, and a current design produces continuous changes of torque and speed from start-up through an overdrive ratio without any intermediate discontinuities while using engine acceleration rates of no more than 90-100 rpm/sec. These remarkable results are achieved with an apparatus that is significantly smaller and lighter than presently available conventional automotive transmissions.
The earlier Torvec IVT designs combined a variable hydraulic pump and a hydraulic motor with a gear orbiter to form an infinitely variable transmission so that, as the speed of the hydraulic motor increases the rotation of the gear orbiter, the output shaft speed increases and the speed of the vehicle increases. This basic design was recently significantly modified to operate in an unconventional manner. Namely, while the engine input was delivered to an input sun gear of the orbiting gear complex, the changes in output gear ratios were obtained by using the combined operation of the variable hydraulic pump and motor to slow the rotation of the web so that, as the rotation of the web in the direction of the engine was slowed, the transmission produced a continuously decreasing gear reduction, and, when the web was brought to a stop, the transmission provided an overdrive ratio of the engine input.
The recent Torvec transmissions just discussed above increase transmission efficiency by using a hydraulic pump and motor combination, rather than the vehicle engine, as a primary control of vehicle speed, thereby avoiding the above-mentioned engine acceleration losses. However, these recent Torvec transmissions still lose efficiency through the split torque path that delivers torque to the hydraulic pump and motor.
As just indicated above, when accelerating a vehicle with both manual and automatic transmissions, the revving of the engine, far exceeding 2,000 rpm, during various gear change levels is an inefficient use of horsepower. Even the relatively new Torvec IVT transmissions are burdened with the inefficient use of horsepower that arises from the division of a portion of the vehicle engine output into a split path for driving the transmission's hydraulics.
Special attention is also called to another prior art apparatus, namely, the Torvec long-piston hydraulic machines disclosed in U.S. Pat. No. 6,983,680 and U.S. 2004/0168567, which are hereby incorporated herein by reference. This special prior art is referred to in greater detail in the Summary portion below.
The invention disclosed herein is a further improvement of the successfully-tested earlier versions of the Torvec IVT just discussed above, and the hydraulic machine in the disclosed preferred embodiment utilizes a variation of the hydraulic machine disclosed in U.S. Pat. No. 6,983,680 and U.S. 2004/0168567.
SUMMARY OF THE INVENTION
The inventive transmission is a remarkably small structure that includes a minimal-orbiter gear complex and a single a rotary control device. The minimal orbiter includes only: a control gear and an output gear interconnected by the different gearing portions of at least one cluster gear supported by an orbiting web responsive to an input drive provided by a primary engine. The rotary control device may be any kind of apparatus that is capable of providing infinitely-variable resistance torque sufficient to match the torque of the primary engine to slow and stop the control gear of the orbital complex. In a preferred embodiment, the rotary control device is a hydraulic jack machine having a drive shaft connected to an adjustable swash plate and having input and output ports connected through a very minimal fluid passage that is closed by a controlled pressure valve.
While the disclosed preferred embodiments of a transmission of the present invention all utilize a single hydraulic machine as the rotary control device, all of these embodiments omit the split torque path that is conventionally used in hydraulically-controlled transmissions. None of the disclosed embodiments directly split off a portion of the engine torque to a path for operating the hydraulics. Instead, the engine torque is directed only through the mechanical gearing of the transmission. Also, the single hydraulic machine that generates resistance torque during vehicle acceleration places negligible load on the vehicle's engine during start-up, engine idle, and vehicle cruising.
To summarize the preferred operation of a transmission of the present invention: When the vehicle's engine is initially started, the orbital web of the small gear complex moves with the engine drive. The transmission output gear is connected to the vehicle's drive shaft, and when the parked vehicle's wheels are standing still on the terrain, the output gear is held in a stopped condition, and the cluster gears spin around the stopped output gear as the orbital web moves with the engine drive. Under these conditions with the preferred gear ratios indicated herein, the control gear rotates at approximately one-half the engine input speed. The swash plate of the hydraulic machine is set at 0°; the control valve is open; and the hydraulic drive gears and the shaft of the hydraulic machine merely rotate freely with the control gear at one-half engine speed, adding only a minimal frictional load.
In this regard, special attention is called to the fact that preferred embodiments of the invention use a variation of the above-mentioned prior art Torvec long-piston hydraulic machine. Commercial-quality prototypes of these Torvec long-piston hydraulic machines have already been successfully built and tested in both large SUVs (sport utility vehicles) and small trucks, and while these remarkable hydraulic machines have not yet enjoyed wide publicity, they are the preferred hydraulic machines for use with the invention described herein. The preference for this design of hydraulic machine cannot be over emphasized, since presently available commercial hydraulic pumps and motors are considered unacceptable for use with the subject invention because: (1) they are much larger and much heavier than the Torvec long-piston machines; (2) they are incapable of providing the high speeds needed for automotive use; (3) they do not have the start-up torque capabilities of the Torvec long-piston machines; (4) their “break-away” torque makes them inappropriate for the invention, requiring tens of pounds of force to begin to turn their drive shafts even when unloaded, whereas the unloaded drive shaft of a Torvec long-piston machine can be rotated by hand or finger grip; and (5) the volumetric efficiency of present commercial hydraulic machines is poor at low swash plate angles, whereas in actual testing, a Torvec machine produced 2000 psi or more at a swash plate angle of 1.5° with an input speed of 1700 rpm, registering a volumetric efficiency of about 95% at this small angle. With these just-listed deficiencies, if such standard hydraulic machines were to be used in the subject transmission, many of the advantages of the invention would be lost, e.g., the invention's neutral “no-load” condition could not be achieved, the vehicle's brake would have to be applied to avoid vehicle “creep” when standing in traffic on level ground, etc.
While the orbital gearing of a transmission of the present invention is preferably connected at all times to the hydraulic machine, the only notable load provided by the hydraulics occurs when the swash plate is adjusted to change the transmission gear ratios during vehicle operation. This hydraulic load provides a resistance torque that gradually slows the speed of rotation of the control gear through a continuum of decreasing speeds that begin when the swash plate is tipped as little as 1-1.5°. The progressive increase in resistance torque generated by the hydraulic machine causes a proportionally progressive slow-down of the control gear. The slow down of the control gear creates driving torque from the transmission output through an infinitely-varying gear ratio that begins, momentarily, from ∞:1-300:1 when the swash plate is tipped as little as 1-1.5°, and ends when the swash plate is at 25°, bringing the control gear to a stop and producing a transmission output at a predetermined overdrive ratio (e.g., 1:0.7).
Special attention is called to the fact that a hydraulic machine is not acting like a conventional hydraulic pump or motor in the present invention. Thus, the increasing torque provided by the hydraulic machine is not generated by an increasing flow of hydraulic fluid. To the contrary, with the minimal passage between the hydraulic input and output ports of the hydraulic machine blocked by a pressure valve, there is no significant volumetric flow of hydraulic fluid at any time. The only flow of fluid is a relatively small blow-by in response to the pressure being developed within the hydraulic machine accompanied by a concomitant replenishing of the blow-by to the low pressure side of the hydraulic machine from the hydraulic system's conventional charge pump. In effect, the hydraulic machine is operating like a hydraulic “jack”. Each infinitely-variable movement of the swash plate corresponds to the cranking of the jack handle, causing movement of the pistons of the machine to create ever-increasing levels of hydraulic pressure that act as resistance torque to slow the rotation of the swash plate, in a manner similar to the way that each crank of the jack handle increases pressure in the small hydraulic jack to raise the load slowly without any appreciable flow of hydraulic fluid.
When vehicle acceleration is desired, the minimal fluid passage that connects the input and output ports of the hydraulic machine is closed off by the pressure valve so that piston movement is limited by the just-mentioned minimal flow of blow-by as pressure is built up by the small angular adjustment of the swash plate that is rapidly rotating at the speed of the control gear. The minimal blow-by, which is less than 5% of the volume of fluid blocked within the machine by the closed valve, permits the angle of the rotating swash plate to be increased, increasing the resistance torque that slows the rotation of the control gear. The minimal blow-by at 1700 rpm is preferably less than 1 gal/min and is conventionally replenished to the low pressure side of the hydraulic machine by a small charge pump.
A transmission of the present invention provides a significant gain in engine efficiency by using the just-described simplified hydraulic-jack apparatus rather than the vehicle engine as the primary means for vehicle acceleration. Efficiency is increased during all accelerations up to highway cruising speeds because: (1) the vehicle engine remains at idle speeds or at a slightly increased rpm level within a continuum of relatively low rpm's (preferably 750-±1500 rpm at a rate of typically 75-100 rpm/sec), and at the same time (2) the simplified transmission provides consecutive infinitely-variable increases in output rpm while concomitantly providing consecutive proportional infinitely-variable decreases in torque (through gear ratio decreases). Because the transmission generates such extremely large starting torques at very low vehicle speeds, and because the changes in torque and vehicle speed remain proportional, the horsepower expended by the engine may thereby be more closely matched to the needs dictated by road and traffic conditions.
The transmission hydraulics are only active when providing the infinitely-decreasing gear reduction during the acceleration process. When the vehicle is stopped, the swash plate is returned to 0° and the pressure valve is opened, deactivating the hydraulic-jack effect, and the deactivated hydraulics consume minimal, if any, horsepower. When the vehicle is at cruising speeds, the hydraulics are pressurized and remain locked to hold the control gear in its stopped position, like a load being held up by a hydraulic jack, again consuming minimal, if any, horsepower except for the energy required for the charge pump to replenish the fluid lost in blow-by.
In actual vehicle testing, a transmission of the present invention reasonably accelerated the vehicle to 30 mph with a relatively minor increase in engine speed (e.g., 750-1000 rpm at about 75-100 rpm/sec). This is a significant improvement over the relative inefficiency of present conventional transmissions that achieve vehicle acceleration by rapidly increasing engine speed to over 1500 rpm during vehicle acceleration, unnecessarily wasting engine efficiency. In actual in-vehicle testing, a transmission of the present invention was found to consume approximately half as much fuel as conventional automatic when in a stopped condition with the vehicle in “drive” (e.g., stopped at a traffic light).
Of course, many operators lack the expertise or patience to learn the manual control procedures just explained above, and many others are unnecessarily “heavy footed” on the accelerator pedal. Therefore, in one embodiment of the present invention vehicle operation is computer-assisted. Such computer programs sense the angle of the accelerator pedal, as well as the rate at which this angle has been increased or decreased by the operator, to progressively select engine speeds from a continuum of relatively low rpm, the rate of engine speed progression being controlled to optimize the horsepower/fuel consumption for the desired acceleration rate indicated by the operator's actions. After the vehicle reaches a desired speed level, as indicated by the operator's released angle of the accelerator, the computer backs off the engine to the lowest rpm level necessary to maintain that speed.
Recent Torvec IVT transmissions have been much smaller and lighter than the conventional transmissions that they replace, and a transmission of the present invention is even smaller and has significantly less volume weight than the earlier IVT designs, since it omits one complete hydraulic machine.
In another embodiment of the present invention, a second hydraulic machine is included to create a hybrid drive. The vehicle's primary drive is provided by either a gas or diesel engine using the invention's just-described simplified hydraulic transmission. However, an accumulator assembly is added to the structure (a) to store the kinetic energy of the vehicle during coasting or braking in the form of pressurized hydraulic fluid and (b) to reuse that stored energy to assist in the acceleration or driving of the vehicle. The rotation of the vehicle's drive shaft during coasting and braking conditions is used as input to a hydraulic machine, acting as a pump, to deliver hydraulic fluid from a reservoir to a pressurized tank. To assist in the acceleration of the vehicle, this same hydraulic machine, acting as a motor, is driven by the stored pressurized fluid to provide supplemental driving torque to the vehicle's drive shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a first embodiment of the present invention, showing a cross section of the orbital gear complex.
FIG. 2 is a block diagram of the transmission in FIG. 1 , showing in schematic form a cross section of the invention's hydraulic jack machine.
FIG. 3 is a partially schematic view of a second embodiment of the present invention including accumulator apparatus appropriate for use in hybrid vehicles.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 and FIG. 2 are schematic diagrams of a remarkably small and compact transmission in embodiments of the present invention attached to the crankshaft 12 of a primary engine 10 that provides an input for an orbital gear complex 14 which is in combination with a rotary control device that is disclosed in this preferred embodiment as a hydraulic jack machine 16 . An input shaft 18 is splined to engine crankshaft 12 , both of which are aligned along a first axis 13 . A central drive plate 20 is positioned between the two end plates 22 , and these just-named three elements together form the orbital web of the transmission that also rotates about first axis 13 . Input shaft 18 is also splined to central drive plate 20 . End plates 22 support the respective ends of orbit shaft 24 that carries a cluster gear that includes cluster gear 26 and cluster gear 28 . While a preferred orbital gear complex comprises at least two or three sets of orbit shafts 24 and cluster gears 26 / 28 , only one set is shown for clarity. Also, engine crankshaft 12 may alternatively be splined directly to the central drive plate 20 . Central drive plate 20 has openings to provide clearance for cluster gears 26 / 28 , and a control gear 30 meshes with cluster gears 26 , while cluster gears 28 mesh with an output gear 32 coupled to a transmission output shaft 34 that, in turn, is connected to a vehicle drive shaft 35 (as will be explained in further detail below).
Control gear 30 is fixed to a control drive gear 36 , and both control gears 30 , 36 are similarly fixed to a hollow shaft 38 that circumscribes transmission input shaft 18 . Control drive gear 36 is in mesh with a hydraulic drive gear 40 fixed to the drive shaft 42 of hydraulic machine 16 that creates the resistance torque that controls the output of orbital gear complex 14 . Control gear 30 is larger than cluster gear 26 , and cluster gear 28 is larger than output gear 32 .
In one preferred embodiment of the present invention, the gear tooth ratios for the orbital gearing are as follows, with reference numerals from FIG. 1 and FIG. 2 :
Gear
No. of Teeth
a.
Control gear 30
32
b.
Cluster gear 26 (in mesh w/30)
19
c.
Cluster gear 26 (fixed to 26)
33
d.
Output gear 32 (in mesh w/28)
22
e.
Control drive gear 36 (fixed to 30)
60
f.
Hyd. machine drive gear 40 (in mesh w/36)
30
Hydraulic jack machine 16 , which operates as the transmission's rotary control device in a disclosed preferred embodiment, includes a plurality of pistons 44 arranged in cylinders (not individually shown). The stroke of the pistons 44 is controlled by the position of an adjustable swash plate 46 that rotates with drive shaft 42 and hydraulic drive gear 40 . The cylinder block 48 includes a cylinder for each piston, each cylinder having input and output ports 50 connected through only a very minimal passage 52 closable by a fluid pressure valve 54 that also serves as a pressure relief valve (e.g., for avoiding increases in pressure above 4000 psi within machine 16 ).
When swash plate 46 is set at 0°, drive shaft 42 and swash plate 46 may freely rotate without resulting in any significant increase of fluid pressure in any portion of hydraulic machine 16 , including minimal passage 52 . However, when pressure valve 54 is closed, blocking off minimal passage 52 , and swash plate 46 is moved in a forward direction, the increasing inclination of swash plate 46 results in increasing hydraulic pressure within the hydraulic machine, slowing the rotation of swash plate 46 , drive shaft 42 , hydraulic drive gear 40 and control drive gear 36 , providing a resistance torque that decreases rotation of control gear 30 proportional to the increase of the resistance torque. This resistance torque varies directly with the fluid pressure in hydraulic machine 16 , and when swash plate 46 is moved to a predetermined maximum angle, the resistance torque prevents rotation of control gear 30 . The changes in hydraulic pressure just described all preferably occur with no fluid motion other than a minimal blow-by replenished by a small conventional charge pump (not shown) to the low pressure side of hydraulic machine 16 at a maximum rate of less than one gallon per minute.
In a disclosed preferred embodiment, output shaft 34 from orbital gear complex 14 preferably connects through a standard clutch mechanism 56 to a standard “forward/reverse” gear complex 58 , this gear change being conventionally controlled by a standard gear-shift lever. While the final output of the forward and/or the reverse gearing of complex 58 can remain at 1:1 with the transmission output, some differing output gear ratios may be desired in some designs. Also, a computer 60 preferably monitors (a) the vehicle accelerator pedal 62 (both position and rate of change), (b) a manual shift lever 63 , and (c) hydraulic fluid pressure in hydraulic machine 16 by a fluid pressure sensor 64 to control (d) adjustment of swash plate 46 , (e) operation of clutch 56 , and (f) adjustment of fluid pressure valve 54 .
Start-Up
When the vehicle is stationary and the engine is first started, the following events preferably occur: The engine begins to operate at idle (e.g., 750 rpm). The orbital web 20 , 22 of small gear complex 14 rotates with engine crankshaft 12 at engine speed. The wheels of the parked vehicle are standing still on the terrain and, since transmission output gear 32 is connected to the vehicle drive shaft 35 , output gear 32 is held in a stopped condition. With orbital web 20 , 22 rotating orbit shaft 24 and cluster gears 26 , 28 about first axis 13 while output gear 32 is held stopped, cluster gear 28 rolls around stopped output gear 32 as the orbital web moves with the engine drive. Under these conditions, with the preferred gear ratios indicated above and with swash plate 46 of hydraulic machine 16 set at 0°, control gear 30 rotates at approximately one-half the engine input speed (e.g., 300 rpm), and hydraulic drive gear 40 , shaft 42 , and swash plate 46 all merely rotate freely at some predetermined overdrive rate faster than the speed of control gear 30 , adding only a minimal frictional load. Once again, special attention is called to the fact that the hydraulic machine disclosed in a preferred embodiment herein uses a variation of the above-mentioned prior art Torvec long-piston hydraulic machine disclosed in U.S. Pat. No. 6,983,680 and U.S. 2004/0168567, which assures the successful operation of the just-described neutral “minimal-load” condition.
From Standing Stop
Upon vehicle startup from a standing stop, the following events preferably occur: While engine 10 remains at idle (e.g., 750 rpm), pressure valve 54 is closed and swash plate 46 is initially moved in the forward direction, either manually or under computer control in response to the depression of accelerator pedal 62 . The immediate pressure build-up within hydraulic jack machine 16 results in sufficient blow-by to permit swash plate 46 to move about 1-1.5°, and this same immediate pressure increase causes a slow down of control gear 30 from its free-wheeling speed at approximately one-half the idling speed of the engine (e.g., 300 rpm). Gear complex 14 responds to this slow down of control gear 30 by creating a momentary near-infinite gear reduction at the output gear that, in a fraction of a second, drops to 1000-300:1 gear reduction, starting the vehicle's wheels to turn at very slow rpm with very high torque.
Thereafter, the vehicle is accelerated in response to the continued movement of swash plate 46 in the forward direction. However, it is important to note that blow-by in closed hydraulic jack machine 16 remains constant (e.g., less than 5% of the total volume of fluid blocked within the machine by the closed valve 54 ) and that the blow-by determines the maximum rate at which the angle of swash plate 46 can continue to increase. Nonetheless, this maximum rate is relatively fast, and pressure in hydraulic machine 16 increases in direct proportion to the movement of swash plate 46 . This increasing pressure creates resistance torque that opposes and slows the rotation of swash plate 46 , hydraulic machine drive shaft 42 , hydraulic drive gear 40 , control drive gear 36 , and control gear 30 . The increasing slow down of control gear 30 results in the concomitant gradual increase in the rotation of transmission output shaft 34 at the just-described extremely high gear ratio that quickly drops to about 30-20:1, multiplying the engine torque proportionally, starting to move the vehicle wheels.
This forward movement of swash plate 46 continues as the vehicle accelerates, further lowering the gear ratio, until the vehicle reaches around 30-40 mph. At this point, the following conditions occur almost simultaneously: (a) swash plate 46 reaches a maximum angle (e.g., 25°); (b) control gear 30 stops; (c) the hydraulic pressure in hydraulic machine 16 remains “locked” (like a hydraulic jack), exerting a constant back pressure that maintains control gear 30 in its stopped condition; and (d) transmission output gear 32 is running at a predetermined overdrive condition as efficiently as if it were held by a clutch.
The locked condition of hydraulic machine 16 is maintained as the continuing blow-by (e.g., less than 1 gal/min at vehicle speeds of 50 mph) is conventionally replaced to the low pressure (suction) side of the machine by a small charge pump.
When Cruising
At highway cruising speeds (i.e., with swash plate 46 at 25° and control gear 30 stopped), when greater drive torque is required, such as for maintaining speed on an incline or passing another vehicle, the operator merely moves shift lever 63 slightly back from its limit position. This is all that is required to move swash plate 46 to a slightly lower angle (e.g., 22°), thereby re-starting movement of hydraulic pistons 44 and control gear 30 , to increase the transmission gear-ratio and output torque.
The vehicle may be provided with a well-known “cruise control” feature. If so, when traveling under cruise control at some desired cruising speed and the vehicle encounters a hill, the increased load on the transmission is noted by the operator, or through fluid pressure sensor 64 in minimal passage 52 by computer 60 , and this pressure increase is compensated by moving swash plate 46 back a few degrees (e.g., from 25° to 22°) either by computer input or by manual movement of shift lever 63 back slightly from its maximum (e.g., 25°) position. This causes some reduction of pressure within hydraulic machine 16 that, in turn, results in some movement of control gear 30 to cause an increase in the gear ratio within the transmission, resulting in an increase in output torque until the vehicle again reaches the desired cruising speed and the pressure within the hydraulic system once again becomes balanced. Swash plate 46 is returned to the maximum (e.g., 25°) position during this increase in vehicle speed, increasing resistance torque to once again stop control gear 30 , and the vehicle maintains its desired speed.
Similarly, when it is desired to slow the vehicle from a cruising speed, accelerator pedal 62 is released and shift lever 63 is moved back towards the 0° swash plate position, creating increasing braking torque from the slowed engine through the resulting rapidly increasing gear-ratios. Should shift lever 63 near the 0° swash plate position, clutch 56 is engaged before the vehicle's drive wheels are locked.
Special attention is called to the fact that hydraulic machine 16 is not operating like a conventional pump or motor, and thus, the increasing resistance torque provided by hydraulic machine 16 is not generated by an increasing flow of hydraulic fluid. To the contrary, with minimal passage 52 between hydraulic input and output ports 50 blocked by pressure valve 54 , there is no significant volumetric flow of hydraulic fluid at any time. As indicated above, the only flow of fluid is a relatively small blow-by in response to the pressure being developed within hydraulic machine 16 accompanied by a concomitant replenishing of the blow-by to the low pressure side from a conventional charge pump. In effect, hydraulic machine 16 operates like a hydraulic “jack”. Each successive movement of swash plate 46 corresponds to the cranking of the jack handle, causing movement of the pistons of the machine to create ever-increasing levels of hydraulic pressure that act as resistance torque to slow the rotation of swash plate 46 , in a manner similar to the way that each crank of the jack handle increases pressure in the small hydraulic jack to slowly raise the load without any appreciable flow of hydraulic fluid.
Special attention is also called to another very important feature of the invention. As indicated above, when the vehicle is stopped and there is no movement of output gear 32 , the orbital gearing creates a mechanical advantage of the engine input to cause control gear 30 to rotate at a predetermined reduction of the idling engine speed. The gear ratio between hydraulic drive gear 42 and control-drive-gear 36 /control gear 30 is intentionally selected to create the same mechanical advantage for the resistance torque pressure developed by the hydraulic machine 16 as that resistance torque enters and affects the orbital gearing and the transmission output. Thus, in effect, the hydraulic resistance torque that slows control gear 30 enters the gear complex at a reduction that matches the engine torque reduction. As just explained above, the preferred embodiment disclosed provides the desired matching-engine resistance torque by selecting a similar 2:1 gear reduction between hydraulic drive gear 40 and control drive gear 36 . However, this reduction can be made even higher to require less initial resistance torque from machine 16 to match engine torque (such as if the transmission is being used with a diesel engine).
In actual vehicle testing, a vehicle with a transmission of the present invention readily attained the 30 mph speed while the engine was maintained at a little over 750 rpm. However, the acceleration of the vehicle from stop to this speed may take as long as 12-15 seconds depending on road conditions. Since most operators prefer a faster acceleration, this preference may be achieved manually by no more than a minor increase in the angle of the accelerator pedal. Computer control 60 senses the indicated pedal angle to increase acceleration at a more generally acceptable rate (e.g., 100 rpm/sec). This increased acceleration is achieved without the conventional racing of the engine to over 2000 rpm. Instead, the operator or computer progressively selects relatively low levels of increasing engine rpm, (e.g., from a continuum of 750-1500 rpm). The rate of this engine speed progression is controlled to optimize the horsepower/fuel consumption for the desired acceleration rate, as indicated by the depression angle of the accelerator. After the vehicle reaches a desired speed level, again indicated by accelerator position, the engine speed is backed off to the lowest rpm level necessary to maintain that attained speed.
While the following may be a reiteration of the above explanation, some persons may best appreciate the general operation of a transmission of the present invention with the help of the following description of a basic embodiment in which the swash plate of the hydraulic machine is manually controlled by using simple shift lever 63 . After the vehicle is started and while engine 10 is still at idling speed, the standing vehicle is initially accelerated by moving shift lever 63 very slightly in the forward direction, just enough to initiate vehicle movement. Immediately thereafter, accelerator pedal 62 is depressed slightly to increase engine speed by only a few hundred rpm. With only small increments of additional pressure on the accelerator pedal, depending on the rate of vehicle acceleration desired, shift lever 63 is continually moved in the forward direction, until the vehicle reaches a desired speed or until the shift lever 63 reaches its limit (e.g., the 25° swash plate position) and the transmission reaches the predetermined overdrive for sustained cruising operation. The rate of acceleration is controlled completely by the operator, and even the fastest acceptable rates can be achieved with relatively minimal increases in engine rpm. Of course, after a cruising speed appropriate for the terrain and traffic conditions is achieved, the shift lever 63 is allowed to remain in the position that provides the desired cruising speed, and accelerator pedal 62 may be relaxed to a lower level of engine rpm necessary to sustain the attained cruising speed.
Accumulator Embodiment
Another embodiment of the present invention, shown in partially schematic FIG. 3 , includes an apparatus that permits operation in regeneration modes similar to those used in well-known “hybrid” vehicle designs.
In this embodiment, the transmission converts torque from engine crankshaft 12 to vehicle drive shaft 35 in the manner just explained above with reference to FIGS. 1 and 2 . A second hydraulic machine 70 is added along with a fluid storage tank 72 , a fluid pressure tank 74 , accumulator transfer gears 76 , 78 , a clutch 80 , and an accumulator control valve 82 .
Whenever the vehicle is braking or coasting, accumulator control valve 82 interconnects hydraulic machine 70 to accumulator tanks 72 , 74 , and, simultaneously, clutch 80 connects transfer gears 76 , 78 to the drive shaft of hydraulic machine 70 . During such coasting or braking conditions, the rotation of vehicle drive shaft 35 is increased by gears 76 , 78 to energize hydraulic machine 70 which acts like a regeneration pump to draw fluid from storage tank 72 and deliver it under pressure to pressure tank 74 . Pressure tank 74 is preferably primarily a steel tube, capped at each end with the interior of pressure tank 74 including a bladder that is filled with a compressible gas in the manner well-known in the art. Regenerative fluid enters pressure tank 74 under pressure that begins to compress the gas in the bladder until pressure tank 74 is full.
Storage tank 72 is preferably similar to pressure tank 74 except that it contains no gas-filled bladder and it is initially filled with fluid sufficient for the normal operation of the regeneration system. For many vehicles, elongated tubes that comprise storage tank 72 and pressure tank 74 may be approximately 8′-10′ long and may be positioned along side each of the respective side rails of the vehicle's frame.
During braking or coasting, engine 10 returns to its idle speed and swash plate 46 is readjusted toward the 0° position, causing transmission 14 to produce an ever-increasing reduction and braking torque in output gear 32 and vehicle crankshaft 35 , and clutch 56 is disengaged before the vehicle is braked to a stop, as explained above.
As soon as pressure tank 74 is full, or as soon as the vehicle reaches a predetermined minimal operating speed, whichever occurs first, the regeneration circuit is closed off (i.e., valve 82 is moved to its closed position and clutch 80 is disengaged), and the transmission is returned to normal operation (i.e., the swash plates of hydraulic machines 16 and 70 are reoriented to their respective normal positions) based upon the vehicle speed condition then prevailing.
When it is desired to restart or reaccelerate the vehicle, hydraulic machine 16 operates in the manner explained above, while clutch 80 is engaged and valve 82 is moved to its open position. The pressurized fluid stored in pressure tank 74 is released to energize hydraulic machine 70 which now acts like a regeneration motor, adding driving torque to engine drive shaft 35 through the reduction of transfer gears 78 , 76 . During the time that pressurized fluid is being delivered from pressure tank 74 , the regeneration system remains activated (i.e., valve 82 remains open) so that the regeneration fluid is returned to storage tank 72 , while engine 10 remains at idle speed. As soon as the vehicle reaches a desired operating speed, or as soon as pressure tank 74 is depleted of pressurized fluid, whichever occurs first, the regeneration circuit is closed off (i.e., valve 82 is closed and clutch 80 is disengaged), and the speed of engine 10 and the transmission are returned to normal operation.
It should be noted that transfer gears 76 , 78 have an increasing ratio (e.g., 1:3 between engine drive shaft 35 and hydraulic machine 70 when the latter 14 is acting as a pump, increasing the effective speed of hydraulic pump 70 to a multiple (e.g., three times) of the speed of output shaft 35 . Thus, the saved energy from the inertia of output shaft 35 is accumulated in pressure tank 74 at a much faster rate (e.g., three times faster) than it is being lost during the coasting/braking operation. As just indicated above, this stored energy is returned to the vehicle wheels through transfer gears 78 , 76 by torque-increasing reduction.
Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention.
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The transmission includes a minimal-orbiter gear complex and a single infinitely-variable rotary control device. The minimal orbiter includes only a control gear and an output gear interconnected by the different gearing portions of at least one cluster gear supported by an orbiting web responsive to an input drive provided by a primary engine. The rotary control device may be any kind of apparatus that is capable of providing resistance torque that can match the torque of the primary engine to slow and stop the control gear of the orbital complex. In a preferred embodiment disclosed, the rotary control device is a hydraulic jack machine having a drive shaft connected to an adjustable swash plate that provides primary control of the flow of fluid through the machine.
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This is a continuation of application Ser. No. 339,440, filed Jan. 8, 1982, now abandoned, and as described and claimed in International Application PCT/CH 81/00051, filed May 11, 1981.
The present invention concerns a method for establishing a galvanic contact between an insulated work piece and welding electrodes; the subsequent welding of this work piece whereby at least one of the electrodes has a heating current loop which is connected to the working area of the electrode as a supply and return whereby a potential difference can be applied through this loop in the heating or in the stripping phase; and an electrode arrangement for the execution of such, and its use.
PRESENT STATE OF TECHNOLOGY
From the Japanese Pat. Nos. 45-15 856 and 49-3 380, a construction is known in which heating current flows before the welding operation. By a decrease in the cross section of the loop conductor, the latter will be correspondingly higher in resistance in its working area in order to ensure the necessary heat in the heating process. The problem arising from the technique described here is that, although advantageous in its use of the same conductor arrangement for the conduction of the heating current and for the conduction of the welding current, the reduced cross section of the conductor (for the heating operation) can lead to undesirable high heating of the electrode during the welding operation.
DESCRIPTION OF THE INVENTION
The present invention serves to alleviate the above-mentioned disadvantage, and to prevent thereby unwanted heating of the electrode in the welding operation as occurs in the type of method previously mentioned. This is achieved by applying an equal potential to the two conductors of the loop, thereby changing them to parallel welding current conductors.
It is now also possible to take a temperature measurement of the electrode in the working area, which the considerable significance if the welding is to take place corresponding to the transfer resistance between electrode and welding piece, since the electrode is heated only slightly due to its own conductor resistance in the welding operation. Preferably, after the temperature is measured, a switch from the heating to the welding operation takes place and the welding operation is controlled or adjusted.
An electrode arrangement for the execution of the described method distinguishes itself in that at least one electrode is constructed as a loop with a current supply to the working area and a return line, and in that welding current connections are provided for both conductors.
Preferably, the electrode has along its working area a portion with a higher resistance for the heating current, the portions bordering on this sides of the working area having a low resistance so that the welding current thereby flows mostly through the portion with the relatively low resistance. Therefore it is ensured that the welding current flows only minimally through the provided portion of increased resistance for the heating operation, i.e., mostly directed to the left and right of this area of the work piece.
A simple design form of the electrode, achieved for use in the mentioned method, is to make it U-shaped. Preferably it is formed such that the U base forms the working area so that it has a reduced cross section in the middle area and in the side areas an enlarged cross section. The reduction of electrode heating in its working area, during the welding process, results in the possibility that on the electrode a thermal sensor can be provided directly on its working area, the output signal of which, especially in the welding operation, represents the temperature of the actual welding operation and not the entire welding current-related electrode heating. The mentioned arrangement is used preferably for spot or aperture welding, especially for micro-spot or micro-aperture welding, and if need be, for soldering, especially micro-soldering.
BRIEF DESCRIPTION OF THE FIGURES
The invention is described in the following with the aid of figures. Shown are:
FIG. 1 a schematic representation of two common aperture welding electrodes on a work piece, with applied welding current,
FIG. 2 a representation similar to FIG. 1 for spot welding electrodes.
FIG. 3 the schematic representation of an electrode according to the invention, and also a completely developed opposing electrode for spot welding according to the invention,
FIG. 4 a schematic representation, similar to FIG. 3, of two completely developed aperture welding electrodes according to the invention,
FIG. 5 a perspective view of two developed spot welding electrodes on the work piece according to the invention,
FIG. 6 a perspective view of two developed aperture welding electrodes on the work piece according to the invention,
FIG. 7 a perspective view of a preferred electrode,
FIG. 8 a schematic arrangement of two developed spot welding or aperture welding electrodes according to the invention, each with one heating current generator and a welding current generator,
FIG. 9 a schematic representation according to FIG. 8 with temperature measurement on one or both electrodes and corresponding regulation of the heating and welding phase,
FIG. 10 a schematic representation of two spot welding or aperture welding electrodes according to the invention, with a common heating current generator and a welding current generator,
FIG. 11 a representation similar to FIG. 10 with temperature measurement on one or both electrodes and corresponding regulation of the heat and welding phase,
FIG. 12 a representation similar to FIG. 10 with the measurement of heating current and corresponding regulation of the heating and welding phase.
DETAILED DESCRIPTION OF THE INVENTION
Shown in FIG. 1 is a known arrangement of two aperture welding electrodes 1a and 1b, which are to be electrically in contact for the welding process, with two working pieces 3a and 3b to be connected, whereby for example 3a is a conductive strip on a carrier substrate 5. The welding current I S flows in the welding operation from the electrode 1a over the work piece 3a, which it is in contact with, and goes thereby to the work piece 3b to be connected to work piece 3a, and back to the opposing electrode 1b. When one and/or the other work piece has an insulation layer 5a or 5b, this must be removed before starting the welding phase, so that the two electrodes 1a and 1b can be brought into electrical contact with the work pieces 3a and 3b.
Represented in FIG. 2, similar to FIG. 1, are two spot welding electrodes 1c and 1d where each is to be electrically in contact with work pieces 3c and 3d to be connected. I S again represents the welding current. Here again an insulation layer 5c or 5d, when present, prevents the electrical connection between the two electrodes 1c and 1d, and must be removed before the welding. In the micro-technique especially, problems are encountered with the stripping, through the typical dimensions, of the work pieces, for example wire cross sections of a few μm. A mechanical removal of the insulation layer is hardly possible without damaging these work pieces. A removal of the insulation layer by means of solvents has to be done beforehand, i.e. in a place away from the welding working station which considerably complicates the work flow.
In FIGS. 3 and 4 a primary basically improved variation of the inventive electrode is represented; in FIG. 3 in the application as a spot welding electrode, in FIG. 4 as aperture welding electrode. The electrode according to the invention will be generally designated with 1 in the following, and an opposing electrode as 12, which should mean that the opposing electrode can be constructed according to the invention (digit 1) or in the typical fashion (digit 2). The electrode 1 includes, in the improved version according to FIGS. 3 and 4, a metallic hollow body 7, closed on one side by the electrode working area 9 having, an improved working area. In the hollow body 11 is a conductive loop 13 which goes to the working area 9 of the electrode. On the working area 9 the current loop 13 has an increased resistance as far as the supply and return 15a and 15b is concerned. With the aid of a schematically represented current generator 17, a heating current I H is fed over the loop 13 and the supply and return line 15a, 15b, and resistor R, whereby, especially in the working area 9, the metallic electrode body 7 will be heated up. Consequently, the insulation layer or at least the insulation layers 19, will be melted away on the work piece, which allows electrical contact of the two work pieces with electrode 1 and electrode 12. When this galvanic connection is ensured by sufficiently little transfer resistance the welding current I S is carried from electrode 12 by means of a schematically represented welding current generator 21. On the opposing electrode 12 is, represented by a dotted line, a conductive loop 13 and heating current generator 17, showing the possibility that this opposing electrode 12 also can be constructed according to the invention, depending on the work piece insulation relationship.
In FIG. 4 the arrangement, similar to FIG. 3, for aperture welding electrodes is represented.
FIGS. 5 and 6 show a perspective view of an additional preferred improved variation of the electrode according to the invention, in FIG. 5 for spot welding and in FIG. 6 for aperture welding. Although both electrodes according to the invention are shown here in the improved form, the opposing electrode can be of a typical type.
The electrode 1 is divided into two sides, by a slit 23, the sides serving as supply and return 25a and 25b to the working area, depending on the direction of flow of the heating current I H .
Adjacent to the working area 27 the slit 23 has an inlet, or opening 29 so that the thickness of the wall formed by the current loop through the supply and return 25a and 25b and also the working area 27 will be smaller on the working area 27 than at the supply and return.
With a heating current generator, not shown here, the heating current I H is forced through the current loop 25a, 25b, 27, whereby, as shown by arrows, the current density is smaller in the supply and return than on the working area 27. Consequently, during the heating phase, the working area 27, which is in contact with the work piece insulator 31, is heated up. Consequently the insulator 31 is melted away and forced away from the metallic work piece material to permit electrical contact. After this heating or stripping phase, a potential difference is applied between the electrode 1 and the opposing electrode 12 as a whole, and the welding current I S is forced from one electrode through the two work pieces to the other electrode. In the welding phase, therefore, the same potential ψ 1 is applied on the electrode 1, supply and return 25a and 25b, and working area 27. While in the heating phase, to cause the heating current flow, a potential difference is applied, shown with Δψ H through the loop 25a, 25b, 27. As shown, the welding potential ψ 1 and ψ 12 are applied equally to the supply and return 25a and 25b in order to ensure a symetrical distribution of the welding current I S to both metallic sides 25a, 25b. The supply and return are thereby connected in series for the heating current I H in the heating phase, parallel for the welding current I S . For the typical relatively higher welding current I S the sum of the side cross sectional surface A and B have to be considered for the losses, the individual cross sectional surface A or B for the heating current I S .
FIG. 6 shows the same electrodes 1 and 12 with the improvement according to FIG. 5. arranged for aperture welding. Here separately provided heating current generators 17, are provided, for example, and are schematically shown. It is understood that the electrode can have different tips and working areas depending on its use.
Shown in FIG. 7 is a preferred design form of electrode 1, which can be used as a spot or aperture welding electrode, especially for micro-spot or micro-aperture welding applications. The slit 23 has adjacent thereto the working area 27 of the electrode, and an eliptical borehole 29a, easily manufactured and analogous to opening 29 of FIG. 5, is provided with which an area of higher resistance can be realized for the heating current I H as indicated with dotted lines by R. During the heating of the working area 27, the supply and return 25a and 25b also radiate heat, although such heat is continuously decreasing with the increased distance from the working area 27. The loss of heat is reduced on the supply and return by the insertion of a thermal and electrical high insulating insert 31, preferably a ceramic insert, whereby, as indicated by dotted lines, a complete embedment can be provided for the supply and return in such a high insulating body 33. However, this would necessitate a considerable cost increase.
The described electrode can, as mentioned many times before, be used as spot weld or aperture weld electrode, whereby the one and/or other of the two provided electrodes can be constructed according to the invention for these methods. The same electrode can be used additionally as a soldering electrode without any changes in construction, and if need be, with a snap-on work tip (not shown), in order to prevent contamination of the welding working area by the soldering. The heating current denoted with I H in the figures for the welding operation would be soldering heat current in the soldering operation.
In FIG. 8 schematically shown are two electrodes 1a, b according to the invention for spot welding or aperture welding. The side by side arrangement of the electrodes 1 in this and the following figures should not be misconstrued as the exclusive arrangement for aperture welding. For the heating phase both electrodes 1 are provided with a separate heat current generator 17a and 17b and each with a control switch H a or H b , shown schematically. Furthermore, both electrodes are connected with a welding current generator 21 by a control switch S. By closing of the control switches H a and H b the heating phase of the electrodes 1a and 1b is actuated and by closing of switch S the welding phase is actuated. It has to be emphasized, therefore, that the switch S, the same as the switches H a and H b , is not needed when, for instance, either the heat currents I H can flow also during the welding current flow and/or the welding current flow I S is actuated by the fact that the working piece insulation is melted away. In the latter case the switch S corresponds to FIG. 8, actually by the switching distance formed by the insulation layer to be melted through.
A possible control is shown in FIG. 9, which is similar to FIG. 8, as to the operation of the two electrodes 1a and 1b and switching of the heating current I H by the actuation of the welding process. For this purpose a thermal sensor 35 is provided at least on one of the two provided electrodes 1a and 1b, preferably in the area of the electrode working surface, which delivers a signal U (δ) in relation to the working surface temperature δ(t). The output signal of the thermal sensor 35 is compared on a unit 37 with an error value U (δ o ) which can preferably be adjusted. The control switches H a and H b in the heat current loop of the two electrodes 1a and 1b are opened by a switching control unit 39 when, as indicated by the characteristic line in the unit 39, the measured temperature δ reaches a predetermined value δ o or when at least a predetermined time has been maintained. When the switch S is a provided switching element in the welding current loop and is not, as previously mentioned, formed by the insulation layer distance, this switch will be closed by the opening of heating current control switch H a and H b . As shown in FIG. 9 by a dotted line, the thermal sensor 35 can be used to monitor temperature for heat and/or welding current regulation, whereby the output signal U (δ) is supplied as a control value to the unit 37 and is compared there with the nominal value U (δ o ) and the output signal of the unit 37 is supplied as a control differential to the heating current and/or a welding current generator 17a, 17b or 21 as adjusting links.
In FIG. 10, which is similar to FIG. 8, the arrangement of two electrodes 1a and 1b of the welding current generators 21, with control switch S, is shown, whereby the same heat current generator 17 with a control switch H for the heating of both electrodes is used. Through the switch H both heating current loops of the electrodes 1a and 1b are connected in series.
In FIG. 11, which is similar to FIG. 9, the control of the control switch switches H and S and the adjustment of the generators 17 and 21, corresponding to the heating and welding current, with the aid of a thermal sensor 35 is shown.
In the series connected heating current of both electrode loops, a further control possibility is the result of the two working phases, the heating phase and the welding phase, which is shown in FIG. 12. In the heating phase the heating current generator 17 is switched through a control switch H and a resistance element R' to the heating current loop of the two electrodes 1a and 1b. Due to the melting of the insulation layer on the work pieces to be connected, a decreasing resistance ρ occurs between the working area and the two electrodes, pointed out in the supplementary picture of the two work pieces according to FIG. 12. Consequently a portion of the heating current ΔI H is commuted to the two work pieces to be connected, since ρ and R' appear to be connected in parallel. The current, through the resistance element R', decreases. If one measures a current in the leg of the current loop containing R', for example with the aid of a current/voltage converter 41, one can, through an error value unit 43 shown schematically, preferably with a predetermined error value, open the control switch H and then close S, in case S is not formed through the insulation layer, when the heating current in the measured current leg does not go below a predetermined value. Therefore it is understood that R' is chosen as small as possible in order to keep the created loss of heat as low as possible.
In conclusion, it must be pointed out that due to the arrangement of the welding current generators 21, especially in the improved variations according to FIGS. 5 to 12, that the supply or return for the heating current may not be connected in the upper, i.e. in the portion away from the working area of the electrode. Since for a symetrical division of the welding current (each I S /2) both heat loop legs of the electrode have to be switched to the same potential in FIGS. 5 to 12, the control switch S is therefore shown with two pole circuits which prevent, in the heating operation, a connecting together of the two legs or of the supply and return, and which instead apply a common potential in the welding operation.
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In the use of U-shaped electrodes with a current supply and return in regards to the working area whereby for the stripping of insulated work pieces a heating current is applied before the welding operation, different conductor cross section requirements for the heating and welding operation present themselves. During the heating operation a cross section reduction is necessary to obtain enough heat output, but this is undesired for the welding operation. In order to solve this contradiction it is proposed to supply an electrode with a heating current supply (25a) and a return (25b), leading to the working area and returning respectively and to apply a common potential to the supply and return for the welding operation.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority of German Patent Application No. 103 52 138.0 filed Nov. 4, 2003, and International Application No. PCT/EP2004/012388 filed Nov. 3, 2004, which are relied on and incorporated herein by reference.
INTRODUCTION AND BACKGROUND
The invention relates to spherical particles comprising magnesium alcoholates or a mixture of magnesium alcoholates, a process for their preparation and their use.
It is known to prepare magnesium alcoholate. Thus, US 2001/0012908 describes the synthesis of magnesium alcoholates at a temperature of 30 to 60° C.
U.S. Pat. No. 5,556,820 (date of application: Feb. 3, 1994, Idemitsu) describes the preparation of magnesium ethanolate from magnesium and ethanol in the presence of 0.019 to 0.06 gram-atom of halogen per mol of magnesium.
U.S. Pat. No. 5,965,478 (date of application: 13/08/1997, Toho Titanium) describes a magnesium ethanolate having a bulk density of 0.25-0.40 g/ml and a particle diameter of 1 to 100 μm as a component of a Ziegler-Natta catalyst. This is prepared by continuous or batchwise addition of alcohol and magnesium to a reaction mixture which is not defined in more detail. The synthesis takes place at the reflux temperature.
The flowability of the powder is of great importance for the processing and handling of pulverulent substances. During filling, transferring and emptying operations in particular, for example from barrels or other drums, a rapid flowing out of the magnesium alcoholate powder saves time and expenditure. A good flowability of the magnesium alcoholate powder must also be ensured because this class of substance is highly sensitive to air and water. Residues of substance in drums which have not been emptied completely are a high safety risk. Due to the good flowability, there is also a reduced risk of bridge formation when transferring to silos. Pneumatic delivery of the powder is also facilitated.
In the case of all the abovementioned known magnesium alcoholates, nothing is said about the flowability of the magnesium alcoholates formed here. There is therefore the need for a form of magnesium alcoholate powders which is distinguished by a good flowability.
The object of the invention is to prepare spherical particles comprising magnesium alcoholate or mixtures of magnesium alcoholates having a good flowability. These particles can serve, for example, as starting substance (catalyst precursor) for olefin polymerization catalysts.
SUMMARY OF THE INVENTION
The invention provides spherical particles comprising magnesium alcoholates or mixtures of magnesium alcoholates, which are characterized in that they have a poured cone height of less than 17 mm.
The lower the poured cone height, the better the flowability of the powder.
Measurement of the poured cone height under precisely defined conditions is a measure of the flowability of a pulverulent substance. The angle of repose is a further evaluation criterion for the flow properties. Since given the same base dimension the poured cone height depends directly on the angle of repose and is considerably easier to determine, this is determined.
Another method for determination of the flowability of powders is, for example, measurement of the discharge speed using a modified Pfrengle discharge funnel [DIN ISO 4324].
The invention also provides a process for the preparation of the spherical particles comprising magnesium alcoholates or mixtures of magnesium alcoholates according to the invention, which is characterized in that magnesium, an alcohol or a mixture of various alcohols and a halogen and/or a halogen compound are reacted with one another at below the boiling point of the alcohol component having the lowest boiling point, and the product obtained is separated off and dried.
The alcohol component having the lowest boiling point can have a boiling point of 68° C. It can be, for example, methanol.
BRIEF DESCRIPTION OF DRAWING
The invention will be further understood with reference to the accompanying drawing which illustrates measurement of poured cone height.
FIG. 1 shows a diagram of the poured cone height measurement.
DETAILED DESCRIPTION OF THE INVENTION
The main constituent of the spherical particles according to the invention can in general be magnesium ethanolate. In the case of mixtures of magnesium alcoholates, the content of the other magnesium alcoholates (in addition to magnesium ethanolate) and of a halogen-containing constituent present can be between 0.001 wt. % and 15 wt. % (in each case based on the total weight).
Particularly preferred spherical particles are those for which a mixture of ethanol, methanol and isopropanol is employed as the alcohol mixture in the preparation and the contents of the alcoholates in the end product are as follows:
magnesium ethanolate>80 wt. %
magnesium methanolate: 0.001-15 wt. %
magnesium isopropanolate: 0.001-10 wt. %
halogen or halogen-containing component: 0.001-10 wt. %
The spherical particles can comprise small amounts of free alcohols and furthermore Mg(OH) 2 and/or MgCO 3 .
The magnesium can be employed in the form of strip, filings, granules or also powder. Magnesium which is not coated or coated only with a thin oxide/hydroxide layer is preferred.
Mono- and polyhydric alcohols which have a linear or branched carbon chain can be employed as alcohols for the synthesis. The alcohols can be aliphatic, aromatic or mixed aliphatic-aromatic. Alcohols having 1-10 carbon atoms are preferably employed.
Examples of the Alcohols are:
Methanol, ethanol, n-propanol, n-butanol, n-pentanol, n-hexanol, n-heptanol, n-octanol, n-nonanol, n-decanol.
2-Propanol, 2-butanol, 2-pentanol, 2-hexanol, 2-heptanol, 2-octanol, 2-nonanol, 2-decanol.
2-Ethylbutanol, 2-ethylhexanol, 4-methyl-2-pentanol, 3,3,5-trimethylpentanol, 4-methyl-3-heptanol.
Phenol, benzyl alcohol, 2-phenylethanol, 1-phenyl-1-propanol ethylene glycol, glycerol.
Ethanol is particularly preferred as the alcohol. If an alcohol mixture is employed, ethanol can be employed as the main constituent and methanol and isopropanol as secondary constituents.
Preferably the mixture of the alcohols can consist of
90±9 wt.-% of ethanol 1 to 10 wt.-% of methanol 1 to 10 wt.-% of isopropanol
To facilitate the reaction, however, alcohols having a water content of <1,000 ppm are preferred. Otherwise, hydroxide layers form on the magnesium, as a result of which the reaction is slowed down.
The molar ratio of the alcohol or alcohol mixture (calculated as the sum of the moles of the individual constituents of the alcohol mixture) to magnesium can be between 1 and 100. It can be particularly preferably between 3 and 20.
A non-limiting selection for the halogen or the halogen-containing component is:
Iodine, bromine, chlorine, magnesium chloride, magnesium bromide, magnesium iodide.
Magnesium alkoxyhalides, such as, for example, magnesium ethoxyiodide, magnesium methoxyiodide, magnesium isopropoxyiodide, hydrogen chloride, chloroacetyl chloride and organic acid halides such as benzoyl chloride, phthaloyl chloride, acetyl chloride, propionyl chloride, butyryl chloride, trimethylacetyl chloride, trifluoroacetyl chloride, and chloroacetyl chloride.
Accordingly, the halogen compound can be an organic acid chloride. The acid chloride can be a chloroacetyl chloride.
Chloroacetyl chloride, iodine, magnesium iodide and magnesium chloride as well as magnesium alkoxyhalides are particularly preferred.
Mixtures of the abovementioned substances can also be employed.
The halogens or halogen-containing substances can be employed in the reaction both in the pure state and in the form of solutions. The halogen or the halogen-containing components can also be present in a chemically modified form after the reaction. Thus, for example, after the reaction iodine can be present partly as magnesium iodide and/or magnesium alkoxyiodide.
The reaction can be carried out at a reaction temperature of between 0° C. and 67° C., it also being possible for the reaction temperature to be changed during the reaction. The particle size can be determined by the choice of the reaction temperature.
The pressure can be between 0.001 and 100 bar. The reaction can preferably be carried out under atmospheric pressure.
The sequence of the addition of the reaction partners can be as desired. The following reaction procedure is particularly preferred:
1) Initial introduction of the alcohol mixture and magnesium into the reaction vessel 2) Addition of the halogen component
The end of the reaction can be recognized by the evolution of hydrogen stopping. The reaction time can in general be 5-50 h.
After the reaction, the product can be washed again, for example with the alcohol mixture used for the preparation, in order to adjust the content of halogen or halogen-containing component.
The molar ratio of the halogen or halogen component to magnesium at the start of the reaction can be between 0.0001 and 0.5. In the end product, it can be between 0.000001 and 0.5.
The average particle diameter (d 50 ) of the spherical particles according to the invention can be between 1 and 200 μm. The particle diameter is particularly preferably between 10 and 50 μm.
The span, which describes the width of the particle size distribution, is in general below 4, particularly preferably below 1.5, the span being determined according to the following formula.
span
=
d
90
-
d
10
d
50
The form of the particles can preferably be spherical.
The specific surface area can be between 2 and 100 m 2 /g.
The specific pore volume is between 0.01 ml/g and 4 ml/g.
The bulk density can be at least 0.25 g/cm 3 . The tapped density can be at least 0.35 g/cm 3 .
The spherical particles according to the invention can be employed as a precursor for olefin polymerization catalysts, thus, for example, as a catalyst support precursor.
EXAMPLES
The specific surface area is determined by nitrogen absorption at 77 K in accordance with DIN 66131 (calculation according to the BET model).
The specific pore volume is measured by mercury intrusion to 2,000 bar in accordance with DIN 66133.
The particle size distribution is measured with a Microtrac-X100 apparatus from Microtrac in accordance with the principle of laser diffraction using unified scatter technique. The apparatus is equipped with one primary (on-axis) laser diode and two secondary (off-axis) laser diodes with one forward and one high-angle photo detector array. The range is 0.04-704 micron. The sample is suspended in ethanol before the measurement. Ultrasound was applied for 60 seconds before measurement.
Alternatively a Horiba LA-920 was used. In this case the samples were suspended in isopropanol and subjected to ultrasound for 60 seconds. A circulation speed of 7 was used before measurement.
The bulk density and the tapped density are determined as follows:
Determination of the Bulk Density (Method A)
For determination of the bulk density, a given volume of the powder is poured through a funnel into a measuring beaker and its weight is determined.
Determination of the Tapped Density (Method B)
For determination of the tapped density, a given volume of the powder is poured through a funnel into a measuring beaker and vibrated and its weight is determined.
Equipment:
*Balance with an error limit of ±0.1 g
*Filling funnel with a volume of about 200 cm 3
*Cylindrical measuring beaker of approx.
100 cm 3 ±0.5 cm 3
*Sheet of paper
Sampling and Pretreatment of the Sample:
Two samples are taken from the magnesium alcoholate powder to be tested, which is in the delivery state. The samples are tested under a nitrogen atmosphere. In the event of deviations of greater than 0.03 g/cm 3 , a triplicate determination is carried out as a control.
Procedure:
Bulk Density:
The measuring beaker is tared on a balance and covered with a sheet of paper. Thereafter, the filling funnel is placed on the paper. A sample of approx. 150 cm 3 is loosely introduced into the filling funnel. The paper is then removed, so that the sample falls into the measuring beaker. If necessary, the flow of the sample can be assisted by stirring with a rod (or spatula). The powder mass piled up above the upper edge of the measuring beaker is skimmed off with a straight-edged blade or ruler at an angle of 45° with respect to the piled-up powder mass. The measuring beaker filled with the powder is weighed to 0.1 g and the weight (weight of magnesium alcoholate powder) is recorded.
Evaluation:
The bulk density is calculated according to the numerical value of bulk density=weight determined/100 (in g/cm 3 or g/ml). The arithmetic mean—in addition to the individual values—of the two determinations is to be stated as the result of the test.
Tapped Density:
The measuring beaker is tared on a balance and covered with a sheet of paper. Thereafter, the filling funnel is placed on the paper. A sample of approx. 150 cm 3 is loosely introduced into the filling funnel. The sheet of paper is then removed, so that the sample falls into the measuring beaker. If necessary, the flow of the sample can be assisted by stirring with a rod (or spatula). Thereafter, the contents of the measuring beaker are vibrated (measuring beaker vibrated and tamped) until the powder cannot be compressed further. During this operation, the measuring beaker is constantly topped up with sample material.
The powder mass piled up above the upper edge of the measuring beaker is skimmed off with a straight-edged blade or ruler at an angle of 45° with respect to the piled-up powder mass. The measuring beaker filled with the powder is weighed to 0.1 g and the weight (weight of magnesium alcoholate powder) is recorded.
Evaluation:
The tapped density is calculated according to the numerical value equation of tapped density=weight determined/100 (in g/cm 3 or g/ml). The arithmetic mean—in addition to the individual values—of the two determinations is to be stated as the result of the test.
The alcoholate contents in the end products are determined by hydrolysis of the alcoholate mixtures with acid. After neutralization, the alcohols released are determined by gas chromatography (HP 5890 gas chromatograph with DB 624 as the stationary phase, 2-butanol as the internal standard).
The halogen content is determined by potentiometric titration after hydrolysis of the sample with ethanol/acetic acid (Metrohm Titroprocessor 682, indicator electrode: silver rod, reference electrode Ag/AgCl/0.1 M HClO 4 )
The poured cone height is determined as follows:
A: Test equipment:
Metal sieve (mesh width: 1 mm)
Vernier
Metal solid cylinder, d=38 mm, h=80 mm
Scraper
B. Test Substances:
Sample material
Procedure:
The wire sieve is fixed to the stand approx. 10 cm above the metal solid cylinder. To establish the final height of the sieve, the powder is poured slowly on to the sieve and carefully passed through the sieve by means of the scraper. The distance from the sieve to the poured cone tip of the powder is then adjusted to 2 cm. When the poured cone of the powder is uniform in shape, sieving of the powder is ended and the poured cone height is read off at the tip of the cone with the surface gauge.
Evaluation:
The poured cone height is stated in mm.
Precision:
The reading error of the poured cone height is 01.1 mm. The average deviation of repeated measurements on a sample is 0.2 mm.
Test Methods for Catalyst and Polymer
MFR: Polymer melt flow rate is measured according to ASTM 1238.
Bulk Density Polymer powder bulk density is measured according to ASTM D1895B.
Catalyst particle size distribution: Spherical magnesium ethoxide material and catalyst particle size distributions are measured using a Malvern Mastersizer™ X.
Polymer particle size distribution: Polypropylene powder particle size distribution and fines are measured using a Malvern Mastersizer™ S.
Examples
Preparation of Magnesium Alcoholate Support Materials
Typical experimental procedure for examples 1 to 4
Magnesium and the alcohol mixture are initially introduced into a 2 l stirred container. Thereafter, a solution of iodine alcohol mixture is added. The reaction mixture is heated, while stirring, until the evolution of hydrogen has stopped. The product is filtered off over a pressure filter and dried in a rotary evaporator.
Example 1
Example 2
Example 3
Example 4
Magnesium [g]
145.0
105.0
145.0
145.0
Iodine [g]
10.78
15.68
10.78
10.78
Alcohol mixture [g]
1549.5
1549.5
1549.5
1549.5
Wt. % (EtOH)
91.2
89.5
91.2
91.2
Wt. % (MeOH)
3.5
5.2
3.5
3.5
Wt. % (i-PrOH)
5.3
5.3
5.3
5.3
Wt. % (iodine) based
7.5
14.8
7.4
7.4
on magnesium
Reaction temperature
50
50
50
50
[° C.]
d 10 [μm]
3.8
12.2
21.5
4.0
d 50 [μm]
18.6
25.0
30.5
22.7
d 90 [μm]
25.5
35.9
43.2
30.7
Span
0.71
0.95
0.71
1.18
Bulk density [g/ml]
0.43
0.39
0.44
0.42
Tapped density [g/ml]
0.54
0.49
0.58
0.55
Poured cone height
12.5
13.3
15.6
13.4
[mm]
methanol after
7.0
9.8
4.1
4.6
hydrolysis [wt. %]
isopropanol after
1.4
0.86
1.9
1.5
hydrolysis [wt. %]
Content of iodine
0.63
0.89
0.37
0.7
[wt. %]
Comparative Example 1
Use of Pure Ethanol, Chloroacetyl Chloride as Catalyst
A 2-L Buchi glass reactor is equipped with an overhead stirrer with a paddle-type agitator on the bottom of the shaft and a U-shaped agitator staggered directly above the paddle. The reactor is charged with absolute ethanol (930 mL, 99.5%, Aldrich), magnesium turnings (40 g), then chloroacetyl chloride (10.0 mL), all under a nitrogen blanket. The stirrer is set to 200 rpm and the reaction is allowed to proceed without temperature control. After 63 hours of stirring, a mixture of needle-like crystals and a flocculent solid is obtained. The solid is unsuitable for converting into a propylene polymerization catalyst. The poured cone height of this material is 24.9 mm. The particle properties were as follows:
d 10 [μm]
5.4
d 50 [μm]
45.8
d 90 [μm]
183.1
Span
3.88
Comparative Example 2
According to U.S. Pat. No. 5,965,478, Toho Titanium
5 g magnesium is added to 0.5 g iodine in 100 g ethanol. The mixture is heated to reflux temperature (78° C.). 8 portions of 2.5 g Mg and 25 g ethanol are added to this mixture every 5 minutes while the temperature is kept at 78° C. (boiling point of ethanol). Excess ethanol is removed and the poured cone height of the dried product is found to be 19.2 mm. The particle parameters are:
d 50 [μm]
42.9
d 10 [μm]
16.4
d 90 [μm]
70.7
Span
1.27
Comparative Example 3
Hy 103
21.8 g magnesium and 275 ml ethanol are filled into a reaction vessel. A solution of 1.62 g iodine in 25 ml ethanol is added. The mixture is stirred under reflux (78° C.) for 20 hours. Excess ethanol is removed and the poured cone height of the dried product is found to be 40.8 mm. The particle parameters are:
d 50 [μm]
11.0
d 10 [μm]
3.2
d 90 [μm]
44.4
Span
3.74
Content of iodine [wt. %]
1.0
Comparative Example 4
Commercially available magnesium ethanolate from Degussa (d50≈700 μm) is ground to an average particle diameter of 25.0 μm with a CSM 165 sifter mill (Netzsch). Measurement of the poured cone height gives a value of 19.8 mm.
Comparative Example 5
Commercially available magnesium ethanolate from Degussa (d50≈700 μm) is ground to an average particle diameter of 5.2 μm with an AFG 100 fluidized bed counter-jet mill (Hosokawa Alpine). Measurement of the poured cone height gives a value of 19.0 mm.
Propylene Polymerizations, Gas Phase.
Gas phase polymerizations are performed in a horizontal, cylindrical reactor measuring 10 cm in diameter and 30 cm in length with a volume of approximately one gallon (3.8 L). The reactor is operated in a continuous fashion. The reactor is equipped with an off-gas port for recycling reactor gas through a condenser and back through a recycle line to the nozzles in the reactor. In the reactor, liquid propylene is used as a quench liquid. The catalyst is introduced as a 0.5 to 1.5 wt % slurry in hexane through a liquid propylene-flushed catalyst addition nozzle. A mixture of organosilane compound and trialkylaluminum in hexane are fed separately to the reactor through a different liquid propylene-flushed addition nozzle. For all polymerizations the Al/Mg molar ratio of 6 and the Al/Si molar ratio of 6 is used.
During operation, polypropylene powder is passed over a weir and discharged through a powder discharge system. The polymer bed in the reactor is agitated by paddles attached to a longitudinal shaft within the reactor that is rotated at about 50 rpm. The reactor pressure is maintained at 300 psig (2.2 MPa). Reactor temperature is maintained at 160 F=71° C. Polymers with targeted melt flow rates are obtained by varying the amount of hydrogen in the reactor. Gas composition in the system is monitored via an on-line process gas chromatograph. Ethylene content in the reactor is adjusted by a mass-flow meter to vary the ethylene content in the final polymer. Ethylene content in the gas composition is monitored via the same on-line process gas chromatograph. The production rate is typically about 200-250 g/hour in order to maintain a stable process.
Example 5
MGE catalyst support (10 g, example 3) is suspended in 200 mL of heptane and transferred under nitrogen to a 1-liter jacketed glass reactor fitted with an overhead stirrer. The heptane is removed by decantation. Toluene (125 mL) is added and the slurry is stirred for 1 minute. The stirrer is turned off and the solid is allowed to settle for 1 minute. The toluene is removed by decantation. Next, 125 mL more of toluene is added, and the stirrer is started. TiCl 4 (105 mL, Akzo) is added slowly. The reactor contents are warmed to 57 C and mixed for an additional 30 minutes. The temperature is increased and as the temperature reached 100 C, 1.3 mL of di-n-butylphthalate (DNBP) is added and the reaction mixture stirred at 100 C for an additional 90 minutes. The stirrer is stopped and the liquid is removed by filtration through a small filter disk inserted into the slurry. After most of the liquid is removed, 125 mL of toluene and 105 mL of TiCl 4 are added and the slurry stirred at 100 C for 30 minutes. The stirrer is stopped, the solid is allowed to settle, and the liquid is removed through the filter disk. An additional 105 mL of TiCl 4 is added and the slurry stirred for 30 minutes at 100 C. The liquid is removed by filtration and 150 mL of heptane is added. The slurry is stirred at 57 C, the solid is then allowed to settle, and the heptane is removed. Four more warm heptane washes are done in the same way. The resulting solid had a uniform particle size and shape. The particle size distribution of the catalyst is: d 10 =21.80, d 50 =33.24, d 90 =45.69 microns, span=0.71. Using diisobutyldimethoxysilane as the organosilane compound, a 6.6 MFR random copolymer containing 3.2 wt % ethylene is obtained. The yield is 33,100 g PP/g catalyst, the copolymer powder had a bulk density of 0.40 g/cc, and there are low fines (<1% under 150 microns).
Example 6
MGE catalyst support (example 4) is made in a similar manner as described in Example 3, except that some of the alcohol mixture is made up of recycled alcohol mixture from a previous support preparation. The support is converted to a catalyst in a similar manner as described in Example 5. The particle size distribution of the catalyst is: d 10 =3.87, d 50 =21.32, d 10 =32.93 microns, span=1.36. Using diisobutyldimethoxysilane as the organosilane compound, a 3.2 MFR polypropylene is obtained. The yield is 24,500 g PP/g catalyst, the polymer powder had a bulk density of 0.46 g/cc, and there are low fines (1.1% under 150 microns). The average particle size is 1150 microns and the span is 1.2.
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Spherical particles comprising magnesium alcoholate and having a poured cone height of less than 17 mm are prepared by reacting magnesium, an alcohol or a mixture of various alcohols and a halogen and/or an optionally organic halogen compound with one another at below the boiling point of the alcohols.
The spherical particles are employed as a precursor for olefin polymerization catalysts.
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TECHNICAL FIELD
The present invention pertains generally to the compression of steam, and more particularly to the use of a hydrophobic liquid in the compression process.
BACKGROUND OF THE INVENTION
Ordinary water evaporators are notoriously expensive to operate since evaporating water requires large quantities of energy because of its high heat of vaporization. To evaporate large quantities of water a heat pump is often employed to efficiently recycle the heat of vaporization. One heat pump method is the mechanical vapor recompression process that when applied to the evaporation of water requires the direct compression of steam. The need for a rugged and simple steam compressor would greatly expand the use of mechanical vapor recompression for water evaporation. Other applications for a rugged and simple steam compressor might arise in any instance where the pressure of the steam available is too low for its intended purpose and must be upgraded by compression.
SUMMARY OF THE INVENTION
The present invention is directed to methods for using a hydrophobic liquid to compress steam. The methods are most often used in the context of mechanical vapor recompression (MVR), which is a method for evaporating water. In MVR, a compressor is used to boost the pressure of steam from the evaporator so that it will condense at a higher temperature. This enables the latent heat in the steam to be returned to the evaporator thus generating more steam. In this way the same heat is continuously reused. Other uses for the present invention include the general upgrading of steam pressure for general heating purposes.
In the methods of the present invention, a compressor evacuates steam, created in a heat exchanger. In the compressor, such as a liquid piston pump, the steam is compressed to a higher pressure and discharged along with a hydrophobic liquid, such as mineral oil, into the other side of the same heat exchanger. There the steam is condensed to water (condensate) giving up its heat of vaporization. The condensate and hydrophobic liquid are drained from the heat exchanger and into a water/hydrophobic liquid separator where the hydrophobic liquid is taken off the top of the condensate and evacuated back into the compressor.
In a useful embodiment of the invention, mineral oil, a material with a very high vapor pressure and immiscibility with water and with low viscosity, is used as a liquid compressant allowing the liquid piston pump to operate without flashing liquid compressant or absorbing the compressed vapor. Also, the mixture of oil and steam is allowed to pass directly to the heat exchanger without attempting to first separate the steam from the oil.
Further, liquid piston pumps are inexpensive, rugged, and quiet compared to positive two-lobed blower that is normally used in this application. The liquid piston pump is inexpensive and rugged compared to the centrifugal compressor that is also used in this application.
In accordance with an embodiment of the invention, a method for using a hydrophobic liquid to compress steam includes:
(a) providing steam; (b) providing a hydrophobic liquid; (c) providing a compressor having a steam input, a hydrophobic liquid input, and a compressed steam-hydrophobic liquid output; (d); routing the steam to the steam input of the compressor; (e) routing the hydrophobic liquid to the hydrophobic liquid input of the compressor; and, (f) obtaining a mixture of compressed steam and hydrophobic liquid from the compressed steam-hydrophobic liquid output of the compressor.
In accordance with another embodiment of the invention, a method for using a hydrophobic liquid to remove water soluble material from an aqueous solution includes:
(a) providing an aqueous solution containing water soluble material; (b) providing a hydrophobic liquid; (c) providing a system for removing the water soluble material from the aqueous solution, the system including:
An evaporator for receiving the aqueous solution, the evaporator having an aqueous solution input, a steam output, and a concentrated aqueous solution output. A heat exchanger transfers heat to the evaporator, the heat exchanger having a compressed steam-hydrophobic liquid input and a water-hydrophobic liquid output. The system further includes a water/hydrophobic liquid separator having a water-hydrophobic liquid input, a hydrophobic liquid output, and a water condensate output. A compressor has a steam input, a hydrophobic liquid input, and a compressed steam-hydrophobic liquid output. The steam input of the compressor is connected to the steam output of the evaporator, the hydrophobic liquid input of the compressor is connected to the hydrophobic liquid output of the water/hydrophobic liquid separator, the compressed steam-hydrophobic liquid output of the compressor is connected to the compressed steam-hydrophobic liquid input of the heat exchanger, and the water-hydrophobic liquid input of the water/hydrophobic liquid separator is connected to the water-hydrophobic liquid output of the heat exchanger.
(d) delivering the aqueous solution to the aqueous solution input of the evaporator; (e) the compressor compressing a mixture of steam from the evaporator and hydrophobic liquid, thereby increasing the temperature of the mixture; (f) routing the mixture from the compressed steam-hydrophobic liquid output of the compressor to the compressed steam-hydrophobic liquid input of the heat exchanger and thence through heat exchanger, thereby evaporating the aqueous solution and causing steam to be routed from the steam output of the evaporator to the steam input of the compressor; (g) routing water and hydrophobic liquid from the water-hydrophobic liquid output of the heat exchanger to the water-hydrophobic liquid input of the water/hydrophobic liquid separator; and, (h) routing the hydrophobic liquid from the hydrophobic liquid output of the water/hydrophobic liquid separator to the hydrophobic liquid input of the compressor.
Other aspects of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram of a first system for using a hydrophobic liquid to compress steam;
FIG. 2 is a flow diagram showing additional features of the first system;
FIG. 3 is a flow diagram of a second system for using a hydrophobic liquid to compress steam; and,
FIG. 4 is flow diagram of a third system for using a hydrophobic liquid to compress steam which combines the features of the first and second systems.
DETAILED DESCRIPTION OF THE INVENTION
Referring initially to FIG. 1 , there is illustrated a flow diagram of a first system for using a hydrophobic liquid to compress steam, generally designated as 20 . In the shown embodiment, first system 20 is utilized for removing a water soluble material from an aqueous solution, and includes an evaporator 22 for receiving the aqueous solution 24 , evaporator 22 having an aqueous solution input 26 , a steam output 28 , and a concentrated aqueous solution output 30 . A heat exchanger 32 transfers heat to evaporator 22 , the heat exchanger 32 having a compressed steam-hydrophobic liquid input 34 and a water/hydrophobic liquid output 36 . System 20 further includes a water/hydrophobic liquid separator 38 having a water-hydrophobic liquid input 40 , a hydrophobic liquid output 42 , and a water condensate output 44 . A compressor 46 has a steam input 48 , a hydrophobic liquid input 50 , and a compressed steam-hydrophobic liquid output 52 . Steam input 48 of compressor 46 is connected to steam output 28 of evaporator 22 , hydrophobic liquid input 50 , of compressor 46 is connected to hydrophobic liquid output 42 of water/hydrophobic liquid separator 38 , compressed steam-hydrophobic liquid output 52 of compressor 46 connected to compressed steam-hydrophobic liquid input 34 of heat exchanger 32 , and water-hydrophobic liquid input 40 of water/hydrophobic liquid separator 38 is connected to water-hydrophobic liquid output 36 of heat exchanger 32 .
As used herein a hyphen (“-”) means “and”, such as in compressed steam-hydrophobic liquid input 34 . This means that both compressed steam and hydrophobic liquid are present at input 34 . Conversely, a slash (“/”) means “from”, such as in water/hydrophobic liquid separator 38 . This means that water is separated from hydrophobic liquid in separator 38 .
In a preferred embodiment of the invention, a hydrophobic liquid having a low viscosity and a low vapor pressure is utilized in system 20 . A mineral oil such as XCELTHERM 600 manufactured by Radeo Industries, P.O. Box 305, La Fox, Ill. 60147 has been found useful.
Also in a preferred embodiment of the invention, compressor 46 comprises a liquid piston pump such as is available from Nash Engineering Company, 9 Trefoil Drive, Trumbull, Conn. 06611-1330. Further regarding compressor 46 , it is noted that in the shown embodiment, steam input 48 and hydrophobic liquid input 50 comprise two separate physical inputs to compressor 46 . It is also noted however that the steam 48 and hydrophobic liquid 50 inputs can be combined into one common compressor input with somewhat lessened results.
Referring now to FIG. 2 , there is illustrated a flow diagram showing additional features of the first system 20 . A mist eliminator 54 is disposed between evaporator 22 and compressor 46 . Mist eliminator 54 serves as a filter which captures water soluble material contained within entrained water droplets with the steam. Mist eliminator 54 can be located at any convenient location between evaporator 22 and compressor 46 . Also, an hydrophobic liquid pump 56 is disposed between water/hydrophobic liquid separator 38 and compressor 46 . Hydrophobic liquid pump 56 pumps hydrophobic liquid from hydrophobic liquid output 42 of water/hydrophobic liquid separator 38 to the hydrophobic liquid input 50 of compressor 46 . In the embodiment shown in FIG. 1 , a vacuum created by compressor 46 pulls hydrophobic liquid from water/hydrophobic liquid separator 38 to compressor 46 . However, in certain applications pump 56 has been found useful. It may be appreciated that mist eliminator 54 and hydrophobic liquid pump 56 may be added individually or in combination to other embodiments of the present invention subsequently discussed herein.
In view of the aforementioned system 20 , a method for using a hydrophobic liquid to compress steam includes:
(a) providing steam; (b) providing a hydrophobic liquid; (c) providing a compressor 46 having a steam input 48 , a hydrophobic liquid input 50 , and a compressed steam-hydrophobic liquid output 52 ; (d) routing the steam to the steam input 48 of compressor 46 ; (e) routing the hydrophobic liquid to hydrophobic liquid input 50 of compressor 46 ; and, (e) obtaining a mixture of compressed steam and hydrophobic liquid from the compressed steam-hydrophobic liquid output 52 of compressor 46 .
During the compression process, it is the steam and not the hydrophobic liquid which is compressed by compressor 46 .
Further in view of system 20 , a method for using a hydrophobic liquid to remove water soluble material from an aqueous solution includes:
(a) providing an aqueous solution containing water soluble material; (b) providing a hydrophobic liquid; (c) providing system 20 (described above) for removing the water soluble material from the aqueous solution; (d) delivering the aqueous solution 24 to the aqueous solution input 26 of evaporator 22 ; (e) compressor 46 compressing a mixture of steam from evaporator 22 and the hydrophobic liquid, thereby increasing the temperature of the mixture; (f) routing the mixture from the compressed steam-hydrophobic liquid output 52 of compressor 46 to the compressed steam-hydrophobic liquid input 34 of heat exchanger 32 and thence through heat exchanger 32 , thereby evaporating the aqueous solution and causing steam to be routed from the steam output 28 of evaporator 22 to steam input 48 of compressor 46 ; (g) routing water and hydrophobic liquid from the water-hydrophobic liquid output 36 of heat exchanger 32 to the water-hydrophobic liquid input 40 of the water/hydrophobic liquid separator 38 ; and, (h) routing the hydrophobic liquid from the hydrophobic liquid output 42 of the water/hydrophobic liquid separator 38 to the hydrophobic liquid input 50 of compressor 46 .
The, method further including:
removing a concentrated aqueous solution containing water soluble material from the concentrated aqueous solution output 30 of evaporator 22 . The concentrated solution can be disposed of in conventional ways or, as appropriate, recycled.
The method further including:
removing water condensate from the water condensate output 44 of water/hydrophobic liquid separator 38 . The condensate typically comprises water of a quality which can be recycled or routed to a water drain.
The method further including:
in step (c), a mist eliminator 54 disposed between evaporator 22 and compressor 46 . Mist eliminator 54 capturing water soluble material contained within entrained water droplets with the steam.
The method further including:
in step (c), an hydrophobic liquid pump 56 disposed between water/hydrophobic liquid separator 38 and compressor 46 ; and, hydrophobic liquid pump 56 pumping hydrophobic liquid from hydrophobic liquid output 42 of water/hydrophobic liquid separator 38 to hydrophobic liquid input 50 of compressor 46 .
Referring now to FIG. 3 , there is illustrated a flow diagram of a second system for using a hydrophobic liquid to compress steam, generally designated as 120 . In the shown embodiment, second system 120 is utilized for removing a water soluble material from an aqueous solution, and includes an evaporator 122 for receiving the aqueous solution 124 , evaporator 122 having an aqueous solution input 126 , a steam output 128 , and a concentrated aqueous solution output 130 . A heat exchanger 132 transfers heat to evaporator 122 , the heat exchanger 132 having a compressed steam input 134 and a water output 136 . A steam/hydrophobic liquid separator 137 has a compressed steam-hydrophobic liquid input 139 , a hydrophobic liquid output 141 , and a compressed steam output 143 . System 120 further includes a compressor 146 having a steam input 148 , a hydrophobic liquid input 150 , and a compressed steam-hydrophobic liquid output 152 . Steam input 148 of compressor 146 is connected to steam output 128 of evaporator 122 , hydrophobic liquid input 150 of compressor 146 is connected to hydrophobic liquid output 141 of steam/hydrophobic liquid separator 137 , compressed steam-hydrophobic liquid output 152 of compressor 146 connected to compressed steam-hydrophobic liquid input 139 , of steam/hydrophobic liquid separator 137 , and compressed steam output 143 of steam/hydrophobic liquid separator 137 is connected to compressed steam input 134 of heat exchanger 132 .
In view of system 120 , a method for using a hydrophobic liquid to remove water soluble material from an aqueous solution includes:
(a) providing an aqueous solution containing water soluble material; (b) providing a hydrophobic liquid; (c) providing system 120 (described above) for removing the water soluble material from the aqueous solution; (d) delivering the aqueous solution 124 to the aqueous solution input 126 of evaporator 122 ; (e) compressor 146 compressing a mixture of steam from evaporator 122 and the hydrophobic liquid, thereby increasing the temperature of the mixture; (f) routing the mixture from the compressed steam-hydrophobic liquid output 152 of compressor 146 to the compressed steam-hydrophobic liquid input 139 of the steam/hydrophobic liquid separator 137 ; (g) routing compressed steam from compressed steam output 143 of the steam/hydrophobic separator 137 to the compressed steam input 134 of heat exchanger 132 and thence through heat exchanger 132 , thereby evaporating the aqueous solution and causing steam to be routed from the steam output 128 of evaporator 122 to the steam input 148 of compressor 146 ; and, (h) routing the hydrophobic liquid from the hydrophobic liquid output 141 of steam/hydrophobic liquid separator 137 to the hydrophobic liquid input 150 of compressor 146 .
The method further including:
removing a concentrated aqueous solution containing water soluble material from the concentrated aqueous solution output 130 of evaporator 122 .
The method further including:
removing water condensate from the water output 136 of heat exchanger 132 .
FIG. 4 is flow diagram of a third system for using a hydrophobic liquid to compress steam, generally designated as 220 , which combines the features of the first 20 and second 120 systems. In the shown embodiment, third system 220 is utilized for removing a water soluble material from an aqueous solution, and includes an evaporator 222 for receiving the aqueous solution 224 , evaporator 222 having an aqueous solution input 226 , a steam output 228 , and a concentrated aqueous solution output 230 . A heat exchanger 232 transfers heat to evaporator 222 , heat exchanger 232 having a compressed steam input 234 and a partially pure water output 236 . A steam/hydrophobic liquid separator 237 has a compressed steam-hydrophobic liquid input 239 , a hydrophobic liquid output 241 , and a compressed steam output 243 . System 220 further includes a compressor 246 having a steam input 248 , a hydrophobic liquid input 250 , and a compressed steam-hydrophobic liquid output 252 . Steam input 248 of compressor 246 is connected to steam output 228 of evaporator 222 , hydrophobic liquid input 250 of compressor 246 is connected to hydrophobic liquid output 241 of steam/hydrophobic liquid separator 237 , compressed steam-hydrophobic liquid output 252 of compressor 246 is connected to compressed steam-hydrophobic liquid input 239 of steam/hydrophobic liquid separator 237 , compressed steam output 243 of steam/hydrophobic liquid separator 237 is connected to compressed steam input 234 of heat exchanger 232 . System 220 further includes a water/hydrophobic liquid separator 238 having an partially pure water input 240 , a hydrophobic liquid output 242 , and a water condensate output 244 . Partially pure water input 240 of water/hydrophobic liquid separator 238 is connected to the partially pure water output 236 of heat exchanger 232 , and the hydrophobic liquid output 242 of water/hydrophobic liquid separator 238 is connected to the hydrophobic liquid input 250 of compressor 246 .
In view of system 220 , a method for using a hydrophobic liquid to remove water soluble material from an aqueous solution includes:
(a) providing an aqueous solution containing water soluble material; (b) providing a hydrophobic liquid; (c) providing system 220 (described above) for removing the water soluble material from the aqueous solution; (d) delivering an aqueous solution 224 to the aqueous solution input 226 of evaporator 222 ; (e) compressor 246 compressing a mixture of steam from evaporator 222 and the hydrophobic liquid, thereby increasing the temperature of the mixture; (f) routing the mixture from the compressed steam-hydrophobic liquid output 252 of compressor 246 to the compressed steam-hydrophobic liquid input 239 of steam/hydrophobic liquid separator 237 ; (g) routing compressed steam from said compressed steam output 243 of the steam/hydrophobic separator 237 to the compressed steam input 234 of heat exchanger 232 and thence through heat exchanger 232 , thereby evaporating the aqueous solution and causing steam to be routed from the steam output 228 of evaporator 222 to the steam input 248 of compressor 246 ; (h) routing hydrophobic liquid from the hydrophobic liquid output 241 of steam/hydrophobic liquid separator 237 to the hydrophobic liquid input 250 of compressor 246 .
(i) routing the partially pure water from the partially pure water output 236 of heat exchanger 232 to the partially pure water input 240 of water/hydrophobic liquid separator 238 ; and,
(j) routing hydrophobic liquid from the hydrophobic liquid output 242 of water/hydrophobic liquid separator 238 to the hydrophobic liquid input 250 of compressor 246 .
The method further including:
removing a concentrated aqueous solution containing water soluble material from the concentrated aqueous solution output 230 of evaporator 246 .
The method further including:
removing water condensate from the water condensate output 244 of water/hydrophobic liquid separator 238 .
It is noted that in system 220 , both the steam/hydrophobic liquid separator 237 and the water/hydrophobic liquid separator 238 are utilized to remove the hydrophobic liquid from the final water condensate. After the first separation, the water emanating from heat exchanger 232 is “partially pure”. The water/hydrophobic liquid separator 238 then serves to further purify the condensate water.
The preferred embodiments of the invention described herein are exemplary and numerous modifications, variations, and rearrangements can be readily envisioned to achieve an equivalent result, all of which are intended to be embraced within the scope of the appended claims.
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Methods for using a hydrophobic liquid, such as mineral oil, to compress steam include using a compressor to compress a mixture of steam and the hydrophobic liquid. One embodiment includes the steam to be compressed coming from a boiling aqueous solution in an evaporator. The steam compressed with a hydrophobic liquid is routed to a heat exchanger which thermally communicates with the evaporator to create more steam. The resulting mixture of condensed steam and hydrophobic liquid from the heat exchanger is routed to a water/hydrophobic liquid separator. The hydrophobic liquid is also recycled to the compressor from the water/hydrophobic liquid separator.
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a thermal printing medium comprising a heat sensitive layer and a protective layer disposed on a substrate. More specifically, the present invention relates to a thermal printing medium exhibiting excellent printing stability such as no blurring of letters, high sensitivity, excellent water resistance, resistance to water dissolved plasticizer, as well as excellent chemical resistance and oil resistance. In particular, the present invention relates to a thermal printing medium having suitable characteristics for a thermally printed-type label, and a method for preparing the same.
In general, a thermal printing medium having a heat sensitive layer chiefly comprised of a colorless or a light colored leuco dye, and a color developing agent which imparts color to the leuco dye by thermally reacting with the leuco dye, is disclosed in Japanese Patent First Publication Serial No. 45- 14035. Such a thermal printing medium is used in a great variety of printing applications. In order to print on this thermal printing medium, a thermal printer device with a built-in thermal head is used. Such a thermal printing technique has many advantages, such as producing low noise, requiring no fixing development process, requiring little maintenance, is relatively inexpensive, may be of compact design, and the color of the produced images is very clear compared to that of other ordinary printing techniques. Therefore, thermal printing media are used in a great variety of printing applications, including computer hard copy, facsimile devices, numerous types of measuring instruments which produce printed output, and labels.
However, because the color-producing reaction in the heat sensitive layer, wherein a reaction occurs between the leuco dye and the color developing agent, is reversible, when the thermal printing medium is used under extreme conditions or when the medium contacts certain chemicals, the color-producing reaction may be readily reversed. As a result, the colored images may disappear. Therefore, it is difficult to maintain the thermal printing medium in good condition. In fact, for example, when the thermal printing medium contacts plasticizer included in wrapping films comprised of polyvinyl chloride, fats and oils included in edible lipids, industrial oils, or adhesive agents included in adhesive tapes or glue sticks, the colored images may readily disappear. In order to more widely use the thermal printing medium by improving the chemical resistance thereof, Japanese Patent Second Publication Serial No. 57-188392 for example, proposes a thermal printing medium in which a protective layer is formed over the heat sensitive layer to prevent the penetration of lipophilic chemicals such as plasticizers, oils or the like into the heat sensitive layer.
The stability of images of the thermal printing medium against the lipophilic chemicals of edible fats and the like is improved by forming the protective layer over the heat sensitive layer. However, in the case in which the thermal printing medium is used a label on food, when the label is soaked in water for a prolonged period, the water resistance of the label decreases. Moreover, because the plasticizer included in the food wrapping film diffuses into water and adheres to the label, resistance to water dissolved plasticizer of the food wrapping film is decreased. Therefore, the stability of preservation of the thermal printing medium is not improved satisfactorily by forming the protective layer over the heat sensitive layer. Because the substrate is made of paper and the protective layer is made of aqueous resin namely water soluble resin or water dispersed resin, the water resistance of the substrate and the protective layer is high. Therefore the heat sensitive layer is influenced easily with water or plasticizer dissolved in water.
Moreover a color developing agent is used to improve above-mentioned high water resistance. For examples, as the color developing agent, in particular 2,2'-bisphenolsulfone and 2,2'-bisphenolsulfide compounds are used (Japanese Patent Second Publication Serial No.56-30896). Certain kind of 4,4'-bisphenolsulfide compounds are used (Japanese Patent Second Publication Serial No.57-41996). Bis(3-allyl-4-hydroxyphenyl)sulfone is used (Japanese Patent Second Publication Serial No.60-208286). Many other examples suggest the compounds as the color developing agent. However, when above-mentioned compounds are used as the color developing agent, the water resistance is improved, but the fog appears in the background of the medium. Moreover, when the protective layer is formed over the heat sensitive layer, printing sensitivity and printing density of the thermal printing media are deteriorated.
In this way, in spite of many countermeasure are tried to make excellent thermal printing media, in fact the thermal printing medium having satisfactory printing sensitive characteristic, excellent chemical resistance and oil resistance, little fog of background, as well as excellent water resistance and resistance to water dissolved plasticizer, cannot be obtained.
SUMMARY OF THE INVENTION
In order to achieve the above described objects, the present invention provides a thermal printing medium having characteristics needed for thermal sensitive-type labels such as excellent chemical resistance, excellent oil resistance, high printing sensitivity, high whiteness of the background, excellent water resistance and resistance to water dissolved plasticizer. Moreover the present invention provides a method for preparing the same.
According to a first aspect of the present invention, a thermal printing medium is provided, comprising of a substrate having an upper and a lower surface; a heat sensitive layer formed over at least one surface of said substrate and including at least one of a colorless and a lightly colored leuco dye, and a color developing agent which imparts color to said leuco dye as main components thereof; and a protective layer comprised of aqueous resin and filler agent as main components thereof; characterized in that said heat sensitive layer is comprising at least one compound indicated by formula (1) ##STR2## (wherein R indicates an alkyl group having 1 to 10 carbon atoms or a benzyl group which may have a substitutional group) as the color developing agent, and aluminum hydroxide.
According to a second aspect of the present invention, a thermal printing medium is provided which comprises a heat sensitive layer including a color developing agent and aluminum hydroxide at a ratio 100 : 10 to 300.
According to a third aspect of the present invention, a thermal printing medium is provided comprising a heat sensitive layer including a color developing agent and aluminum hydroxide at a ratio 100 : 20 to 150.
According to a fourth aspect of the present invention, a thermal printing medium is provided in which the color developing agent is 4-hydroxy-4'-isopropoxydiphenylsulfone.
According to a fifth aspect of the present invention, a method for obtaining a thermal printing medium is provided, comprising the steps of:
forming a heat sensitive layer over at least one surface of a substrate, the heat sensitive layer including at least one of a colorless and a lightly colored leuco dye, and a color developing agent which imparts color to the leuco dye, as main components thereof;
forming a protective layer over the heat sensitive layer, which is comprised of aqueous resin and filler agent as main components thereof;
characterized in that in forming the heat sensitive layer, a coating for forming the heat sensitive layer is prepared by blending a dispersed solution ground by a media-type wet grinding machine is used, the dispersed solution comprising of at least one composition indicated by formula (1) ##STR3## (wherein R indicates an alkyl group having 1 to 10 carbon atoms or a benzyl group which may have a substitutional group) as the color developing agent, aluminum hydroxide, and a dispersant.
According to a sixth aspect of the present invention, a method for obtaining a thermal printing medium is provided, comprising the steps of:
forming the heat sensitive layer over at least one surface of the substrate, the heat sensitive layer including at least one of a colorless and a lightly colored leuco dye, and a color developing agent which imparts color to the leuco dye, as main components thereof;
forming a protective layer over said heat sensitive layer, which is comprised of aqueous resin and filler agent as main components thereof;
characterized in that in forming the heat sensitive layer, a coating for forming the heat sensitive layer is prepared by a blending dispersed solution ground by a media-type wet grinding machine is used, the dispersed solution comprising at least one composition indicated by formula (1) ##STR4## (wherein R indicates an alkyl group having 1 to 10 carbon atoms or a benzyl group which may have a substitutional group) as the color developing agent, aluminum hydroxide, and a dispersant which is at least one kind of ammonium salt selected from the group comprising (di)isobutylene-maleic anhydride copolymer, styrene-mono maleate copolymer, styrene-(meta)acrylic acid copolymer, and styrene-(meta)acrylic acid-(meta)acrylamide copolymer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Representative examples of the diphenylsulfone compounds indicated by the formula (I) used as the color developing agent included in the heat sensitive layer include, but are not limited to, 4-hydroxy-4'-methoxydiphenylsulfone, 4-hydroxy-4'-ethoxydiphenylsulfone, 4-hydroxy-4'-isopropoxydiphenylsulfone, 4-hydroxy-4'-n-propoxydiphenylsulfone, 4-hydroxy-4'-n-butoxydiphenylsulfone, 4-hydroxy-4'-n-pentyloxydiphenylsulfone, 4-hydroxy-4'-n-hexyldiphenylsulfone, 4-hydroxy-4'-n-heptyloxydiphenylsulfone, 4-hydroxy-4'-n-octyloxydiphenylsulfone, 4-hydroxy-4'-n-nonyloxydiphenylsulfone, 4-hydroxy-4'-n-decyloxydiphenylsulfone, 4-hydroxy-4'-benzyloxydiphenylsulfone, 4-hydroxy-4'-(4-methylbenzyloxy)diphenylsulfone, 4-hydroxy-4'-(4-methoxybenzyloxy)diphenylsulfone, 4-hydroxy-4'-(4-chlorobenzyloxy)diphenylsulfone, 4-hydroxy-4'-(2,6-dimethylbenzyloxy)diphenylsulfone and the like. In particular, 4-hydroxy-4'-isopropoxydiphenylsulfone is preferable, because the compound is stable, has high printing sensitivity, and is smudge resistant. These characteristics are well-balanced.
Aluminum hydroxide included in the heat sensitive layer of the present invention is indicated by the chemical formula of Al(OH) 3 , and is an inorganic pigment having a monoclinic system crystal form. For example Hygillite (trade name, marketed by Showa Denko Co.) is used as the aluminum hydroxide. In the present invention, the thermal printing medium which exhibits little smudging of the background and has high thermal sensitivity, printing stability, particularly excellent water resistance, and resistance to water dissolved plasticizer are provided by the combination of the color developing agent indicated by formula (I) and aluminum hydroxide. The ratio between the color developing agent indicated by formula (I) and aluminum hydroxide is preferably 100 : 10 to 300, and more preferably 100 : 20 to 150. When the ratio of parts aluminum hydroxide per 100 of the color developing agent is less than 10, a problem may arise in that the water resistance, resistance to water dissolved plasticizer, and the whiteness of the background are not satisfactorily improved. When the ratio is more than 300, because the amount of the aluminum hydroxide as filler is excessive, it is likely to deteriorate the printing sensitivity of the thermal printing medium.
All leuco dyes used for a thermal printing media may be in the present invention. Representative examples of leuco dyes include fluoran compounds, triarylmethanphthalide compounds, fluorenephthalide compounds, divinylphthalide compounds, phenothiazine compounds, auramine compounds, spiropyrane compounds and rhodaminelactam compounds. Concretely, examples of leuco dyes include fluoran compounds such as 3-diethylamino-6-methyl-7-anilinofluoran, 3-di-n-butylamino-6-methyl-7-anilinofluoran, 3-di-n-pentyl-6-methyl-7-anilinofluoran, 3-N-ethyl-N-isopropylamino-6-methyl-7-anilinofluoran, 3-N-ethyl-N-isoamylamino-6-methyl-7-anilinofluoran, 3-N-methyl-N-cyclohexylamino-6-methyl-7-anilinofluoran, 3-N-methyl-N-isobutylamino-6-methyl-7-anilinofluoran, 3-N-ethyl-N-p-tolylamino-6-methyl-7-anilinofluoran, 3-N-pyrrolidino-N-methylamino-6-methyl-7-anilinofluoran, 3-N-piperidino-N-methylamino-6-methyl-7-anilinofluoran, 3-N-ethyl-N-tetrahydrofurfurylamino-6-methyl-7-anilinofluoran, 3-diethylamino-6-chloro-7-anilinofluoran, 3-N-ethyl-N-(2-ethoxypropyl)amino-6-methyl-7-anilinofluoran, 3-diethylamino-6-methyl-7-(o-chloroanilino)fluoran, 3-di-n-butylamino-6-methyl-7-(o-chloroanilino)fluoran, 3-diethylamino-6-methyl-7-(o-trifluoromethylanilino)fluoran, 3-diethylamino-7-chlorofluoran, 3-diethylamino-6-methyl-7-chlorofluoran, 3-cyclohexylamino-6-chlorofluoran, 3-N-ethyl-N-p-tolylamino-7-methylfluoran, 3-diethylamino-7,8-benzofluoran, 3-diethylamino-7-t-butylfluoran, 3-N-ethyl-p-tolylamino-7-N-methyl-N-phenylaminofluoran, 3-diethylamino-7-dibenzylaminofluoran, 2-methyl-6-p-(p-dimethylaminophenyl)aminoanilinofluoran, 2-chloro-3-methyl-6-p-(p-dimethylaminophenyl)aminoanilinofluoran and the like, triarylmethanphthalide compounds such as 3,3'-bis(p-dimethylaminophenyl)phthalide, 3,3'-bis(p-dimethylaminophenyl)-6-dimethylaminophthalide, 3-(p-dimethylaminophenyl)-3-(1,2-dimethylindole-3-yl)phthalide, 3-(p-dimethylaminophenyl)-3-(2-methylindole-3-yl)phthalide, 3,3-bis(1,2-dimethylindole-3-yl)-5-dimethylaminophthalide, 3,3-bis(1,2-dimethylindole-3-yl)-6-dimethylaminophthalide, 3,3-bis(9-ethylcarbazole-3-yl)-6-dimethylaminophthalide, 3,3-bis(2-phenylindole-3-yl)-6-dimethylaminophthalide, 3-p-dimethylaminophenyl-3-(1-methylpyrrole-3-yl)-6-dimethylaminophthalide and the like, fluorenephthalide compounds such as 3,6-bis(dimethylamino)fluorene-9-spiro-3'-(6'-dimethylamino)phthalide, 3,6-bis(diethylamino) spiro-3'-(6'-diethylamino)phthalide and the like, divinylphthalide compounds such as 3,3-bis[2-(p-dimethylaminophenyl)-2-(p-methoxyphenyl)ethenyl]-4,5,6,7-tetrachlorophthalide, 3,3-bis[2-(p-dimethylaminophenyl)-2-(p-methoxyphenyl)ethenyl]-4,5,6,7-tetrabromophthalide, 3,3-bis[2-(p-pyrrolidinophenyl)- 2-(p-methoxyphenyl)ethenyl]-4,5,6,7-tetrachlorophthalide and the like, phenothiazine compounds such as benzoyleucomethyleneblue and the like, auramine compounds such as 4,4'-bisdimethylaminobenzohydrylbenzylether, N-halophenyl-leucoauramine and the like, spiropyrane compounds such as 3-methyl-spiro-dinaphthopyrane and 3-ethyl-spirodinaphthopyrane and the like, and lactam compounds such as rhodamine B-anilinolactam, rhodamine(p-nitroanilino)lactam and the like. In particular, leuco dyes comprised of fluoran compounds can themselves turn black. Moreover, the stability of images caused by the fluoran compounds is superior to that of the other compounds. Therefore the leuco dye comprised of fluoran compounds are especially desirable.
All of the constituents making up the heat sensitive layer are held together using a binder agent. Aqueous resin, namely, water soluble resin or water dispersed resin, is used for the binder agent of the heat sensitive layer of the thermal printing media of the present invention. Examples of suitable binder agents are polyvinyl alcohol, modified polyvinyl alcohol, hydroxyethylcellulose, methylcellulose, carboxymethylcellulose, starch, derivatives of starch, casein, gelatin, sodium alginate, polyvinylpyrolidone, polyacrylamide, modified polyacrylamide, water soluble resins such as alkalinized solution of isobutylene-maleic anhydride resin, alkalinized solution of diisobutylene-maleic anhydride resin, alkalinized solution of styrene-maleic anhydride resin and the like, and water dispersed resin such as polyester, polyurethane, (meta)acrylate copolymer, styrene-(meta)acrylate copolymer, polyvinyl acetate, polyvinylidene chloride and their derivatives or the like, as well as mixtures of any of the preceding.
In the present invention, in order to improve the printing sensitivity, a variety of heat fusible materials can be added to the heat sensitive layer, depending on the situation. Examples of suitable organic compounds having suitable melting points include higher fatty acid amidos such as stearamide, N-methylolated stearamide and the like, higher fatty acids, higher fatty acid esters, aromatic carboxylates such as dimethylterephthalate, diphenylphthalate and the like, diarylalkylate as dibasic acid of aliphatic compounds such as dibenzyl oxalate, di(p-methylbenzyl) oxalate, naphthalene derivatives such as β-naphthoic phenyl ether, phenyl β-naphthoate, phenyl 1-hydroxy-2-naphthoilate and the like, biphenyl derivatives such as p-benzylbiphenyl and the like, terphenyl derivatives or the like.
Moreover, as filler agents, in addition of aluminum hydroxide, organic fillers and inorganic fillers such as heavy calcium carbonate, light calcium carbonate, titanium oxide, zinc oxide, barium sulfate, talc, clay, satin white, kaolinite, polyolefine grains, urea-formalin resin grains and the like can be added to the heat sensitive layer. Moreover, dispersant, surface active agent, antioxidant, ultraviolet absorbent and the like can be added to the heat sensitive layer, depending on the situation.
The resin, which is easily turned into a film and having high chemical resistance, and a filler agent are the main components of the protective layer of the present invention Moreover, in order to obtain high water resistance, a waterproof agent can be added to the layer, depending on the situation. The resin of the protective layer of the present invention comprises at least one kind of resin selected from the group comprised of aqueous resin, namely, water soluble resin and water dispersed resin. Specifically, the resin of the protective layer is the same as the binder agent used in the heat sensitive layer Moreover, organic fillers and inorganic fillers such as heavy calcium carbonate, light calcium carbonate, titanium oxide, zinc oxide, barium sulfate, talc, clay, satin white, kaolinite, polyolefine grain, ureaformalin resin grain and the like can be used as filler agents of the protective layer. Moreover, glyoxal, chromium alum, melamine resin, melamine formaldehyde resin, polyamide resin, polyamide-epichlorohydrine resin, zirconium compounds or the like can be added to the protective layer as a waterproof agent. Moreover, in order to improve the matching property between the thermal printing medium and the thermal head, metallic soap, wax and the like can be added to the protective layer, depending on the situation.
In the following, methods for preparing the thermal printing medium of the present invention will be described in detail.
The thermal printing medium of the present invention is formed by layering the heat sensitive layer on the substrate made up of natural paper, synthesized paper, resin film, their composites, or the like, then layering the protective layer over the heat sensitive layer. The heat sensitive layer is formed by coating the said substrate with the dispersed solution which is comprised of the above-mentioned components by well-know coating methods such as air knife coating, roll coating, bar coating, and blade coating, then drying. Similarly, the protective layer is also formed. The dispersed solution coated over the substrate is prepared as follows. The leuco dye is ground using a media-type wet grinding machine, combining the aqueous resin used as the dispersant and binder agent. The color developing agent indicated by the formula (1) is ground, using a media-type wet grinding machine, combining the aqueous resin used as the dispersant and binder agent. The leuco dye is dispersed until the grain diameter of the dispersed grain becomes equal to or less than 5 μm, and preferably 2 μm. Similarly, the color developing agent is also dispersed. Then the dispersed solution of leuco dye and that of the color developing agent are mixed. The coating for forming the heat sensitive layer (a heat sensitive coating) is prepared by adding a dispersed solution of aluminum hydroxide to the above-mentioned mixture.
Furthermore, in forming the thermal printing medium of the present invention, in order to obtain an improved printing sensitivity, resistance to water dissolved plasticizer and the like, it is preferably to grind using a media-type wet grinding machine, the color developing agent indicated by formula (1), aluminum hydroxide, and dispersant. That is, the heat sensitive coating is prepared by combining the color developing agent indicated by formula (1) with aluminum hydroxide and dispersant, and by grinding them using a media-type wet grinding machine. The obtained mixture of dispersed solution is mixed with the dispersed solution of leuco dye and the other dispersed solution at a desirable ratio. Moreover, representative examples of a media-type wet grinding machine include, but are not limited to, a ball mill, an attritor, a sand grinder, and the like.
In dispersing the color developing agent indicated by formula (1) and aluminum hydroxide, the dispersants used at the same time are water soluble resins such as polyvinylalcohol, its derivatives, cellulose derivatives, (di)isobutylene-maleic anhydride copolymer, styrene copolymer, acryl copolymer and the like. In particular, a solution of (di)isobutylene-maleic anhydride copolymer and styrene copolymer is preferable. That is, a solution of dissolved ammonium salt such as diisobutylene-maleic anhydride copolymer ammonium salt, isobutylene-maleic anhydride copolymer ammonium salt, styrene-mono maleate copolymer ammonium salt, styrene-(meta)acrylic acid copolymer ammonium salt, styrene-(meta)acrylic acid-(meta)acrylamide copolymer ammonium salt and the like are preferable. In particular, the solution of styrene-(meta)acrylic acid-(meta)acrylamide copolymer ammonium salt is preferable. The compound has improved fine grinding ability and stability of dispersed solution, therefore the compound is most preferable among the above-mentioned compounds. The improved properties are obtained because the compound comprises the components of styrene, (meta)acrylic acid, and (meta)acrylamide; the styrene has hydrophobic properties, (meta)acrylic acid has hydrophilic properties and can make the dispersed particles stable ionically, and (meta)acrylamide has hydrophilic properties and can make the dispersed particles stable as protective colloid function, and they are copolymerized moderately
The amount of heat sensitive coating of the present invention is 2 to 10 g/m 2 , preferably 4 to 8 g/m 2 . On the other hand, the amount of the coating for forming the protective layer (protective coating) is 1 to 10 g/m 2 . When the amount of coating applied to the protective layer is less than 1 g/m 2 , the protective layer does not operate as a barrier layer which improves chemical resistance of the thermal printing medium. Moreover, when it is more than 10 g/m 2 , because the protective layer prevents heat transference to the heat sensitive layer, the printing sensitivity of the thermal printing medium deteriorates. In particular, the amount of protective coating is preferably 2 to 8 g/m 2 .
Moreover, in order to obtain excellent printing sensitivity by improving the contact between the thermal printing medium and a thermal head, it is desirable to smooth the surface of the protective layer after the heat sensitive layer and the protective layer are formed. In particular, the smoothing treatment is carried out so that the Beck smoothness is equal to 700 seconds or more, and is preferably equal to 1000 seconds or more. A calender machine comprised of a metallic roll and an elastic roll is used for the smoothing treatment.
Moreover, in the thermal printing medium of the present invention, it is possible to improve the resolution of the image by enhancing the smoothness of the surface of substrate. Enhancing the smoothness is achieved by forming an under layer comprised of filler agent and binder agent as main components between the substrate and the heat sensitive layer, depending on the situation. Furthermore, it is possible to prevent disappearance of the color of the printed image and undesired coloring by preventing the infiltration of many kinds of chemicals from the reverse side of the thermal printing medium against the heat sensitive layer. The prevention of the infiltration of chemicals is achieved by forming a back layer comprised of a polymer having a film-forming property as the main component on the surface, wherever the heat sensitive layer is not formed on the substrate.
In the thermal printing medium of the present invention, when the compound indicated by formula (1) is used as the color developing agent for the heat sensitive layer and aluminum hydroxide is included in the heat sensitive layer, the whiteness of the background becomes too high. The supposed reason is that the pH buffer action of aluminum hydroxide prevents the production of fog. The fog is produced by the intense reaction between the leuco dye and the color developing agent indicated by formula (1), which present in the solution for the color developing agent. The reaction also occurs after the heat sensitive layer is formed by coating the heat sensitive coating on the substrate. Moreover, water resistance or resistance to water dissolved plasticizer of the heat sensitive layer is improved. It is supposed that the acid-base coloring reaction between the leuco dye and the color developing agent indicated by formula (1) in the mixed state by heating, is stabilized by the aluminum hydroxide. Therefore, properties of the heat sensitive layer are improved, and a unique image stability is obtained.
The present invention will be explained in detail hereinbelow with reference to the examples In the examples, all "parts" designate "parts by weight".
EXAMPLE 1
In order to prepare the heat sensitive coating, solution [A] and solution [B] having the compositions listed below were dispersed respectively by a sand grinder, and solution [C] was dispersed by homogenizer.
______________________________________Solution [A]:4-hydroxy-4'-isopropoxydiphenylsulfone 30 parts30% styrene-mono maleate copolymer ammoniumsalt solution (trade name Discoat N-14: marketed by 10 partsDaiichi Kogyoseiyaku Co.)water 60 partsSolution [B]:3-N-ethyl-N-isoamylamino-6-methyl-7-anilinofuluorane 30 parts10% polyvinylalcohol solution (trade name PVA203: 45 partsmarketed by Kurare Co.)water 25 partsSolution [C]:aluminum hydroxide (trade name Hygillite H-42: 30 partsShowa Denko Co.)30% styrene-mono maleate copolymer ammonium 5 partssalt solution (trade name Discoat N-14: marketed byDaiichi Kogyoseiyaku Co.)water 65 partsThe obtained dispersed solutions [A], [B], [C] andanother dispersed solution were mixed in the ratio below.Dispersed solution [A] 100 partsDispersed solution [B] 30 partsDispersed solution [C] 100 parts25% styrene-acrylic acid-acrylamide copolymer 60 partsammonium salt solution (trade name SA-6N-604:marketed by Kindai Chemicals Co.)______________________________________
The heat sensitive layer was obtained by heat sensitive coating prepared by the above-mentioned method on the wood free paper having a weight of 56 g/m 2 as the substrate, and dried to form a heat sensitive layer, such that the dry weight thereof was 6 g/m 2 .
A protective layer coating having the composition listed below was obtained.
______________________________________10% carboxyl modified polyvinylalcohol solution 100 parts(trade name Gosenol T-330: marketed by Nippon GoseiKagaku Co.)40% china clay aqueous dispersed solution 20 parts30% zinc stearate aqueous dispersed solution 5 parts20% polyamidoepichlorohydrine resin solution 20 parts(trade name Polyfix 203: marketed by Showa PolymerCo.)water 15 parts______________________________________
Thus prepared, the protective layer material was then coated over the previously prepared thermal sensitive layer and dried to form a protective layer, such that the dry weight thereof was 4 g/m 2 .
COMPARATIVE EXAMPLE 1
A comparative thermal printing medium was prepared identical to that of Example 1 of the present invention, except that the solution [C] was replaced with the solution [C-1] having the composition listed below.
______________________________________Solution [C-1]:______________________________________light calcium carbonate (trade name Brilliant 15: 30 partsmarketed by Shiraishi Industries Co.)30% styrene-mono maleate copolymer ammoniumsalt solution (trade name Discoat N-14: marketed by 5 partsDaiichi Kogyoseiyaku Co.)water 65 parts______________________________________
COMPARATIVE EXAMPLE 2
A comparative thermal printing medium was prepared identical to that of Example 1 of the present invention, except that the solution [C] was replaced with the solution [C-2] having the composition listed below.
______________________________________Solution [C-2]:______________________________________magnesium carbonate (trade name Kinsei: marketed by 30 partsKounoshima Chemicals Co.)30% styrene-mono maleate copolymer ammonium 5 partssalt solution (trade name Discoat N-14: marketed byDaiichi Kogyoseiyaku Co.)water 65 parts______________________________________
COMPARATIVE EXAMPLE 3
A comparative thermal printing medium was prepared identical to that of Example 1 of the present invention, except that the solution [C] was replaced with the solution C-3] having the composition listed below.
______________________________________Solution [C-3]:______________________________________clay (trade name Alpha coat: marketed by Anglo- 30 partsAmerican Clay Co.)30% styrene-mono maleate copolymer ammonium 5 partssalt solution (trade name Discoat N-14: marketed byDaiichi Kogyoseiyaku Co.)water 65 parts______________________________________
COMPARATIVE EXAMPLE 4
A comparative thermal printing medium was prepared identical to that of Example 1 of the present invention, except that the solution [C] was replaced with the solution C-4] having the composition listed below.
______________________________________Solution [C-4]:______________________________________pulverized silica (trade name P-4527D: marketed by 30 partsMizusawa Chemicals Co.)30% styrene-mono maleate copolymer ammonium 5 partssalt solution (trade name Discoat N-14: marketed byDaiichi Kogyoseiyaku Co.)water 65 parts______________________________________
EXAMPLE 2
A thermal printing medium was prepared identical to that of Example 1 of the present invention, except that 100 parts of the solution [C] was replaced with 30 parts of the solution [C] and 70 parts of solution [C-1]. The composition of the heat sensitive coating was as follows.
______________________________________Dispersed solution [A] 100 partsDispersed solution [B] 30 partsDispersed solution [C] 30 partsDispersed solution [C-1] 70 parts25% styrene-acrylic acid-acrylamide copolymer 60 partsammonium salt solution (trade name SA-6N-604:marketed by Kindai Chemicals Co.)______________________________________
EXAMPLE 3
A thermal printing medium was prepared identical to that of Example 1 of the present invention, except that the solution [A] was replaced with the solution [A-1]. The composition of the solution [A-1] was as follows.
______________________________________Solution [A-1]:______________________________________4-hydroxy-4'-benzyloxydiphenylsulfone 30 parts30% styrene-mono maleate copolymer ammonium 10 partssalt solution (trade name Discoat N-14: marketed byKindai Chemicals Co.)water 60 parts______________________________________
salt solution (trade name Discoat N-14: marketed by
COMPARATIVE EXAMPLE 5
A comparative thermal printing medium was prepared identical to that of Example 1 of the present invention, except that 4-hydroxy-4'-isopropoxydiphenylsulfone of the solution [A] which is the dispersed solution of the color developing agent for the heat sensitive layer was replaced with 2,2-bis(4-hydroxyphenyl)propane.
COMPARATIVE EXAMPLE 6
A comparative thermal printing medium was prepared identical to that of Example 1 of the present invention, except that 4-hydroxy-4'-isopropoxydiphenylsulfone of the solution [A] which is the dispersed solution of the color developing agent for the heat sensitive layer was replaced with benzyl 4-hydroxy benzoate.
COMPARATIVE EXAMPLE 7
A comparative thermal printing medium was prepared identical to that of Example 1 of the present invention, except that 4-hydroxy-4'-isopropoxydiphenylsulfone of the solution [A] which is the dispersed solution of the color developing agent for the heat sensitive layer was replaced with bis(3-allyl-4-hydroxyphenyl)sulfone.
EXAMPLE 4
In order to prepare the heat sensitive coating, solution [D] and solution [E] having the composition listed below were dispersed by sand grinder.
______________________________________Solution [D]:4-hydroxy-4'-isopropoxydiphenylsulfone 30 parts25% styrene-acrylic acid-acrylamide copolymer 20 partsammonium salt solution (trade name SA-6N-604:marketed by Kindai Chemicals Co.)aluminum hydroxide (trade name Hygillite H-42: 30 partsmarketed by Showa Denko Co.)water 120 partsSolution [E]:3-N-ethyl-N-isoamylamino-6-methyl-7-anilinofuluorane 30 parts10% polyvinyl alcohol solution (trade name PVA203: 45 partsmarketed by Kurare Co.)water 25 parts______________________________________
Moreover, obtained dispersed solutions [D], [E], and another dispersed solution were mixed in the ratio below.
______________________________________Dispersed solution [D] 200 partsDispersed solution [E] 30 parts25% styrene-acrylic acid-acrylamide copolymer 60 partsammonium salt solution (trade name SA-6N-604:marketed by Kindai Chemicals Co.)______________________________________
The obtained heat sensitive coating was coated over the wood free paper having a weight of 56 g/m 2 which is the substrate, and was dried to form a thermal sensitive layer, such that the dry weight thereof was 6 g/m 2 .
The protective coating was prepared having the composition listed below:
______________________________________10% carboxyl modified polyvinyl alcohol solution 100 parts(trade name Gosenol T-330: marketed by Nippon GoseiKagaku Co.)40% china clay aqueous dispersed solution 20 parts30% zinc stearate aqueous dispersed solution 5 parts20% polyamidoepichlorohydrine resin aqueous solution 20 parts(trade name Polyfix 203: marketed by Showa PolymerCo.)water 15 parts______________________________________
A thermal printing medium produced by the method of the present invention was prepared by coating the protective coating over the previously prepared heat sensitive layer and drying it to form a protective layer, such that the dry weight thereof was 4 g/m 2 .
EXAMPLE 5
A thermal printing medium was prepared identical to that of Example 4 of the present invention, except that 4-hydroxy-4'-isopropoxydiphenylsulfone which is the color developing agent of the solution [D] was replaced with 4-hydroxyphenyl-4'-benzyloxydiphenylsulfone.
COMPARATIVE EXAMPLE 8
A comparative thermal printing medium was prepared identical to that of Example 4 of the present invention, except that aluminum hydroxide of the solution [D] was replaced with light calcium carbonate (trade name Brilliant 15: marketed by Shiraishi Industries Co.).
COMPARATIVE EXAMPLE 9
A comparative thermal printing medium was prepared identical to that of Example 4 of the present invention, except that 4-hydroxy-4'-isopropoxydiphenylsulfone of the solution [D] was replaced with 2,2-bis(4-hydroxyphenyl)propane.
COMPARATIVE EXAMPLE 10
A comparative thermal printing medium was prepared identical to that of Example 4 of the present invention, except that 4-hydroxy-4'-isopropoxydiphenylsulfone of the solution [D] was replaced with benzyl 4-hydroxy benzoate.
The thermal printing media prepared in Examples 1 to 5 and Comparative Examples 1 to 10, were evaluated in the manner explained below. The results are shown in table 1.
1. Printing density
Using a thermal printer (produced by Matsushita Electric, Inc.), thermal printing at an electrical printing power of 0.5W/dot and pulse width of 1.0 msec was carried out using each of the example sheets of thermal printing media of the present invention and comparative example sheets of thermal printing media prepared as described above. Printing densities were then evaluated using a Macbeth RD-914 reflective densitometer.
2. Background density
Background densities were evaluated using a Macbeth RD-914 reflective densitometer.
3. Water resistance
Using a label printer (produced by Teraoka, Inc.), printed samples were prepared. After the printed samples were submerged in water at 25° C. for 24 hours, printing densities thereof were evaluated using the Macbeth RD-914 reflective densitometer. The water resistances thereof were evaluated by survival rates calculated from the formula indicated below.
______________________________________Water resistance (Survival rate, %) =(Printing density of the thermal printing medium which wassubmerged in water/Printing density of the thermal printingmedium which was not submerged in water) × 100______________________________________
4. Resistance to water dissolved plasticizer
Using a label printer (produced by Teraoka, Inc.), printed samples were prepared. The printed samples were submerged in water added wrap for food (trade name Diawrap G, marketed by Mitsubishi Resin Co.) at 25° C. for 24 hours. 1 g of the wrap for food per 1 liter of water was added. Then, printed densities on the thermal printing media were evaluated using the Macbeth RD-914 reflective densitometer. The resistances to water dissolved plasticizer of the thermal printing media were evaluated by survival rates calculated from the formula indicated below.
______________________________________Resistance to water dissolved plasticizer(Survival rate, %) = (Printing density of the thermal printingmedium which was submerged in water/Printing density of thethermal printing medium which was not submerged in water) ×______________________________________100
5. Oil resistance
Using a label printer (produced by Teraoka, Inc.), printed samples were prepared The surface of the printed samples were coated with castor oil at 40° C. After the printed samples were allowed to stand for 24 hours, printed densities of the thermal printing media were evaluated using the Macbeth RD-914 reflective densitometer. The oil resistances of the thermal printing media were evaluated by the survival rate calculated from the formula indicated below.
______________________________________Oil resistance (Survival rate, %) =(Printing density of the thermal printing medium which wasoil-coated and allowed to stand/Printing density of thethermal printing medium which was not oil-coated) × 100______________________________________
TABLE 1______________________________________ Resistance to water Oil Back- Water dissolved resis- Printing ground resistance plastici- tance density density (%) zer (%) (%)______________________________________Example 1 1.37 0.06 91.0 88.0 99.0Example 2 1.36 0.06 90.0 84.2 97.0Comparative 1.28 0.07 65.0 60.0 90.0Example 1Comparative 1.25 0.08 66.4 61.2 92.0Example 2Comparative 1.15 0.12 55.0 48.0 86.0Example 3Comparative 1.29 0.09 40.0 35.2 78.0Example 4Example 3 1.35 0.06 88.0 86.0 97.8Comparative 1.15 0.14 42.0 30.0 78.0Example 5Comparative 1.35 0.06 48.0 40.5 56.0Example 6Comparative 0.98 0.18 88.5 84.0 97.2Example 7Example 4 1.49 0.05 93.0 91.2 100Example 5 1.47 0.05 92.0 90.0 100Comparative 1.30 0.08 65.2 61.0 91.0Example 8Comparative 1.18 0.17 43.0 31.2 87.0Example 9Comparative 1.49 0.08 50.0 41.5 79.0Example 10______________________________________
As is clear from Table 1 above, the thermal printing media of the present invention exhibit improved thermal printing sensitivity as evidenced by the printing density, high whiteness of the background, superior water resistance, and resistance to water dissolved plasticizer, as well as excellent chemical resistance. Moreover, the thermal printing media of examples 4 and 5 prepared in a method of the present invention even exhibit excellent printing sensitive (printing density) and printing stability (water resistance, resistance to water dissolved plasticizer, and oil resistance).
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A thermal printing medium comprising
a substrate having an upper and lower surface;
a heat sensitive layer formed over at least one surface of said substrate and including at least one of a colorless and a lightly colored leuco dye, and a color developing agent which imparts color to said leuco dye; and
a protective layer comprised of aqueous resin and filler agent as main components thereof;
characterized in that said heat sensitive layer is comprising at least one compound indicated by formula (1) ##STR1## (wherein R indicates an alkyl group having 1 to 10 carbon atoms or a benzyl group which may have a substitutional group) as a color developing agent, and aluminum hydroxide.
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BACKGROUND OF THE INVENTION
The invention relates to an x-ray diagnostic installation for x-ray tomographic images comprising at least one x-ray tube for the generation of an x-ray beam, a patient support, an image detector and a control generator, connected with the x-ray tube and the image detector, for the purpose of moving the x-ray beam and, synchronously therewith, the image field of the image detector.
In the German OS No. 2,712,320 such an x-ray diagnostic installation is described in which, by means of a synchronous movement of the x-radiation and of the image of the image detector, designed in the form of an x-ray image intensifier, a body layer is imaged in a sharply defined fashion, whereas all other body parts not disposed in this layer are suppressed through blurring. The desired layer can be selected either through alteration of the distance of the image detector from the patient support and the x-ray tube or, in the case of an x-ray image intensifier-television chain, through alteration of the deflection of the electron image in the x-ray image intensifier. The position of the layer is determined through the distances: x-ray tube-body layer and body layer-image detector, so that varying scales of enlargement result which are unknown to the observer. Therefore, mechanical auxiliary means, for example, measuring a tape, a measuring cylinder or a measuring sphere, can be provided in the ray path in order to be able to determine therefrom the dimensions of the body parts. Due to the known geometric dimensions of these auxiliary means, via specific tables, a scale indication can be associated with each layer height. In the case of an x-ray image intensifier-television chain the deflection of the electron image in the x-ray image intensifier determines the layer height so that the dimensions of a body part are to be ascertained here also via tables or mechanical auxiliary means. However, these methods are difficult and time-consuming, so that most frequently they are not employed.
SUMMARY OF THE INVENTION
The invention proceeds from the objective of producing an x-ray diagnostic installation of the type initially cited in which values are faded into the x-ray image which form a scale so that, on the basis of these fadings-in, the dimensions of the body part can be directly ascertained.
The object is achieved in accordance with the invention in that there is connected to the control generator a layer height computer which calculates the enlargement from the geometric data for the tomogram, and that the image detector exhibits an apparatus--connected with the layer height computer--for the purpose of fading-in a marking for the dimensions in the layer plane. Due to this fading-in one obtains in the x-ray image a scale indication so that the dimensions can thus be determined.
An advantageous scale indication is obtained if the marking to be faded in represents a scale which is comprised of a stationary part, which corresponds to a standardized distance disposed parallel to the image detector plane, and of a variable part which characterizes the enlargement. A simple apparatus without parts to be moved mechanically results if, for the generation and movement of the x-ray beam, a number of x-ray tubes is present which are capable of being switched on individually in succession by means of the control generator, and if the image detector is comprised of an x-ray image intensifier with deflection coils which are connected with a deflection circuit connected to the control generator.
Indirect radiographs can be prepared if a film camera is aligned with the output fluorescent screen of the x-ray image intensifier, and if the apparatus effects with optical means an exposure of the marking on the film. A simple arrangement is achieved if, for the purpose of photographic exposure of the scale, a luminescent diode chain is present, if the one part of the luminescent diode chain, which corresponds to the calibrated length, is always photographically exposed, and if the second part of the luminescent diode chain, which characterizes the enlargement, is controlled by a voltage which is proportional to the amplitude of the deflection of the electron image in the x-ray image intensifier.
An electronic fading-in into the television image can proceed if a television camera is coupled with the optical output of the x-ray image intensifer, a mixing stage is provided to which the output signals of the apparatus are supplied, and if a monitor is connected to the output of the mixing stage. An alternative solution is achieved if the enlargement or the scale is digitally calculated in the layer height computer and faded into the television image as a numerical value.
The invention shall be explained in greater detail in the following on the basis of an exemplary embodiment illustrated in the Figures on the accompanying drawing sheets; and other objects, features and advantages will be apparent from this detailed disclosure and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a graphic illustration for the purpose of explaining the inventive idea;
FIG. 2 shows an x-ray diagnostic installation according to the invention; and
FIG. 3 shows an exemplary embodiment of a circuit for the x-ray diagnostic installation according to FIG. 2.
DETAILED DESCRIPTION
On the basis of FIG. 1, the enlargement within an x-ray beam is now explained. In the radiator plane there is disposed an x-ray radiator S which emits a radiation beam to the image detector-plane, of which two rays SB 1 and SB 2 are illustrated. These two rays bound or delimit at the points E 1 and E 2 , a distance a in the layer plane which is disposed parallel to the image detector plane. The distance of the x-ray radiator S relative to the image detector is characterized by the distance d. The layer plane lies at a height h above the image detector. The distance a', imaged in the image detector plane, can be calculated from the ray set: ##EQU1## The distance a' can be expressed as a distance a enlarged by the extension v. The extension then results from:
v=a'-a (2)
If one inserts (1) into (2), one then obtains: ##EQU2## Following solution of the equation there results for the extension: ##EQU3##
Thus, the imaged distance can be expressed by a distance a, disposed in the layer plane, which distance a can, for example, by standardized, and by an extension v. This is utilized, in case of the fading-in of the scale, in such a manner that the fading-in exhibits a fixed component (a) and a variable component (v).
In FIG. 2, an x-ray diagnostic installation is illustrated which exhibits six x-ray tubes 1 arranged in a series which are provided with control grids. For the purpose of simplicity, the high voltage transformer for the x-ray tubes 1 is not illustrated. The x-ray tubes 1 generate x-ray beams which penetrate a patient lying on a patient support 2 and which cast radiation images on the inlet fluorescent screen of an x-ray image intensifier 3. The output image of the x-ray image intensifier 3 is picked up by a television camera 4 and supplied to a monitor 6 via a mixer 5.
The electron image of the x-ray image intensifier 3 is magnetically deflected by means of two pairs of deflection coils 7. The activation of the deflection coils proceeds by means of a deflection circuit 8 which is synchronized by a control generator 9. The position displacement necessary for the tomogram selection is effected by means of a position adjustment circuit 10. The control generator 9 effects, synchronously with the image displacement in the x-ray image intensifier 3, the step-wise switching-on of the x-ray tubes 1 via a control circuit 11 to which the grids of the x-ray tubes 1 are connected. The vertical pulses V of the television system are supplied to the control generator 9. An adjustment means 12, secured to the control generator 9, which adjustment means can be designed as a potentiometer, serves the purpose of selection of the layer height.
The control generator 9 causes the x-ray beam emanating from the x-ray tubes 1 to be moved, through a step-wise switching-on of one of the x-ray tubes 1 at a time, and actuates the displacement circuit 10 and the deflection circuit 8 such that the electron image in the x-ray image intensifier 3 is moved oppositely in relation thereto, so that only the parts lying in a specific body longitudinal layer, determined by the pivot axis of the x-ray beam, are imaged on the monitor 6 in a sharply defined fashion, whereas the details lying outside this specific body longitudinal layer are rendered in a blurred fashion.
The body layer whose details are represented on the monitor 6 in a sharply defined fashion can be selected, in addition to selection by change of the magnetic image deflection, also by adjustment of the distance between the x-ray tubes 1 and the patient support 2 as well as by adjustment of the distance between the x-ray image intensifier 3 and the patient support 2.
For the fading-in of a scale a layer height computer 13 is connected to the control generator 9, said computer calculating the scale from the geometric dimensions and the deflection selected by the adjustment means 12. Connected to the layer height computer 13 is a circuit 14 whose output is connected with the second input of the mixer 5.
On the basis of FIG. 3, the method of operation of the circuit 14 shall now be explained in greater detail. This circuit fades a bar as a scale into the television image. The vertical pulses V of the television system are supplied to a first monostable flip-flop 20 whose output is connected to a second monostable flip-flop 21. The output of the second monostable flip-flop 21 is connected with the first input of an AND circuit 22, to the second input of which the horizontal pulses H of the television system are supplied. Connected to the output of the AND circuit 22 is a series connection of a third and of a fourth monostable flip-flop 23 and 24. The output signal of the fourth monostable flip-flop 24 is supplied to the one input of an OR circuit 25 and to the set input of a D flip-flop 26. The output of the D flip-flop 26 is connected with the other input of the OR circuit 25. Simultaneously, the output signal of the D flip-flop 26 is supplied to an integrator 27 whose output signal is compared in a comparator 28 with a voltage U S . This voltage U S is generated in the layer height computer 13 and is proportional to the amplitude of the deflection of the electron image in the x-ray image intensifier 3. The output of the comparator 28 is connected with the reset input of the D flip-flop 26. The output signal of the OR circuit 25 is superimposed in the mixing stage 5 with the composite video signal (BAS) coming from the television camera 4 and is displayed on the monitor 6.
The delay time of the first monostable flip-flop 20 determines the vertical position of the faded-in scale in the image. The first monostable flip-flop 20 triggers the second monostable flip-flop 21 which determines how many lines high the scale is. The second monostable flip-flop enables the AND circuit 22 and thus through-connects the horizontal pulses to the third monostable flip-flop 23 which determines a horizontal position of the scale. The fourth monostable flip-flop 24, triggered by the third monostable flip-flop 23, determines the length of the standard scale which corresponds to the distance a. The fourth monostable flip-flop 24 sets the D flip-flop 26 whose output releases the integrator 27. The rising output voltage of the integrator 27 is compared with the voltage U S in the comparator 28. The voltage U S is proportional to the extension v. When the output voltage of the integrator 27 corresponds to the voltage U S , the D flip-flop 26 is reset. The output signals of the fourth monostable flip-flop 24 and the D flip-flop 26 are combined in the OR circuit 25 and displayed, via the mixing stage 5, on the monitor 6 in the form of a scale.
Instead of a scale fading-in, the enlargement can be digitally calculated in the layer height computer 13 and can be faded-in as a numerical value into the television image.
If indirect tomograms are to be prepared, then, as illustrated in FIG. 2, a film camera 15 is coupled, via a non-illustrated optics, to the output fluorescent screen of the x-ray image intensifier 3. Via a semitransmissive mirror, a luminescent diode chain, arranged in a device 16, can be jointly exposed on the film. The luminescent diode chain of the device 16 is controlled by the layer height computer 13. The luminescent diode chain consists of a fixed part which is always jointly exposed, and a variable part which corresponds to the extension v. This activation of the variable part can, for example, proceed through integrated modules of the type UAA 180 which are subjected to the voltage U S .
The scale can, however, also be exposed by means of an additional device 17 applied on the film camera 15. This additional device 17 likewise exhibits a luminescent diode chain. It is directly arranged on the film of the film camera 15 and is switched on during the exposure.
The invention is not restricted to the described exemplary embodiment; on the contrary, it is applicable also in the case of tomographs in which a mechanical synchronous movement of an x-ray radiator and an image layer takes place.
Through the inventive apparatus one obtains x-ray tomographic images into which a scale is faded, so that the size of body parts disposed in the layer plane can be directly determined.
It will be apparent that many modifications and variations may be effected without departing from the scope of the novel concepts and teachings of the present invention.
SUPPLEMENTAL DISCUSSION
The disclosure of the Haendle et al. U.S. Pat. No. 4,149,082 issued Apr. 10, 1979 is incorporated herein by reference by way of background. This patent shows exemplary detailed circuitry for components 8 through 11 of FIG. 2 of the present disclosure.
Referring to the sixth figure of U.S. Pat. No. 4,149,082, the value of the output of potentiometer twenty-seven represents the value of the selected layer height and may be connected with the layer height computer 13. This potentiometer twenty-seven may be coupled with control knob 12 of the control generator.
For the sake of exemplary illustration, a black bar is indicated at 30a on the screen of monitor 6 in FIG. 3 whose height is controlled by the time constant of monostable 21 and whose length is controlled by monostable 24 to represent the length a in the layer plane. The system of FIG. 2 may be operated so that the length of bar 30a represents a standarized distance, and the parameters of integrator 27 may be adjusted so as to represent the varying scale of enlargement in relation to such standarized distance. The length of bar 30v on the screen of monitor 6 in FIG. 3 represents the timing of the output from comparator 28 in FIG. 3 in relation to the black bar 30a (for each horizontal line sync pulse transmitted by gate 22). Where the time constant of monostable 24 is maintained at a fixed value, the length of bar 30a will be a constant value on the screen of monitor 6. If the bistable circuit 26 is triggered by a negative going edge of the output of monostable 24, the integrator 27 will be turned on at the conclusion of each line portion of bar 30a. The output of the bistable circuit 26 will produce a portion of bar 30v in a time interval representing the magnitude of the layer height adjustment U S . The OR gate 25 may be actuated to produce the bar 30v until the output pulse from bistable 26 will be zero in response to the comparison output from comparator 28.
More generally, the layer height computer 13, FIG. 2, may receive input data representing the geometry of the system such as the distance d between the source plane S and the input screen of the x-ray image intensifier, and the angular relationships between the x-ray beam axes and the axis of the x-ray image intensifier, as well as the layer height setting.
Referring to FIG. 2, a luminescent diode chain is indicated at 16-1 in association with device 16. A similar diode chain is indicated at 17-1 in association with device 17. One portion of each diode chain produces an optical bar such as indicated at 30a in FIG. 3, while further luminescent diodes produces an optical bar such as the bar 30v in FIG. 3.
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An exemplary embodiment includes at least one x-ray tube for the generation of an x-ray beam, a patient support, an image detector, and a control generator--connected with the x-ray tube and the image detector--for the purpose of moving the x-ray beam, and in opposition thereto, the image field of the image detector. There is connected to the control generator a layer height computer which calculates the enlargement from the geometric data for the tomogram. The image detector has a circuit--connected with the layer height computer--for the purpose of fading-in a marking for the dimensions in the layer plane.
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BACKGROUND OF THE INVENTION
This invention relates to hammocks and particularly to hammocks comprising nettings and swingable bases.
When a conventional hammock having no supports is to be installed in an open area, or the like, it is usually swung from cords at both ends between two trees. In installing this kind of hammock, a lot of time and efforts is required for adjusting for distance between trees, height of a netting, and load resistant capacity.
When other conventional hammocks having supports, i.e., tripod supports are to be installed indoors, or the like, brackets are used for supporting the tripod supports. The tripod supports are complicated to install, heavy and bulky, thus extremely difficult to keep and carry.
In addition, users are likely to get bored with the conventional hammocks because they sway only sidewards with respect to a user's body.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a hammock having a non-folding swingable base attached thereto, which swings lengthwise and widthwise, thus comforting and amusing a user.
Another object of the present invention is to provide a hammock having a sectional base member which are easy to assemble and disassemble
Still another object of the present invention is to provide a hammock having a telescopic base member which is readily collapsible when not in use and which folds into a comparatively small package for storage and shipment.
Another object of the present invention is to provide a hammock which is easy to install, light in weight and simple in construction.
A hammock according to an embodiment of the present invention includes a netting of strong toughness having opposite cords for being slung, the netting being adapted to receive a user, a base member including pipe assembly lines and connecting members for connecting the pipe assembly lines, the connecting members having anchor means for anchoring the cords of the netting thereto, and means for folding the base member lengthwise.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in detail by means of constructional examples with reference to the drawings.
In the drawings:
FIG. 1 is a perspective view of a hammock of the present invention, showing two arc-shaped pipe assembly lines which are connected by V-shaped connecting pipes, the two pipe assembly lines constituting a base member;
FIG. 2 is similar to FIG. 1, but showing a plate or board base member;
FIG. 3 is similar to FIG. 1, but showing telescopic pipe assembly lines;
FIG. 4 is a cross-section showing the fastening of a middle pipe and a side pipe which is accomplished by press fitting a cylindrical protrusion of the side pipe into matching axial opening of the middle pipe;
FIG. 5 shows a pivotal lock lever holding two pipes in place;
FIG. 6 is a longitudinal sectional view of FIG. 5;
FIG. 7 is a plan view of a cross-shaped folding means for folding pipe assembly lines with respect to each other;
FIG. 8A shows the middle pipe having two sections which are hingedly connected to each other by a pivot pin;
FIG. 8B is a longitudinal sectional view of FIG. 8A;
FIG. 9 is a longitudinal sectional view showing two pipes held in place by pivotal lock lever;
FIG. 10 is an exploded perspective view of FIG. 5, showing bead groove formed axially on the periphery of side pipes;
FIG. 11 is a longitudinal sectional view of FIG. 5;
FIG. 12 is a longitudinal sectional view of a lock button locking means;
FIG. 13 shows a linkage for folding pipe assembly lines with respect to each other; and
FIG. 14 is a sectional view taken along lines A--A' of FIG. 13.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, and particularly to FIG. 1, a base member 100 comprises upwardly facing arc-shaped front and rear sectional pipe lines which are connected by V-shaped connecting pipes 140. Each pipe line comprises a middle pipe 100 and side pipes 120. Each side pipe 120 has studs 161 at opposite ends thereof which constitutes an assembly means 300 for press fitting into matching axial bores in the middle pipe 110 and the V-shaped connecting means 140, respectively, when assembled.
Each V-shaped connecting pipe 140 has anchor means 146 fixed thereto for anchoring cords 210 thereto. A netting 200 is slung by the cords 200. The netting 210 of preferably large meshes is made of synthetic resin or nylon having toughness and sized to snugly receive a user's body.
The pipe assembly base 100 is upwardly facing arc-shaped and at least one point thereof is adjusted to contact with the floor or ground. When viewed from sides, at least two points are adjusted to contact with the floor or ground for accomplishing safe swinging movement of the hammock.
With this arrangement, the engagement and disengagement of the pipes 110, 120 are accomplished only by a slight intentional force. The sectional base member 100 of this embodiment is easy to keep.
In FIG. 2, instead of the pipes 110, 120 a non-folding integral plate or board 101 is used as the base member 100. Cords 210 are anchored at both ends by anchor means 147. The integral plate or board 101 is comparatively easy to manufacture and it has a bottom face contacting with the floor or ground larger than the sectional pipe base member 100 in FIG. 1. In detail, the largest width of the plate or board 101 contacts with the floor or ground so that swinging movement is achieved more safely than by the pipes 110 and 120 in FIG. 1. As the plate or board 101, a wistaria or compression wood having elasticity and strength, or synthetic resin of high strength are preferably used. In addition, aluminium having anti-corrosion, elastic, strength properties is preferably used.
FIG. 3 shows telescopic pipes 110, 120 and 130 constituting the base member 100. To positively prevent any inadvertent collapsing or moving of the structure, there is provided locking brace means 500 (FIGS. 5-6 and 9-12) in the form of a pivotable lock lever 510 which has an integral eccentric cam 511 at the lower end thereof. The cam 511 is hinged to opposite side ribs 521 by a pivot pin 520. As shown in FIG. 9, a friction pad 540 is provided at the contact face of the eccentric cam 511 and the side pipes 120, 130, thus preventing any possible scratching or marring of the contact face. The middle pipe 110 has a diameter larger than side pipes 120, 130 and is of arc-shape and the side pipes 110 have diameter corresponding to the inner diameter of the middle pipe 110. Other elements in the embodiment in FIG. 3 function the same as in the embodiment in FIG. 1.
As shown in FIG. 10, alternatively, the telescopic side pipes 120 and 130 may have axially extending bead grooves 121 and 131 on the periphery thereof for reinforcement and twisting-prevention purpose.
In FIGS. 5 and 6, the pivotal movement of the lock lever 510 is shown in full outline and in dashed outline. When in use, the outer face of the eccentric cam 511 presses the side pipes 120 and 130 as shown in full outline in FIG. 5. When being telescoped, the lock lever 510 is pivoted and assumes the position shown in solid line in FIG. 6.
Another locking brace means 500 shown in FIG. 10 may be used in the hammock of the embodiment in FIG. 3. In the Figure, the lock lever 510 is hinged to an outer support pipe 530 by the pivot pin 520.
As shown in FIG. 12, the pipes 110, 120 and 130 may have bores 552 on the peripheries thereof which receive a button 550 when the pipe base 100 is unfolded. This button structure is arranged together with the lock lever 510 structure. With this arrangements, the telescopic pipe base 100 is not inadvertently collapsed.
FIGS. 8A and 8B show the middle pipe 110 having two halves hinged by a pivot pin 310, which constitute forms part of the assembly means 300. One half of the pipe 110 has an integral hemispherical protrusion 320 having a latch recess 321. Reinforcing pipes 340 and 341 are mounted within the two halves and retained in the two halves by means of pins 343, with one reinforcing pipe having a matching recess 330 for receiving the hemispherical protrusion 320. With the hemispherical protrusion 320, the two halves are folded smoothly.
A pivotable step element 440 is hingedly attached to the integral rib 521 by the pivot pin 310 for preventing any inadvertent rotation of a latch member 400, thus for preventing any inadvertent collapsing or moving of the folding pipe 110. The latch member 400 comprising an upper end 410 and a tip 411 is hingedly attached to the reinforcing pipe 341 by a pivot pin 420. The tip 411 is biased in the latching position by a coil spring 430. When it is desired to fold the middle pipe 110, the lever member 400 is manually operated to disengage the tip 411 from the latch recess 321.
With this arrangement, with the stop element 440 in the positon in FIG. 8B, the rotation of the lever member 400 is prevented.
FIG. 7 shows width folding means 170 for folding the front and rear pipe lines. A pair of links 171 are hingedly attached to the pipes 110 by pivot pins 172. At the opposite ends of the pipes 110 are provided slits for slidingly guiding the pins 172. With this arrangements, the links 171 perform scissors-like operation, thus adjusting the width of the front and rear pipe lines. The links 171 are provided to positively prevent any inadvertent unfolding of the base member 100. To prevent any inadvertent collapsing or moving of the base member 100, the latch member 400 is provided.
Instead of the V-shaped connecting pipes 140, another connecting member 140 may be used as shown FIGS. 13 and 14. The connecting member 140 is hingedly attached to pivotal leg members 141. Two pivotal brace sections 142, 143 interconnect the pivotal leg members 141 and hingedly and frictionally retained in aligned relation in a conventional manner as at 144 for retaining the base member 100 in unfolded position. By turning the brace sections 142 and 143 around the hinge and frictional lock connection 144 and turning the sections 142 and 143 in relation to each other, the distance between the leg members 141 is decreased, thus making the folding base member 100 folded.
As shown in FIG. 10, the outer support pipe 530 has anchor means 531 to which are attached cords or bands 532, thus preventing over widening of the front and rear pipe lines from each other.
As shown in FIG. 2, for anchoring the cords 210 to the base member 100, bores 147 are provided in the opposite top ends of the base member 100. The cords 210 pass through the bores 147. In addition, as shown in FIG. 13, a large opening 147 and a cross loop 146 are provided. The cords 210 are fixed to the loop 146. Of course, other cord fixing means may be used.
With the hammock having the above structures, when a user lies in and sways the hammock, the hammock will swing sidewards, and back and forth by inertia force and reaction of loads.
For increasing inertia force at the opposite ends of the base member 100, weight member 190 is provided. With this arrangement, the lengthwise swinging movement is maintained continuously, thus giving the user no tedious feeling.
As shown in FIG. 1, a parasol 180 may be mounted on one top end of the base member 100 for blocking off strong sunshine. For providing angle-adjustable parasol 180, a flexible tube 181 is preferably used to connect the parasol 180 and its mounting portion of the base member 100. While this invention has been illustrated and described in accordance with a preferred embodiment, it is recognized that variations and changes may be made therein without departing from the invention as set forth in the claims.
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A hammock includes a netting for receiving a user, the netting having cords at opposite ends thereof. The hammock further includes a base member, the base member including left and right pipe assembly lines and front and rear connecting members for connecting the pipe assembly lines. The connecting members have anchors for anchoring the cords of the netting thereto. The left and right pipe assembly lines of the base member are foldable lengthwise.
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FIELD OF THE INVENTION
The present invention relates to a novel catalyst system, to the use thereof for the solution, suspension and vapour phase polymerization of dienes and to the use of the diene rubbers produced therewith, which have a high cis content, average vinyl content and low gel content.
BACKGROUND OF THE INVENTION
The preparation of polydienes, e.g. cis-polybutadiene (BR), on the basis of metal-organic Ziegler-Natta catalysts is a process which has been used on the industrial scale for a long time. The commercially available grades are characterized by different microstructures. The high-cis grades have cis contents of over 90% and vinyl contents of up to 4%: Nd—BR (97% cis, 2% trans, 1% vinyl), Ni—BR (96% cis, 2% trans, 2% vinyl), Co—BR (95% cis, 3% trans, 2% vinyl), Ti—BR (92% cis, 4% trans, 4% vinyl) (Ullmanns Encyklopädie der technischen Chemie (Ullmann's Encyclopaedia of Chemical Technology), Verlag Chemie, Weinheim, 4th edition, volume 13, pages 602-604; “Handbuch für die Gummi-Industrie” (“Handbook for the Rubber Industry”), Bayer AG, 2nd edition, chapter A8.1).
Li—BR, on the other hand, is prepared by an anionic process using lithium alkyl catalysts. The trans content exceeds the cis content in this case (35% cis, 55% trans, 10% vinyl).
It is further known that high-cis diene rubbers with vinyl contents of >10% can be prepared using metal-organic catalyst systems, especially metallocenes, e.g. cyclo-pentadienyltitanium trichloride (CpTiCl 3 )/methylaluminoxane (MAO) (L. Oliva, P. Longo, A. Grassi, P. Ammendola, C. Pellecchia, MaKromol. Chem., Rapid Commun. 11 (1990) 519-524) or cyclopentadienyltributoxytitanium/MAO (G. Ricci, L. Porri, A. Giarrusso, Macromol. Symp. 89 (1995) 383-392).
It is also known to polymerize conjugated dienes in the liquid monomers without the addition of solvents. However, such a process has the disadvantage that complete polymerization is accompanied by the evolution of a large quantity of heat, which is difficult to regulate and is therefore potentially hazardous. Moreover, this process also causes environmental pollution when the polymers are separated from the monomers.
In recent years the vapour phase process has proved particularly advantageous especially for the preparation of polyethylenes and polypropylenes and has achieved industrial success. The environmentally relevant advantages of the vapour phase process are based especially on the fact that no solvents are used and emissions and effluent pollution can be reduced.
EP 647 657 discloses a catalyst system which polymerizes butadiene to very high-cis polybutadiene in the vapour phase. It is further known that a system consisting of CpTiCl 3 and MAO is capable of polymerizing butadiene without a solvent (WO 96/04322).
The main areas of application for polybutadiene are tyre manufacture, industrial rubber goods and the modification of plastics.
In tyre manufacture, it is known that the various components, such as tread, side wall, steel belt plies, carcass and heel, are made into the blank and then vulcanized. A high cis content therefore has a positive effect in tyre manufacture because of the compounding adhesiveness and unvulcanized strength (“Kunststoffe und Elastomere in Kraftfahrzeugen” (“Plastics and Elastomers in Motor Vehicles”), G. Walter, Verlag W. Kohlhammer Stuttgart, Berlin, Cologne, Mainz, 1985, chapter 4.7.17; “Handbuch für die Gummi-Industrie” (“Handbook for the Rubber Industry”), Bayer A G, 2nd edition, chapter A8.1).
On the other hand it is known that increasing the vinyl content improves certain properties of the tyre, especially the wet grip. Improving the wet grip ensures greater safety on the road.
For conventional tread compounds, however, an improvement in wet grip is accompanied by a decrease in rolling resistance and hence an increase in motor vehicle fuel consumption and emissions. It has been found that the rolling resistance can be correlated well with the loss factor tan δ recorded at a frequency of 10 Hz and a temperature of 60° C., a drop in the loss factor at 60° C. being accompanied by a decrease in rolling resistance (K. H. Nordsiek, Kautschuk, Gummi, Kunststoffe 39 (1986) 599-611; R. Bond, G. F. Morton, L. H. Krol, Polymer 25 (1984) 132-140).
It is known that tyre properties can be adjusted by compounding various types of synthetic rubber. However, this process is expensive and the problem of phase separation can arise during compounding.
SUMMARY OF THE INVENTION
The object consists in providing a novel catalyst system for the production, in solution, suspension and vapour phase processes, of diene rubbers with a high cis content, average vinyl content and low gel content which have a lower loss factor tan δ at 60° C. (rolling resistance) in rubber compounds, said catalyst system not possessing the disadvantages of the state of the art.
Surprisingly it has now been found that diene rubbers can be produced in high space-time yields by using a fluorine-containing metal-organic compound together with a co-catalyst, and that diene rubbers with low gel contents can be produced in high space-time yields by heterogenizing a fluorine-containing metal-organic compound together with a co-catalyst on an inorganic support and using it in vapour phase polymerization.
Furthermore it has now been found that diene rubbers which have a high cis content and average vinyl content and have a lower loss factor tan δ at 60° C. as well as high elasticity in rubber compounds, and which are thus outstandingly suitable as raw materials in the tyre sector for use in treads and side walls, can be produced in high space-time yields by means of metal-organic catalysts in a one-stage process.
DETAILED DESCRIPTION OF THE INVENTION
Said object is achieved according to the invention by the use of novel, highly active metal-organic catalysts of formula 1:
R n MX m (1),
wherein M is a metal, the radicals R are identical or different, can be in a bridged or unbridged form and are a mononuclear or polynuclear hydrocarbon radical coordinated with the central atom M, the radicals X are identical or different and are a fluorine, chlorine, bromine or iodine, a hydrogen radical, C 1 - to C 10 -alkyl, C 6 - to C 15 -aryl, OR′ or OC(O)R′, R′ being C 1 - to C 10 -alkyl, C 6 - to C 15 -aryl, alkylaryl, fluorine, fluoroalkyl or fluoroaryl each having 1 to 10 C atoms in the alkyl moiety and 6 to 20 C atoms in the aryl moiety, and n and m each denote the numbers 0, 1, 2, 3 or 4, where n+m<5.
M is preferably titanium, zirconium, hafnium, vanadium, niobium, tantalum, scandium, yttrium or a rare earth metal, particularly preferably titanium.
X is preferably fluorine or a mixture of fluorine and chlorine, bromine or iodine.
n is preferably 1 or 2, m is preferably 3, 2 or 1 and m+n is preferably 3 or 4.
n is particularly preferably 1, m is particularly preferably 3 and m+n is particularly preferably 4.
R is preferably a substituted or unsubstituted cyclopentadienyl group (R″) k Cp, R″ being a hydrogen radical, C 1 - to C 10 -alkyl, C 6 - to C 15 -aryl, arylalkyl, alkenyl, fluoroalkyl or fluoroaryl and k is 1-5.
Examples of substituted cyclopentadienyl groups are methylcyclopentadienyl, dimethylcyclopentadienyl, trimethylcyclopentadienyl, pentamethylcyclopentadienyl, ethylcyclopentadienyl, diethylcyclopentadienyl, triethylcyclopentadienyl, tetraethyl-cyclopentadienyl, pentaethylcyclopentadienyl, propylcyclopentadienyl, phenylcyclopentadienyl, ethyltetramethylcyclopentadienyl, propyltetramethylcyclopentadienyl, butyltetramethylcyclopentadienyl, silylcyclopentadienyl, indenyl, methylindenyl, dimethylindenyl, benzindenyl, methylbenzindenyl, dimethylbenzindenyl and trimethylbenzindenyl.
Examples of particularly preferred compounds of formula 1 are:
CpTiF 3
MeCpTiF 3
Me 5 CpTiF 3
(Me 5 Cp) 2 TiF
IndTiF 3
IndTiClF 2
IndTiCl 2 F
MeIndTiF 3
MeIndTiClF 2
MeIndTiCl 2 F
Me 2 IndTiF 3
BenzindTiF 3
MeBenzindTiF 3
Co-catalysts which can be used in the process according to the invention are alkylaluminoxanes, butyl-modified aluminoxanes, aluminium alkyls, fluorine-substituted triarylboranes or mixtures of the components. Methylaluminoxane and butyl-modified methylaluminoxane (so-called co-methylaluminoxane) are preferred.
Dienes which can be used in the process according to the invention are butadiene, isoprene, pentadiene and 2,3-dimethylbutadiene, especially butadiene and isoprene. Said dienes can be used either individually or in a mixture with one another to form either homopolymers or copolymers of said dienes.
The polymerization according to the invention is preferably carried out in the presence of inert organic solvents. Examples of suitable inert organic solvents are aromatic, aliphatic and/or cycloaliphatic hydrocarbons such as, preferably, benzene, toluene, hexane, pentane, heptane and/or cyclohexane. The polymerization is preferably carried out in solution or in suspension.
In another preferred embodiment the process according to the invention is carried out in the vapour phase. The polymerization of olefins in the vapour phase was first carried out technologically in 1962 (U.S. Pat. No. 3,023,203). Corresponding fluidized bed reactors have been state of the art for a long time.
The metal-organic compound of formula 1 and the co-catalyst are preferably applied to an inorganic support and used in heterogeneous form. Particularly suitable inert inorganic solids are silica gels, clays, aluminosilicates, talcum, zeolites, carbon black, inorganic oxides such as silicon dioxide, aluminium oxide, magnesium oxide and titanium dioxide, and silicon carbide, preferably silica gels, zeolites and carbon black. Said inert inorganic solids can be used individually or in a mixture with one another. In another preferred embodiment organic supports are used individually or in a mixture with one another or with inorganic supports. Examples of organic supports are porous polystyrene, porous polypropylene or porous polyethylene.
The polymerization according to the invention can be carried out in a temperature range from −90° C. to 180° C., preferably in a temperature range from 50° C. to 150° C.
The present invention further relates to the use of the diene rubbers produced according to the invention, preferably for the manufacture of tyres.
The vinyl content of the diene rubbers is preferably in a range from 5 to 50%, particularly preferably in a range from 10 to 30%. The cis content of the diene rubbers produced according to the invention is preferably over 50%, particularly preferably over 70%, the aim being to minimize the gel contents in all cases.
By virtue of their high cis content coupled with an increased vinyl content, the diene rubbers according to the invention, for example polybutadiene or polyisoprene, produced in a one-stage process by means of metal-organic catalysts, serve as valuable raw materials for the rubber industry and for the modification of plastics. For use in the tyre sector in particular, there are major advantages in respect of rolling resistance by virtue of the low values of the loss factor tan δ at 60° C. as well as elasticity in the tread and side wall.
EXAMPLES
In Examples 1 to 12 below, the polymerizations were carried out batchwise in a glass autoclave. All operations were performed under inert gas.
Example 1
The reactor was thoroughly heated, flushed several times with inert gas, thermo-statted and then charged with 99 ml of toluene, 10 g of butadiene and 0.58 g of methylaluminoxane. A solution of CpTiF 3 in toluene (1×10 −4 mol/l) was injected into the reactor through a septum by means of a gastight syringe and the polymerization was started at a temperature of 30° C.
After a polymerization time of 30 minutes, the butadiene was discharged and the mixture was quenched with ethanol. Precipitation was induced by adding the toluene solution dropwise to ethanol containing Vulkanox KB as stabilizer, and the precipitate was filtered off and dried. The activity was 54 kg BR/mol Ti.h.C butadiene . Analysis of the microstructure showed 74% of 1,4-cis, 23% of 1,2-vinyl and 3% of 1,4-trans.
Example 2
The procedure of Example 1 was followed except that the CpTiF 3 was replaced with MeCpTiF 3 . The activity was 80 kg BR/mol Ti.h.C butadiene . Analysis of the micro-structure showed 78% of 1,4-cis, 21% of 1,2-vinyl and 1% of 1,4-trans. cl Example 3
The procedure of Example 1 was followed except that the CpTiF 3 was replaced with Cp*TiF 3 (5×10 −4 mol/l). The activity was 40 kg BR/mol Ti.h.C butadiene . Analysis of the microstructure showed 76% of 1,4-cis, 22% of 1,2-vinyl and 2% of 1,4-trans.
Example 4
The procedure of Example 1 was followed except that the CpTiF 3 was replaced with Cp* 2 TiF. The activity was 6 kg BR/mol Ti.h.C butadiene . Analysis of the microstructure showed 73% of 1,4-cis, 25% of 1,2-vinyl and 2% of 1,4-trans.
Example 5
The reactor was thoroughly heated, flushed several times with inert gas, thermo-statted and then charged with 1000 ml of hexane, 100 g of butadiene and 100 mmol of co-methylaluminoxane. A solution of CpTiF 3 in toluene (3×10 −5 mol/l) was injected into the reactor through a septum by means of a gastight syringe and the polymerization was started at a temperature of 70° C.
After a polymerization time of 150 minutes, the butadiene was discharged and the mixture was quenched with ethanol. Precipitation was induced by adding the toluene solution dropwise to ethanol containing Vulkanox KB as stabilizer, and the precipitate was filtered off and dried. The activity was 365 kg BR/mol Ti.h.C butadiene . Analysis of the microstructure showed 78% of 1,4-cis, 20% of 1,2-vinyl and 2% of 1,4-trans.
Example 6
The procedure of Example 1 was followed except that 49 ml of toluene were used and the butadiene was replaced with 50 ml of isoprene. The catalyst concentration was 5×10 −4 mol/l, the methylaluminoxane concentration was 0.15 mol/l and the polymerization time was 240 minutes. The activity was 840 g PI/mol Ti.h.C isoprene .
Example 7
The procedure of Example 6 was followed except that the CpTiF 3 was replaced with MeCpTiF 3 . The activity was 250 g PI/mol Ti.h.C isoprene .
Example 8
The procedure of Example 6 was followed except that the CpTiF 3 was replaced with Cp*TiF 3 . The activity was 29 g PI/mol Ti.h.C isoprene .
Example 9
The procedure of Example 1 was followed except that the CpTiF 3 was replaced with CpTiCl 3 . The activity was 45 kg BR/mol Ti.h.C butadiene .
Example 10
The procedure of Example 1 was followed except that the CpTiF 3 was replaced with Cp*TiCl 3 . The activity was 10 kg BR/mol Ti.h.C butadiene .
Example 11
The procedure of Example 6 was followed except that the CpTiF 3 was replaced with CpTiCl 3 . The activity was 28 g PI/mol Ti.h.C isoprene .
Example 12
The procedure of Example 6 was followed except that the CpTiF 3 was replaced with Cp*TiCl 3 . The activity was 8 g PI/mol Ti.h.C isoprene .
Example 13
About 5 g of the metallocene of structure CpTiF 3 , supported on an SiO 2 /MAO precursor, were used in the polymerization, this amount containing approx. 0.15 mmol of the metallocene. The reaction was started at 60° C. in a vertical stirred glass autoclave, into which the polymerization-active material had previously been introduced under a nitrogen atmosphere, by applying a butadiene partial pressure of 2 bar. To improve the stirrability of the small amount of starting material, the catalyst can also be premixed or “extended”, for example with a silica. The beginning of the reaction was signalled by a slight temperature rise (about 3° C.) inside the reactor and also by a visible increase in the total amount of stirred solid. After three hours the experiment was ended and the reaction product could be removed via the discharge cock at the bottom. The activity was 183 kg BR/mol Ti.h.
The gel content of the product was then determined, taking the heterogeneous support into account. The gel content was 0.8%.
Example 14
The procedure of Example 13 was followed except that the CpTiF 3 was replaced with CpTiCl 3 . The activity was 37 kg BR/mol Ti.h. The gel content was 1.5%.
Example 15
Six rubber compounds with the compositions shown in Table 1 were prepared, said Table indicating the parts by weight of each component in the compounds. Compounds 3 and 6 are compounds according to the invention and compounds 1, 2, 4 and 5 are comparative compounds. Compounds 1-3 correspond to conventional tread compounds and compounds 4-6 correspond to conventional side wall compounds.
TABLE 1
Rubber compound
C1
C2
C3
C4
C5
C6
Constituent
tread compound
side wall compound
NR(TSR 5 D. 700)
80
80
80
60
60
60
Buna ® CB 24
20
40
Buna ® CB 10
20
40
Metallocene BR
20
40
Carbon black N 375
55
55
55
Carbon black N 339
55
55
55
Renopal 450
3
3
3
6
6
6
Stearic acid
2.5
2.5
2.5
2
2
2
Antilux ® 111
1
1
1
2
2
2
Vulkanox ® 4010NA
2.5
2.5
2.5
2.5
2.5
2.5
Vulkanox ® HS/LG
1.5
1.5
1.5
1.5
1.5
1.5
ZnO active
5
5
5
5
5
5
Vulkacit ® NZ/EG
1.2
1.2
1.2
0.8
0.8
0.8
Rhenogran ® IS60-G
1.56
1.56
1.56
2.2
2.2
2.2
NR is a commercially available natural rubber. The feedstock Buna® CB 24 is a commercial polybutadiene from BAYER AG which has been produced with a neodymium catalyst. The feedstock Buna® CB 10 is a commercial polybutadiene from BAYER AG which has been produced with a cobalt catalyst. Both polymers are characterized by a high cis content of more than 94%. Metallocene BR was produced according to the invention with the aid of the catalyst system comprising CpTiCl 3 and methylaluminoxane. The microstructure of this polymer is 74% of 1,4-cis, 2% of 1,4-trans and 20% of 1,2-vinyl. Carbon blacks N 375 and N 339 can be obtained e.g. from Cabot. The products Vulkanox® and Vulkacit® are from BAYER AG and the products Antilux® and Rhenogran® are from Rhein Chemie Rheinau GmbH.
Rubber compounds 1-6 were all prepared as follows: The constituents were introduced into a kneader at a temperature of 50° C. and a speed of rotation of 40 rpm and the compounds were then worked up on a roller.
The test pieces produced from the rubber compounds were used to determine the loss factor tan δ at 60° C. and a frequency of 10 Hz as specified in DIN 53513 and the resilience at 70° C. as specified in DIN 53512.
TABLE 2
Rubber compound
C1
C2
C3
C4
C5
C6
Resilience, 70° C.
[%]
50
49
55
54
53
59
tan δ, 60° C.
0.166
0.155
0.117
0.126
0.130
0.099
TABLE 3
Example
Catalyst
Activity [kg BR/mol Ti.h.C butadiene ]
1
CpTiF 3
54
9
CpTiCl 3
45
2
MeCpTiF 3
80
3
Cp*TiF 3
40
10
Cp*TiCl 3
10
4
Cp* 2 TiF
6
5
CpTiF 3
365
Activity [g PI/mol Ti.h.C isoprene ]
6
CpTiF 3
840
11
CpTiCl 3
28
7
MeCpTiF 3
250
8
Cp*TiF 3
29
12
Cp*TiCl 3
8
|
The present invention is directed to a catalyst system, the use thereof in the polymerization of dienes in a solution, suspension and vapor phase, and the use of diene rubbers produced therewith, exhibiting a high cis content, an average vinyl content and a low gel content.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to Germany Patent Application No. 102005060676.8 filed 19 Dec. 2005.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not Applicable
BACKGROUND OF THE INVENTION
The invention regards position sensors in stick form according to a non-contacting functional principle for application in fluids, among other things. Position sensors in stick form measure the position of a position indicator fastened to a component moveable relative to the stick position sensor.
Such sensors are used, among other things, in an interior of hydraulic or pneumatic cylinders in order to know the exact extension of the piston/cylinder unit, which is of great importance for the control of the machinery and equipment operated therewith.
The position sensor is thereby located in a tight housing which comprises a long, slender sensor-stick-housing and a connected, shorter sensor sensor-head-housing which has a larger diameter and wherein the processor electronics are located.
Thereby, the sensor with its sensor-head-housing is located in the piston/cylinder unit in a longitudinal fixed manner so that the slender sensor-stick-housing extends into a typically central bore of the piston or the piston rod where the position indicator is mounted.
Since the sensor-stick-housing, and thereby the measuring length of the sensor, extends along an entire possible extension length of the piston rod, the current position of the piston rod relative to the cylinder is known at any time.
Thereby, the housing of the sensor at its exterior side is in direct contact with operating fluid of the piston/cylinder unit and is also exposed to its operating pressure. Especially in hydraulic units with very high pressures, therefore, it is of great importance that the sensor housing is provided stable and tight and that a sufficient sealing between the housing of the sensor and the piston/cylinder unit is provided, mostly through a respective seal at an exterior circumference of the sensor-head-housing relative to the surrounding wall of the pneumatic or hydraulic cylinder.
As a non-contacting sensor principle thereby differential transformatoric measuring procedures (LVDT's), non-contacting inductive measuring procedures (LVP's), inductive potentiometric measuring procedures (DC/DC-sensors), Eddy current procedures and often also magnetic, in particular magnetostrictive functional principles are being used. With the latter ones a permanent magnet is being used as a position indicator with other processes a tube sleeve, a submerged anchor, or a similar component. With PCLD-sensors through a magnet a virtual air gap is being created in a ferromagnetic core.
As it is well known, magnetostrictive position sensors function as follows:
A wave conductor typically consists of a tube, a wire, or a band and can also serve as an electric conductor. The wave conductor can also be located in a shape generating linear or circular body made from non-magnetic material, such as plastic or metal, for receiving the wave conductor and holding it in bearings.
Based on the Wiedemann-Effect an electric impulse fed into the wave conductor generates a mechanic elastic wave when superimposed with a position magnet.
At a certain location, typically at one end of the wave conductor, in particular, the torsion component of this mechanic/elastic impulse is detected by a detector unit, mostly located in a fixed position relative to the wave conductor. The duration between the triggering of the electrical excitation impulse and the reception of this mechanic-elastic wave, thereby, is a measure of the distance of the slideable position element, e.g. of a position magnet, from the detection device.
A typical such sensor is described in the U.S. Pat. Nos. 5,590,091 and 5,736,855.
Subsequently, only magnetostrictive position sensors are referred to without limiting the invention to this position measurement principle.
In such position sensors used in piston/cylinder units there are several problem areas.
One problem area is an increase of overall length of the piston/cylinder unit through the position sensor.
While the slender sensor-stick-housing extends into an interior of the piston rod, the wider sensor-head-housing requires a respective interior length in the cylinder of the piston/cylinder unit for housing, which increases the overall length of the piston/cylinder unit.
It is attempted to also shorten the sensor-head-housing in axial direction through miniaturization of the processing electronics housed in the sensor-head-housing. However, with most position sensors only a single cable exit direction is offered for the position signals from the sensor-head-housing, and this is mostly the axial exit of the cable or the connector from the front face of the sensor-stick-housing opposed to the sensor-head-housing.
However, when depending on the installed solution this front face of the sensor-head-housing is built over the cylinder unit, e.g. through a mounting eyelet required on this side of the piston/cylinder unit, the exit of the cable from the piston/cylinder unit has to be performed towards the side.
The necessary angulation towards the side of the cable exiting the sensor-head-housing alone, again, requires additional axial volume of the piston/cylinder unit.
An initially provided exit direction of the cable, or of the connector, perpendicular to the axial direction is disadvantageous, on the other hand, if in the actual installation situation a further axial track of the cable is required and insufficient space is available on the sides.
Repairs constitute anther problem area.
Due to the described, often high operating pressures in such piston/cylinder units and a rough operating environment, like for instance, strong vibrations as they often occur in equipment, a failure of the piston sensor can occur so that it needs to be replaced completely, or components of it, possibly a part of the processing electronics or of the wave conductor unit of the magnetostrictive sensor.
In this case the piston/cylinder unit had to be opened, until presently, and the whole position sensor with its housing had to be removed from the piston/cylinder unit since, especially due to the above mentioned operating conditions, the processing electronics in the sensor-head-housing of the sensor were generally encased solid.
However, this means that before removing the senso, the operating fluid in the respective piston/cylinder unit has to have ambient pressure, since otherwise large amounts of operating fluid exit into the environment and the connected actuators change positions unintentionally.
On the other hand, after replacing the position sensor, the respective piston/cylinder unit or the whole operating loop to which it is connected may have to be refilled or at least bled, which entails a considerable effort and poses an additional source for failures if performed incorrectly.
BRIEF SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide a stick-shaped position sensor according to the magnetostrictive operating principle which can be exchanged in a piston/cylinder unit without leakage, thus without opening the loop of the operating fluid, and/or, in addition, requires only little axial space for housing a sensor-head-housing in a cylinder unit.
Through locating an easily removable sensor-head-cover on the sensor-stick-housing so it faces away from the sensor-head-housing, the functional components of the position sensor initially in the sensor head housing, and after removal of the functional components located there, also in the stick housing, can be reached and extracted completely, without having to remove the housing of the sensor from its installed position.
Easy disassembly in this context means primarily disengaging a positively locking connection, thus a thread, a lock ring or a similar component and, in particular, not disassembling a connection which is not meant to be disassembled, such as a glue joint, an encasement, a weld, a solder joint, or similar though thereby under certain circumstances the lid would not be destroyed, but the respective connection area.
When the sensor-head-cover can thus be disassembled without destruction and can be reassembled, therefore, even the same sensor-head-cover can be used again.
Thereby, it is possible to leave the housing of the position sensor in its sealed assembled position in a piston/cylinder unit, while the position components of the position sensor are tested, repaired, or replaced. Therefore, a draining of the operating medium and a subsequent pressurization and bleeding is not necessary, so that work on the sensor can be performed much quicker.
All functional components of the sensor can be replaced this way, including the whole position sensor, besides its outer housing. Replacing the sensor housing itself is rarely necessary since the housing is typically stable enough so that it is not damaged during normal operation.
In order for removal of the functional components and of the sensor-head-cover to be performed with as few problems as possible, an extraction in axial direction towards the side facing away from the sensor-stick-housing is provided.
This is accomplished e.g. through the sensor-head-cover extending into an interior diameter of a wall of the sensor-head-housing and being secured there through positive locking, thus through a thread or a securing element like a lock ring.
In order to keep the axial space requirement in the installation environment for the sensor-head-housing and, thereby, for the position sensor as small as possible, the connection towards the outside from the sensor-head-housing and from the processing electronics located therein are designed specifically either with a connector located in the sensor-head-housing or with a cable exit for passing through the cable.
The sensor-head-cover has a high dome, and the cable exit or the connector is located in its side wall. Through positioning not in the enveloping surface of the side wall but through the side wall of a cylindrical shape having an indentation, preferably a flat area formed as a secant, the cable outlet can be located in this indentation or flat area and, thereby, it does not extend exactly radially but partially tangentially out of the dome area.
Especially because the dome has a smaller exterior diameter than the sensor head, it is possible to run a cable pointing away from the dome in this manner either according to the direction of the cable outlet or of the connector in a radial-tangential manner through the surrounding components to the outside, or to angulate the cable in the area of the flat or indentation into the axial direction and to run it away. Even a partial running of the cable is possible around the dome over a part of the circumference in order to run the cable at a certain location of the circumference axially or radially further to the outside. For the often occurring case of running the cable away in a radial or tangential manner from the sensor-head-housing, thereby, the otherwise required room for angulating the cable is no longer required, so that for the volume requirement only the actual axial extension of the sensor-head-housing, including the dome of the sensor-head-cover, need to be considered.
The cable outlet can be provided through a connector or a cable pass-through opening, e.g. a cable grommet inserted into a bore of the outer wall or also through an interior thread fabricated into this bore whose diameter is sized relative to the outer circumference of the cable to be run through so that the core diameter of the interior thread is smaller than an exterior diameter of insulation of the cable but larger than an interior diameter of the cable. Thereby, the cable insulation is threaded in the interior thread and fixed in a longitudinal direction.
In order to make the exit of the cable or socket possible at any desired location on the circumference, the sensor-head-cover is preferably usable in any rotation position relative to the sensor-head-housing and can be fixed there preferably through positive locking between the sensor-head-cover and the sensor-head-housing.
The housing of the sensor is fixed in the surrounding unit, such as the piston cylinder unit, with a thread and sealed with a gasket. The thread is either located in an outer circumference of the sensor-head-housing or in an outer circumference of the sensor-stick-housing in the section adjacent to the sensor-head-housing, preferably in a diameter area slightly enlarged relative to the sensor-stick-housing. The seal is hereby located on the side of the thread opposite to the sensor-stick-housing in order not to be able to damage the gasket through contact through the interior thread of the surrounding component.
If an O-ring is used for a gasket, a support ring located axially behind it is to be preferred due to the high occurring pressures. In order to be able to tighten the thread sufficiently, the outer circumference of the sensor-head-housing is partially provided as an external hexagonal shape in order to be able to apply an opened end wrench.
Also, in order to protect the processing electronics against strong vibrations while still being able to replace the processing electronics and/or the wave conductor unit without having to open the tight installation of the housing of the position sensor in the surrounding assembly group, inside the sensor-head-housing an inside dish can be provided opened toward the sensor-head-cover, e.g. made from plastic, inside which the processing electronics are located and encased relative to the interior dish. The encased electronics can be replaced as a separate component after disconnecting the signal wires and after removing the unit consisting of the processing electronics and the interior dish and the wave conductor unit located behind it can be extracted because of the tight reception of the interior dish in the sensor-head-housing and of the signal connections, e.g. plug connections or threaded connections of the processing electronics, on the one hand, toward the wave conductor unit and, on the other side, toward the cable exit.
A mounting of the interior dish with little clearance and thereby without vibration relative to the sensor-head-housing can be performed through axial clamping with the sensor-head-cover to be inserted.
The cover for closing the head housing can furthermore be used for performing error diagnosis and/or programming of the processing electronics located in the interior of the head housing in a simple manner.
Thus, the processing electronics in the interior of the head housing can include a light source, such as an LED or an infrared unit, emitting only light of a certain wave length.
When the lid consists of a material, such as plastic, which is permeable to all light or at least to light of this special wave length, an optical signal emitted by the light source located in the interior of the head housing, e.g. a flash rhythm, can be detected from the outside in a non-contact manner and/or vise versa wherein a respective sensor is located in the interior of the head housing and the respective light source is located externally.
A simple solution is to provide an opening in the lid at the location of the light source through which the light source and, thereby, the optical signal are visible. Thereby, however the housing is not tight anymore.
DETAILED DESCRIPTION OF THE DRAWINGS
Embodiments according to the invention are described in more detail.
FIGS. 1 a through 1 d show the position sensors according to the invention in a side view and in an axial face view from a sensor head housing.
FIG. 2 a shows the position sensor according to FIG. 1 a in a longitudinal sectional view, and FIGS. 2 b through 2 g show enlarged detail views of the sensor head areas.
FIGS. 3 a and 3 b shows the sensor carrier unit as a whole.
FIGS. 4 a and 4 b show a typical installation situation of a stick position sensor.
FIGS. 5 a and 5 b illustrate a position sensor with an alternative lid shape.
FIGS. 6 a and 6 b show an alternate design of the sensor of the present invention.
FIGS. 7 a and 7 b show a further design of the sensor of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 a shows a position sensor 1 , e.g. a magnetostrictive type sensor, in side view.
In an interior of a sensor-stick-housing 2 , extending in a longitudinal direction 10 , a measuring device is located. Therein extends a wave conductor unit 24 visible only in a sectional view of FIG. 2 f with a central wave conductor 23 .
At a left end of sensor-stick-housing 2 , a sensor-head-housing 3 is connected in a tight manner having an external diameter 12 several times larger than the diameter of sensor-stick-housing 2 , but only has a fraction of its length. At a transition to sensor-stick-housing 2 , sensor-head-housing 3 comprises an area 16 with an enlarged diameter relative to sensor-stick-housing 2 however significantly smaller than the largest diameter 12 of the otherwise cylindrical sensor-head-housing 3 , which is dish shaped, thus open toward a front side, facing away from sensor-stick-housing 2 .
Since sensor-stick-housing 2 is closed tight at the right end facing away from sensor-head-housing 3 , e.g. through an end cap, the whole housing of the position sensor is open towards the left end as in FIGS. 1 and 2 , and closed there by a sensor head cover 8 having a central dome 8 a protruding beyond the open face of sensor-head-housing 3 as seen in the FIGS. 1 and 2 towards the left.
Along sensor-head-housing 2 , an annular position magnet 29 is moved in a radial distance and without contacting. The position of position magnet 29 in longitudinal direction 10 is to be measured by position sensor 1 . An alternate sleeve-shaped position indicator is shown in FIG. 2 a.
FIG. 2 b shows an interior layout of position sensor 1 in an enlarged longitudinal cross section, especially in the head area, which is of particular interest here.
Initially, a housing of the position sensor is manufactured by inserting stick-sensor-housing 2 into an opening of a bottom of the dish-shaped sensor-head-housing 3 and connecting it on an exterior side of sensor-stick-housing 2 , or its front face with sensor head housing 3 through at least one annular circumferential weld 21 in a tight manner. Sensor stick housing 2 is also sealed tight at the other end through a cover lid, which is also welded on.
The functional elements of position sensor 1 are installed into this housing, wherein initially a positioning sleeve 27 is placed onto a mouth of a pass-through in the bottom of sensor-head-housing 3 in axial direction in a positively locking manner. It is pressed onto the bottom of an indentation of sensor-head-housing 3 and fixed by inserting a dish-shaped printed circuit board 26 over an exterior circumference of positioning sleeve 27 , onto which processing electronics 20 are built. Positioning sleeve 27 is axially fixed through engaging an outer rim of printed circuit board 26 with a spacer sleeve 28 in an axial manner, which on the other hand is engaged by a sensor-head-cover 8 inserted into a free space of sensor-head-housing 3 and fixed through a lock ring 9 . Through a respective annular shoulder in sensor-head-housing 3 , positioning sleeve 27 is also radially fixed in sensor-head-housing 3 .
Before inserting sensor head cover 8 , a wave conductor unit 23 , which extends substantially over a whole length within sensor-stick-housing 2 , is moved forward through positioning sleeve 27 into sensor-stick-housing 2 until a shoulder of the rearward, slightly expanded end of a sensor carrier unit 24 touches at a front annular face of positioning sleeve 27 . Detector unit 22 is located within sensor carrier unit 24 .
In this final position, sensor carrier unit 24 , in whose longitudinal middle the indicated wave conductor 23 extends, protrudes in the direction of sensor-head-cover 8 beyond printed circuit board 20 of processing electronics 20 into a dome 8 a of sensor-head-cover 8 . Through a long overhang over a plane of processing electronics 20 a dead zone of the position sensor is reduced, where no position determination is possible. At the right end, facing away from sensor head housing 3 , a damper can be seen at sensor carrier unit 24 , damping an electro mechanic wave arriving in wave conductor 23 .
FIG. 2 b furthermore shows a gasket 7 ″ located in an exterior circumference of sensor-head-cover 8 through which a penetration of dust into an area of the processing electronics is to be prevented.
However, it can be difficult to avoid turning head cover 8 in sensor-head-housing 3 with this mounting of cover 8 in the head housing through a radially abutting gasket 7 ″, and through axially positively securing through locking ring 9 . This can have a disadvantageous effects on the cable connections.
Alternatively, FIG. 2 f shows a mounting method wherein an outer edge 8 c of cover 8 pointing into an interior space of sensor-head-housing 3 is beveled so that in the non-beveled, internally circumferential abutting shoulder of sensor-head-housing 3 an annular free space remains which is triangular in cross section. As shown in the expanded illustration of FIG. 2 f , in this free space a gasket 7 ″, preferably an O-ring made from elastic material, is housed and sized so that it is wedged at the respective axial shoulder of sensor-head-housing 3 in a free space 41 , when cover 8 comes into axial contact, thereby imparting axial and radial forces onto cover 8 .
Through the radial support of the gasket or the O-ring at sensor-head-housing 3 and also at cover 8 , penetration of dirt into the interior and thereby into processing electronics 20 is avoided. Through axial compression, cover 8 is pressed against an interior side of a lock ring 9 , and thereby through force engagement is prevented from turning relative to lock ring 9 , and also turning of lock ring 9 relative to sensor-head-housing 3 is reliably prevented, whereby the strength of this force engaging connection depends on the degree of compression and elasticity of gasket 7 ″.
In the same way, a dish 28 receiving processing electronics 20 and printed circuit board 26 in an interior of head housing 3 can be secured against rotation in sensor-head-housing 3 . The dish on the other hand is supported at its free end at a bottom side of cover 8 , again, axially preloaded through a gasket 7 ″ compressed between the bottom of sensor-head-housing 3 and an outer edge of the bottom of interior dish 19 into a triangular free space 41 .
On a large cylindrical outer circumference of sensor-head-housing 3 a first annular groove close to sensor-stick-housing 2 can be seen, wherein a seal 7 is shown as an O-ring sealing relative to the surrounding component. In an axially connecting direction towards a free end of sensor-head-housing 2 , a support ring 17 is located in the same groove, greatly increasing the load bearing capability of O-ring 7 and preventing a squeezing out of the groove under pressure.
In a second annular groove located towards the free end in FIG. 2 b further to the left, an additional supplementary O-ring can be located in an outer circumference as shown in the lower half of the picture.
This layout of the outer circumference and sealing relative to the environment is also chosen in the solution according to FIG. 2 f.
On the other hand, in a solution according to FIG. 2 g , outer circumferential seal 7 is located in an outer circumference of an enlarged diameter area 16 at a transition between sensor-head-housing 3 and sensor-stick-housing 2 .
An upper half of the picture shows how an exterior hexagonal shape 18 can be provided on an exterior circumference of sensor-head-housing 3 for engaging an opened end wrench in order to be able to thread or tighten it.
Thereby, a significant feature is the shape of sensor-head-cover 8 and the manner of running cable 6 out of sensor-head-housing 3 in order to be able to conduct data derived by processing electronics 20 and to process it outside of the sensor. For this, exit of cable 6 through a cable exit 4 is illustrated. However, a connector or a connector socket could be located in sensor head cover 8 at the same location and in the same orientation as cable exit 4 . An illustration of a further path of cable 6 in an interior of sensor-head-housing 3 was left out in order to make FIGS. 2 b , 3 and 4 clear.
Also FIG. 2 b in connection with a face view of FIG. 1 b shows sensor head cap 8 with its exterior circumference located tight in an interior circumference of dish shaped sensor-head-housing 3 . A cap shaped dome 8 a thereby extends out of the interior of sensor-head-housing 3 with a reduced exterior diameter relative to an outer rim of sensor-head-cover 8 toward the left, thus out of an opening of sensor-head-housing 3 . Into dome 8 a protrudes, on the one hand on the interior side, sensor carrier unit 24 with its left end and, on the other hand in side wall 8 b of dome 8 a , is located cable exit 4 for cable 6 .
As FIG. 1 b shows, a cylindrical enveloping surface of side wall 8 b has an indentation 13 toward the inside, e.g. shaped as a secant, through which a flat area 14 is formed, displaced from an outer circumference of dome 8 a toward the inside, wherein cable outlet 4 is located. Cable 6 thereby is not completely radial at the location of the cable outlet, but slightly tangential to the enveloping surface of dome 8 a , wherein indentation 13 is preferably sized so that in its area the cable exiting from cable outlet 4 within indentation 13 can be bent into the desired path without nicking, either into a further axial path or into a radial or tangential path.
The FIGS. 1 c and 1 d , on the other hand, show a solution wherein at the same location at dome 8 a , a connector 5 is located as a cable exit for inserting a connector, which is not shown.
The FIGS. 6 and 7 show further embodiments of the shape of dome 8 a in lid 8 which are different than those seen in FIG. 1 .
While the dome in side view, thus seen perpendicular to the longitudinal direction 10 in the FIGS. 1 a and 1 b is substantially rectangular, dome 8 a in the solution according to FIGS. 6 and 7 in side view is beveled at an outer circumferential annular edge.
FIG. 6 shows a variant with a connector socket 6 ′ as cable outlet 4 ; while in FIG. 7 b cable 6 is run out of an opening in dome 8 a without a connector.
The design of the sensor-head-housing with dome 8 a thereby entails, besides gaining space for installing the connector or cable, a reduced installation space requirement in axial direction for the head area of the position sensor in e.g. a piston/cylinder unit 30 , as shown in FIG. 4 .
Piston/cylinder unit 30 , of which only one end is shown in FIG. 4 , comprises a cylinder 32 shaped as a tubular section closed on one side through a face plate 34 . At an interior circumference of cylinder 32 , a piston 33 ′ abuts tight but moveable, forming a thickened end of a piston rod 33 located in cylinder 32 . Face plate 34 has a central pass-through opening 34 a.
Position sensor 1 is located with thicker sensor-head-housing 3 on/or in face plate 34 and extends with slender sensor-stick-housing 2 through pass-through opening 34 a and piston 33 ′ into a central dead end bore of piston rod 33 ; having a slightly larger diameter, so that no contact can occur between piston rod 33 and sensor-stick-housing 2 . The element acting as a position indicator for the position of piston 33 ′, e.g. the annular position magnet 29 , is inserted into piston 33 ′ and/or the piston rod.
Due to the position of a slideable piston 33 ′ shown in FIG. 4 , between the piston and the cylinder in this case only a small amount of operating fluid 31 is enclosed, wherein, however, it is apparent that this operating fluid is in direct contact with the housing of position sensor 1 .
Most piston cylinder units 30 have to be coupled at their two longitudinal ends with abutting components and, for this purpose, have to comprise a respective mounting element on both ends, e.g. a depicted mounting eyelet 37 .
Mounting eyelet 37 cannot be directly mounted to face plate 34 or provided in one piece together with it, since on the side of face plate 34 facing away from piston 33 ′, sensor-head-housing 3 of position sensor 1 is located and mounted, and it has to be disassembled.
A front cover 35 is placed therefore onto a free front face of face plate 34 and mounted through longitudinal threading 36 . On the one hand, sensor-head-housing 3 is protected and covered. On the other hand, at the free end of this front cover 35 the necessary mounting element can be mounted, such as mounting eyelet 37 .
Thereby, FIG. 4 a shows that front cover 35 can reach close to the front end of sensor-head-housing 3 , thus sensor head cover 8 , since no additional axial space is required for cable 6 to axially run out of the sensor head cover. Cable 6 can either be run out through face cover 35 radially between threads 36 or can be run out in an axial manner, wherein for deflecting into axial direction indentation 13 in dome 8 a is sufficient, as shown in FIG. 4 b.
In comparison, FIG. 4 b shows the advantage of a beveled circumferential edge of dome 8 a of lid 8 .
Thereby, an interior contour in a superimposed front cover 35 between an interior wall and a bottom can be beveled, which greatly improves the torsion resistance of front cover 35 relative to a rectangular position of FIG. 4 a in this location, since in such a beveled interior edge the occurrence and inception of a fatigue fracture is much less likely than with a sharp rectangular interior circumferential edge, as in the front cover 35 according to FIG. 4 a . Analogously, front cover 35 can have reduced dimensions with a beveled interior edge according to FIG. 4 b.
On the other hand, FIG. 4 shows that after loosening threaded connection 36 and removing front cover 35 , the functional components of functional positional sensor 1 are accessible and can also be replaced without having to loosen the tight connection between the housing, ⅔ of the sensor and the face plate 34 , and thereby from piston cylinder unit 30 in its entirety.
It is only necessary to pull off sensor cover 8 in order to get into the interior of sensor-head-housing 3 and thereby to the processing electronics housed therein (not shown in FIG. 4 ) or also after its removal, to be able to pull wave conductor unit 23 out of sensor-stick-housing 2 .
Such a complete sensor unit, comprising sensor carrier unit 24 including wave conductor 23 located therein, detection unit 22 and interior dish 19 with processing electronics 20 housed therein, which is not shown, FIG. 3 a also shows in a longitudinal sectional view, wherein in this solution, the interior dish 19 is connected with all other mentioned components in a positively manner into a unit, which can be handled in its entirety.
On the other hand, FIG. 3 b shows a sensor unit according to another measuring principle in which a coil 42 extends along sensor carrier 24 in measuring direction instead of a wave conductor. Also a magnet 29 or another element is being used as position generator.
In case of FIG. 4 , the exterior circumference of the sensor-head-housing and the mounting and sealing relative to the piston cylinder unit are designed differently from FIGS. 1 and 2 , thus analogous to FIG. 2 d.
The area 16 with an enlarged diameter relative to sensor-stick-housing 2 at the transition between sensor-stick-housing 2 and sensor-head-housing 3 serves only for mechanical central alignment in pass-through opening 34 a of face plate 34 and does not have an external thread.
The mechanical fixation between sensor-head-housing 3 and face plate 34 is performed through a thread 15 at an outer circumference of sensor-head-housing 3 close to its free end and through a respective interior thread in face plate 34 . The sealing between both components is performed via a seal 7 with an adjacent support ring 17 in a respective annular groove in the outer circumference of sensor-head-housing 3 on the side facing sensor-stick-housing 2 , which is supported by an interior diameter of face plate 34 which is reduced relative to thread 15 .
FIGS. 2 e and 2 g also show a radial seal ring 7 , however, positioned in a groove radially open to the outside not of the large exterior diameter 12 , but of the enlarged diameter area 16 at a transition between sensors-stick-housing 2 and sensor-head-housing 3 .
Instead of the radial seal ring 7 , a seal 7 *, as shown in FIG. 2 c , can be located at a shoulder of the sensor head housing 3 in a groove open in an axial direction toward sensor-stick-housing 2 , supported against a respective frontal shoulder of front plate 34 , e.g. when tightening thread 15 .
Furthermore, FIG. 5 a shows another design of the head area in a longitudinal sectional view, differing from the analogous depiction of FIG. 2 b with regard to the design of the cover.
The lid cover does not have a dome, but it is a flat cover with a pass-through opening in the middle through which in a customary manner, using a protective cable grommet made from rubber or plastic. Cable 6 extends from the inside to the outside.
Furthermore, in FIG. 5 a at a location in the interior of the head housing, a LED 38 is shown in the processing electronics, located under a respective LED opening 39 in the cover 8 , so that the lighting or non-lighting of this LED 38 can be seen from the outside through the opening 39 .
Alternatively, to this non-tight variant with opening 39 , an infrared unit 40 can be located in the interior of the head housing 3 , including an infrared sensor and/or a infrared source. The cover 8 is made from a material which is permeable for infrared light. Thereby, the transmission of optical signals through infrared light through the otherwise tight closing cover is possible for error diagnosis and programming of processing electronics 20 in the interior of the head housing 3 .
This design, without dome 8 a in lid 8 , is suitable for very small processing electronics 20 or for housing of the processing electronics outside head housing 3 . Also, with this design a leak free repair and a replacement of the sensor unit is possible through the removable lid 8 .
FIG. 5 b shows the installation situation of this variant into a piston cylinder unit according to FIG. 4 .
REFERENCE NUMERALS
1 Position sensor
2 Sensor stick housing
3 Sensor head housing
3 a Wall
3 b Flange
4 Cable exit
5 . Connector
6 Cable
6 ′. Connector socket
7 Seal
7 ′, 7 ″, 7 * Seal
8 , 8 ′ Sensor head cover
8 a Dome
8 b Side wall
8 c Outer edge
9 Lock ring
10 Longitudinal direction
11 Diameter
12 Outer diameter of the sensor head housing
13 Indentation
14 Flat surface
15 Thread
16 Enlarged diameter area
17 Support ring
18 External hexagonal shape
19 Interior dish
20 Processing electronics
21 Weld
22 Sensor element
23 Wave conductor
24 Sensor carrier unit
26 Printed circuit board
27 . Positioning sleeve
28 Spacer
29 Position indicator magnet
30 Piston cylinder unit
31 Operating fluid
32 Cylinder
33 Piston rod
33 ′ Piston
34 Face plate
34 a Pass-through opening
35 Front cover
36 Longitudinal thread
37 Mounting eyelet
38 LED
39 LED opening
40 Infrared unit
41 Free space
42 Coil
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The present invention refers to position sensors in stick design, for installation in hydraulic cylinders, which may be maintained and replaced without having to open the hydraulic system of the cylinder and thus causing leakage. According to the invention the sensor includes a sensor head housing having an attachable and detachable sensor head cover which can be opened without removing the remaining housing out of the piston cylinder unit. Opening of the sensor-head-cover allows easy access to the functional components of the sensor.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
This application is a continuation of U.S. application Ser. No. 11/877,469, filed Oct. 23, 2007, which claims the benefit of U.S. Provisional Application No. 60/853,822, filed on Oct. 24, 2006, and U.S. Provisional Application No. 60/927,084, filed on May 1, 2007, all of which are incorporated by reference herein in their entireties.
BACKGROUND
The present inventions relate generally to washroom fixtures. The present inventions also relate to a washroom fixture such as a lavatory system having a control system suitable for providing “hands-free” operation of one or more fixtures (e.g., sprayheads, faucets, showerheads, soap or lotion dispensers, hand dryers, flushers for toilets and/or urinals, emergency fixtures, etc.) within the lavatory system. More particularly, the present inventions relate to a lavatory system having a control system utilizing a capacitive sensing system to detect the presence of an object (e.g., the hand of a user, etc.) and actuate the one or more fixtures. The present invention further relates to various features and combinations of features shown and described in the disclosed embodiments. Other ways in which the objects and features of the disclosed embodiments are accomplished will be described in the following specification or will become apparent to those skilled in the art after they have read this specification. Such other ways are deemed to fall within the scope of the disclosed embodiments if they fall within the scope of the embodiments which follow.
It is generally known to provide a lavatory system having at least one fixture that conventionally requires manual manipulation by a user in order to operate. It is further known to provide an electrical and/or electronic control system for providing “hands-free” operation of the fixture. Not requiring a user to physically contact or touch the fixture for its operation may be desirable for various sanitary and/or accessibility considerations.
It is also generally known to provide an electrical and/or electronic control system utilizing an infrared (IR) sensor to detect the presence of an object and actuate one or more fixtures of the lavatory system. Such control systems generally have a transmitter that is configured to emit pulses of infrared light into a sensing region (e.g., an area adjacent to the fixture, etc.) and a receiver that is configured to measure the level of infrared light in the sensing region. Ideally, when an object enters the sensing region, at least a portion of the infrared light emitted from the transmitter will be reflected by the object and detected by the receiver which in turn creates a signal representative of the level of infrared light in the sensing region that can be used to determine whether the fixture should be actuated.
In the case of control systems utilizing an IR sensor, false activations of a fixture and/or a failure to detect an object may arise due to variations in the reflectivity of objects near the fixture and/or damage (e.g., contamination, etc.) of the optics of the IR sensor. False activations may ultimately result in a waste of resources (e.g., water, soap, towels, energy, etc.) that is contrary to the benefits of having a “hands free” operated fixture. Likewise, missed detections may frustrate a user attempting to realize the benefits of the fixture.
An alternative to an IR sensor, is a capacitive sensing system. Capacitive sensing systems generally provide an electric field and rely on a change in the electric field for sensing purposes. While capacitive sensing systems may be advantageous to IR sensors since capacitive sensing systems are not susceptible to false and/or missed detections due to reflectivity variations and/or optic damage, the use of capacitive sensing systems create additional issues. For example, variations in the environment may cause interfering variations in capacitance which may lead to false and/or missed detections. Such variations may be caused by contaminants on the surface of the electrodes or other objects in the electric field, changes in ambient humidity, gradual variations in the proximity or composition of nearby objects, or variations in the sensor mounting locations. All of such variations are likely occurrences in the environment of a lavatory system.
It would be advantageous to provide a lavatory system for use in commercial, educational, or residential applications, having one or more fixtures and a control system for enabling “hands-free” operation of the fixtures wherein the control system utilizes a capacitive sensing system. It would also be advantageous to provide a control system utilizing a capacitive sensing system that is capable of improved sensitivity and reliability, particularly in the typical environment of a lavatory system. It would further be advantageous to provide a control system utilizing a capacitive sensing system that reduces or minimizes the number of missed detections by providing an improved electrode plate configuration. It would further be advantageous to provide a power management system providing for the efficient use of the electrical energy required to operate a control system utilizing a capacitive sensing system, such as electrical energy generated by one or more photovoltaic cells. It would further be advantageous to provide a capacitive sensing system that detects an object within a sensing region regardless of the direction in which the object enters the sensing region, allows for use of a large plate size to maximize the detection signal, does not require the use of a guard plate, is able to extend detection window farther from an output of the fixture, and/or offers less difference between wet and dry conditions.
Accordingly, it would be desirable to provide for a lavatory system and/or capacitive sensing system having one or more of these or other advantageous features. To provide an inexpensive, reliable, and widely adaptable capacitive sensing system for a lavatory system that avoids the above-referenced and other problems would represent a significant advance in the art.
SUMMARY
One embodiment of the present invention relates to a hand-washing lavatory system comprising a receptacle defining a hand washing area; a fixture configured to deliver water to the hand washing area; a first sense electrode coupled to the receptacle and configured to measure a first capacitive value; a second sense electrode coupled to the receptacle spaced apart from the first sense electrode and configured to measure a second capacitive value; and a circuit configured to control operation of the fixture in response to a change in the first capacitive value relative to the second capacitive value.
Another embodiment of the present invention relates to a hand-washing lavatory station comprising a deck having one or more receptacles providing one or more hand washing stations, and a sink line defining the top of the one or more receptacles. The hand-washing lavatory station also comprises at least one fixture located at least partially above the sink line and configured to deliver water to one or more of the hand washing areas. The hand-washing lavatory station also comprises a first sense electrode integrated with the deck and located below the sink line, and configured to measure a first capacitive value in the one or more hand washing area. The hand-washing lavatory station also comprises a second sense electrode integrated with the deck and located adjacent to the first electrode and below the sink line and configured to measure a second capacitive value in the one or more hand washing area. The hand-washing lavatory station also comprises a valve movable between an open position wherein water is permitted to flow through the fixture and a closed position wherein water is prevented from flowing through the fixture. The hand-washing lavatory station also comprises a circuit coupled to the first electrode, the second electrode, and the valve, and configured to move the valve between the open position and the closed position in response to a change in the first capacitive value relative to the second capacitive value.
Another embodiment of the present invention relates to a method of operating the hand washing lavatory station. The hand washing lavatory station may comprise a deck, a first sense electrode, and a second sense electrode, the deck includes one or more hand-washing receptacles and a sink line defining the top of the one or more receptacles, the first sense electrode is integrated with the deck and located below the sink line and is configured to measure a first capacitive value in the one or more hand washing area, the second sense electrode is integrated with the deck and located adjacent to the first electrode and below the sink line and is configured to measure a second capacitive value in the one or more hand washing area. The method comprises operating within a non-activated loop wherein the fixture is waiting to be used; detecting a first capacitive value with a first sense electrode and a second capacitive value with a second sense electrode; calculating a difference between the first capacitive value and the second capacitive value over a predetermined time period; returning to the non-activated loop if an activation event has not occurred; operating within an activated loop and activating a fixture for a hand washing operation if an activation event has occurred; detecting a third capacitive value with the first sense electrode and a fourth capacitive value with the second sense electrode; calculating a difference between the third capacitive value and the fourth capacitive value over a predetermined time period; resetting the run time if a reactivation activation event has occurred the system; decrementing the run time if the reactivation event has not occurred; and deactivating the fixture after expiration of the run time and returning to the delay period to check for further activation of the system.
The present invention further relates to various features and combinations of features shown and described in the disclosed embodiments. Other ways in which the objects and features of the disclosed embodiments are accomplished will be described in the following specification or will become apparent to those skilled in the art after they have read this specification. Such other ways are deemed to fall within the scope of the disclosed embodiments if they fall within the scope of the claims which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating a capacitive sensing system for use in a hand-washing lavatory system according to an exemplary embodiment.
FIG. 2 is a perspective view of a side-by-side sensor plate configuration in the capacitive sensing system of FIG. 1 according to an exemplary embodiment.
FIG. 3 is a perspective view of a U-shaped sensor plate configuration in the capacitive sensing system of FIG. 1 according to an exemplary embodiment.
FIG. 4 is a perspective view of a single sheet metal sensor plate configuration in the capacitive sensing system of FIG. 1 according to an exemplary embodiment.
FIG. 5 is a perspective view of a single conductive coating sensor plate configuration in the capacitive sensing system of FIG. 1 according to an exemplary embodiment.
FIG. 6 is a perspective view of a sensor plate configuration with grounded guard plates in the capacitive sensing system of FIG. 1 according to an exemplary embodiment.
FIG. 7 is a perspective view of a single sensor plate configuration below the wash area in the capacitive sensing system of FIG. 1 according to an exemplary embodiment.
FIG. 8 is a sensing control and detection circuit of the capacitive sensing system of FIG. 1 according to an exemplary embodiment.
FIG. 9 illustrates an internal oscillator voltage curve for the circuit of FIG. 8 , according to an exemplary embodiment.
FIG. 10 illustrates an internal sensor curve before the output filter of the circuit of FIG. 8 , according to an exemplary embodiment.
FIG. 11 is a block diagram of a power management system in the capacitive sensing system of FIG. 1 according to an exemplary embodiment.
FIG. 12 is a perspective view of a hand-washing lavatory system that includes the capacitive sensing system of FIG. 1 according to an exemplary embodiment.
FIG. 13 is a perspective view of the sensor plates, electronics module, and circuit board of the capacitive sensing system of FIG. 1 according to an exemplary embodiment.
FIG. 14 is a process flow diagram illustrating a process for capacitive sensing in the capacitive sensing system of FIG. 1 according to an exemplary embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a capacitive sensing system 100 for use in a hand-washing lavatory system 110 with any of a variety of washroom fixtures (e.g., sprayheads, faucets, showerheads, soap or lotion dispensers, hand dryers, flushers for toilets and/or urinals, emergency fixtures, towel dispenser, wash fountains, etc.). Capacitive system 100 includes a sensing circuit 120 and a power management and valve actuation circuit 130 are typically controlled by software. Capacitive system 100 includes a sensor 140 , a sensing control and detection circuit 150 , and a processor 160 (e.g., a CPU, standard control logic, field programmable gate array (FPGA), etc.). Sensing circuit 120 is coupled to a pair of solenoid valves (e.g., a DC latching solenoid valve, an AC non-latching solenoid valve, etc.) that are typically driven and/or controlled by a hardware controlled solenoid driver.
The system is configured to detect the presence of a user seeking to activate the fixture. In the illustrated embodiments of FIGS. 2-7 and 12 , the fixture is shown as a sprayhead on a lavatory system or wash fountain. According to other exemplary embodiments, the fixture may be a faucet, shower, showerhead, soap or lotion dispenser, hand dryer, flushers for toilets and/or urinals, emergency fixture, towel dispenser, drinking fountain, or the like. The system operates based on a user's internal dielectric—by detecting a sensed capacitance and evaluating it over time. The faucet/sprayhead may be any of a variety of commercially available products configured to be electronically actuated by an input signal. According to an alternative embodiment, the system operates based on a user's internal ground—by detecting a sensed capacitance and comparing to a comparison value.
Sensor 140 (e.g. sense electrodes, antennas, etc.) may include one or more plate members that detect a change in capacitance within a sensed area (field, space, region, etc.). For example, FIGS. 4, 5, and 7 show a single plate member; FIGS. 2, 3, and 6 show two plate members; alternatively there may be three or more plate members. The plate members are configured so that a user's hand will provide a strong field when crossing the field generated by the plate member(s). Alternatively, the sensor is wire shaped or coiled to provide a desired field. According to a preferred embodiment, the sensor comprises two or more plate members. Using two or more plate members reduces or eliminates the effect of water passing through the sensed area (i.e., over or above the plate members). Each plate member measures the capacitance or charge relative to the other plates. Because the measurement is not absolute to ground, the relative measurement of the plate members zeros or eliminates the effect of the flowing water. For example, when a hand of a user enters the space above the plate members, there is an imbalance or change in the capacitance values being measured by the plate members. The system measures the capacitance between a first plate and its environment and measures the capacitance between a second plate and its environment. The processor then calculates the difference between the two measured capacitance values and calculates the change over time to determine whether to change the operational status of the fixture.
According to an alternative embodiment, each plate member measures the capacitance or charge relative to its environment (e.g., to a theoretical or actual ground). The measurement of each plate member to ground zeros or eliminates the effect of the flowing water. The processor then calculates the difference between the two measured capacitance values and determines whether to change the operational status of the fixture.
According to an exemplary embodiment shown in FIG. 2 , the sensor includes two (side by side) plate members 200 below a wash area 210 . Locating sensor plate members 200 below wash area 210 allows for the use of a large plate size maximized detection signal, does not require the use of a guard plate, is able to extend detection window farther from the water nozzle, offers less difference between wet and dry conditions, and simplifies installation. Plate members 200 are disposed near one another and the user is sensed by changes of capacitance in electric fields generated by the plate members due to dielectric or conductive effects.
According to a preferred embodiment shown in FIG. 3 , the sensor includes first and second plate members 300 and 305 below the wash area in a U-shaped configuration. Plate 300 and 305 members are configured so that a user's hand will provide a strong field on the outer plate when it is crossed and a strong field on the inner plate when it is crossed. Plate members 300 and 305 are shaped and configured to provide good detection from any approach by a user's hands entering the wash area, allow for use of a large plate size maximized detection signal, does not require the use of a guard plate, is able to extend detection window farther from the water nozzle, and offers less difference between wet and dry conditions.
According to alternative embodiments shown in FIGS. 4-6 , the sensor includes a single plate member located above the wash area. Locating the plate member above the wash area is intended to minimize the effect of water. FIG. 4 shows a sensor plate configuration where a single metal plate 400 (e.g., sheet metal) is located above a wash area 410 . FIG. 5 shows a sensor plate configuration where a single plate 500 is located above a wash area 510 using a conductive coating on a nozzle insert 520 . FIG. 6 shows a sensor plate configuration where a single plate 600 above a wash area 610 along with a grounded plate 620 to shape the capacitive field.
According to an alternative embodiment shown in FIG. 7 , the sensor includes a single plate member 700 below a wash area 710 . Locating sensor plate member 700 below wash area 710 allows for the use of a large plate size that maximizes detection signal, does not require a guard plate, and is able to extend detection window farther from the water nozzle.
According to other alternative embodiments, the one or more plate members may be sized and orientated in a variety of configurations and arrangements.
Sensing control and detection circuit 150 is configured to control the sensing and detection operation and provide an output signal that ultimately actuates the fixture (e.g., turns a faucet on and off). Sensing control and detection circuit 150 may be configured to operate continuously or operated only as long as required for one or more measurements to be taken. According to a preferred embodiment, sensing control and detection circuit 150 operates sensor 140 as a proximity sensor by calculating the change in relative capacitance between the plates over time. According to an alternative embodiment, sensing control and detection circuit 150 operates sensor 140 as a proximity sensor by calculating the change in capacitance with respect to a reference level that does not vary or only slowly varies over a time period, rather than motion sensing that measures a rapid change in capacitance.
According to a particularly preferred embodiment shown in FIGS. 8-10 , sensing control and detection circuit 150 is provided by a “CAV424” chip or circuit 800 commercially available from Analog Microelectronics, which has a detection frequency of up to about 2 kHz, an output op-amp available to maximize detection signal, and a DC level output. An exemplary operation of the CAV424 chip would provide for it to be on for approximately 3 ms. FIG. 9 illustrates an exemplary internal oscillator voltage curve 900 for the CAV424 chip. FIG. 10 illustrates an exemplary internal sensor curve 1000 before the output filter. According to alternative embodiments, the processing may be conducted by standard control logic, a field programmable gate array (FPGA), a programmable logic array (PLA), or the like.
The sensing control is derived by watching for acceleration of the differential capacitive signals (i.e., a change in the rate of change of the relative capacitance between the different plates). This is used to detect the differences between noise, user activity and water effects (e.g., splashing, draining, and standing water). For example the circuit may take samples measurements every quarter second, calculate the difference from the last recorded sample and then look for patterns in the rising and falling of a signal (for example, a rising signal by 3% followed by a falling signal of 2% within 3 samples) to indicate that a person has placed his or her hands into the field to activate the device.
According to an alternative embodiment, sensing control and detection circuit 150 is programmed to operate by continuously calculating an average of multiple capacitive measurements (i.e., progressive or rolling average value) measured at regular intervals. For example, the circuit may take sample measurements every quarter second and maintain the average over the past minute. Alternatively, any of a variety of sampling may be used. When a user places his or her hands in the capacitive field, the (instantaneous) detected value is compared to the average value. If the change or difference is greater than a predetermined level, then the faucet is triggered (turned on).
The power supply may be provided by any of a variety of power supplies 170 . According to an exemplary embodiment, the power supply is a 24 VAC transformer 180 . According to another exemplary embodiment, the power supply is a 6 VDC battery 190 .
According to another exemplary embodiment, the power supply is a “green” or more environmentally friendly photovoltaic cell system. FIG. 11 shows a block diagram of a power management system 650 and components thereof that advantageously provides for an efficient use of the electrical energy generated by a photovoltaic cell system, shown as photovoltaic cells 602 . Power management system 650 is shown as generally including an energy storage element 660 configured to receive and store electrical energy generated by photovoltaic cells 602 , a detector 670 configured to measure the level (intensity) of ambient light, a switch 680 configured to disconnect energy storage element 660 from control system 50 if the level of ambient light drops below a predetermined value, and a voltage regulator 690 for adjusting the voltage being outputted to control system 50 .
According to an exemplary embodiment, energy storage element 660 includes one or more capacitors suitable for receiving a electric charge from photovoltaic cells 602 and supplying an output voltage to a control system 50 utilizing a capacitive sensing system. According to a preferred embodiment, energy storage element 660 includes a plurality of capacitors arranged in series to provide a desired capacitance. Any number and/or type of capacitors may be used and such capacitors may be arranged in series and/or in parallel.
Energy storage element 660 may be fully charged or partially charged by photovoltaic cells 602 . The rate at which energy storage element 660 is charged depends at least partially on the intensity of the ambient light and the effectiveness (e.g., number, size, efficiency, etc.) of photovoltaic cells 602 . During an initial setup (e.g., anytime energy storage element 660 is fully discharged), the time required to charge energy storage element 660 to a level sufficient to operate the components of control system 50 may be relatively long. The charging time during the initial setup can be reduced by adding a supplemental power source (e.g., a battery, etc.) to charge energy storage element 660 . The supplemental power source provides a “jump-start” for energy storage element 660 , and may significantly reduce the charging time. Preferably, any supplemental power source is removed once energy storage element 660 is sufficiently charged, but alternatively, may remain coupled to the system but electrically disconnected from energy storage element 660 .
A fully charged energy storage element 660 is capable of providing a sufficient amount of electrical energy to power control system 50 for the selective operation of one or more hands-free fixtures. According to an exemplary embodiment, energy storage element 660 is capable of providing a sufficient amount electrical energy to allow for more than one activation of the fixtures before energy storage element 660 needs to be recharged. In a typical application (e.g., an application wherein photovoltaic cells 602 are exposed to ambient light while lavatory system 10 is being used), photovoltaic cells 602 will continue to charge energy storage element 660 as electrical energy is provided for the activation of the fixtures.
Control system 50 constitutes a load on energy storage element 660 that when electrically coupled thereto diminishes the electrical energy stored in energy storage element 660 . Disconnecting energy storage element 660 from such a load will help maintain the charge of energy storage element 660 . To determine whether power should be conserved by disconnecting control system 50 from energy storage element 660 , power management system 650 further includes voltage detector 670 . Voltage detector 670 includes an input 672 electrically coupled to an output from photovoltaic cells 602 . Voltage detector 670 also includes an output 674 electrically coupled to switch 680 .
An output voltage is provided by photovoltaic cells 602 . The magnitude of the output voltage may be based upon the intensity of the ambient light and the efficiency of photovoltaic cells 602 . Voltage detector 670 detects whether photovoltaic cells 602 are being exposed to a level of ambient light sufficient to meet the power demands of control system 50 . According to an exemplary embodiment, a reference voltage value (a baseline value) representative of the sufficient level of ambient light is maintained by voltage detector 670 . Such a reference value may be changed depending on the power requirements of control system 50 .
According to an exemplary embodiment, if photovoltaic cells 602 are not being exposed to a sufficient level of ambient light, the assumption is that lavatory system 10 is not in use (e.g., the lights have been turned down and/or off) and that control system 50 does not need to be powered. In such a situation, control system 50 may be disconnected from power management system 650 in an effort to conserve electrical energy. Alternatively, the control system may require a delay prior to turning on or off, may not turn off, or the like. According to a preferred embodiment, voltage detector 670 measures the output voltage of photovoltaic cells 602 (received at input 672 ) and compares the output voltage with the reference voltage value. If the output voltage level is below the reference voltage level, voltage detector 670 will send an output signal (at output 674 ) to switch 680 indicating that control system 50 should be electrically disconnected from power management system 650 . According to various alternative embodiments, voltage detector 670 may be replaced with any detector suitable for detecting the intensity of the ambient light at photovoltaic cells 602 including, but not limited to, a photodetector configured to monitor the ambient light and send a corresponding signal to switch 680 . According to an alternative embodiment, control system 50 compares incoming power to outgoing power to determine if sufficient power is available to maintain the operation of control system 50 . If there is not sufficient power, control system 50 is disconnected from the power management system 650 .
Preferably, energy storage element 660 is capable of holding a charge with minimal leakage when disconnected from the load (control system 50 ). Providing energy storage element 660 that is capable of maintaining a charge with minimal leakage, may allow energy storage element 660 to meet the electrical power requirements of control system 50 after photovoltaic cells 602 have not been exposed to ambient light for an extended period of time (e.g., a weekend, etc.). This will eliminate the need to recharge energy storage element 660 (e.g., by a supplemental power source and/or by photovoltaic cells 602 , etc.), or at least reduce the time required to recharge energy storage element 602 , when the ambient light returns and a user seeks to use fixtures 14 of lavatory system 10 . When voltage detector 670 measures a voltage at or above the predetermined baseline voltage, switch 680 reconnects power management system 650 to control system 50 .
Power management system 650 is further shown as including voltage regulator 690 adapted for receiving a first voltage from photovoltaic cells 602 and providing a second voltage to control system 50 . According to an exemplary embodiment, voltage regulator 690 is capable of providing a relatively stable operating voltage to control system 50 . According to an exemplary embodiment, voltage regulator 690 is shown schematically as a dc-to-dc converter. As can be appreciated, the input and output voltages may vary in alternative embodiments.
As for the activation of the one or more valves controlling the output from the fixtures, any suitable valve control system may be provided. According to an exemplary embodiment, one or more solenoid valves are provided for controlling the output from the fixtures. These solenoid valves are configured to receive a signal representative of whether the valves should be in an open or closed position. Such a valve configuration may be substantially the same as the one disclosed in U.S. patent application Ser. No. 11/041,882, filed Jan. 21, 2005 and entitled “Lavatory System,” the complete disclosure of which is hereby incorporated by reference in its entirety.
Processor 160 is configured to operate the entire system. According to exemplary embodiments, processor 160 may be any of a variety of circuits configured to control the operation (e.g., CPU, standard control logic, field programmable gate array (FPGA), etc.). According to a particularly preferred embodiment, processor 160 is commercially available as PIC16F886 from Microchip. According to an alternative embodiment, processor 160 is commercially available as PIC16LF876 from Microchip. Alternatively, any of a variety of processors may be used.
FIG. 12 shows an exemplary lavatory system 1200 configured to accommodate multiple users with independent hand-washing stations for users to attend to their washing needs. Lavatory system 1200 includes a deck 1210 (e.g., lavatory deck, countertop, etc.), a drain system disposed below the deck, a cover configured to enclose plumbing system, and a capacitive sensing system 1230 (with the capacitive sensing plates/electrodes/antennas shown schematically in broken lines) mounted below the receptacles. The broken lines identifying the sensing system 1230 plates schematically illustrate that one, two, three, or more plates may be used for the sensing system. Lavatory system 1200 may be configured for attachment to a surface such as a wall of a restroom or other area where it may be desirable to provide a lavatory services, or configured as a free-standing structure. An adjacent wall may be provided with the plumbing source (including both (or either) a hot and cold water supply, preferably combined with a thermostatic mixing valve, or a tempered water supply, a drain, etc.) and an optional source such as an electrical outlet (preferably providing 110 volts GFCI).
The hand washing stations generally each include a receptacle 1240 (e.g., bowl, sink, basin, etc.) and a spray head 1250 (e.g., faucet assembly). Receptacle 1240 may be a separate component coupled to countertop 1210 or integrally formed (e.g., cast, molded, etc.). A front apron 1260 extends down from the countertop and is configured to provide a frontal surface to conceal certain components of the lavatory system and may have any number of a variety of contours or shapes. A backsplash extends up from the countertop and is configured to protect the wall adjacent to countertop 1210 (e.g., from water splashed from the lower and upper stations or other physical damage).
Deck 1210 may be made from any of a variety of materials, including solid surface materials, stainless steel, laminates, fiberglass, and the like. When a metallic or conductive material is used, the deck needs to be insulated from the sensor(s). According to a particular preferred embodiment, the deck is made from a densified solid surface material that complies with ANSI Z124.3 and Z124.6. According to a particularly preferred embodiment, the surface material is of a type commercially available under the trade name TERREON® from Bradley Corporation of Menomonee Falls, Wis.
According to an exemplary embodiment shown in FIG. 13 , a sensor 1340 and a circuit 1310 are integrally provided on a common integrated circuit board 1300 . Circuit 1300 may include sensing control and detection circuit(s) 150 , power management and valve actuation circuit(s) 130 , and processor 160 . Sensor(s) 1340 and/or integrated circuit board 1300 is preferably located at or below the receptacle/bowl of the lavatory (e.g., rather than in the faucet, header, spray head, etc.). Alternatively, sensor(s) 1340 and/or integrated circuit board 1300 is located at a variety of locations below the sink line. Sensor(s) 1340 and/or integrated circuit board 1300 is preferably coupled to a bottom surface of lavatory deck 1210 or bowl 1240 (e.g., mounted on stand offs or bosses with fasteners or clips). Alternatively, bowl 1240 or lavatory deck 1210 is molded or cast around sensor(s) 1340 and/or integrated circuit board 1300 (i.e., encapsulated). Alternatively, the plate members may be wires or strips of conductive material (e.g., copper) molded into the bowl or lavatory deck rather than on the circuit board.
FIG. 14 shows an exemplary process 1500 for capacitive sensing of the lavatory system/fixture. After activation, at a step 1502 , the system checks for any stored calibration constants (e.g., magnetic field values, sensor configuration information, etc.). The calibration steps are preferably include calibration when the lavatory is dry (e.g., no water in the sinks/bowls) and when wet (e.g., water in and/or flowing through the sink area). If no calibration constants exist, then the system calibrates and stores values at a step 1504 followed by a delay period at a step 1506 . If any calibration constants do exist, then the system has been calibrated and may proceed to delay period 1506 . The delay step or period is configured to minimize power consumption and allow the lavatory system to operate and/or react to inputs/outputs. Generally, after the system has been calibrated, process 1500 works in a non-activated loop (left side below calibration steps, fixture is waiting to be used) or an activated loop (right side, fixture has been activated for a hand washing operation).
At a step 1508 in the non-activated loop, the system reads one or more sensor electrodes and/or plates. At a step 1510 , the system calculates any difference in the sensor values obtained in step 1508 over a predetermined time period (e.g., 1 second, 0.5 seconds, 100 milliseconds, etc.). For example, if a user has placed his or her hands near the sensor, the system may sense different sensor values than when the hands were not present. According to an exemplary embodiment, the system counts the number of cycles that one or more oscillators oscillates over the predetermined time period and compares the counted cycles to a value (e.g., the previous cycle count) to determine whether the environment in the hand washing area is changing (e.g., in the bowl/sink and its surrounding area, etc.). For example, the system may use an oscillator that oscillates at 40 kHz to avoid other electrical/electronic “noise” in the room (e.g., produced by fluorescent lighting). A hand moving near the plates will cause the oscillation frequency of the oscillator to decrease (e.g., from 40 kHz to 37 kHz) because the oscillation frequency is determined by the resistance and capacitance, which are affected by the hand moving near the plates. The system may provide one oscillator per sensing plate. To inhibit or prevent an activation due to the presence of water in the sink, the system uses two or more sensing plates (e.g., 2, 3, 4, etc.). Although water will affect the sensed capacitive value, the effect on the two or more oscillators will be approximately the same as the water spreads across the bottom of the sink whereas a hand passing into the hand washing area will have a different effect on the sensed capacitive values (i.e., will change the frequency of the oscillators differently). The oscillators functionality may be provided by comparator(s) integrated in the CPU or by op-amps (i.e., oscillator frequency is changed by the environment). According to a preferred embodiment, the oscillator is provided as an RC oscillator (i.e., tuned circuit built using resistors and capacitors). Alternatively, the capacitive sensing function may be provided by the commercially available CAV424 as discussed above (which has a reference oscillator at a single frequency and integrates the signals received).
At a step 1512 , if an activation event has not occurred, the system returns to delay period 1506 , for example to read the sensors again. If an activation event has occurred, the system continues to a step 1514 to check if the water level of the system is beyond a threshold value or is too high. The water level height query, for example, determines whether there may be a blocked drain. If the water level is too high, the system returns to delay period 1506 and may be configured to initiate an alarm. If the water level is below the threshold, the system moves to a step 1516 in the activated loop.
At step 1516 , the fixture (e.g., faucet, spray head, etc.) is activated. At a step 1518 , a run time that the fixture should be active for is set. At a step 1520 , a delay period is configured to minimize power consumption and allow the lavatory system to operate and/or react to inputs/outputs. At a step 1522 , the system reads one or more sensor electrodes and/or plates. At a step 1524 , the system calculates any difference in the sensor values obtained in step 1522 over a predetermined time period (e.g., ranging from 2 seconds to 50 milliseconds, such as 2 seconds, 1 second, 0.5 seconds, 100 milliseconds, 50 milliseconds, etc.). For example, if a user's hands remain in an area near the sensor, the system may sense little to no difference in sensor values than when the system was inactive. At a step 1526 , if a reactivation activation event has occurred (e.g., a user's hand remain near the sensor), the system returns to step 1518 to reset the run time. If an activation event has not occurred, the system continues to a step 1528 to decrement the run time by a predetermined value. At a step 1530 , if the time period has not expired, the system returns to delay period 1520 for further sensing and decrementing until the run time has expired. If the time period has expired, the system deactivates the fixture at a step 1532 and returns to delay period 1506 to check for further activation of the system. According to other alternative embodiments, the process may comprise a variety of other steps and sequences.
It is also important to note that the construction and arrangement of the elements of the capacitive system as shown in the preferred and other exemplary embodiments are illustrative only. Although only a few embodiments of the present invention have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the embodiments. For example, for purposes of this disclosure, the term “coupled” shall mean the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature. Such joining may also relate to mechanical, fluid, or electrical relationship between the two components. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the disclosed embodiments. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the embodiments, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and/or omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present invention as expressed in the embodiments described.
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A capacitive sensing system and method for a hand washing lavatory system is disclosed. The lavatory system comprises a receptacle defining a hand washing area, a fixture configured to deliver water to the receptacle, and a capacitive sensing system configured to detect the presence of a user and actuate the fixture. The capacitive sensing system comprises a first sense electrode coupled to the receptacle and configured to measure a first capacitive value, a second sense electrode coupled to the receptacle spaced apart from the first sense electrode and configured to measure a second capacitive value, and a circuit configured to control operation of the fixture in response to a change in the first capacitive value relative to the second capacitive value.
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This application is a continuation of U.S. patent application Ser. No. 10/150,268, entitled “Delivery of Stimulants Through an Inhalation Route,” filed May 15, 2002, now U.S. Pat. No. 6,780,399, Rabinowitz and Zaffaroni, which claims priority to U.S. provisional application Ser. No. 60/294,203 entitled “Thermal Vapor Delivery of Drugs,” filed May 24, 2001, Rabinowitz and Zaffaroni, the entire disclosure of which is hereby incorporated by reference. This application further claims priority to U.S. provisional application Ser. No. 60/317,479 entitled “Aerosol Drug Delivery,” filed Sep. 5, 2001, Rabinowitz and Zaffaroni, the entire disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to the delivery of stimulants through an inhalation route. Specifically, it relates to aerosols containing ephedrine or fenfluramine that are used in inhalation therapy.
BACKGROUND OF THE INVENTION
There are a number of compositions currently marketed as stimulants. The compositions contain at least one active ingredient that provides for observed therapeutic effects. Among the active ingredients given in stimulant compositions are ephedrine and fenfluramine.
It is desirable to provide a new route of administration for ephedrine and fenfluramine that rapidly produces peak plasma concentrations of the compounds. The provision of such a route is an object of the present invention.
SUMMARY OF THE INVENTION
The present invention relates to the delivery of stimulants through an inhalation route. Specifically, it relates to aerosols containing ephedrine or fenfluramine that are used in inhalation therapy.
In a composition aspect of the present invention, the aerosol comprises particles comprising at least 5 percent by weight of ephedrine or fenfluramine. Preferably, the particles comprise at least 10 percent by weight of ephedrine or fenfluramine. More preferably, the particles comprise at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent or 99.97 percent by weight of ephedrine or fenfluramine.
Typically, the aerosol has a mass of at least 10 μg. Preferably, the aerosol has a mass of at least 100 μg. More preferably, the aerosol has a mass of at least 200 μg.
Typically, the particles comprise less than 10 percent by weight of ephedrine or fenfluramine degradation products. Preferably, the particles comprise less than 5 percent by weight of ephedrine or fenfluramine degradation products. More preferably, the particles comprise less than 2.5, 1, 0.5, 0.1 or 0.03 percent by weight of ephedrine or fenfluramine degradation products.
Typically, the particles comprise less than 90 percent by weight of water. Preferably, the particles comprise less than 80 percent by weight of water. More preferably, the particles comprise less than 70 percent, 60 percent, 50 percent, 40 percent, 30 percent, 20 percent, 10 percent, or 5 percent by weight of water.
Typically, at least 50 percent by weight of the aerosol is amorphous in form, wherein crystalline forms make up less than 50 percent by weight of the total aerosol weight, regardless of the nature of individual particles. Preferably, at least 75 percent by weight of the aerosol is amorphous in form. More preferably, at least 90 percent by weight of the aerosol is in amorphous form.
Typically, where the aerosol comprises ephedrine, the aerosol has an inhalable aerosol drug mass density of between 2 mg/L and 20 mg/L. Preferably, the aerosol has an inhalable aerosol drug mass density of between 2 mg/L and 15 mg/L. More preferably, the aerosol has an inhalable aerosol drug mass density of between 2 mg/L and 12.5 mg/L.
Typically, where the aerosol comprises fenfluramine, the aerosol has an inhalable aerosol drug mass density of between 4 mg/L and 30 mg/L. Preferably, the aerosol has an inhalable aerosol drug mass density of between 4 mg/L and 25 mg/L. More preferably, the aerosol has an inhalable aerosol drug mass density of between 4 mg/L and 22.5 mg/L.
Typically, the aerosol has an inhalable aerosol particle density greater than 10 6 particles/mL. Preferably, the aerosol has an inhalable aerosol particle density greater than 10 7 particles/mL or 10 8 particles/mL.
Typically, the aerosol particles have a mass median aerodynamic diameter of less than 5 microns. Preferably, the particles have a mass median aerodynamic diameter of less than 3 microns. More preferably, the particles have a mass median aerodynamic diameter of less than 2 or 1 micron(s). “In certain embodiments the particles have a mass median aerodynamic diameter of about 0.2 to about 3 microns.”.
Typically, the geometric standard deviation around the mass median aerodynamic diameter of the aerosol particles is less than 3.0. Preferably, the geometric standard deviation is less than 2.5. More preferably, the geometric standard deviation is less than 2.1.
Typically, the aerosol is formed by heating a composition containing ephedrine or fenfluramine to form a vapor and subsequently allowing the vapor to condense into an aerosol.
In a method aspect of the present invention, either ephedrine or fenfluramine is delivered to a mammal through an inhalation route. The method comprises: a) heating a composition, wherein the composition comprises at least 5 percent by weight of ephedrine or fenfluramine, to form a vapor; and, b) allowing the vapor to cool, thereby forming a condensation aerosol comprising particles, which is inhaled by the mammal. Preferably, the composition that is heated comprises at least 10 percent by weight of ephedrine or fenfluramine. More preferably, the composition comprises at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent, 99.9 percent or 99.97 percent by weight of ephedrine or fenfluramine.
Typically, the particles comprise at least 5 percent by weight of ephedrine or fenfluramine. Preferably, the particles comprise at least 10 percent by weight of ephedrine or fenfluramine. More preferably, the particles comprise at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent, 99.9 percent or 99.97 percent by weight of ephedrine or fenfluramine.
Typically, the aerosol has a mass of at least 10 μg. Preferably, the aerosol has a mass of at least 100 μg. More preferably, the aerosol has a mass of at least 200 μg.
Typically, the particles comprise less than 10 percent by weight of ephedrine or fenfluramine degradation products. Preferably, the particles comprise less than 5 percent by weight of ephedrine or fenfluramine degradation products. More preferably, the particles comprise 2.5, 1, 0.5, 0.1 or 0.03 percent by weight of ephedrine or fenfluramine degradation products.
Typically, the particles comprise less than 90 percent by weight of water. Preferably, the particles comprise less than 80 percent by weight of water. More preferably, the particles comprise less than 70 percent, 60 percent, 50 percent, 40 percent, 30 percent, 20 percent, 10 percent, or 5 percent by weight of water.
Typically, the particles of the delivered condensation aerosol have a mass median aerodynamic diameter of less than 5 microns. Preferably, the particles have a mass median aerodynamic diameter of less than 3 microns. More preferably, the particles have a mass median aerodynamic diameter of less than 2 or 1 micron(s).
Typically, the geometric standard deviation around the mass median aerodynamic diameter of the aerosol particles is less than 3.0. Preferably, the geometric standard deviation is less than 2.5. More preferably, the geometric standard deviation is less than 2.1.
Typically, where the aerosol comprises ephedrine, the delivered aerosol has an inhalable aerosol drug mass density of between 2 mg/L and 20 mg/L. Preferably, the aerosol has an inhalable aerosol drug mass density of between 2 mg/L and 15 mg/L. More preferably, the aerosol has an inhalable aerosol drug mass density of between 2 mg/L and 12.5 mg/L.
Typically, where the aerosol comprises fenfluramine, the delivered aerosol has an inhalable aerosol drug mass density of between 4 mg/L and 30 mg/L. Preferably, the aerosol has an inhalable aerosol drug mass density of between 4 mg/L and 25 mg/L. More preferably, the aerosol has an inhalable aerosol drug mass density of between 4 mg/L and 22.5 mg/L.
Typically, the delivered aerosol has an inhalable aerosol particle density greater than 10 6 particles/mL. Preferably, the aerosol has an inhalable aerosol particle density greater than 10 7 particles/mL or 10 8 particles/mL.
Typically, the rate of inhalable aerosol particle formation of the delivered condensation aerosol is greater than 10 8 particles per second. Preferably, the aerosol is formed at a rate greater than 10 9 inhalable particles per second. More preferably, the aerosol is formed at a rate greater than 10 10 inhalable particles per second.
Typically, the delivered condensation aerosol is formed at a rate greater than 0.5 mg/second. Preferably, the aerosol is formed at a rate greater than 0.75 mg/second. More preferably, the aerosol is formed at a rate greater than 1 mg/second, 1.5 mg/second or 2 mg/second.
Typically, where the condensation aerosol comprises ephedrine, between 2 mg and 20 mg of ephedrine are delivered to the mammal in a single inspiration. Preferably, between 2 mg and 15 mg of ephedrine are delivered to the mammal in a single inspiration. More preferably, between 2 mg and 12.5 mg of ephedrine are delivered in a single inspiration.
Typically, where the condensation aerosol comprises fenfluramine, between 4 mg and 30 mg of fenfluramine are delivered to the mammal in a single inspiration. Preferably, between 4 mg and 25 mg of fenfluramine are delivered to the mammal in a single inspiration. More preferably, between 4 mg and 22.5 mg of fenfluramine are delivered to the mammal in a single inspiration.
Typically, the delivered condensation aerosol results in a peak plasma concentration of ephedrine or fenfluramine in the mammal in less than 1 h. Preferably, the peak plasma concentration is reached in less than 0.5 h. More preferably, the peak plasma concentration is reached in less than 0.2, 0.1, 0.05, 0.02 or 0.01 h.
In a kit aspect of the present invention, a kit for delivering ephedrine or fenfluramine through an inhalation route to a mammal is provided which comprises: a) a composition comprising at least 5 percent by weight of ephedrine or fenfluramine; and, b) a device that forms an ephedrine or fenfluramine aerosol from the composition, for inhalation by the mammal. Preferably, the composition comprises at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent, 99.9 percent or 99.97 percent by weight of ephedrine or fenfluramine.
Typically, the device contained in the kit comprises: a) an element for heating the ephedrine or fenfluramine composition to form a vapor; b) an element allowing the vapor to cool to form an aerosol; and, c) an element permitting the mammal to inhale the aerosol.
BRIEF DESCRIPTION OF THE FIGURE
FIG. 1 shows a cross-sectional view of a device used to deliver ephedrine or fenfluramine aerosols to a mammal through an inhalation route.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
“Aerodynamic diameter” of a given particle refers to the diameter of a spherical droplet with a density of 1 g/mL (the density of water) that has the same settling velocity as the given particle.
“Aerosol” refers to a suspension of solid or liquid particles in a gas.
“Aerosol drug mass density” refers to the mass of ephedrine or fenfluramine per unit volume of aerosol.
“Aerosol mass density” refers to the mass of particulate matter per unit volume of aerosol.
“Aerosol particle density” refers to the number of particles per unit volume of aerosol.
“Amorphous particle” refers to a particle that does not contain more than 50 percent by weight of a crystalline form. Preferably, the particle does not contain more than 25 percent by weight of a crystalline form. More preferably, the particle does not contain more than 10 percent of a crystalline form.
“Condensation aerosol” refers to an aerosol formed by vaporization of a substance followed by condensation of the substance into an aerosol.
“Ephedrine” refers to 2-methylamino-1-phenyl-1-propanol.
“Ephedrine degradation product” refers to a compound resulting from a chemical modification of ephedrine. The modification, for example, can be the result of a thermally or photochemically induced reaction. Such reactions include, without limitation, oxidation and hydrolysis.
“Fenfluramine” refers to 2-ethylamino-1-(3-trifluoromethylphenyl)propane.
“Fenfluramine degradation product” refers to a compound resulting from a chemical modification of fenfluramine. The modification, for example, can be the result of a thermally or photochemically induced reaction. Such reactions include, without limitation, oxidation and hydrolysis.
“Inhalable aerosol drug mass density” refers to the aerosol drug mass density produced by an inhalation device and delivered into a typical patient tidal volume.
“Inhalable aerosol mass density” refers to the aerosol mass density produced by an inhalation device and delivered into a typical patient tidal volume.
“Inhalable aerosol particle density” refers to the aerosol particle density of particles of size between 100 nm and 5 microns produced by an inhalation device and delivered into a typical patient tidal volume.
“Mass median aerodynamic diameter” or “MMAD” of an aerosol refers to the aerodynamic diameter for which half the particulate mass of the aerosol is contributed by particles with an aerodynamic diameter larger than the MMAD and half by particles with an aerodynamic diameter smaller than the MMAD.
“Rate of aerosol formation” refers to the mass of aerosolized particulate matter produced by an inhalation device per unit time.
“Rate of inhalable aerosol particle formation” refers to the number of particles of size between 100 nm and 5 microns produced by an inhalation device per unit time.
“Rate of drug aerosol formation” refers to the mass of aerosolized ephedrine or fenfluramine produced by an inhalation device per unit time.
“Settling velocity” refers to the terminal velocity of an aerosol particle undergoing gravitational settling in air.
“Typical patient tidal volume” refers to 1 L for an adult patient and 15 mL/kg for a pediatric patient.
“Vapor” refers to a gas, and “vapor phase” refers to a gas phase. The term “thermal vapor” refers to a vapor phase, aerosol, or mixture of aerosol-vapor phases, formed preferably by heating.
Formation of Ephedrine or Fenfluramine Containing Aerosols
Any suitable method is used to form the aerosols of the present invention. A preferred method, however, involves heating a composition comprising ephedrine or fenfluramine to form a vapor, followed by cooling of the vapor such that it condenses to provide an ephedrine or fenfluramine comprising aerosol (condensation aerosol). The composition is heated in one of four forms: as pure active compound (i.e., pure ephedrine or fenfluramine); as a mixture of active compound and a pharmaceutically acceptable excipient; as a salt form of the pure active compound; and, as a mixture of active compound salt form and a pharmaceutically acceptable excipient.
Salt forms of ephedrine or fenfluramine are either commercially available or are obtained from the corresponding free base using well known methods in the art. A variety of pharmaceutically acceptable salts are suitable for aerosolization. Such salts include, without limitation, the following: hydrochloric acid, hydrobromic acid, acetic acid, maleic acid, formic acid, and fumaric acid salts.
Pharmaceutically acceptable excipients may be volatile or nonvolatile. Volatile excipients, when heated, are concurrently volatilized, aerosolized and inhaled with ephedrine or fenfluramine. Classes of such excipients are known in the art and include, without limitation, gaseous, supercritical fluid, liquid and solid solvents. The following is a list of exemplary carriers within the classes: water; terpenes, such as menthol; alcohols, such as ethanol, propylene glycol, glycerol and other similar alcohols; dimethylformamide; dimethylacetamide; wax; supercritical carbon dioxide; dry ice; and mixtures thereof.
Solid supports on which the composition is heated are of a variety of shapes. Examples of such shapes include, without limitation, cylinders of less than 1.0 mm in diameter, boxes of less than 1.0 mm thickness and virtually any shape permeated by small (e.g., less than 1.0 mm-sized) pores. Preferably, solid supports provide a large surface to volume ratio (e.g., greater than 100 per meter) and a large surface to mass ratio (e.g., greater than 1 cm 2 per gram).
A solid support of one shape can also be transformed into another shape with different properties. For example, a flat sheet of 0.25 mm thickness has a surface to volume ratio of approximately 8,000 per meter. Rolling the sheet into a hollow cylinder of 1 cm diameter produces a support that retains the high surface to mass ratio of the original sheet but has a lower surface to volume ratio (about 400 per meter).
A number of different materials are used to construct the solid supports. Classes of such materials include, without limitation, metals, inorganic materials, carbonaceous materials and polymers. The following are examples of the material classes: aluminum, silver, gold, stainless steel, copper and tungsten; silica, glass, silicon and alumina; graphite, porous carbons, carbon yarns and carbon felts; polytetrafluoroethylene and polyethylene glycol. Combinations of materials and coated variants of materials are used as well.
Where aluminum is used as a solid support, aluminum foil is a suitable material. Examples of silica, alumina and silicon based materials include amphorous silica S-5631 (Sigma, St. Louis, Mo.), BCR171 (an alumina of defined surface area greater than 2 m 2 /g from Aldrich, St. Louis, Mo.) and a silicon wafer as used in the semiconductor industry. Carbon yarns and felts are available from American Kynol, Inc., New York, N.Y. Chromatography resins such as octadecycl silane chemically bonded to porous silica are exemplary coated variants of silica.
The heating of the ephedrine or fenfluramine compositions is performed using any suitable method. Examples of methods by which heat can be generated include the following: passage of current through an electrical resistance element; absorption of electromagnetic radiation, such as microwave or laser light; and, exothermic chemical reactions, such as exothermic solvation, hydration of pyrophoric materials and oxidation of combustible materials.
Delivery of Ephedrine or Fenfluramine Containing Aerosols
Ephedrine or fenfluramine containing aerosols of the present invention are delivered to a mammal using an inhalation device. Where the aerosol is a condensation aerosol, the device has at least three elements: an element for heating an ephedrine or fenfluramine containing composition to form a vapor; an element allowing the vapor to cool, thereby providing a condensation aerosol; and, an element permitting the mammal to inhale the aerosol. Various suitable heating methods are described above. The element that allows cooling is, in it simplest form, an inert passageway linking the heating means to the inhalation means. The element permitting inhalation is an aerosol exit portal that forms a connection between the cooling element and the mammal's respiratory system.
One device used to deliver the ephedrine or fenfluramine containing aerosol is described in reference to FIG. 1 . Delivery device 100 has a proximal end 102 and a distal end 104 , a heating module 106 , a power source 108 , and a mouthpiece 110 . An ephedrine or fenfluramine composition is deposited on a surface 112 of heating module 106 . Upon activation of a user activated switch 114 , power source 108 initiates heating of heating module 106 (e.g, through ignition of combustible fuel or passage of current through a resistive heating element). The ephedrine or fenfluramine composition volatilizes due to the heating of heating module 106 and condenses to form a condensation aerosol prior to reaching the mouthpiece 110 at the proximal end of the device 102 . Air flow traveling from the device distal end 104 to the mouthpiece 110 carries the condensation aerosol to the mouthpiece 110 , where it is inhaled by the mammal.
Devices, if desired, contain a variety of components to facilitate the delivery of ephedrine or fenfluramine containing aerosols. For instance, the device may include any component known in the art to control the timing of drug aerosolization relative to inhalation (e.g., breath-actuation), to provide feedback to patients on the rate and/or volume of inhalation, to prevent excessive use (i.e., “lock-out” feature), to prevent use by unauthorized individuals, and/or to record dosing histories.
Dosage of Ephedrine or Fenfluramine Containing Aerosols
Ephedrine and fenfluramine are given at strengths of 10 mg and 20 mg respectively for appetite suppression. As aerosols, 2 mg to 20 mg of ephendrine, and 4 mg to 30 mg of fenfluramine are generally provided per inspiration for the same indication. A typical dosage of an ephedrine or fenfluramine aerosol is either administered as a single inhalation or as a series of inhalations taken within an hour or less (dosage equals sum of inhaled amounts). Where the drug is administered as a series of inhalations, a different amount may be delivered in each inhalation. The dosage amount of ephedrine or fenfluramine in aerosol form is generally no greater than twice the standard dose of the drug given orally.
One can determine the appropriate dose of ephedrine or fenfluramine containing aerosols to treat a particular condition using methods such as animal experiments and a dose-finding (Phase I/II) clinical trial. One animal experiment involves measuring plasma concentrations of drug in an animal after its exposure to the aerosol. Mammals such as dogs or primates are typically used in such studies, since their respiratory systems are similar to that of a human. Initial dose levels for testing in humans is generally less than or equal to the dose in the mammal model that resulted in plasma drug levels associated with a therapeutic effect in humans. Dose escalation in humans is then performed, until either an optimal therapeutic response is obtained or a dose-limiting toxicity is encountered.
Analysis of Ephedrine or Fenfluramine Containing Aerosols
Purity of an ephedrine or fenfluramine containing aerosol is determined using a number of methods, examples of which are described in Sekine et al., Journal of Forensic Science 32:1271–1280 (1987) and Martin et al., Journal of Analytic Toxicology 13:158–162 (1989). One method involves forming the aerosol in a device through which a gas flow (e.g., air flow) is maintained, generally at a rate between 0.4 and 60 L/min. The gas flow carries the aerosol into one or more traps. After isolation from the trap, the aerosol is subjected to an analytical technique, such as gas or liquid chromatography, that permits a determination of composition purity.
A variety of different traps are used for aerosol collection. The following list contains examples of such traps: filters; glass wool; impingers; solvent traps, such as dry ice-cooled ethanol, methanol, acetone and dichloromethane traps at various pH values; syringes that sample the aerosol; empty, low-pressure (e.g., vacuum) containers into which the aerosol is drawn; and, empty containers that fully surround and enclose the aerosol generating device. Where a solid such as glass wool is used, it is typically extracted with a solvent such as ethanol. The solvent extract is subjected to analysis rather than the solid (i.e., glass wool) itself. Where a syringe or container is used, the container is similarly extracted with a solvent.
The gas or liquid chromatograph discussed above contains a detection system (i.e., detector). Such detection systems are well known in the art and include, for example, flame ionization, photon absorption and mass spectrometry detectors. An advantage of a mass spectrometry detector is that it can be used to determine the structure of ephedrine or fenfluramine degradation products.
Particle size distribution of an ephedrine or fenfluramine containing aerosol is determined using any suitable method in the art (e.g., cascade impaction). An Andersen Eight Stage Non-viable Cascade Impactor (Andersen Instruments, Smyrna, Ga.) linked to a furnace tube by a mock throat (USP throat, Andersen Instruments, Smyrna, Ga.) is one system used for cascade impaction studies.
Inhalable aerosol mass density is determined, for example, by delivering a drug-containing aerosol into a confined chamber via an inhalation device and measuring the mass collected in the chamber. Typically, the aerosol is drawn into the chamber by having a pressure gradient between the device and the chamber, wherein the chamber is at lower pressure than the device. The volume of the chamber should approximate the tidal volume of an inhaling patient.
Inhalable aerosol drug mass density is determined, for example, by delivering a drug-containing aerosol into a confined chamber via an inhalation device and measuring the amount of active drug compound collected in the chamber. Typically, the aerosol is drawn into the chamber by having a pressure gradient between the device and the chamber, wherein the chamber is at lower pressure than the device. The volume of the chamber should approximate the tidal volume of an inhaling patient. The amount of active drug compound collected in the chamber is determined by extracting the chamber, conducting chromatographic analysis of the extract and comparing the results of the chromatographic analysis to those of a standard containing known amounts of drug.
Inhalable aerosol particle density is determined, for example, by delivering aerosol phase drug into a confined chamber via an inhalation device and measuring the number of particles of given size collected in the chamber. The number of particles of a given size may be directly measured based on the light-scattering properties of the particles. Alternatively, the number of particles of a given size is determined by measuring the mass of particles within the given size range and calculating the number of particles based on the mass as follows: Total number of particles=Sum (from size range 1 to size range N) of number of particles in each size range. Number of particles in a given size range=Mass in the size range/Mass of a typical particle in the size range. Mass of a typical particle in a given size range=π*D 3 *φ/6, where D is a typical particle diameter in the size range (generally, the mean boundary MMADs defining the size range) in microns, φ is the particle density (in g/mL) and mass is given in units of picograms (g −12 ).
Rate of inhalable aerosol particle formation is determined, for example, by delivering aerosol phase drug into a confined chamber via an inhalation device. The delivery is for a set period of time (e.g., 3 s), and the number of particles of a given size collected in the chamber is determined as outlined above. The rate of particle formation is equal to the number of 100 nm to 5 micron particles collected divided by the duration of the collection time.
Rate of aerosol formation is determined, for example, by delivering aerosol phase drug into a confined chamber via an inhalation device. The delivery is for a set period of time (e.g., 3 s), and the mass of particulate matter collected is determined by weighing the confined chamber before and after the delivery of the particulate matter. The rate of aerosol formation is equal to the increase in mass in the chamber divided by the duration of the collection time. Alternatively, where a change in mass of the delivery device or component thereof can only occur through release of the aerosol phase particulate matter, the mass of particulate matter may be equated with the mass lost from the device or component during the delivery of the aerosol. In this case, the rate of aerosol formation is equal to the decrease in mass of the device or component during the delivery event divided by the duration of the delivery event.
Rate of drug aerosol formation is determined, for example, by delivering an ephedrine or fenfluramine containing aerosol into a confined chamber via an inhalation device over a set period of time (e.g., 3 s). Where the aerosol is pure ephedrine or fenfluramine, the amount of drug collected in the chamber is measured as described above. The rate of drug aerosol formation is equal to the amount of ephedrine or fenfluramine collected in the chamber divided by the duration of the collection time. Where the ephedrine or fenfluramine containing aerosol comprises a pharmaceutically acceptable excipient, multiplying the rate of aerosol formation by the percentage of ephedrine or fenfluramine in the aerosol provides the rate of drug aerosol formation.
Utility of Ephedrine or Fenfluramine Containing Aerosols
The ephedrine or fenfluramine containing aerosols of the present invention are typically used for appetite suppression, for increasing one's energy level, or for a positive inotropic effect.
The following examples are meant to illustrate, rather than limit, the present invention.
Ephedrine and fenfluramine hydrochloride are commercially available from Sigma (www.sigma-aldrich.com).
EXAMPLE 1
General Procedure for Obtaining Free Base of a Compound Salt
Approximately 1 g of salt (e.g., mono hydrochloride) is dissolved in deionized water (˜30 mL). Three equivalents of sodium hydroxide (1 N NaOH aq ) is added dropwise to the solution, and the pH is checked to ensure it is basic. The aqueous solution is extracted four times with dichloromethane (˜50 mL), and the extracts are combined, dried (Na 2 SO 4 ) and filtered. The filtered organic solution is concentrated using a rotary evaporator to provide the desired free base. If necessary, purification of the free base is performed using standard methods such as chromatography or recrystallization.
EXAMPLE 2
General Procedure for Volatilizing Compounds from Halogen Bulb
A solution of drug in approximately 120 μL dichloromethane is coated on a 3.5 cm×7.5 cm piece of aluminum foil (precleaned with acetone). The dichloromethane is allowed to evaporate. The coated foil is wrapped around a 300 watt halogen tube (Feit Electric Company, Pico Rivera, Calif.), which is inserted into a glass tube sealed at one end with a rubber stopper. Running 60 V of alternating current (driven by line power controlled by a variac) through the bulb for 6 s or 90 V for 3.5 s affords thermal vapor (including aerosol), which is collected on the glass tube walls. Reverse-phase HPLC analysis with detection by absorption of 225 nm light is used to determine the purity of the aerosol. (When desired, the system is flushed through with argon prior to volatilization.)
Ephedrine aerosol (7.26 mg) was obtained in approximately 99% purity using this procedure, while fenfluramine aerosol (˜10 mg) was obtained in approximately 100% purity.
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The present invention relates to the delivery of stimulants through an inhalation route. Specifically, it relates to aerosols containing stimulants that are used in inhalation therapy. In a method aspect of the present invention, a stimulant is delivered to a patient through an inhalation route. The method comprises: a) heating a coating of a stimulant, on a solid support, to form a vapor; and, b) passing air through the heated vapor to produce aerosol particles having less than 5% stimulant degradation products. In a kit aspect of the present invention, a kit for delivering a stimulant through an inhalation route is provided which comprises: a) a coating of a stimulant drug and b) a device for dispensing said coating a stimulant as a condensation aerosol.
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This is a continuation, of application Ser. No. 08/056,482, filed May 3, 1993, now U.S. Pat. No. 5,750,659 which in turn is a continuation of Ser. No. 07/806,771, filed Dec. 6, 1991, now abandoned, which in turn is a continuation of Ser. No. 07/177,506, filed Apr. 4, 1988, now abandoned, which in turn is a continuation-in-part of Ser. No. 07/062,925, filed Jun. 16, 1987, now abandoned.
The United States Government has rights to this invention by virtue of grant No. CA-42568 from the National Institutes of Health.
BACKGROUND OF THE INVENTION
This invention is related to a novel polypeptide having mammalian growth factor activity and to methods for using it.
A variety of diffusible factors which stimulate the growth of cells in a hormone-like manner are generally called “growth factors”. Growth factors are present in serum and have also been isolated from a variety of organs. They are protein molecules (or groups of such molecules) and in all known cases they interact with specific cell surface receptors to promote cellular growth and/or differentiation. Growth factors vary in their tissue specificity, i.e. some interact only with specific cell types, while others are active on a wider cell type range.
Among the best known groups of growth factors are: (1) platelet derived growth factor (PDGF), released from platelets; (2) epidermal growth factor (EGF); (3) hematopoietic growth factors (including interleukins 1, 2, and 3), required for growth and differentiation of lymphocytes, and colony stimulating factors (CSF), promoting growth and differentiation of hematopoietic stem cells; (4) angiogenic (literally “blood-vessel-forming”) growth factors, such as the fibroblast growth factors (FGF) believed to promote growth and organization of endothelial cells into new blood vessels; (5) a variety of growth factors released by tumor cells and falling into two groups: alpha and beta, corresponding to their chains.
The only well-characterized angiogenic factors are basic and acidic fibroblast growth factors (FGF); believed to be most important in vivo for endothelial cell growth.
It is known that the oncogene that is characteristic of simian sarcoma virus encodes the B chain of PDGF. However, none of the remaining growth factors mentioned above are produced by oncogenes. Nor do other known oncogenes produce growth factors.
Growth factors are believed to promote wound healing. For example, EGF present in saliva is believed to accelerate wound healing in mice. Schultz G. S et al ( Science 232:350-352, 1986) report that transforming growth factor (TGF)-alpha and vaccinia virus growth factor (VGF), both of which are substantially homologous to EGF, accelerated epidermal wound healing in pigs when topically applied to second degree burns and were significantly more active than EGF.
Of the above-mentioned growth factors, the angiogenic growth factors would be particularly useful as wound healing agents because of their ability to promote the formation and growth of new blood vessels. Preliminary evidence indicates that the two known (sequenced) angiogenic growth factors, basic and acidic FGF (so named due to the total net charge on the molecules) may be of use as wound healing agents.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide a growth factor useful as a wound healing agent in mammals.
It is another object of the present invention to provide a mammalian growth factor with a tissue specificity wider than either acidic or basic FGF.
Another object is to provide novel pharmaceutical formulations and methods for promoting would healing.
These and other objects of the present invention will be apparent to those of ordinary skill in the art in light of the present description, accompanying claims and appended drawings.
SUMMARY OF THE INVENTION
The present inventors have unexpectedly discovered a single polypeptide which displays substantial homology to each of basic and acidic fibroblast growth factor, said polypeptide having growth factor activity and having an amino acid sequence consisting essentially of the amino acid sequence of the expression product of a fragment of an oncogene isolated from Kaposi's sarcoma DNA. In another aspect, the present invention is directed to a DNA molecule coding for the above polypeptide.
In yet another aspect, the present invention is directed to methods for promoting the healing of mammalian wounds or burns comprising administering to a mammal in need of such treatment a healing-promoting effective amount of the above polypeptide and to pharmaceutical formulations comprising said polypeptide and a pharmaceutically acceptable carrier or diluent.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of the organization of the human DNA sequences (and probes made thereto) inserted into the mouse genome in the secondary Neo-2 transformant.
FIG. 2 is a schematic representation of the specific region of human DNA sequences shown in FIG. 1 encoding the polypeptide of the present invention.
FIGS. 3A and 3B are autoradiographs of Northern blots showing the novel mRNA species encoding the polypeptide of the present invention.
FIGS. 4A-C are schematic representations of the plasmids used in cloning the genomic DNA fragments and the cDNA encoding the polypeptide of the present invention.
FIGS. 5A-D are series of photographs demonstrating the promotion of growth in agar of hamster BHK-21 cells superimposed on a layer of cells transformed in accordance with present the invention.
FIGS. 6A and 6B are autoradiographs of sodium dodecyl sulfate polyacrylamide (SDS-PAGE) gels demonstrating the expression of the polypeptide of the present invention as a fusion protein in bacteria.
FIGS. 7A and 7B are graphs demonstrating the growth-promoting effects of the polypeptide of the present invention on the growth of NIH3T3 cells.
FIG. 8 is an autoradiograph of an SDS-PAGE gel demonstrating the production of the polypeptide of the present invention by transfected COS cells, and its specific immunoprecipitation by rabbit antibodies directed against said polypeptide.
FIGS. 9A-C are autoradiographs of SDS-PAGE gels showing the secretion of the polypeptide of the present invention in the absence (A) or presence (B) of tunicamycin and of the in vitro translation product (C) which was immunoprecipitated by rabbit antibodies directed against the polypeptide of the present invention. Presented in FIG. 9D is the amino acid sequence of the polypeptide showing the sites of glycosylation, cleavage of the signal sequence and potential sites of intramolecular disulfide bonds.
FIGS. 10A-D are autoradiographs an SDS-PAGE gels showing the kinetics of secretion of the polypeptide of the present invention, after a 1 hour pulse (A), a 1 hour chase (B), a 7 hour chase (C) or a 19 hour chase (D) and its stabilization by heparin.
FIG. 11 is a graph showing the induction of plasminogen activator by bovine capillary endothelial (BCE) cells treated with the polypeptide of the present invention.
FIG. 12 is a bar graph showing the induction of DNA synthesis in BCE cells treated with either basic fibroblast growth factor or the polypeptide of the present invention.
FIG. 13 is a bar graph showing the effect of the polypeptide of the present invention on the proliferation of human umbilical cord endothelial cells (HUVE) in culture and its potentiation by heparin.
DETAILED DESCRIPTION OF THE INVENTION
The present inventors have unexpectedly isolated a gene coding for a mammalian growth factor. The growth factor gene was produced when the DNA isolated from a Kaposi's Sarcoma (KS) skin lesion, obtained from a patient suffering from AIDS, was transfected into mouse cells. Kaposi's Sarcoma (KS) is a multifocal neoplastic disorder common in patients suffering from acquired immune deficiency syndrome (AIDS), and also found in other immunosuppressed individuals.
The gene of the present invention may be a novel human oncogene and one of its protein products is significantly homologous to each of the two well-known angiogenic growth factors, basic and acidic FGF and has growth factor activity. The oncogene which is “activated” in KS cells has not been heretofore identified.
The gene coding for the growth factor polypeptide of the present invention was isolated by transfecting DNA extracted from KS skin lesions of an AIDS patient into mouse NIH3T3 cells (available as ATCC CRL 1658, American Type Culture Collection, Rockville, Md.). The transfected cells' ability to produce transformed foci when cultured in vitro was then determined.
A transformed focus is a distinct clustering of visually identifiable cells arising from the uncontrolled growth of tumorigenic cells. Any cells capable of taking up and expressing foreign DNA can be employed as the recipient (the recipient cells are hereinafter referred to as primary transformants) of the DNA sequences, such as rat F2408, hamster BHK-21 or preferably mouse NIH3T3 cells.
In a preferred embodiment of the present invention, the DNA sequences encoding the growth factor can be isolated from the primary transformants and transferred to normal NIH3T3 cells in a second round of transfection (hereinafter referred to as secondary transformants) with a selectable genetic marker. The selectable genetic marker can be any gene which confers a selective growth advantage to the recipient cell. Suitable selectable markers include, but are not limited to, resistance to the antibiotic hygromycin, and preferably resistance to the antibiotic neomycin or G418 (GIBCO, Grand Island, N.Y.). Cells which are transfected by both the DNA sequence encoding the growth factor of the present invention and, for example a gene encoding resistance to G418, can then be selected for their ability to grow in the presence of concentrations of about 250 micrograms per ml of G418 present in the growth medium.
After the secondary transformants were selected for their ability to grow in the presence of neomycin, or G418 and those cells which had been transformed to the neoplastic state isolated, the human DNA sequences which had been taken up and integrated into the mouse genome were identified, molecularly cloned, using an appropriate vector (EMBL3, described in Frischauf, A. M. et al, J. Mol. Biol . 170: 827-842, 1983) although other vectors could have been used, and mapped by restriction endonuclease digestion, as detailed in Example 2 below. The sequences encoded in this DNA region which are transcribed into mRNA (and, presumably into protein) in these cells were identified employing the well-known Northern hybridization technique with probes obtained by restriction endonuclease digesting the cloned vector-DNA.
Two unique mRNAs, 1.2 and 3.5 Kb in length were identified, of which the 1.2 Kb species encodes the growth factor of the present invention. The sequence of this 1.2 Kb MRNA is shown in Example 5 below. The 1.2 Kb species was found to encode a polypeptide with mammalian growth factor activity. A comparison of this sequence with the known growth factor sequences revealed that it displayed substantial sequence homology with both basic and acidic FGF.
In order to determine whether a novel oncogene had been identified following the DNA mediated gene transfection, a comparison with other known viral and cellular oncogenes was performed.
The transforming DNA sequence m-RNA of the present invention did not demonstrate any sequence homology to Human Immunodeficiency Virus (the causative agent of AIDS) or cytomegalovirus DNA as well as herpes virus DNA (viruses which commonly infect AIDS patients cells, the source of the DNA sequences of the present invention). In addition, probes corresponding to a number of viral and cellular oncogenes did not hybridize (i.e. no significant sequence homology existed) with the following known oncogenes: three ras oncogenes, myc, sis, erbB, Rel, raf, myb, p53, mos and fos. However, a probe corresponding to the oncogene v-fms (isolated from feline sarcoma virus) revealed a region of homology in the cloned (i.e. 32 Kb) genomic DNA sequences. This region (indicated in FIG. 1) was homologous to a portion of the cellular fms oncogene but it is not transcribed (i.e. these sequences are not present in the novel mRNA specie described above). Therefore, the fms oncogene is not responsible for the growth factor activity of the present invention. However, the c-fms DNA sequences may contain elements which activate the expression of the growth factor sequences in the original genomic configuration in the transformants.
Once isolated, the DNA encoding the growth factor of the present invention can be cloned and the protein can be expressed in any eukaryotic or prokaryotic system known in the art. Eukaryotic expression systems, such as yeast expression vectors (described by Brake, A. et al, Proc. Nat. Acad. Sci. USA 81: 4642-4646, 1984), Polyoma virus based expression vectors (described in Kern, F. G. et al Gene 43: 237-245, 1986) or Simian virus 40 (SV40) based expression vectors in COS-1 Simian cells (as described in Gething, M. J. et al Nature 293: 620-625, 1981) are preferred because they are capable of secretion and of performing modifications (such as glycosylation) necessary for the production of eukaryotic proteins in their “natural” state, and do so at a high efficiency. Also, the nucleotide sequences of the growth factor of the present invention presented in Example 5 below can be used to chemically synthesize the gene using techniques known in the art.
The sequence of the expression product of the present invention has been derived from the DNA sequence. The polypeptide of the present invention can be prepared by techniques known in the art. In addition, by routine experimentation (involving modification of the DNA sequences) the minimum polypeptide sequence having growth factor activity can be identified. In addition, other modifications to the amino acid sequence of the present polypeptide may be made provided that they do not affect the growth factor activity of said polypeptide. The polypeptide of the present invention has a sequence that corresponds to the expression product of a fragment of the oncogene from which the present polypeptide was identified. This is an advantage because the entire expression product of the oncogene need not be produced. Without wishing to be bound by theory, it is believed that the polypeptide of the present invention is similar to, if not identical with, its cellular protooncogene.
The present inventors have also found that the growth factor of the present invention stimulated proliferation and plasminogen activator production in endothelial cells in culture. It has also been found that heparin is required for the above-mentioned effects to be manifested in endothelial cells, but not in cells of fibroblast origin. In human cord vein endothelia, heparin potentiates the effect, but is not essential. It is believed that heparin may protect the mammalian growth factor from degradation and/or assist in the formation of a temperature table complex. Therefore, pharmaceutical formulations comprising the mammalian growth factor of the present invention may also contain an effective amount of heparin or fragments thereof as a stabilizing agent. The amount of heparin to be added can be obtained by routine experimentation well known in the art.
Studies described below in Example 9 show that the mammalian growth factor of the present invention may be provided as a secreted glycoprotein and is processed in mammalian cells so that approximately 30 amino acids (representing a signal sequence) are removed in order to form the mature protein. Therefore, the mammalian growth factor can be obtained from the conditioned medium of mammalian cells transfected with the DNA sequences encoding this glycoprotein, such as COS-1 cells described below.
The mammalian growth factor of the present invention can be employed as a wound-healing agent for various wounds, such as decubitus ulcers or burns. When employed as a wound or burn healing agent, the growth factor of the present invention may be administered to a mammal in need of such treatment orally, parenterally, or preferably, topically, directly to the affected area in amounts broadly ranging between about 10 nanograms and about 10 micrograms per dose. The number of treatments and the duration can vary from individual to individual depending upon the severity of the wound or burn. A typical treatment would comprise 2 or 3 applications per day, topically administered directly to the wound or burn.
The growth factor of the present invention can be prepared in pharmaceutical formulations to be used as a wound or burn healing agent. Pharmaceutical formulations comprising the mammalian growth factor of the present invention (or physiologically acceptable salts thereof) as at least one of the active ingredients, would in addition contain pharmaceutically-acceptable carriers, diluents, fillers, salts and other materials well-known in the art depending upon the dosage form utilized. For example, parenteral dosage forms would comprise a physiologic, sterile saline solution. Such formulations may also contain heparin or fragments thereof as stabilizing agents. In a particularly preferred embodiment, the mammalian growth factor of the present invention may be mixed with antibiotic creams (such as Silvadene, Marion Laboratories, Kansas City, Mich., Achromycin, Lederle Laboratories, Pearl River, N.Y., or Terramycin, Pfipharmecs, New York, N.Y.) well-known in the art.
Although the growth factor of the present invention is particularly useful as a wound or burn healing agent, it additionally can be employed as a growth promoting agent for cells in tissue culture and/or as a partial serum substitute. The growth-promoting properties are illustrated in Example-6 below.
The invention is described further below and specific examples which are intended to illustrate the present invention without limiting its scope.
EXAMPLE 1: TRANSFECTION OF NIH3T3 CELLS
High molecular weight DNA was extracted from one KS skin lesion, as described in Delli Bovi, P. et al, Cancer Res . 46: 6333-6338, 1986, (incorporated by reference) and transfected into NIH3T3 cells using the well-known calcium phosphate precipitation technique (Graham, F. L. et al Virology 52: 456-467, 1973). A distinct focus of highly retractile cells was produced over the background of non-transfected NIH3T3 cells indicating the presence of transformed cells. To insure the homogeneity of the cell population, cells from the primary focus were recloned in agar suspension medium (Stoker, M. et al Nature 203: 1355-1357, 1964 incorporated by reference) since only transformed cells are capable of such growth.
Southern blot hybridization, performed with the Blur-8 plasmid (Jelinek, W. R. et al Proc. Nat. Acad. Sci. USA 77: 1398-1402, 1980 incorporated by reference), containing DNA sequences representative of the AluI family of repetitive DNA (a repetitive DNA sequence present in and indicative of DNA isolated from human cells), revealed that all cells which were transformed were capable of growth in agar had acquired human DNA sequences.
Cells from one agar colony isolated as above, were injected into athymic mice (106 cells per mouse) and two out of three mice developed tumors. DNA from one of the tumors (A15T) was used to transfect NIH3T3 cells together with a selectable marker, plasmid pIW3 (Pellegrini, S. et al Cell . 36: 943-949, 1984 incorporated by reference) which contains sequences conferring resistance to the aminoglycoside antibiotic G418 (a neomycin derivative). Mammalian cells, such as NIH3T3 cells, are sensitive to and are killed by these aminoglycoside antibiotics. However, plasmid pIW3 encodes a gene which allows cells to grow in the presence of neomycin or G418. Selection for cells resistant to G418 revealed the presence of two colonies with transformed morphology, such as a disorganized piling of cell, and a loss of contact inhibition of growth, while selection for focus formation also resulted in the isolation of two morphologically transformed foci.
DNA from one of the colonies resistant to G418 was used for a third cycle of NIH3T3 transfection and again produced a small but significant number of AluI positive transformed foci. This demonstrated that the human DNA sequences identified and used to transfect NIH3T3 cells were capable of reproducibly transforming these cells, since the transformed phenotype correlated with the presence of the human AluI repetitive DNA in every stage of the assay.
EXAMPLE 2: MOLECULAR CLONING
A genomic library of DNA extracted from one of the neomycin-resistant secondary transformants (Neo-2) was constructed after endonuclease MboI partial digestion and cloned into the EMBL3 lambda phage vector (Frischauf, A. M. et al J. Mol. Biol . 170: 827-842, 1983 incorporated by reference). The library was screened for the presence of recombinant phages containing human AluI repetitive DNA by plating the recombinant phages on a lawn of phage-susceptible bacteria, and allowing them to form plaques of bacterial lysis. Phage DNA was collected from the individual lysates and transferred to nitrocellulose filters (Schleicher and Schul, Keene, NH) and hybridized with a nick-translated, 32 P-labeled purified 300 basepair BamHI restriction fragment from plasmid Blur-8 (as described in Maniatis et al, Molecular Cloning: A Laboratory Manual . Cold Spring Harbor Lab, NY, 1982). One recombinant phage (KS-2) was isolated by this procedure. Hybridization with the Blur-8 AluI plasmid and total mouse DNA revealed that it contained one AluI sequence and two stretches of repetitive mouse DNA sequences and, thus represented one of the junctions between mouse and human DNA in the secondary Neo-2 transformant.
Several restriction enzyme fragments indicated in FIG. 1 were used to perform two further rounds of screening of the same library by hybridization to the above-mentioned DNA fragments. Several recombinant phages were thus isolated which appeared to span the entire insertion of human DNA into the Neo-2 transformant. The restriction map of the human genomic DNA sequences present in the transfected cells as reconstructed from four overlapping recombinant phages among those isolated is shown in FIG. 1 .
In FIG. 1, A, B, C, D, E, F, G, H, and I in the upper part of the figure represent DNA fragments derived from the phages shown and used in the characterization of these sequences by Southern and Northern blotting analysis. The interrupted lines indicate mouse DNA. The continuous dark lines indicate human DNA. The “V” indicates the regions of joining between mouse and human DNA. Open boxes indicate regions containing mouse repetitive DNA. The hatched boxes indicate the regions containing the human AluI repetitive DNA sequences. Squiggles indicate the approximate sites of DNA rearrangements. Restriction sites are indicated as follows: E, EcoR1; B, BamHI; X, XbaI; S, SailI, Sc, SacI.
The restriction map presented in FIG. 1 encompasses approximately 32 Kb (from the X at approximately 12 Kb to just before the V at the 43 Kb marker in FIG. 1) of human DNA and contains 3 AluI sequences. Several DNA fragments derived from these sequences in FIG. 1 were used to determine the presence and arrangement of the transfected human DNA in primary and secondary transformants, as well as in normal human DNA. Southern blot hybridization using these probes revealed that all these sequences studied were present in the secondary and tertiary transformants, in the two primary tumors, and also in the DNA isolated from the primary focus (primary transformant). Restriction enzyme analysis and blot hybridization of the cloned human sequences revealed that they contained four rearrangements with respect to normal human DNA, i.e. they were derived from the junction of five DNA fragments which are normally not contiguous in the human genome.
EXAMPLE 3: TRANSCRIPTION OF HUMAN SEQUENCES PRESENT IN NIH3T3 TRANSFORMANTS
In order to detect whether the specific human sequences present in the secondary NIH3T3 transformants were transcribed into mRNAs (and presumably translated into protein) in the transfected NIH3T3 cells, several of the DNA fragments indicated in FIG. 1 (A through H) were used as probes in Northern blot hybridization. Total RNA from the secondary transformants was extracted and purified by the guanidinium-cesium chloride method as described in Kern, F. G. et al Mol. Cell. Biol . 5: 797-807, 1985 incorporated by reference. Poly (A)+RNA was selected (using Hybond m-AP paper, Amersham, Arlington Heights, Ill.), and RNAs were fractionated in the presence of formaldehyde by agarose gel electrophoresis and transferred to nitrocellulose filters as described by Maniatis et al. (supra). Nucleic acid hybridization, washing and autoradiography were performed as described in Kern et al (supra). The results are shown in FIGS. 3A and 3B.
FIGS. 3A and 3B show the results of the Northern blots using probes G and H to detect novel mRNA species in transformants by hybridization to 1.5 micrograms of poly(A)+RNA prepared from NIH3T3(lane 1); secondary transformant (designated F1A1) (lane 2); secondary transformant (Neo-2) (lane 3); A15T tumor cells (lane 4); human umbilical vein endothelial cells transformed by SV40 (designated HUVE-SV, lane 5).
Probes A, B, C, D, and E (identified in FIG. 1) did not hybridize with any distinct mRNA species among the poly (A)+RNAs extracted from primary or secondary transformants. Probes F and G hybridized with two novel mRNA species of about 1.2 and 3.5 Kb (FIG. 3A) in primary and secondary transformants and also with some larger RNA species of variable length in some of the cell lines tested (e.g., lanes 2 and 3). These probes did not detect any distinct RNA species in normal, non-transfected NIH3T3 cells (lane 1) and only a faint band of approximately 4 Kb in length in the RNA extracted from human endothelial cells (lane 5,). Probe H. recognized only the longer mRNA, but not the 1.2 Kb species (FIG. 3 B). Thus, it appeared that the transcribed sequences were restricted to about 10 Kb of human DNA, and they were expressed in these two novel species of mRNA which contain common and unique sequences. An enlargement of the map of FIG. 1 showing the region encoding these sequences is shown in FIG. 2 (indicated by the arrow 5′-3′).
EXAMPLE 4: BIOLOGICAL ACTIVITY
To map more precisely the transforming DNA sequences, a 11 Kb fragment going from the left polylinker SalI (at about 28 Kb in FIG. 2) site of phage WII-1 rightward to the next SalI site (FIG. 2) was subcloned into the XhoI site of the pCD SV40 expression vector (Okayama, H. et al, Mol. Cell. Biol 3: 280-289, 1983, incorporated by reference), in both orientations with respect to the SV40 promoter, and the resulting plasmids (pCD6.6A and pCD10A, shown in FIGS. 4A and 4B) were tested for their biological activity. Both plasmids produced transformed foci on mouse NIH3T3 cells and rat F2408 cells with an efficiency comparable to that of a control plasmid (pTB-1) containing an activated ras oncogene (as described in Goldfarb, H. et al, Nature 296: 404-409, 1982 incorporated by reference).
Cells (approximately 1×10 6 per dish) were transfected using the calcium phosphate precipitation technique as described above with the plasmid DNA together with 20 micrograms of mouse carrier DNA. Each culture was then subdivided into five plates. Foci were counted at 2-3 weeks after transfection. The results are presented below in Table I.
TABLE I
Transformation of Mouse and Rat Fibroblasts
with Recombinant Plasmid DNAs
Foci/microgram DNA
Plasmids
NIH3T3
Rat F2408
EXPT. I
pCD (WII-1) 10 A*
900
192
pCD (WII-1) 10 B*
800
—
pGEM (WII-1) 10
120
—
pTB-1 (ras)
800
520
EXPT. II
pCD (WII-2) 6.6 A*
2500
150
pCD (WII-2) 6.6 B*
1400
80
pGEM (WII-2) 6.6
40
—
pTB-1
2500
400
EXPT. III
pTB-1
500
—
p9BKS3A**
2000
—
p9BKS3B**
<1
—
pCD (WII-1) 10 A
1400
—
*A and B indicate the position of the SV40 promoter/enhancer element with respect to the polarity of transcription (going from left to the right in FIG. 1) of the inserted SalI genomic fragments contained in the pCD expression vector. The “A” constructs have the SV40 promoter/enhancer in 5′ position and the “B” constructs in 3′ position.
**The p9BKS3 plasmids contain the cDNA encoding the growth factor of the present invention in the 5′-3′ polarity (A) or 3′-5′ polarity (B).
As can be seen from Table I above, the same DNA fragment was capable of producing transformed foci when inserted into the pCD and pGEM3 bacterial vector (the latter available from Promega Biotech, Madison, Wis.), but in the case of the pGEM3 vector, with about 8-fold lower efficiency.
A 6.6 Kb DNA fragment going from the left SalI site of phage WII-2 to the same SalI site used for the above-mentioned constructs FIG. 1) was also cloned using both pCD and pGEM vectors. The pCD-6.6 constructs transformed both mouse and rat cells with high efficiency similar to that of pTB-1 and that of the pCD10 plasmids, whereas the pGEM constructs were transformed with an efficiency about 40 fold lower (Experiment II, Table I). Therefore the 6.6 Kb fragment appeared to contain all of the sequences encoding a transforming gene and also a transcriptional promoter since it functioned in a plasmid vector devoid of any mammalian transcriptional regulatory elements. The higher efficiency of transformation of the pCD plasmids is probably due to the presence of the SV40 “enhancer” sequences.
EXAMPLE 5: C-DNA CLONING
To precisely identify the DNA sequences responsible for the growth factor activity of the cloned DNA products, a complementary DNA (cDNA) library was constructed from the poly(A)+RNA isolated from one of the transformants (A15T). This library was constructed in a bacteriophage lambda gt10 vector (Huynh, T. V. et al in DNA Cloninq : A Practical Approach D. Glover, ed. Vol 1: 49-78, Oxford Press, 1985 incorporated by reference), and the recombinant phages plaques (from Example 2) screened with the probes G and H (in FIG. 1 ). The library was constructed using a cDNA synthesis system (Amersham Corporation, Arlington Heights, IL) and the poly(A)+RNA obtained from the AI5T cell line isolated by the guanidiumisothiocyanate procedure as described in Example 3 above. Following methylation with EcoRI methylase and the addition of EcoRI linkers, the linkers were digested and the cDNA size-fractionated by column chromatography (A50m column, BioRad, Richmond, Calif.). The cDNA was then ligated to EcoRI digested, dephosphorylated lambda-gt10 arms (Promega Biotech, Madison, Wis.). The ligated cDNA was then packaged (using Gigapack extracts, Stratagene Cloning Systems, San Diego, Calif.) and plated, using C600 Hf1 ( E.coli ) as a host strain. A cDNA corresponding to the 1.2 Kb mRNA was isolated by plaque hybridization to probe G.
Subcloning of the cDNA insert cD3, a clone which contained the cDNA corresponding to the 1.2 Kb mRNA above, into mammalian expression vector 91023B (Kauffman, R. J. Proc. Nat. Acad. Sci. USA 82: 689-693, 1985 incorporated by reference) produced plasmid p9BKS3A and its biological activity was confirmed, i.e. it was capable of transforming NIH3T3 cells with a high efficiency upon transfection (Table I, Expt III). This cDNA was also subcloned into pGEM-3 sequencing vector (Promega Biotec, Madison, Wis.) and sequenced by the dideoxy method of Sanger, F. ( Proc. Nat. Acad. Sci. USA 74: 5463-5467, 1977 incorporated by reference) and in part by the method of Maxam, A. U. and Gilbert, W. ( Methods Enzymol 65: 499-560, 1980, incorporated by reference). The nucleotide sequence is presented below.
10 20 30 40
* * *
GG CGC GCA CTG CTC CTC AGA GTC CCA GCT CCA GCC GCG CGC TTT CCG
50 60 70 80 90
* * * * *
CCC GGC TCG CCG CTC CAT GCA GCC GGG GTA GAG CCC GGC GCC CGG GGG
100 110 120 130 140
* * * * *
CCC CGT CGC TTG CCT CCC GCA CCT CCT CGG TTG CGC ACT CCC GCC CGA
150 160 170 180 190
* * * * *
GGT CGG CCG TGC GCT CCC GCG GGA CGC CAC AGG CGC AGC TCT GCC CCC
200 210 220 230
* * * *
CAG CTT CCC GGG CGC ACT GAC CGC CTG ACC GAC GCA CGC CCT CGG GCC
240 250 260 270 280
* * * * *
GGG ATG TCG GGG CCC GGG ACG GCC GCG GTA GCG CTG CTC CCG GCG GTC
\Met Ser Gly Pro Gly Thr Ala Ala Val Ala Leu Leu Pro Ala Val
290 300 310 320 330
* * * * *
CTG CTG GCC TTG CTG GCG CCC TGG GCG GGC CGA GGG GGC GCC GCC GCA
Leu Leu Ala Leu Leu Ala Pro Trp Ala Gly Arg Gly Gly Ala Ala Ala
340 350 360 370 380
* * * * *
CCC ACT GCA CCC AAC GGC ACG CTG GAG GCC GAG CTG GAG CGC CGC TGG
Pro Thr Ala Pro Asn Gly Thr Leu Glu Ala Glu Leu Glu Arg Arg Trp
390 400 410 420 430
* * * * *
GAG AGC CTG GTG GCG CTC TCG TTG GCG CGC CTG CCG GTG GCA GCG CAG
Glu Ser Leu Val Ala Leu Ser Leu Ala Arg Leu Pro Val Ala Ala Gln
450 460 470
* * * *
CCC AAG GAG GCG GCC GTC CAG AGC GGC GCC GGC GAC TAC CTG CTG GGC
Pro Lys Glu Ala Ala Val Gln Ser Gly Ala Gly Asp Tyr Leu Leu Gly
480 490 500 510 520
* * * * *
ATC AAG CGG CTG CGG CGG CTC TAC TGC AAC GTG GGC ATC GGC TTC CAC
Ile Lys Arg Leu Arg Arg Leu Tyr Cys Asn Val Gly Ile Gly Phe His
530 540 550 560 570
* * * * *
CTC CAG GCG CTC CCC GAC GGC CGC ATC GGC GGC GCG CAC GCG GAC ACC
Leu Gln Ala Leu Pro Asp Gly Arg Ile Gly Gly Ala His Ala Asp Thr
580 590 600 610 620
* * * * *
CGC GAC AGC CTG CTG GAG CTC TCG CCC GTG GAG CGG GGC GTG GTG AGC
Arg Asp Ser Leu Leu Glu Leu Ser Pro Val Glu Arg Gly Val Val Ser
630 640 650 660 670
* * * * *
ATC TTC GGC GTG GCC AGC CGG TTC TTC GTG GCC ATG AGC AGC AAG GGC
Ile Phe Gly Val Ala Ser Arg Phe Phe Val Ala Met Ser Ser Lys Gly
680 690 700 710
* * * *
AAG CTC TAT GGC TCG CCC TTC TTC ACC GAT GAG TGC ACG TTC AAG GAG
Lys Leu Tyr Gly Ser Pro Phe Phe Thr Asp Glu Cys Thr Phe Lys Glu
720 730 740 750 760
* * * * *
ATT CTC CTT CCC AAC AAC TAC AAC GCC TAC GAG TCC TAC AAG TAC CCC
Ile Leu Leu Pro Asn Asn Tyr Asn Ala Tyr Glu Ser Tyr Lys Tyr Pro
770 780 790 800 810
* * * * *
GGC ATG TTC ATC GCC CTG AGC AAG AAT GGG AAG ACC AAG AAG GGG AAC
Gly Met Phe Ile Ala Leu Ser Lys Asn Gly Lys Thr Lys Lys Gly Asn
830 840 850 860
* * * * *
CGA GTG TCG CCC ACC ATG AAG GTC ACC CAC TTC CTC CCC AGG CTG TGA
Arg Val Ser Pro Thr Met Lys Val Thr His Phe Leu Pro Arg Leu ---
870 880 890 900 910
* * * * *
CCC TCC AGA GGA CCC TTG CCT CAG CCT CGG GAA GCC CCT GGG AGG GCA
920 930 940 950
* * * *
GTG CGA GGG TCA CCT TGG TGC ACT TTC TTC GGA TGA AGA GTT TAA TGC
960 970 980 990 1000
* * * * *
AAG AGT AGG TGT AAG ATA TTT AAA TTA ATT ATT TAA ATG TGT ATA TAT
1010 1020 1030 1040 1050
* * * * *
TGC CAC CAA ATT ATT TAT AGT TCT GCG GGT GTG TTT TTT AAT TTT CTG
1060 1070 1080 1090 1100
* * * * *
GGG GGA AAA AAA GAC AAA ACA AAA AAC CAA CTC TGA CTT TTC TGG TGC
1110 1120 1130 1140
* * * *
AAC AGT GGA GAA TCT TAC CAT TGG ATT TCT TTA ACT TGT
The above nucleotide sequence is unusual in many respects. It is extremely G-C rich (75-85%) in approximately the first 650 nucleotides (5′-3′) while its 3′ part is rich in sequences of the ATTT(A) type characteristic of unstable mRNAs. There was only one open reading frame (encoding a protein) with an in-frame ATG (the initiation codon for protein translation) which would encode a protein comprising 206 amino acids. Analysis of the predicted protein sequences revealed a significant (substantial) homology (approximately 45%) to mature bovine basic as well as human basic FGF as described by Abraham, J. A. et al ( Science 233: 545-548, 1986 ; EMBO J . 5: 2528, 1986). A less stringent (but still substantial) homology (approximately 35%) was noted with respect to bovine acidic FGF whose sequences was described in Gimenez-Gallego, G. et al, Science 230: 1385, 1985. If one takes into account not only amino acid identity, but also conserved substitutions, the deduced homology becomes higher (approximately 65% and 60% for basic and acidic FGF, respectively). The first portion of the growth factor of the present invention (approximately 70 amino acids) did not demonstrate any homology to the two FGF primary sequences and strictly speaking may not be necessary for growth factor activity. This portion contained a possible signal peptide important for secretion of secretory proteins. A comparison of the protein sequence of the growth factor of the present invention and those of bovine basic and acidic FGF is shown below in Table II.
TABLE II
BOVINE BASIC FIBROBLAST GROWTH FACTOR
1′
MSGPGTAAVALLPAVLLALLAPWAGRGGAAAPTAPNGTLEAELERRWESLVALSLARLPV
61′
AAQPKEAAVQSGAGDYLLG-IKRLRRLYCNVGIGFHLQALPDGRIGGAHADTRDSL-LEL
..:.:.. : .: .::::. : :: :. ::::..:..... . :.:
1″
PALPEDGGSGAFPPGHFKDPKRLYCKNG-GFFLRIHPDGRVDGVREKSDPHIKLQL
119′
SPVERGVVSIFGVASRFFVAMSSKGKLYGSPFFTDECTFKEILLPNNYNAYESYKYPGMF
. ::::::: :: .. ..::...:.: .: :::: : : : .::::.: : ::.. .
56″
QAEERGVVSIKGVCANRYLAMKEDGRLLASKCVTDECFFFERLESNNYNTYRSRKYSSWY
179′
IALSKNGKTKKGNRVSPTMKVTHFLPRL
.::...:. : : ...:. :.. :::
116″
VALKRTGQYKLGPKTGPGQKAILFLPMSAKS
TC,1 BOVINE ACIDIC FIBROBLAST GROWTH FACTOR
1′
MSGPGTAAVALLPAVLLALLAPWAGRGGAAAPTAPNGTLEAELERRWESLVALSLARLPV
61′
AAQPKEAAVQSGAGDYLLGIKRLRRLYCNVGIGFHLQALPDGRIGGAHADTRDSL-LELS
: . :. . :::. : :. :. :::: ..:... . . . :.:.
l″
FNLPLGNYKKPKLLYCSNG-GYFLRILPDGTVDGTKDRSDQHIQLQLC
120′
PVERGVVSIFGVASRFFVAMSSKGKLYGSPFFTDECTFKEILLPNNYNAYESYKYPGM--
. . : : : .... :.::...: ::::. ..:: : : : :.::.: : :....
48″
AESIGEVYIKSTETGQFLAMDTDGLLYGSQTPNEECLFLERLEENHYNTYISKKHAEKHW
178′
FIALSKNGKTKKGNRVSPTMKVTHFLPRL
:..:.:::..: : :. . :.. :::
108″
FVGLKKNGRSKLGPRTHFGQKAILFLPLPVSSD
A = Ala; R = Arg; N = Asn; D = Asp; C = Cys; Q = Gln; E = Glu
G = Gly; H = His; I = Ile; L = Leu; K = Lys; M = Met; F = Phe
P = Pro; S = Ser; T = Thr; W = Trp; Y = Tyr; V = Val.
In Table II, two dots between a particular set of amino acid residues indicate exact identity between the growth factor of the present invention and either one of the basic or acidic FGF, and one dot indicates a conservative substitution, e.g. substitution of the same type of amino acid. In addition, the amino acid sequence of the growth factor of the present invention is presented as the sequences numbered 1′-206′, while the FGF sequences are presented as the sequences numbered 1″-146″ and 1″-141″ for basic and acidic FGF, respectively.
EXAMPLE 6: BIOLOGICAL ACTIVITY OF MEDIUM OBTAINED BY THE GROWTH OF TRANSFECTED CELLS
In order to demonstrate that cells transfected with the 1.2 Kb cDNA sequences indeed produce the growth factor of the present invention, the media obtained from culturing the NIH3T3 transformants were tested for ability to stimulate cell proliferation and/or to induce in these cells properties typical of transformed cells in vitro (e.g. changes in morphology, ability to grow in suspension in medium containing 0.34% agar). Medium conditioned by incubating monolayer cultures of two transformed cell lines (A15T and 91B3-1) for twenty hours in Dulbecco's modified Eagle's medium (DMEM, GIBCO, Grand Island, N.Y.) plus 0.4% serum was applied to cultures of normal NIH3T3 cells which had been plated in 0.4% calf serum. The medium caused striking morphologic changes in the cells, indicative of transformed cells. When the cell number was measured after six days in culture, the control cultures (kept in 0.4% serum without any other additions) showed practically no growth during this time, while cells incubated in conditioned medium doubled in number every 48 hours.
The ability of the cells transfected with the growth factor of the present invention to secrete the protein was tested in the following manner: NIH3T3 cells transformed with p9BKS3A (shown in FIG. 4C) or the A15T primary transformant cell line were plated on the bottom of a 50 mm petri dish, allowed to grow until semi-confluent, and then covered with 7 mls of agar-containing medium. After this agar layer was hardened, a new thin layer (1.5 ml) of agar medium containing 20,000 normal hamster BHK-21 cells (available as ATCC CCL 8, American Type Culture Collection, Rockville, MD) was added. In this way the cells attached to the bottom of the dish metabolize and still grow to some extent, but they cannot enter in physical contact with the BHK-21 cells of the upper layer. Controls were BHK-21 cells without a “feeder” layer or NIH3T3 cells transformed by an “activated” ras oncogene (PTB1), an oncogene known to transform these cells. Plates were incubated at 37° C. for about twelve days. The results are shown in FIGS. 5A-D.
No agar growing colonies of BHK-21 cells were observed in negative controls (FIG. 5A) while the ras-transformed cells induced the growth of only about 100 microcolonies (FIG. 5 B). However, both the A15T cell line and cells transformed by p9BKS3A plasmids secreted a factor which induced the formation of very large colonies in 50 to 90% of the BHK-21 cells present in the agar overlay (FIGS. 5 C and 5 D).
EXAMPLE 7: EXPRESSION OF THE GROWTH FACTOR OF THE PRESENT INVENTION IN BACTERIAL CELLS
To prove conclusively that the growth factor of the present invention was encoded in the CDNA sequences (approximately 1.2 Kb in length discussed above), the sequences were expressed in E. coli under the control of an inducible bacterial expression vector.
The vector used was pEx34C (a derivative of pEx31, described in Strebel, K. et al. J. Virol . 57: 983-991, 1986 incorporated by reference) which contains the DNA sequences encoding the N-terminal 99 amino acids of the polymerase of RNA bacteriophage MS2 under the control of an inducible bacteriophage lambda PL promoter. The vector was cut with restriction endonuclease BamHI, the ends blunted using the Klenow fragment of DNA polymerase, and the blunt-end was ligated to SmaI-cut cDNA contained in the pGEM-3 vector. SmaI cuts the cDNA at nucleotide 254 (see sequence) and then downstream in the polylinker region of the pGEM-3 plasmid. Using the pEx34C vector, a fusion gene was constructed which encoded a fusion protein of approximately 30,000 daltons, comprising the first 99 amino acids of the bacteriophage MS2 polymerase followed by all amino acids encoded by the cDNA inserted except the first four. Induction of expression in the appropriate bacterial host (by raising the temperature to 42° C., as described in Strebel, et al, supra) resulted in the synthesis of large amounts of a protein of the expected molecular weight, which was absent under non-induced conditions as evidenced by SDS-PAGE of cell extracts (FIG. 6A, lane 2 at 42° C.).
In FIG. 6A, lanes 1 represent the SDS-PAGE results for bacterial extracts transformed with a vector without the cDNA; lanes 2 represent the results of extracts transformed by a cDNA-bearing vector. The arrow next to the 31 kD markers in FIG. 6A represents the position of the polypeptide of the present invention.
Since this protein, like many other bacterial fusion proteins was insoluble, the insoluble fraction of the protein extract was partially purified by extraction with 7M urea. This resulted in a protein preparation containing the fusion protein and about seven to eight other bacterial proteins (see the SDS-PAGE of cell extracts in FIG. 6B, lane 2). The fusion protein was estimated to represent about 20% of the total protein mass. After dialysis, the entire 7M urea protein extract (containing the growth factor fusion protein) was applied to normal NIH3T3 cells at various concentrations and the cells incubated in DMEM plus 0.5% serum for five days. Two controls were used involving cells which either received nothing, (except DMEM +0.5% calf serum) or cells which received the insoluble, 7M urea-extracted protein fraction from bacteria expressing only the pEx34C vector (without a cDNA insert). The results are shown graphically in FIG. 7 A.
In FIG. 7A; the symbol “-” represents no addition of extract, “A” represents addition of cell extracts from cells which received the vector without an insert, “A15” represents addition of conditioned medium from the A15T-transformed cell line mentioned above; and “C” represents addition of cell extracts from cells transformed with vectors encoding the fusion protein of the present invention. In FIG. 7A, the striped bars represent: for A15 a 1 to 2 dilution of the conditioned medium; for C an amount of bacterial extract estimated to correspond to 100 nanograms/ml of the fusion protein, and for A an equivalent amount of bacterial proteins extracted from bacteria expressing the vector alone. The solid bars in FIG. 7A represent: for A15 a 1 to 4 dilution of the conditioned medium, for C an amount of extract corresponding to 40 nanograms/ml of the fusion protein, and for A an equivalent amount of extract from bacteria expressing the vector alone.
While cells in the control cultures did not proliferate appreciably in 5 days, cells receiving the fusion protein (containing the growth factor) showed appreciable growth (FIG. 7 ), in a dose-dependent fashion. These data therefore show that a growth factor gene was isolated and that the protein it encodes was expressed in bacteria.
EXAMPLE 8: EXPRESSION OF THE MAMMALIAN GROWTH FACTOR IN MAMMALIAN CELLS
The plasmid p9BKS3A, containing the cDNA encoding the mammalian growth factor of the present invention, was transfected into monkey COS cells. COS-1 cells (Gluzman, Y. Cell . 23: 175, 1981 incorporated by reference) are a line of simian cells which constitutively express the SV40 large T antigen, and thus, any DNA molecule containing the SV40 replication origin (such as plasmid P9BKS3A) introduced into these cells can be amplified and expressed. COS cells are available as ATCC CRL 1650 and ATCC CRL 1651 from the American Type culture collection Rockville, Md.). By using such a system, the cDNA encoding the growth factor of the present invention was amplified and its gene product was overproduced.
COS cells were plated at 1×10 6 cells per petri dish and incubated overnight before transfection. Three micrograms of recombinant plasmid DNA (p9BKS3A, FIG. 4C) were transfected using the DEAE-dextran technique followed by chloroquine treatment (Luthman, H. et al Nuc. Acid Res . 11: 1265-1308, 1983) to improve the uptake of the transfected DNA. After 45 hours, the transfected cells were labeled with 35 S-methionine for two hours (200 microci per ml) and total cell lysates were prepared as follows. Cells were washed in ice cold STE buffer (15mM NaCl; 10 mM Tris pH 7.2; 1 mM EDTA) lysed in RIPA buffer (10 mM Tris pH 7.4; 0.15M NaCl; 1% sodium deoxycholate; 1% Nonidet P-40; 1 mM EDTA; 10 mM KCl; 1% APROTININ), the cell lysate was vortexed for 30 seconds and then centrifuged at 4° C. in a microfuge for 30 seconds. The supernatant was recovered and the same number of counts for each sample were analyzed by sodium dodecylsulfate polyacrylamide gel electrophoresis (SDS-PAGE). The results are shown in FIG. 8 .
In FIG. 8, the first three lanes from the left contain (1) labeled total cell extract proteins from COS cells not transfected with any DNA; (2) COS cells transfected with the vector without any inserted DNA; (3) contains labeled total proteins from cells transfected with the vector with the inserted cDNA encoding the growth factor of the present invention. The arrow between molecular weight markers 21 and 31 kD on the right side indicates the polypeptide of the present invention (very faint).
As can be seen from FIG. 8, lane 3 a band of about 24 kD not present in the control cells, was visualized. The smearing of the band is probably due to post-translational modifications such as glycosylation. When cos cell extracts were reacted with a rabbit antiserum directed against the growth factor of the present invention (raised by immunization against the bacterial fusion protein), a 24 kD protein was specifically precipitated by two different antisera A and B (right hand side of FIG. 8, labelled A and B; “N” represents preimmune and “I” represents immune serum).
Extracts of COS cells (transfected with plasmid p9BKS3A) were also applied to mouse NIH3T3 cells incubated in DMEM plus 0.5% calf serum in order to probe for growth factor activity. In FIG. 7B the cells received: no addition (−), extracts from non-transfected COS cells (COS), extracts from cells transfected with the vector alone (COS/91023B) or extracts from cells transfected with the vector encoding the growth factor of the present invention (COS/p9BKS3A). As shown in FIG. 7B, soluble protein extracts of sonically-disrupted, transfected COS cells produced a considerable increase in cell number during the four days of incubation whereas control extracts (from COS cells which were not transfected at all) did not.
Example 9: SECRETION OF THE MAMMALIAN GROWTH FACTOR FROM TRANSFECTED CELLS
To study the processing of the mammalian growth factor of the present invention, the COS-1 cells transfected with plasmid p9BKS3A of Example 8 were labeled with 35 S-methionine (1,200 Ci per mmol, New England Nuclear, Boston, Mass.) at 200 microci per ml 48-52 hours after transfection in the presence or absence of tunicamycin (Tu, 10 micrograms per ml, Calbiochem-Behring, San Diego, Calif.), cell extracts prepared as in Example 8 above), and the cell extracts or the culture media were subjected to immunoprecipitation using the rabbit antiserum specific for the mammalian growth factor of the present invention described above. The immunoprecipitates were then run on 12.5% SDS-PAGE. The results are shown in FIGS. 9A-C.
In FIGS. 9A-C, N=non-immune (or control) sera; I=immune sera. Present on the right are molecular weight markers (in kilodaltons, Kd). Present in FIG. 9D is the amino acid sequence of the polypeptide of the present invention. Arrows indicate the positions of cleavage of the pre-protein, stars under the sequence indicate potential glycosylation signals and dots indicate potential cysteine residues which could form intramolecular disulfide bonds; the underlined amino acid residues are the presumptive signal sequence.
As can be seen in FIG. 9A an appreciable proportion of the mammalian growth factor of the present invention, migrating with an apparent molecular weight of 22,000 to 23,000 Daltons, is found in the culture medium as would be expected for a secreted protein (lane 2) and was specifically immunoprecipitated with immune serum.
In addition, the mature growth factor of the present invention as produced by mammalian cells is a glycoprotein as demonstrated by the fact that incubation of cells with tunicamycin, a specific inhibitor of N-linked glycosylation, resulted in the production of a protein with a reduced apparent molecular weight (approximately 19,000 Daltons) which was not efficiently secreted (Lane 2, FIG. 9 B). The molecular weight of the protein produced in vivo in the presence of tunicamycin was compared with that of the protein translated in vitro in order to determine whether any additional processing of the mammalian growth factor of the present invention occurred, such as cleavage of the signal peptide. The mammalian growth factor RNA and an “anti-sense” RNA were transcribed in vitro using SP6 polymerase (Promega Biotech, Madison, Wis.), the resulting RNAs translated in vitro using a rabbit reticulocyte translation system (Promega Biotech), and the product immunoprecipitated with rabbit antiserum generated against the mammalian growth factor.
FIG. 9C shows that the primary in vitro translation product of the mammalian growth factor obtained from the reticulocyte translation system had a molecular weight of approximately 22,000 Daltons, in agreement with that predicted from the amino acid sequence (FIG. 9C, lane 2). This is about 3,000 Daltons higher than the unglycosylated protein produced in vivo, indicated that the primary translation product is processed to a mature form lacking approximately 30 amino acid residues. Neither non-immune serum nor the translation product of antisense RNA resulted in the immunoprecipitation of any product.
To determine whether the site of cleavage corresponds to the putative signal peptide, the N-terminus of the secreted mammalian growth factor protein was determined as described below.
COS-1 cells transfected with plasmid p9BKS3A were grown for 48 h after transfection. The cells were washed twice in phosphate-buffered saline and a small volume of media (Earle's MEM, Select Amine Kit, Difco, available from Sigma Chemical Co., St. Louis, Mo.) containing either [ 3 H]leucine or [ 3 H]arginine, replacing the corresponding cold amino acid, was added and the cells grown for a further 7 h. The media was removed, clarified by centrifugation and the mammalian growth factor was immunoprecipitated as described in Delli-Bovi et al., Cell 50: 729-737, 1987, incorporated by reference. The labeled protein was released from protein A-Sepharose 4B beads (Pharmacia Fine Chemicals, Piscataway, New Jersey) by heating at 80° C. for 10 minutes in 10 mM Tris (pH 7.6), 1 mM EDTA, 0.1% SDS. A small aliquot of this material was run on SDS-PAGE and fluorographed to verify its purity. The protein/antibody complex was precipitated with trichloroacetic acid to remove SDS, the precipitate resuspended in 50% trifluoroacetic acid, loaded directly onto a protein sequencer (Applied Biosystems model 470A) and sequenced as described in Hewick et al., J. Biol. Chem ., 256:7990, 1981, incorporated by reference. Fractions containing labeled residues were aligned with the predicted amino acid sequence to determine the amino terminal residue.
The results obtained indicated that the mature mammalian growth factor protein had two possible N terminal amino acids, either Ala31 or Pro32 (arrows under sequence in FIG. 9 D), and had lost the signal peptide. Therefore, as is the case for normal mammalian secretory proteins, the pre-protein co-translationally entered the endoplasmic reticulum (ER) through the normal secretory pathway where the signal peptide was cleaved at residue 30 or 31, and was glycosylated in the ER and the Golgi apparatus before being finally secreted into the culture medium as a mature protein of either 175 or 176 amino acids. Immunofluorescence staining of transfected COS-1 cells expressing the mammalian growth factor of the present invention provided a visual demonstration of the localization of this growth factor in the ER and cytoplasm when the cells were made permeable to the antibodies (data not shown). When the cells were fixed with formalin, most of the cross-reacting material was visualized on the cell surface (data not shown).
Example 10: SECRETION AND STABILIZATION OF THE MAMMALIAN GROWTH FACTOR BY HEPARIN
The time course of the secretion of the mammalian growth factor from COS-1 cells transfected with the p9BKS3A expression plasmid was examined. Since the biological activity of fibroblast growth factors are known to be potentiated and/or stabilized by heparin, the effect of the presence of heparin on the stability of the secreted mammalian growth factor of the present invention was examined. Cells were pulse-labeled for twenty minutes with 35 S-methionine,washed, and the label chased with an excess of cold methionine in the presence or absence of heparin (45 micrograms per ml, Sigma Chemical Co., St. Louis, Mo.). The presence of the mammalian growth factor protein contained in the cell extract (C) or the medium (M) of the transfected cultures was determined by SDS-PAGE after immunoprecipitation. Presented on the left in FIGS. 10A-D are molecular weight markers (in kilodaltons, Kd); the large arrow indicates the position of migration of the polypeptide of the present invention (approximately 23 Kd). In addition, N=non-immune (control) sera and I=immune sera. It should be noted that in all of the data presented in FIGS. 10A-D, only immune sera was capable of immunoprecipitating any product.
FIG. 10B shows that one hour after the pulse, there was an approximate 60:40 partition of the mammalian growth factor between the intracellular and the extracellular fraction, respectively, both in the presence (lanes 4-8) or absence (lanes 1-4) of heparin. After a seven hour chase (FIG. 10 C), there was a dramatic difference between the two types of cultures. In the absence of heparin (lanes 1-4), the mammalian growth factor of the present invention had practically disappeared from the culture medium (lane 4) and only a small amount of the protein remained in the cells (lane 2). In the presence of heparin (lanes 5-8), a large quantity of the mammalian growth factor could be detected in the medium. This difference was even more pronounced after a nineteen hour chase (FIG. 10 D). No labelled protein was detectable in control cultures (lanes 1-4), while those incubated with heparin (lanes 5-8) still contain a significant amount of the factor in the culture medium (lane 8). Increasing the concentration of heparin (to 90 micrograms per ml, lanes 9-12) resulted in an even higher stability of the protein (lane 12), although this effect was not always reproducible. Thus, the presence of heparin increased the half-life of the mammalian growth factor protein after secretion suggesting that it may protect the protein from protease attack and/or help in the formation of a temperature-stable complex.
The effect of the mammalian growth factor of the present invention on the growth of bovine capillary endothelial (BCE) cells was examined. The induction or plasminogen activator (PA) activity, DNA synthesis and cell proliferation in the presence of the mammalian growth factor of the present invention was compared with that obtained with basic fibroblast growth (bFGF, Amgen Biologicals, Thousand Oaks, Calif.) as these are activities known to be affected by bFGF. Plasminogen activator activity was assayed as described in Gross et al. J. Cell Biol . 95:924-981, 1982 (incorporated by reference). Conditioned medium produced by COS-1 cells transfected with the p9BKS3A plasmid was used as the source of the mammalian growth factor of the present invention. This medium effectively stimulated PA production in BCE cells if the medium was assayed in the presence of heparin (FIG. 11 ). In the absence of heparin, there was practically no stimulatory activity above that obtained by control COS-1 cell condition medium (FIG. 11 ). Heparin by itself had no stimulatory effect. Neutralizing antibodies to bFGF (as described in Presta, M. et al., Mol. Cell. Biol . 6:4060-4066, 1986) were unable to block the stimulation of PA production induced by the mammalian growth factor of the present invention. This result indicated that the stimulatory effect was not due to bFGF which might have been released from the COS-1 cells.
The culture medium from transfected COS-1 cells was also capable of stimulating DNA synthesis in growth arrested BCE cells. Confluent monolayers of BCE cells were maintained for seven days in DMEM plus 5% calf serum. The medium was then replaced with fresh DMEM plus 0.5% calf serum containing various additions detailed below. After 20 hours, the cells were labeled with 1 microCi per ml of methyl-[ 3 H]thymidine (6.7 Ci per mmol; New England Nuclear, Boston, Mass.) for 3 hours. Cells were washed twice with phosphate buffered saline and the incorporation of label into trichloroacetic acid preciptable material was determined.
The results of the above-described experiment are shown in FIG. 12 where lane 1 is control BCE cells, lane 2, BCE cells plus bFGF (10 ng per ml); lane 3, BCE cells incubated with conditioned medium (CM) from control COS-1 cells at a 1:20 dilution; lane 4, CM plus heparan (10 micrograms per ml); lane 5, BCE cells incubated with conditioned medium from COS-1 cells expressing the growth factor of the present invention (COS-K-FGF-CM) at a 1:20 dilution; lane 6, BCE cells incubated with COS-K-FGF-CM plus heparin (10 micrograms per ml).
Conditioned medium, obtained from COS-1 cells expressing the growth factor of the present invention plus heparin (FIG. 12, lane 5) was almost as stimulatory as medium supplemented with bFGF (obtained from Amgen Biologicals, Thousand Oaks, Calif.), (FIG. 12, lane 2) while medium from control cells was non-stimulatory (FIG. 12, lane 3). The proliferative effect of the mammalian growth factor of the present invention was also apparent when the number of cells was determined.
The results presented above show that the mammalian growth factor of the present invention acted as a growth factor for capillary endothelial cells in culture.
In addition FIG. 13 shows that the mammalian growth factor could also promote growth of the human endothelial cells lining large vessels. In this experiment, cultures of human umbilical cord vein endothelial cells (HUVE) were plated on multiwell dishes (each well having a surface of about 1.5 cm 2 ) in a culture medium consisting of DMEM/F12 Medium mixed 1:1 (GIBCO, Grand Island, N.Y.) supplemented with 20% fetal calf serum and either endothelial cells growth supplement at 120 micrograms/ml (ECGS, Collaborative Research, Bedford, Mass.) or the growth factor of the present invention (K-FGF, i.e. conditioned medium from COS cell transfected with the p9BKS3A plasmid diluted to a final concentration of 5%) with or without heparin (90 micrograms/ml). The media were changed every two days and the final cell number determined at day 7.
It can be seen from the data presented in FIG. 13 that the HUVE cells did not proliferate in absence of added growth factors (−) or with heparin alone (Hep.). The growth factor of the present invention (K-FGF+HEP) was approximately as effective as ECGS+heparin in promoting proliferation of HUVE cells. Although the growth promoting effect of the polypeptide of the present invention was decreased in the absence of heparin, it was still very substantial (K-FGF, FIG. 13 ).
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A homogeneous K-FGF polypeptide having a molecular weight of about 19,000 daltons when analyzed by SDS polyacrylamide gel electrophoresis, wherein the polypeptide is substantially free of oligosaccharide moieties attached to the polypeptide, appears as a single band on SDS-PAGE, exhibits a detectable level of mitogenic activity on growth arrested cells in a 3 H-thymidine uptake assay, and is substantially free from other mammalian proteins, is provided.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of extracorporeal treatment of blood by dialysis and/or by ultrafiltration. More particularly, the invention relates to a hydraulic circuit for an artificial kidney in which the dialysis-liquid circuit includes an ultrafilter intended to rid the dialysis liquid of microorganisms and possibly pyrogenic elements which it might contain.
2. Description of the Related Art
With the development of high-permeability haemodialyzers, there has been increased interest in the use of dialysis liquid having good biological properties to protect against blood contamination which may occur if portions of the dialysis liquid enter the blood stream. While exchanges in a haemodialyzer during blood purification are intended to only occur from the blood compartment toward the dialysis-liquid compartment, the possibility remains of having, on the contrary, a transfer from the dialysis liquid towards the blood. This may occur either by diffusion or by convection in situations where the pressure in the dialysis-liquid compartment becomes greater than the pressure in the blood compartment.
U.S. Pat. No. 4,834,888 discloses an artificial kidney comprising a filter for in-line sterilization of dialysis liquid before its entry into the haemodialyzer. According to this document, the filter used for sterilizing the dialysis liquid comprises two compartments separated by a membrane capable of retaining germs. The liquid coming from a dialysis-liquid source is completely filtered through this filter before entering the haemodialyzer. In order to avoid filter clogging, the compartment connected to the dialysis-liquid source is rinsed at the end of each haemodialysis session, and may also be rinsed during a session as well.
For this purpose, this compartment has an output connected to a line for draining the used dialysis liquid coming from the haemodialyzer. During the filter-rinsing phase, sterilizing the liquid by filtration is stopped, and the liquid entering the filter then sweeps along the surface of the membrane in order to detach the germs and pyrogenic elements which are deposited thereon. Thereafter, the liquid directly rejoins a line for draining the used dialysis liquid.
In order to check the integrity of the membrane of this sterilization filter, this document describes a specific test performed between two dialysis sessions. This test involves introducing air into at least one part of the dialysis-liquid circuit, and can therefore only be performed when the haemodialyzer is disconnected from the dialysis apparatus.
Thus, the device described in this document has the drawback of not allowing the integrity and efficiency of the membrane of the filter to be checked during use.
SUMMARY OF THE INVENTION
The subject of the present invention is a hydraulic circuit for an artificial kidney allowing continuous checking of the correct state of the ultrafilter without stopping its operation.
A subject of the present invention is also a hydraulic circuit for an artificial kidney allowing its user to be warned in case of clogging or breakage of the membrane filtering the dialysis liquid. For this purpose, the present invention provides a hydraulic circuit for an artificial kidney comprising at least one line connected to a dialysis-liquid source, and provided with at least one ultrafilter having two chambers separated by a membrane capable of retaining the microbial and pyrogenic elements. The first chamber is connected to a line which is connected to a dialysis-liquid source. The invention also includes means for determining the transmembrane pressure existing on either side of the membrane of the ultrafilter, means for fixing at least one threshold value for this transmembrane pressure, and means for comparing the transmembrane pressure value determined with the threshold value, in order to act on control means in the case where the transmembrane pressure value determined reaches the fixed threshold value.
Advantageously, the hydraulic circuit according to the present invention may further comprise means for sustaining a continuous tangential flow of liquid along the membrane of the ultrafilter. Thus, the deposition of microorganisms of pyrogenic elements and consequently the clogging of the membrane are reduced as much as possible thereby permitting the life of the ultrafilter to be increased while simultaneously decreasing the risk that undersirable elements will pass into the liquid entering the haemodialyzer or into the extracorporeal blood circuit, in situations where the membrane of the ultrafilter has been damaged.
According to a particular embodiment, the hydraulic circuit of the invention further comprises, downstream of the ultrafilter, means for precisely controlling the flow of liquid. Thus, whatever the pressure loss caused in the dialysis-liquid circuit by the presence of an ultrafilter, the flow rate of dialysis liquid entering the haemodialyzer or the extracorporeal blood circuit can be held constant.
According to another embodiment of the present invention, the hydraulic circuit further comprises a branch circuit allowing the dialysis liquid to short-circuit the ultrafilter. This is particularly advantageous when the liquid filtered is used as the dialysis liquid, because, when a defect in the integrity of the membrane is detected, it is not necessary to stop the treatment, but rather, it is possible to continue the session without exposing the patient to serious risks.
Other features and advantages will emerge in the description which follows, with reference to the drawing.
BRIEF DESCRIPTION OF THE FIGURE
FIG. 1 schematically illustrates an artificial kidney circuit in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, a part of the artificial kidney is diagrammatically represented (only the elements relating to the invention have been represented), which comprises a conventional haemodialyzer 1 divided by membrane 2 into two compartments 3 and 4. Blood to be treated flows through compartment 3 and dialysis liquid for purifying the blood passes through compartment 4. The circuit for circulating dialysis liquid inside the artificial kidney comprises an upstream portion 5 for conveying fresh dialysis liquid entering haemodialyzer 1 through an inlet 6, as well as a downstream portion 7 for conveying used dialysis liquid leaving haemodialyzer 1 through an outlet 8. The upstream portion 5 of the dialysis-liquid circuit consists of a mainline 9 capable of conveying fresh dialysis liquid from a source (not shown) towards the haemodialyzer. Line 9 comprises an ultrafilter 10 having an ultrafiltration membrane 11 capable of retaining microorganisms and pyrogenic elements of the dialysis liquid.
Membrane 11 therefore separates the ultrafilter 10 into two compartments; a compartment 12 for receiving fresh dialysis liquid which may be contaminated, and a compartment 13 for collecting the ultrafiltered dialysis liquid.
Compartment 12 includes an inlet opening 14 for the dialysis liquid to be filtered, connected to line 9, as well as an outlet opening 15 for the unfiltered dialysis liquid, connected to line 16, itself connected to the downstream portion 7 of the dialysis-liquid circuit. Compartment 13 of ultrafilter 10 is provided with an outlet opening 18 for the filtered liquid.
Line 9 also comprises, upstream of the ultrafilter 10, a pump 19 for circulating the dialysis liquid. According to the invention, a pressure sensor 23 is arranged in line 9, upstream of the ultrafilter and downstream of the pump 19, which pressure sensor makes it possible to continuously measure the pressure of the dialysis liquid upstream of the ultrafilter.
Similarly, a pressure sensor 24 situated between the ultrafilter 10 and the haemodialyzer 1 makes it possible to continuously measure the pressure of the filtered dialysis liquid at the output of the ultrafilter.
Advantageously, a three-way valve is arranged on either side of the ultrafilter 10. Specifically, valve 20 is situated upstream of the ultrafilter 10 but downstream of the pressure sensor 23, whereas a valve 21 is situated downstream of the ultrafilter but upstream of the pressure sensor 24. These valves 20 and 21 are directly connected to each other by a branch line 22.
A flow meter 25 as well as a circulating pump 26 are arranged downstream of the pressure sensor 24. A control unit 27 receives the information coming from the pressure sensors 23 and 24 as well as from the flow meter 25, and controls the operation of the valves 20, 21, and of the pumps 19 and 26.
The artificial kidney, as described above, operates as follows. Dialysis liquid is circulated by the action of the pump 19 whose delivery is fixed for example at 0.54 1/min, with the valves 20 and 21 being positioned such that liquid circulates through the ultrafilter 10 and not through branch line 22. More specifically, the dialysis liquid flows through line 9, then enters the ultrafilter 10.
By virtue of the action of the pump 26 whose delivery is fixed for example at 0.5 1/min, a large fraction of the liquid entering ultrafilter 10 is filtered by passage through the membrane 11 and enters haemodialyzer 1 through inlet 6. The liquid then leaves haemodialyzer 1 through opening 8 and is conveyed, by virtue of the downstream portion of the dialysis-liquid circuit, towards drainage or regeneration means (not shown).
According to one characteristic of the invention, the pressure values measured by the sensors 23 and 24 and corresponding to the pressure values on the liquid on either side of the ultrafiltration membrane 11 are transmitted during a first mode of operation of the ultrafilter to the control unit 27 which thus determines the value of the transmembrane pressure. During the first mode of operation, dialysis liquid is prefiltered through ultrafilter 10 as discussed in greater detail above. This transmembrane pressure value (TMP) is compared with one or more threshold values previously recorded by the operator in the control unit as a function of the ultrafilter used. Thus, it is possible to fix an upper threshold value corresponding to clogging of the membrane 11, and a lower threshold value corresponding to damage of the membrane, such as breakage. If the TMP value calculated reaches one or the other of the threshold values, the control unit 27 emits a threshold signal intended to warn the operator, by triggering, for example, a visual and/or acoustic alarm, or by displaying a suitable message on a screen (not shown) acting as an interface between the operator and the machine. The operator may then act manually on the control means of valves 20 and 21 in order to operate them so that the dialysis liquid no longer flows through the ultrafilter 10 but follows the branch line 22 in accordance with a second mode of operation, whereby prefiltration by ultrafilter 10 is bypassed. Thus, the threshold values demarcate a desired switch-over-point from the first mode of operation to the second mode of operation, allowing the blood-treatment session to continue with unfiltered dialysis liquid until the operator has replaced the filter.
Alternatively, the control unit 27 may directly control the operation of the valves 20 and 21 when the transmembrane pressure calculated reaches one or other of the threshold values.
According to an advantageous characteristic of the invention, a fraction of the dialysis liquid entering the ultrafilter 10 does not pass through membrane 11, but emerges directly through opening 15 in ultrafilter 10 in order to rejoin, through line 16, the used dialysis liquid coming from haemodialyzer 1. This continuous tangential flow is obtained by virtue of the difference existing between the delivery provided by pump 19 and that of pump 26. Alternatively, it is possible to provide line 16 with a low-delivery pump (not shown) which allows the rate of the tangential flow to be controlled precisely. The continuous sweeping of the ultrafiltration membrane by a tangential flow of liquid has the advantage of carrying with it microorganisms, fewer of which are deposited on the membrane. This increases the life of the ultrafilter and reduces the risk that a large amount of microbial and/or pyrogenic elements will pass to the haemodialyzer in the event that the ultrafiltration membrane is damaged.
According to another characteristic of the invention, the flow of filtered dialysis liquid through membrane 11 is controlled very precisely, by virtue of, for example, pump 26 with very precise delivery, or by the addition of a flow meter 25 that transmits information to control unit 27 which consequently controls the operation of pump 26. This slaving of pump 26 to the flow rate measured by the flow meter 25 allows the flow of dialysis liquid entering haemodialyzer 1 to be held constant.
Numerous variant embodiments are within the capability of a person skilled in the art without departing from the scope of the present invention. For example, it is possible to provide for the transmembrane pressure several upper and lower threshold values corresponding to various degrees of clogging or damage of the ultrafiltration membrane, which require different actions on the part of the operator or the machine.
Similarly, it is possible to improve the precision of the flow rate of the liquid delivered by the circulation pump 19 by adding to line 9 a flow meter (not shown) to which the operation of the pump 19 would be slaved.
The present invention has been described in its particular application to the case where the filtered liquid is used as the dialysis liquid. It is also possible to apply the invention to situations where the filtered dialysis liquid is injected as a substitution liquid into the extracorporeal blood circuit. This may be the case during haemofiltration when blood purification is performed solely by ultrafiltration without circulation of dialysis liquid on a side of the membrane opposite to the circulating blood. Alternatively the invention can be used in connection with haemodiafiltration where blood is purified both by dialysis and by ultrafiltration with reinjection of a substitution liquid into the extracorporeal blood circuit.
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A filtration device includes an ultrafilter having an inlet chamber, an outlet chamber, and an ultrafiltration membrane separating the inlet chamber from the outlet chamber. An inlet line flow connects the inlet chamber to a source of dialysis liquid. Pressure sensors determine pressure values on opposite sides of the membrane, and a controller calculates a transmembrane pressure therefrom and compares the calculated transmembrane pressure with a predetermined threshold value. If the threshold value is reached, the controller emits a threshold signal to either warn an operator or alternatively to automatically divert flow to bypass the ultrafilter.
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CROSS REFERENCE OF RELATED APPLICATION
This is a Divisional application of a non-provisional application having an application Ser. No. 10/510,198 and filing date of Sep. 29, 2004 now abandoned.
BACKGROUND OF THE PRESENT INVENTION
1. Field of Invention
The present invention relates to switch power supply, more particularly, relates to a switch power supply having current overloading proof function and it's IC.
2. Description of Related Arts
Switching power converters are used in a wide variety of applications to convert electrical power from one form to another form. For example, DC/DC converters are used to convert DC power provided at one voltage level to DC power at another voltage level and AC-DC converters are employed to convert alternate current power into direct current power. At the same time, switching power converter could be categorized into isolated or non-isolated power converter, and the basic circuit of the converter can be configured to step up (boost), step down (buck), or invert type, even CCM (continuous conduction mode) or DCM (discontinuous conduction mode).
The isolated power converter could be further classified into single ended mode (including forward and flyback converter) and double ended mode (push-pull, half bridge and full bridge converter); the converting technique comprises hard-switched converters and soft-switched converters, and the controlling techniques comprise PFM (Pulse Frequency Modulation) mode control, PWM (Pulse Width Modulation), current mode control, voltage mode control and so on.
Regardless what methods or mode are used, a switching power circuit generally comprises a converter circuit having one or more field effect transistor, a transformer or an inductance, and at least one rectifying filter output circuit, wherein the quantity of the field effect transistor is subject to the choice of power converter mode, commonly, single ended converter comprises a field effect transistor, the double ended converter comprises a plurality of field effect transistors. In case of the soft switch is applied, at least one more supplemental field effect transistor is necessary. The inductance here is being used for the simple non-isolated DC/DC converter, while the choice of the chosen converter will simultaneously determine whether the inductance, single-ended or double-ended mode, hard switching or soft switching, to be applied in practice.
Further, the switching power circuit comprises a feedback circuit having a sample circuit, an error amplifier, and occasionally a feedback isolating circuit, wherein the sample circuit is adapted for sampling the current and voltage signal from the output circuit, and sending the sampled current and voltage signal to the error amplifier to obtain a comparative value, afterwards, the error amplifier will output an error signal.
Additionally, the switching power circuit comprises a control circuit including an adjustable pulse circuit and a drive circuit, wherein the adjustable pulse circuit having PFM (pulse frequency modulation) mode, PWM mode and so on. According to the error signal, the adjustable pulse circuit is capable generating a basic pulse, for double-ended mode, there is a scaling-down complementary double pulse circuit, for soft switching multi-pulse circuit, there is a multi pulse circuit. Commonly, basic pulse, double pulse and multi-pulse are supposed to be directed into the driven circuit. It is noted that a bigger error signal will result to a larger duty cycle ratio, as well as a higher peak value of the field effect transistor current and a saturation susceptible transformer.
Finally, the switching power circuit also comprises an supplemental circuit which is selected from a group consisting of initiating circuit, protective circuit, voltage reference circuit, EMC circuit, and alternate rectifying filter circuit, wherein the protective circuit could be further classified into the lower voltage protective circuit, high voltage protective circuit and upper limit current protective circuit. Whenever the switch power supply is initiated or overloaded, the transformer and induction is susceptible to be saturated, and field effect transistor is apt to be loaded with over current. So within the art, the power switching IC employs the upper limit protective circuit for protection, that is to say, when the current reach the upper limit, the field effect transistor will be automatically shut off. Therefore, it is required that the control circuit to be promptly responsible and the field effect transistor be equipped with instantaneously shutting-off function. Otherwise, there exist some sort of hidden risks for the field effect transistor and transformer. For the initiating circuit, there are resistance initiating circuit and switch-off constant current source initiating circuit available within the art.
SUMMARY OF THE PRESENT INVENTION
A primary object of the present invention is to provide a method for preventing current overloading and saturation of a switch power supply.
The present invention further provides a method for preventing current overloading and saturation of a switch power supply, comprising the following steps:
1) checking whether a primary current of a transformer (or a current of an induction), or a current of field effect transistor being excess an upper limit current;
2) generating an adjusting signal so as to directly or indirectly adjusting an error signal if the upper limit current is excess the upper limit, so that during subsequent pulse adjustable periods, a duty cycle is reduced, the primary current (or the induction current) or field effect transistor peak current value are reduced, wherein the error signal is outputting signal from an error amplifier or is inputting signal from a pulse adjustable circuit, the error adjustable signal is a direct error adjustable signal, the indirect adjusting signal is an inputting signal from the error amplifier or an outputting signal from a sample adjustable circuit to adjust the error signal;
In the step 2), if an over-limit current was detected, the error signal would be adjusted, and the adjusting capacity is a fixed value.
The step 2) further comprises a step for continuously adjusting the error signal during the subsequent pulse adjustable periods if an over-limit current is detected, wherein the adjusting capacity is an gradually decreased value, from a maximum value to 0; It is noted that during the subsequent adjustable periods, in case of the upper limit current is excess again, the adjusting procedure will be restarted gradually decreasing from the maximum value to 0.
The present invention further provides an overloading and saturation preventative switch power supply according to the above mentioned procedure, comprising:
a converter circuit comprising one or more field effect transistor, a transformer (or an induction), at least a path of rectifying filter outputting circuit, and sometimes a soft switch circuit;
a feedback circuit comprising a sample circuit, an error amplifier, and sometimes a feedback isolation circuit;
a control circuit comprising a pulse adjustable circuit and a driven circuit, where the pulse adjustable circuit is selected from a group consisting of PFM mode, PWM mode and so on; and
a supplemental circuit;
wherein a protective circuit of the supplemental circuit comprises a serial of transformer primary (or inductance) or field effect transistor current sample circuit, a serial of transformer primary (or inductance) or field effect transistor upper limit current detecting circuit, and a regulating circuit adapted for directly and indirectly regulating the error signal according the outputted signal from said detecting circuit, wherein the regulating circuit is a D flip-flop being downward edge triggered and high electrical level preset. The clock signal of the D flip-flop is the pulse signal of the pulse adjustable circuit of the control circuit. The data terminal of the D flip-flop will be feed into with a low electrical level. And the preset input terminal of the D flip-flop will be feed into the outputted signal from the detecting circuit. If the D flip-flop is under a high electrical level, the open circuit will output an error regulating signal. Therefore, whenever an over limit current is detected, the regulating circuit will automatically regulate the error signal. It is noted that the regulating volume is a fixed value.
According to the present invention, the converter circuit of the switch power supply is single ended converter circuit, and the field effect transistor is transistor, the driven circuit comprise at least two path of output signal, one path is coupled with the base of the transistor, and the other path is coupled with the emitter of the transistor. The base of the transistor is electrically connected with a high voltage power source via a highly resistible resistance. Associated with related circuits, the highly resistible resistance and transistor of the converter could be applied as a portion of the power on initiating circuit, so as to improve the withstanding of the transistor.
The switch power supply of the present invention utilizes a single switch power supply IC which at least integrates a portion of control circuit and protective circuit.
Accordingly, the switch power supply of the present invention is adapted to prevent current overloading and saturation so as to ensure a higher quality and performance, and at the same time, to reduce the overall costs.
These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an undefined PWM switch power supply having an initiating circuit to prevent overload and saturation.
FIG. 2 is a schematic diagram showing an alternative mode of an unqualified PWM switch power supply having an initiating circuit to prevent overload and saturation.
FIG. 3 is a schematic diagram of an overload and saturation preventative undefined PWM switch power supply according to the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 and FIG. 2 , the independently used switch power supply, for example a charger, a green switch power supply IC standby power supply unit, or a universal switch power supply is illustrated. Q 1 is an economical power transistor; Qd is a field effect transistor; the region circumscribed within the dash line is IC portion. It is noted that Rb and Qa could integrated in the IC portion or apart with the IC portion according to the semiconductor manufacturing process. Furthermore, Rb could be integrated within the IC portion according to the optimizing request of a lower power output. In case of a higher output power is needed, the Rb could be coupled with an external resistor in a parallel manner for outputting a bigger power.
As shown in FIG. 3 , a main power supply adapted for being used as a green switch power supply is illustrated. The region circumscribed by the dash line is IC portion, the field effect transistor Q 2 could be either integrated in the IC portion or disposed outside the IC portion. Ia, Ib are current source.
S 0 is a Schmidt comparator. The working condition of the IC power supply voltage monitoring circuit is subject to the condition of the S 0 . That is to say, if the S 0 is in a lower level, the IC power supply voltage monitoring circuit is set in an initiating state, instead, if the S 0 is in a high level, the IC power supply voltage monitoring circuit is set in a normal state.
As shown in FIG. 1 , the IC power supply voltage monitoring circuit is set in an initiating state, PCL.QC is high resistance (or output is controllable), the high-voltage high-resistance value R 1 provides a base micro-current enabling the power transistor Q 1 to be conductible under a lower current of the collector, and to be charging the IC power supply capacitor C 0 through diode Da to form an initiating circuit. To ensure that Q 1 could be safely initiated, the following procedures could be followed, such as checking the charging current, controlling the PCL.QC outputting, altering Q 1 base current, and enabling the Q 1 current to be safe value. While the IC power supply voltage monitoring circuit is set in a normal state, PCL.QC and Qa is outputting normally, R 1 is disabled. Therefore, if the Q 1 's amplifying function is considered and compared with the resistance limited current initiating circuit, the initiating circuit under a normal state will be reduced to a less extent.
As shown in FIG. 2 , under an initiating state, capacitor C 0 is charged by high voltage high current power supply to form PWMs initiating circuit; under a normal state, PWMs is resumed to be a normal state, and the high voltage current power supply is cut off. As shown in FIG. 3 , since the main power supply and the standby power supply share IC power supply voltage monitoring circuit, so that S 0 is effective towards PWM 2 , under the initiating state, PWM 2 is cut off.
As shown in FIG. 1 , under a normal state, the output from PCL.QC and PCL.Q is the same. For example, if the output is high electrical level, Q 1 and Qa is conductible, Rb is adapted to check the instantaneous current of Q 1 ; if the high level output converts to a lower level, Qa will be cut off, due to the fact of memory effect, Q 1 will not cut off immediately, and diode Da will be fly-wheel, or a time delay circuit is designed to delay Qa′ off until Q 1 is cut off, or Qa force emission terminal of Q 1 clamping to be a value 1.5V, as a result, the base voltage of Q 1 0V will be reverse bias so as to increase the withstand voltage of the collector of Q 1 .
As shown in FIG. 2 , under a normal state, if PCLs.Q outputs a high electrical level, Qd will be conductible, Rb is adapted for checking the instantaneous current of Qd; if the output is a lower electrical level, Qd will be cut off. As shown in FIG. 3 , under a normal state, if PCL 2 .Q outputs a high electrical level, Q 2 is conductible, R 2 is adapted for checking the instantaneous current of Q 2 ; if the output is low level, Q 2 is cut off.
S 2 and PWM comparator shares a same mechanism, that is, as long as the oscillator Q arisen, the field effect transistor is conductible, the primary current of the transformer will be increased as well as the voltage drop. When the voltage drop equal to or bigger than the error signal which are represented as voltage UC 1 or UC 2 , S 2 will output a lower electrical level and the field effect transistor will be cut off; However, the maximum cycle ration is determined by the oscillator, that is to say, if the output from the S 2 is high level, oscillator Q will convert to a lower level and the field effect transistor will be cut off; here, the schmiter comparator S 1 could be embodied as a main power supply prohibitive circuit. if the error signal has a value less than the threshold value, then the field effect transistor cycle will be forcedly cut off, instead, if the error signal value higher than the threshold value, the field effect transistor cycle will be turned on, so as to increase the conversion efficiency while the switch power supply is light loaded.
The upper limit current comparator S 3 could be embodied as an upper limit current checking circuit. In case of the primary transformer or field effect transistor reach the upper limit current, S 3 is capable of enabling the overloading and saturation preventative logic S 5 and simultaneously turn off the field effect transistor. There are several methods available, according to the present invention, S 5 is enabled only once, and S 4 is adapted for conducting an oscillator cycle if the following circumstance is satisfied. The current of S 4 , namely I 4 , should be bigger current than the current source Ia or the main voltage feedback current minus current source Ib. (as shown in FIG. 3 , the difference value is Ic). It is noted that I 4 , Ia and Ic have attributed to the UC 1 and UC 2 within a single PWM cycle are ranged within 2.8V*(−10%), while the maximum current output should be above 95%. In case of the assignment from Ia towards UC 1 is 2.8V*3.3%, I 4 could be selected three or four times bigger than Ia. As a result, the error signal will be weakened, so in the next PWM cycle or the following PWM cycle, the duty cycle will be decreased and the primary current of the transformer and the peak current of field effect transistor will be decreased as well.
For those quick power tubes, transformers having bigger capacities, and quick responding control circuit, the error signal will be located close to the maximum value if overloading. For those slow field effect transistors, transformers having limited capacities (once the transformer is saturated, the primary current will increase to excess the upper limit), or retarded response control circuit, the error signal will be less than the theoretical maximum value, so the control circuit will turn off the field effect transistor in advance. Even though there are still existed some chances that power tube having upper limited current or transformer saturation, however, the time is limited and the safety of the field effect transistor and transformer could be guaranteed.
Another method is to enable S 5 once, I 4 =Ia(Ic)*1.2; In the succeeding PWM cycle, if the S 5 is not enabled, I 4 =Ia(Ic)*0.8, afterwards, the S 5 is disabled. It is noted that above multiple constant 1.2 and 0.8 could be bigger than 1 or less than 1, the exact value should be referenced by the instantaneous response of the switch power supply. This method could further improve the protection for the field effect transistor and transformer so as to increase the maximum current output. What is more, S 5 could be embodied as a digital processing logic to deal with the overloaded I 4 . To achieve a better monitoring effect, S 5 is optimized to output an overloading monitoring signal.
As shown in FIG. 1 , FIG. 2 and FIG. 3 , the single ended continuous current mode is embodied, as a result, PCL, PCLs, PCL 2 and S 5 are implemented with time delay circuit for preventing a pinnacle from being started which could accidentally turn off or enable S 5 .
It is worth to mention that above overloading and saturation preventative switch power supply PWM control techniques are also applied in push-pull, half-bridge, and full-bridge structure. If primary current of transformer or a current of field effect transistor is checked over upper limit by the overloading and saturation preventative circuit, then the error signal will be forcedly adjusted (for example,TL494 adding force adjusting pin 3 and pin 4 level to S 3 , S 5 ), so that in the next or subsequent PWM cycle, the duty cycle ration will be fall down, and the peak current of the field effect transistor and transform-primary will be reduced as well, as a result, the field effect transistor and the transformer are well protected thus significantly improving the security and reliability of the switch power supply.
In other words, a single ended PWM control circuit which adopted an economical switch power transistor, comprises an input and output respectively coupled with the base and emitter of the transistor, wherein the base of the transistor includes a high voltage, highly resistant resistance connected with the high voltage source or collector of the transistor (via the transformer-primary to coupled with high voltage source). Under the enabling state, the high voltage, highly resistant resistance (output being controllable), which is coupled with the base, is adapted for providing the transistor a base micro-current, and the current of the emitter of the transistor will charge the IC power supply filter capacitor through the diode so as to accomplish the starting up process. Under the normal state, PWM is in positive period, one path enables the transistor to be positive biased, while another path drops down the emitter of the transistor, then the transistor is conductible; if the PWM is in negative period, one path drops down the base of the transistor. Due to the fact of the memory effect, the transistor will not be cut off immediately, the emitter of the transistor could be fly wheeled by the diode, or the emitter of the transistor could be dropped down to delay the time until the transistor is cut off, or until the emitter of the transistor being clamped. It is noted that after the transistor is cut off, the base of the transistor is negative biased so that the voltage withstanding of the collector of the transistor have been significantly improved.
One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.
It will thus be seen that the objects of the present invention have been fully and effectively accomplished. It embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure form such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.
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The present invention provides a method for preventing current overloading and saturation of a switch power supply, including one of the steps of checking whether a primary current of an transformer, and a current of an induction or a current of field effect transistor being excess an upper limit current; and a step for generating an adjusting signal so as to directly or indirectly adjust an error signal if the upper limit current is excess the upper limit, so that during subsequent pulse adjustable periods, a duty cycle is reduced, the primary current or the induction current or field effect transistor peak current value are reduced.
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[0001] This is a continuation of U.S. patent application Ser. No. 12/635,097, filed Dec. 10, 2009, and allowed Aug. 14, 2012.
FIELD OF THE INVENTION AND RELATED ART
[0002] The present invention relates to a belt feeding device for feeding a belt member used for an image formation. More specifically, the present invention relates to a belt unit for feeding an intermediary transfer belt, the transfer belt, a photosensitive belt, and so on and an image forming apparatus such as a copying machine, a printer, a printer provided with such a belt unit. The present invention is suitable for a belt member (transportation belt for a recording material, fixing belt for a fixing device, for example) which is not directly used for the image formation.
[0003] Recently, with an improvement in the speed in the image forming operation of the image forming apparatus, a plurality of image forming stations are disposed on an endless belt shape image bearing member, and the image formation processes of the multi-color for are processed-like in parallel. For example, the intermediary transfer belt in a full color image forming apparatus of an electrophotographic type is the typical example thereof. Onto the intermediary transfer belt, the different color toner images are sequentially superimposedly transferred onto the belt surface, and a color toner image is transferred all together onto a recording material. This intermediary transfer belt is stretched by the a plurality of stretching members which include a driving roller and is rotatable. As for such a belt member, the problem of offsetting toward one side of the widthwise end portions at the time of a travelling is involved depending on a diametral accuracy of the roller or an alignment accuracy between the rollers and so on.
[0004] In order to solve such the problem, Japanese Laid-open Patent Application Hei 9-169449 proposes a steering roller control by an actuator. In addition, Japanese Laid-open Patent Application 2001-146335 proposes a belt offset regulating member.
[0005] However, Japanese Laid-open Patent Application Hei 9-169449 requires a complicated control algorithm, and electrical components such as the sensor and the actuator used result in the high cost. Japanese Laid-open Patent Application 2001-146335 does not require the sensor and the actuator, but since the regulating member always receives the offsetting force from the belt member during the feeding, it is the limitation in increasing of the speed of the image forming apparatus. Moreover, for a mounting accuracy of the regulating member, the inspection and the management cost increases.
[0006] Under the circumstances, Japanese Patent Application Publication 2001-52061 proposes a system, wherein (automatic alignment) for which the steering roller carries out the belt alignment automatically by a balance of the frictional force a 1 and, wherein the number of parts is small, the structure is simple and the cost is low.
[0007] The device of the Japanese Patent Application Publication 2001-520611 is provided with a steering system as shown in FIG. 9 . A steering roller 97 has a followable central roller portion 90 with the rotation of the belt member and the non-followable end members 91 , and is supported by a supporting plates 92 rotatable in the direction of an arrow S relative to a steering shaft 93 provided at a central portion. Here, the supporting plates 92 are urged in the direction of arrow K by tension application means 95 compressed by a pressure releasing cam 96 , and as a result, an outer surface of the steering roller applies a tension to an unshown belt member inner surface.
[0008] Referring to FIG. 10 , the principle of the belt automatic alignment will be described.
[0009] As has been described hereinbefore, the end members 91 are non-followable, and therefore, the inside of the belt feeding always receives a frictional resistance from the inner surface of the belt member.
[0010] In (a) of FIG. 10 , a belt member 50 driven in a direction of arrow V wraps, with a wrapping angle OS, on the end members 91 . Here, as for the width (measured in direction perpendicular to the sheet of the drawing), a unit width is taken. As to a belt length corresponding to an infinitesimal wrapping angle dθ of a wrapping angle θ, a upstream side thereof is a loose side, and a tension there is T, and a downstream side thereof is a tight side, and the tension there is T+dT. these tension forces face in a tangential direction. Therefore, in the infinitesimal belt length, approximately Tdθ is applied in a centripetal direction of the end members 91 by the belt. When a friction coefficient of the end members 91 is μS, a frictional force dF is:
[0000] dF=μ S Tdθ (1)
[0011] Here, tension T is governed by a unshown driving roller, and when the driving roller has the friction coefficient μr,
[0000] dT=μ r Tdθ (2)
[0012] That is,
[0000]
T
T
=
-
μ
r
d
θ
(
2
′
)
[0013] When the formula (2′) is integrated with respect to the wrapping angle θS, the tension T is:
[0000] T=T 1 e −μ r θ (3)
[0014] Here, T 1 is the tension at θ=0.
[0015] From equations (1) and (3),
[0000] dF=μ S T 1 e −μ r θ dθ (4)
[0016] As shown in (a) of FIG. 10 , in the case where the direction of a rotation of a supporting table relative to a steering shaft is the direction of an arrow S, a position of the winding start (θ=0) is the position inclined by an angle of deviation α relative to the rotational direction. Therefore, the a downward S direction component of the force expressed by formula (4) is
[0000] dF S =μ S T 1 e −μ r θ sin(θ+α) dθ (5)
[0017] Moreover, by integrating formula (5) with respect to the wrapping angle θS,
[0000] F S =μ S T 1 ∫ 0 θ S e −μγθ sin(θ+α) dθ (6)
[0018] In this manner, the force (per unit width) in the direction of downward arrow S received from the belt member by the end member 91 in the inside of the belt feeding is obtained.
[0019] (b) of FIG. 10 is a top plan view of (a) of FIG. 10 , as seen in the direction of an arrow TV. It is assumed that as shown in FIG. 10 ( b ), when the belt member 50 is fed in the direction of arrow V, the belt leftwardly offsets. At this time, a relation between the riding widths of the belt member 50 on the end members is, such that the riding width w exists only in left-hand side, as shown in (b) of FIG. 10 . More particularly, the left end member 91 receives the force FSw in the downward direction of S, and the right end member 91 receives the force 0 in the same direction. Such a difference in a frictional forces at the ends produces a moment FSwL about the steering shaft (downward at the left side). Hereinafter, the moment about the steering shaft will be called a steering torque.
[0020] The direction of a steering angle of the steering roller 97 produced by the above described principle is the direction by which the off-set of the belt member 50 is reduced, and therefore, the automatic alignment is accomplished.
[0021] In the automatic alignment for the belt which does not use an actuator, the steering forces are frictional forces produced by the end members 91 . As is disclosed in the Japanese Patent Application Publication 2001-520611, or as will be apparent also from the principle based on formula (6), the steering force FS increases with the value of the friction coefficients μS of the end members 91 .
[0022] The large steering force FS, that is the large steering torque FSwL means high in the correcting effect for the belt offsetting, but they cause a large change in a stretching orientation of the belt member 50 . A temporal change (change with time) of such a stretching orientation causes the color misregistration in a main scanning direction, in the case of the belt member (typically, intermediary transfer belt) related with the image forming operation. Therefore, as for the belt member 50 related with the image formation, it is necessary that both the problems of the belt offsetting and the color misregistration in the main scanning direction are considered, and therefore, the friction coefficient μS cannot be increased simply.
[0023] Referring to FIGS. 12 and 13 , the relation between the attitude change of the belt member 50 and the color misregistration in the main scanning direction will be described.
[0024] FIG. 12 is a top plan view of the belt member 50 , wherein during the movement of the belt, the stretched attitude is constant. At the time t, the belt member 50 is stretched at the position indicated by a solid line around the rollers which include the driving roller 604 and the steering roller 97 , with some inclinations γ depending on an alignment error between the rollers and the like.
[0025] When the belt is fed in the direction of arrow V with the constant inclination γ, the belt member 50 is shifted to the position shown by a broken line at time t+δt. The position of a belt edge is detected in the detecting positions M 1 and M 2 . The point Pt detected at the detecting position M 1 at the time t and the point Pt+δt detected at the detecting position M 2 at the time t+δt are the same mass points. For this reason, a relative difference between them is zero ideally.
[0026] When the belt is fed with the constant inclined attitude *γ, as shown in FIG. 12 , the locus from the point Pt to the point Pt+δt goes straight in the x direction (sub-scanning direction), and therefore, it is in the ideal conditions, and the positional deviation does not occur in the y direction (main scanning direction) between the detecting positions M 1 and M 2 .
[0027] On the other hand, FIG. 13 is a top plan view of the belt member 50 fed with the stretched attitude which is not constant. The belt member 50 is stretched with the inclination γ at the position indicated by the solid line at the time t. When the belt is fed in the direction of arrow V with the changing inclination γ, the belt member 50 is moved to the position shown by the broken line at the time t+δt. Similarly to FIG. 12 , the position of the belt edge is measured in the detecting positions M 1 and M 2 . When the belt is fed with the changing inclination γ, the locus to the point Pt+δt from the point Pt is inclined relative to the x direction (sub-scanning direction). For this reason, the positional deviation occurs in the y direction (main scanning direction) between the detecting positions M 1 and M 2 . Assuming that the detecting positions M 1 and M 2 s are first color and second color image forming stations, respectively, the positional deviation in the main scanning direction occurs between the two colors (main scanning direction color misregistration). In this manner, in the case of the belt member 50 related to the image formation, the temporal change of the stretched attitude causes the main scanning direction color misregistration, and there is a correlation between the amount of the attitude change and the amount of the main scanning direction color misregistration.
[0028] FIG. 16 illustrates the change of a belt behavior, in the case where the end members 91 are made of silicone rubber which has a relatively high friction coefficient μS (μS=approx. 1.0).
[0029] (a) of FIG. 16 illustrates a belt edge position detected in the detecting position M 1 described in FIGS. 12 and 13 vs. time. (b) of FIG. 16 illustrates the main scanning position deviation which is the difference between the belt edge positions detected in the detecting positions M 1 and M 2 described in FIGS. 12 and 13 vs time. FIG. 16 shows the result of a transient response, when a disturbance is intentionally imparted at the time 0 (sec), in order to show clearly the production of the main scanning position deviation resulting from the belt automatic alignment.
[0030] The steering moment produced increases with increase of the friction coefficient μS, but the belt edge position is changed with a transient overshoot OS as shown in (a) of FIG. 16 . The temporal change of the inclination of the tangent line as shown at the times t 1 , t 2 and t 3 in the graph of (a) of FIG. 16 is the temporal change of the stretched attitude described in FIGS. 12 and 13 . More particularly, in (b) of FIG. 16 , there is a produced peak which causes a first main scanning position deviation z 1 between t=0 and the transient overshoot production time tos. Thereafter, there is a produced peak which causes a second main scanning position deviation z 2 also between tos and the time of the steady state ts.
[0031] As will be understood, in the system which involves the transient overshoot OS, it is preferable that the steering is certainly turned back in the process to the steady state, and therefore, the additional the temporal change of the stretched attitude, that is, the production of the main scanning position deviation cannot be avoided.
[0032] In the example of (a) of FIG. 16 , the steady state is reached only by the one transient overshoot, but when the friction coefficient μS is high, n (n=integer) transient overshoots are required to reach to the steady state. In this case, the produced peaks which cause the first to n-th main scanning position deviations zn result. In the case of a full color image forming apparatus, the detecting positions M 1 and M 2 shown in FIGS. 12 and 13 correspond to the adjacent image forming stations which have the developing means for the different colors normally, and therefore, the main scanning position deviation is called the main scanning direction color misregistration.
[0033] As will be understood, in the system in which the belt member related with the image formation is automatically aligned, the friction coefficient μS is the prime power of the steering, but in order to suppress the production of the main scanning direction color misregistration, the friction coefficient μS cannot be increased too much.
[0034] For this reason, the function which produces a force which properly moves the belt member is desired with the small friction coefficient μS.
SUMMARY OF THE INVENTION
[0035] According to an aspect of the present invention and there is provided a mechanism and an image forming apparatus, wherein a suitable force which moves a belt member is produced with a small friction coefficient of a friction part.
[0036] According to an aspect of the present invention, there is provided a An image forming apparatus comprising a rotatable belt member; stretching means for stretching said belt member; and steering means for stretching and steering said belt member, wherein said steering means includes a rotatable portion rotatable with rotation of said belt member, a frictional portion, provided at each of opposite axial end of said rotation portion, for slidable contact with said belt member, supporting means for supporting said rotatable portion and said frictional portion, a rotation shaft rotatably supporting said supporting means, and said steering means is capable of steering said belt member by rotation thereof by forces resulting from sliding between said belt member and said frictional portion, wherein each of said frictional portions is provided with an inclined surface which is inclined to be further from a rotational axis of said rotation portion axially toward an outside, and wherein said belt member is contacted to at least one of said inclined portions.
[0037] These and other objects features and advantages of the present invention will become more apparent upon consideration of the following description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a perspective view of an automatic alignment mechanism portion according to an embodiment of the present invention.
[0039] FIG. 2 is a detailed view of the central part of an automatic alignment portion in the embodiment of the present invention.
[0040] FIG. 3 is a detailed view of an end of the automatic alignment portion in the embodiment of the present invention.
[0041] FIG. 4 illustrates the relation between the forces which function to the present invention at the time of an automatic alignment in the present embodiment.
[0042] FIG. 5 is a perspective view of an intermediary transfer belt unit according to Embodiment 1 of the present invention.
[0043] FIG. 6 is a sectional view of an image forming apparatus of an intermediate transfer type.
[0044] FIG. 7 is a sectional view of an image forming apparatus of a direct transfer type.
[0045] FIG. 8 is a sectional view of an image forming apparatus of a photosensitive belt type.
[0046] FIG. 9 is a perspective view illustrating a belt automatic alignment according to a conventional example.
[0047] FIG. 10 illustrates a principle of the belt automatic alignment.
[0048] FIG. 11 illustrates the riding width of the belt on a sliding ring.
[0049] FIG. 12 is a top plan view ( 1 ) illustrating the relation between a belt offsetting and a main scanning position deviation.
[0050] FIG. 13 is a top plan view ( 2 ) illustrating the relation between the belt offsetting and the main scanning position deviation.
[0051] FIG. 14 shows a graph in which the relation between the offsetting force P and the belt return force Q is shown.
[0052] FIG. 15 shows a graph in which the relation between a steering torque Tr and the steering angle occurred β is shown.
[0053] FIG. 16 shows a graph illustrating a problem in the conventional automatic belt alignment.
[0054] FIG. 17 shows a graph illustrating an effect by the belt automatic alignment according to the present invention.
[0055] FIG. 18 shows a graph illustrating two automatic alignment modes according to the present invention.
[0056] FIG. 19 is a sectional view of a belt stretched in a fixing device according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
<Image Forming Apparatus>
[0057] An image forming apparatuses according to the preferred embodiments of the present invention will be described in conjunction with the accompanying drawings.
[0058] First, referring to FIG. 6 , the operation of the image forming apparatus will be described. The image forming apparatus may be of an electrophotographic type, an off-set printing type, an ink jet type, and so on. In the example shown in FIG. 6 , the image forming apparatus 60 is a color image forming apparatus of the electrophotographic type. The image forming apparatus 60 is of a so-called tandem intermediate transfer type, wherein on the intermediary transfer belt, four color image forming stations are juxtaposed. This is excellent in a thick paper processing and productivity. FIG. 6 is a sectional view of this device.
<Feeding Process for Recording Material>
[0059] Recording materials S are stacked on the lifting-up device 62 in the recording material accommodating portion 61 , and is fed in timed relation with the image formation by a sheet feeding apparatus 63 . The sheet feeding apparatus 63 may be of a friction seprating type which uses a sheet feeding roller and so on or an attraction separating type which uses the air, and in the example of FIG. 6 , the latter is used. The recording material S fed by the sheet feeding apparatus 63 passes along a feeding path 64 a of a feeding unit 64 and is fed to a registration device 65 . In the registration device 65 , the recording material S is subjected to an inclination correction and a timing correction, and thereafter, it is fed to a secondary transfer portion. The secondary transfer portion includes an internal secondary transfer roller 603 which is a first secondary transfer member and an external secondary transfer roller 66 which is a second secondary transfer member, and a transfer nip portion is formed by these rollers opposing to each other. By applying predetermined pressure and electrostatic load bias, a toner image is transferred onto recording material S from the intermediary transfer belt.
[0000] <Image formation process> An image forming process to the secondary transfer portion is carried out in timed relation with the recording material feeding process to the secondary transfer portion described in the foregoing. This image forming process will be described
[0060] In the present embodiment, there are provided an image forming station 613 Y for forming the image by the yellow (Y) toner, an image forming station M for forming the image by the magenta (M) toner, an image forming station 613 C for forming the image by the cyan (C) toner, and an image forming station 613 BK for forming the image by the black (BK) toner. The image forming station 613 Y, the image forming station 613 M, the image forming station 613 C, and the image forming station 613 BK include the similar structures, except for the difference in colors of the toner, and therefore, only the image forming station 613 Y will be described.
[0061] The image forming station 613 Y which is toner image forming means comprises a photosensitive member 608 which is an image bearing member, a charger 612 for charging the photosensitive member 608 , an exposure device 611 a , a developing device 610 , a primary transfer device 607 and a photosensitive member cleaner 609 . The photosensitive member 608 is rotated in the direction of an arrow m in the Figure, and it is uniformly charged by the charger 612 . The exposure device 611 a is driven on the basis of a signal of an inputted image information and it impinges on the charged photosensitive member 608 by way of light bending members 611 b to form an electrostatic latent image. The electrostatic latent image formed on the photosensitive member 608 is developed by the developing device 610 , so that the toner image is formed on the photosensitive member. Thereafter, the yellow toner image is transferred onto the intermediary transfer belt 606 which is the belt member, by a predetermined pressure and a predetermined electrostatic load bias in the primary transfer device 607 . Thereafter, an untransferred toner which remains on the photosensitive member 608 is removed and collected by the photosensitive member cleaner 609 , to be prepared for a next image formation.
[0062] In the case of the image forming station 613 of FIG. 6 described in the foregoing, the image forming stations for the yellow (Y), the magenta (M), the cyan (C), and the black (Bk) are provided. By this, the magenta toner image formed by image forming station M is transferred onto the yellow toner image on an intermediary transfer belt 606 . In addition, the cyan toner image formed by an image forming station C is transferred onto the formed magenta toner image. Furthermore, the black toner image formed by an image forming station BK is transferred onto the intermediary transfer belt 606 onto the cyan toner image. In this manner, the different color toner images are superimposedly formed on the intermediary transfer belt 606 , so that a full-color image is formed on the intermediary transfer belt 606 . In this embodiment, the number of the colors is four, but it is not limited to four, and the order of the colors is not limited to this example.
[0063] The intermediary transfer belt 606 will be described. The intermediary transfer belt 606 is stretched by a driving roller 604 which is a driving member, a steering roller 1 which is steering means, a stretching roller 617 which is a stretching member, and the internal secondary transfer roller 603 which is an internal secondary transfer member (stretching member). It is driven in the direction of arrow V in the Figure. It is preferable that an angle in which the intermediary transfer belt 606 wraps on the stretching roller 617 which is a first stretching member adjacent the steering roller 1 , and an angle in which the internal secondary transfer roller 603 which is a second stretching member are acute. This is because, a frictional force between the intermediary transfer belt 606 and the stretching roller 617 and a frictional force between the intermediary transfer belt 606 and the internal secondary transfer roller 603 can be reduced, and therefore, the efficiency in the belt automatic alignment as will be described hereinafter is high. The frictional force is large when the wrapping angle, on steering roller 1 , of the intermediary transfer belt 606 is an obtuse angle, and therefore, the efficiency of the automatic belt alignment can be increased.
[0064] A function of a tension roller for applying a predetermined tension to the intermediary transfer belt 606 is allotted to the steering roller 1 . The image forming processes carried out in parallel by the image forming stations 613 Y, 613 M, 613 C, 613 BK are timed so that the toner images are superimposed onto the upstream color toner image or images transferred (primary transfer) onto the intermediary transfer belt 606 . As a result, finally a full-color toner image is formed on the intermediary transfer belt 606 , and is fed to the secondary transfer portion. The number of the rollers which stretch the intermediary transfer belt 606 is not limited to that of FIG. 6 .
[0000] <Process after Secondary Transfer>
[0065] The full-color toner image is formed on recording material S in the secondary transfer portion through the above described recording material feeding process and the image forming process. Thereafter, the recording material S is fed to the fixing device 68 by a pre-fixing feeding portion 67 . As for a fixing device 68 , various structures and types are available, but in the example of FIG. 6 , a fixing roller 615 and a pressing belt 614 which oppose to each other are employed and they form a fixing nip. The nip gives the predetermined the pressure and heat to the recording sheet to melt and fix the toner image on recording material S. Here, the fixing roller 615 is provided with a heater which is a heat source in an inside, and the pressing belt 614 is provided with a plurality of stretching rollers and a pressing pad 616 urged from a belt inner surface. The recording material S which has passed through the fixing device is selectively fed by a branching feeding device 69 to the sheet discharge tray 600 or to an inversing device 601 (In the case of double-sided image formation). In the case of the double-sided image formation, the recording material S fed to the inversing device 601 is switched back and is fed from the trailing end to double-sided feeding device 602 . Thereafter, while the recording material avoids the interference with a subsequent job recording material from the sheet feeding apparatus 61 , it is fed to the secondary transfer portion through a re-feeding path 64 b of the feeding unit 64 . The image forming process for the back side is the same as that for the front surface, and therefore, the description is omitted.
<Structure of Steering System for Intermediary Transfer Belt>
[0066] FIG. 5 is a perspective view of the intermediary transfer belt unit 500 which the image forming apparatus 60 shown in FIG. 6 has. FIG. 5( a ) shows the intermediary transfer belt unit 500 when the intermediary transfer belt 606 of the belt unit 500 is in the stretched state. FIG. 5( b ) shows the intermediary transfer belt unit 500 after the removal of the intermediary transfer belt 602 . The intermediary transfer belt 606 is circularly moved in the direction indicated by an arrow mark V, by the belt driving force inputted into the drive roller 604 (belt driving member) through a drive gear (driving force transmitting member). In this embodiment, the steering roller 1 , which is a steering means, is provided with a mechanism for automatically centering the intermediary transfer belt 606 by utilizing the unbalance in friction.
[0067] FIG. 1 is a perspective view of the essential portion of the automatic belt centering mechanism in accordance with the present invention. The steering roller 1 has a follower roller 2 and a pair of friction rings 3 . The follower roller 2 is the center portion of the steering roller 1 , and is the rotational portion of the steering roller 1 . The follower roller 2 is in connection with the friction rings 3 , and is supported by the same shaft as the shaft with which the friction rings 3 are supported. The friction rings 3 are at the lengthwise ends of the follower roller 2 , and are the portions for providing the intermediary transfer belt 500 with friction. The steering roller 1 is supported by its lengthwise ends, by a pair of sliding bearings 4 . The sliding bearings 4 are in the groove (unshown) of a lateral supporting member 6 , being kept pressed in the direction indicated by an arrow mark K′, by a tension spring 5 (compression spring), which is an elastic member. Thus, the steering roller 1 functions also as the tension roller which provides the intermediary transfer belt 606 with such a tension that is applied in the direction indicated by the arrow mark K′ through the inward surface of the intermediary transfer belt 606 . Further, the lateral supporting member 6 and a rotational plate 7 make up a supporting plate (supporting means) for supporting the follower roller 2 and frictional rings 3 . The lateral supporting member 6 is supported so that it is rotatable about the cental axial line J, in the direction indicated by an arrow mark S. A frame stay 8 is one of the structural members of the frame portion of the intermediary transfer belt unit 500 , and bridges between the front and rear plates 51 F and 51 R, respectively, of the intermediary transfer belt unit 500 . The frame stay 8 is provided with slidably movable rollers 9 , which are at the lengthwise ends of the frame stay 8 , one for one. The slidably movable rollers 9 play the role of reducing the rotational plate 7 in rotational resistance.
<Details of Structure of Intermediary Transfer Belt Centering Automatic Mechanism>
[0068] Next, referring to FIGS. 2 and 3 , the further details of the structure of the intermediary transfer belt centering automatic mechanism will be described.
[0069] FIG. 2 is a partially sectional view of the rotational center portion of the supporting plate, and shows the structure of the rotational center portion. The steering mechanism is provided a steering shaft 21 , which is fitted in the center portion of the rotational plate 7 . The steering shaft 21 is shaped as if two D-shaped portions have been removed from the opposite sides of the shaft 21 . It is integrally attached to the rotational plate 7 by one of its lengthwise ends, with small screws. The other lengthwise end of the steering shaft 21 is put through a bearing 23 held by the frame stay 8 , and is fitted with a stopper 26 for preventing the steering shaft 21 from becoming disengaged by a thrust.
[0070] FIG. 3 shows the details of one of the lengthwise end portions of the automatic belt centering mechanism in accordance with the present invention.
[0071] The friction ring 3 a , which is the friction providing portion of the steering roller 1 , is tapered in such a manner that its outward end, in terms of its axial direction, is the largest in diameter, and its inward end is smallest in diameter. However, it is not mandatory that the friction ring 3 a is shaped as it is in this embodiment. For example, the friction ring 3 a may be shaped so that its portion which does not come into contact with the intermediary transfer belt 606 is square in cross-section, and only its portion which comes into contact with the belt is tapered in such a manner that the outward end is largest in diameter. In other words, all that is required of the friction roller 3 a , or the like, is to be provided with a portion tapered so that the more outward in terms of the direction of the roller shaft axis, the greater the distance between the rotational axis of the friction roller 3 a , or the like, and the peripheral surface of the friction roller 3 a , or the like.
[0072] The follower roller 2 is rotatably supported by the steering roller shaft 30 , with the presence of the internal bearings of the follower roller 2 between the follower roller 2 and steering roller shaft 30 . As for the friction rings 3 a attached to the lengthwise ends of the follower roller 2 , they also are supported by the steering roller shaft 30 , but, are prevented by a parallel pin or the like, from rotating with the steering roller shaft 30 . In this embodiment, the belt centering mechanism is structured so that the friction rings 3 do not rotate in the same direction as the rotational direction of the follower roller 2 . However, it is not mandatory that the belt centering mechanism is structured as it is in this embodiment. For example, the belt centering mechanism may be structured so that the friction rings 3 a are allowed to rotate. In a case where the friction rings 3 a are allowed to rotate, as long as the mechanism is structured so that the amount of torque necessary to rotate the friction rings 3 in the same direction as the moving direction of the intermediary transfer belt 606 is greater than the amount of torque necessary to rotate the follower roller 2 in the same direction as the moving direction of the intermediary transfer belt 606 , it is possible to steer the intermediary transfer belt 606 .
[0073] One of the lengthwise end portions of the steering roller shaft 30 is shaped so that its cross-section is in the shaped of letter D. Thus, the steering roller shaft 30 is non-rotatably supported by the sliding bearing 4 . Therefore, when the stretched intermediary transfer belt 606 is circularly moved, the rotatable portion 2 (follower roller) of the steering roller 1 does not rub the inward surface of the intermediary transfer belt 606 , but, the frictional rings 3 a , which are the lengthwise end portions, one for one, of the steering roller 1 , rub the intermediary transfer belt 606 . The principle of the belt centering automatic mechanism, which is based on the above described structural arrangement, is exactly as described above in (1)-(6).
[0074] Next, referring to FIG. 4 , the structure of the belt centering automatic mechanism having the tapered friction rings 3 a will be described in more detail. Referring to FIG. 4( a ), the frictional ring 3 a is tapered at an angle of φ, and the more outward the given point of the peripheral surface of the friction ring 3 a relative to the center of the steering roller 1 in terms of the axial line of the steering roller 1 , the greater in external diameter the given point. The intermediary transfer belt 606 is suspended in such a manner that the area of contact between the frictional ring 3 a and the intermediary transfer belt 606 has a width of W in terms of the lengthwise direction of the axial line of the steering roller 1 . In this embodiment, the belt centering automatic mechanism is structured so that while the intermediary transfer belt 606 is stable in position in terms of the axial direction of the steering roller 1 , the intermediary transfer belt 606 remains in contact with both of the friction rollers 3 a , and the area of contact between each frictional ring 3 a and the corresponding edge portion of the intermediary transfer belt 606 is W in width. Incidentally, the belt centering automatic mechanism is structured so that the intermediary transfer belt 606 is enabled to come into contact with the outermost edge of each friction ring 3 a . However, if the intermediary transfer belt 606 is shifted in position far enough for one of its edges to be placed outside the outward edge of the friction ring 3 a , it becomes difficult for the intermediary transfer belt 606 to be corrected in position (centered).
[0075] FIG. 4( b ) is an enlarged sectional drawing of one of the edge portion of the intermediary transfer belt 606 , which is in contact with the corresponding friction ring 3 a by the width of W (D portion). It shows the relationship between the deviatory force P by which the intermediary transfer belt 606 is pushed outward, and the force which works in the direction to center the intermediary transfer belt 606 . In this embodiment, the angle φ f the tapering of the friction ring 3 a is approximately 8° (φ≈8°). It is desired that the angle φ of the tapering is greater than 0° and no more than 90°:0°<φ<90°, preferably, 0°<φ<30°.
<Forces Which Act on Intermediary Transfer Belt (Member in Belt Form)>
[0076] Generally speaking, the belt deviation occurs because of the occurrence of the difference γ in angle between the direction in which the intermediary transfer belt 606 belt is circularly moved, and the direction in which the belt 606 is suspended (stretched), as described with reference to FIG. 12 . Further, there is a correlation between the amount of the deviation and the angle γ. In a case where a means, such as the tapered portion of the friction ring 3 a in this embodiment, for resisting the force which acts in the direction to cause the belt 606 to deviate, is present, the amount of the belt deviation may be thought to be the amount of the deviatory force P which acts in the direction to cause the belt 606 to deviate. FIG. 4( b ) is drawn in such a manner that the border between friction ring 3 a and follower roller 2 is the referential point (Point 0 ) of the axis y. It is assumed that the intermediary transfer belt 606 is deviated so that a given point of the inward surface of the intermediary transfer belt 606 , which was at the intersection H 0 between the inward surface of the intermediary transfer belt 606 and the cross-sectional plane y 0 (y=y 0 ), was moved by an amount Δy (distance) to a point H 1 . At point H 1 , the given point catches a reactive force P′, which is perpendicular to the peripheral surface of the tapered friction ring 3 a . The relationship among the abovementioned forces can be summarized as follows, with reference to axis y.
[0000] (1) Reactive Force from Tapered Friction Ring
[0077] In the case of the belt centering system in which the friction ring 3 a is tapered at the angle of φ, the component of the deviatory force P, the direction of which is parallel to axis y, acts on the intermediary transfer belt 606 across the portion of the intermediary transfer belt 606 , which corresponds to an angle θs ( FIG. 10( a )).
[0078] Thus,
[0000] F 1 =θ s P sin φ (7)
[0000] (2) Friction Attributable to Reactive Force from Tapering of Friction Ring
[0079] The component of the friction which is parallel to axis y, and is perpendicular to the deviatory force P, acts on the intermediary transfer belt 606 across the wrapping angle θs.
[0080] Therefore,
[0000] F 2 =θ s μ s P cos φ (8)
[0081] Here, μs is the coefficient of friction of the peripheral surface of the friction ring 3 a.
(3) Reactive Force Caused by Tensional Stress of Intermediary Transfer Belt
[0082] The amount of tensional stress which acts on the intermediary transfer belt 606 at point y 0 (y=y 0 ) and y 1 (y=y 1 ) can be expressed in the form of the following mathematical equation, in which r and (r+dr) stands for radii of the friction ring 3 a at points y 0 and y 1 , respectively:
[0000]
σ
=
E
r
r
=
E
Δ
y
r
tan
φ
(
9
)
[0083] Regarding a given small portion of the peripheral surface of the friction ring 3 a , the width of which is dθ in angle, the amount of the component q which is perpendicular to the peripheral surface of the friction ring 3 a , and the amount of which is obtainable from Equation (9);
[0000] q=σdθ (10)
[0084] The force df, which was described in Sections (1) and (2), is similarly generated also by force q.
[0085] Thus,
[0000] df=q sin φ+μ s q cos φ (11)
[0086] Therefore, the reactive force F 3 can be obtained from Mathematical Equations (9)-(11).
[0000]
[
Mathematical
Equation
10
]
F
3
=
∫
0
θ
s
f
=
∫
0
θ
s
E
Δ
y
r
tan
φ
(
sin
φ
+
μ
s
cos
φ
)
θ
=
θ
s
E
Δ
y
r
tan
φ
(
sin
φ
+
μ
s
cos
φ
)
(
12
)
[0087] Here, E stands for the coefficient of tensional elasticity of the intermediary transfer belt 606 .
(4) Static Frictional Force of Follower Roller
[0088] When the intermediary transfer belt 606 is being returned to its normal position, the frictional force which the intermediary transfer belt 606 receives from the peripheral surface of the follower roller 2 functions as resistive force F 4 . When the coefficient of static friction of the peripheral surface of the follower roller 2 is μSTR, and the perpendicular resistive force is N,
[0000] F 4 =μ STR N (13)
(5) Static Friction of Friction Ring
[0089] Similarly, when the intermediary transfer belt 606 is being returned to its normal position against the deviatory force P, the friction which the intermediary transfer belt 606 receives from the friction ring 3 a functions as resistive force F 5 .
[0090] Therefore,
[0000]
F
5
=
μ
S
∫
0
θ
s
T
1
-
μ
γ
θ
θ
cos
φ
=
μ
s
μ
r
T
1
(
1
-
-
μ
γ
θ
s
)
cos
φ
(
14
)
[0091] Here, μr stands for the coefficient of friction of drive roller 604 . In this embodiment, in order to prevent the electrostatic load in the primary transfer station, and/or contact load from the belt cleaning apparatus 85 , from causing slip between the drive roller 604 and intermediary transfer belt 606 , the belt centering mechanism is designed so that the coefficient of friction pr the drive roller 604 is in a range of 1.5-2.0 (μr=1.5-2.0).
[0000] (6) Counter Deviatory force P′ to be Generated by Steering Roller
[0092] In the case of a belt centering system equipped with a steering roller, in order to cancel the angular deviation, the steering roller is intentionally steered at a certain angle to generate counter deviatory force P′, which counters the deviatory force P.
<Belt Centering Mode Based on Tapering, and Belt Centering Mode Based on Steering Roller>
[0093] Summarizing in consideration of the directions of the forces in (1)-(6), the total amount Q of belt centering (returning) force can be obtained. The requirement for the belt centering (returning) force Q for automatically centering the intermediary transfer belt 606 is:
[0000] Q=F 1 +F 2 +F 3 −F 4 −F 5 +P′>P (15)
[0094] In other words,
[0000]
P
sin
φ
+
μ
s
P
cos
φ
+
θ
s
E
Δ
y
r
tan
φ
(
sin
φ
+
μ
s
cos
φ
)
-
μ
STR
N
-
μ
s
μ
r
T
1
(
1
-
-
1
μ
r
θ
s
)
cos
φ
+
P
′
>
P
(
15
′
)
[0095] In other words, Mathematical Formula (15′) means that as the amount Q of the total of the forces (1)-(6) exceeds the deviatory force P, the intermediary transfer belt 606 becomes automatically centered.
[0096] In comparison, in the case of a friction ring 3 b , shown in FIG. 3( b ), which is not tapered, the first to third terms in Formula (15′), which are related to the angle φ of the “taper” of the friction ring 3 a , is zero. Therefore, the entirety of the force for overcoming the deviatory force P has to be provided by the counter deviatory force P′. In other words, the automatic belt centering system has to rely more on the angle of the steering roller, and therefore, the belt attitude (in which the intermediary transfer belt 606 is suspended (stretched)), which is the primary cause of the color deviation in the primary direction, is substantially changed. In the present invention, therefore, the belt centering system is reduced in the dependency upon steering angle, by setting low the value for the coefficient of friction p s of the friction ring 3 a , and also, utilizing the first to third items (F 1 -F 3 ) related to the tapering angle φ, as shown in Formula (15′).
[0097] The greatest characteristic realized by the above described settings is that in the area where the deviatory force P is small, the deviation is dealt with only by the first to third items (F 1 -F 3 ) in Formula (15′), which are related to the tapering angle φ. That is, the correction (centering) is made even if the steering roller 1 does not tilt. Further, as the deviatory force P exceeds a certain value (limit value, the counter deviatory force P′ is also used. That is, the steering roller 1 is tilted to make the correction (centering). In other words, the greatest characteristic is that the automatic centering mode has two stages.
[0098] To describe this characteristic from the viewpoint of the deviation amount Δy, while the deviation amount Δy is in a range in which the difference between the width of contact between one of the friction rings 3 a and the intermediary transfer belt 606 , and the width of contact between the other friction ring 3 a and the intermediary transfer belt 606 , is no larger than a preset value Δwc, the intermediary transfer belt 606 is centered without using the steering roller angle. Then, as a relatively large deviation amount Δy is inputted, that is, as the difference between the width of contact between one of the friction rings 3 a and the intermediary transfer belt 606 , and the width of contact between the other friction ring 3 a and the intermediary transfer belt 606 , becomes larger than the preset value Δwc, the automatic belt centering system is switched to the mode in which the steering roller (angle) is used.
[0099] Next, referring to FIGS. 14 and 18 , the automatic belt centering mode with two stages, which is the primary characteristic of the present invention, will be described in detail. FIG. 14 is a graph, the abscissa and ordinate of which represent the deviatory force P and belt returning (centering) force Q, respectively. The dotted line in FIG. 4 is a straight line, where Q=P. That is, the dotted straight line (Q=P) is the border line between where the automatic centering is possible and where the automatic centering is not possible. This means that if the belt returning (centering) force Q is above the dotted line, the belt can be automatically centered. PT 1 , PT 2 , and PT 3 in the graph represent the total of the first to fifth items in Formula (15′). As will be evident also from Formula (15′), they are functions of the deviatory force P. As the deviatory force P switches between positiveness and negativeness (that is, direction of belt deviation), they discontinuously change. PT 1 , PT 2 , and PT 3 correspond to belt deviation amounts Δy 1 , Δy 2 , and Δy 3 (Δy 1 <Δy 2 <Δy 3 ). In other words, they are the functions of the deviation amount Δy, as will be evident also from Formula (15′).
[0100] In this embodiment, each of the two friction rings 3 a is tapered at angle φ, and is made relatively low (μs≈0.3) in the coefficient of friction μs of the peripheral surface of the friction ring 3 a , so that the difference between the contact width between one of the friction ring 3 a and the intermediary transfer belt 606 , and the contact width between the other friction ring 3 a and the intermediary transfer belt 606 , will become large enough to generate steering torque only when the amount of deviation reaches or exceeds the amount Δy 3 . The coefficient of friction μs of the peripheral surface of the friction ring 3 a is greater than that of the peripheral surface of the follower roller 2 .
[0101] FIG. 18 is a graph, the abscissa of which represents the deviation amount Δy, and the ordinate of which represents the steering angle β. It shows the changes in the amount of steering angle β, which correspond to deviation amounts Δy 1 , Δy 2 , and Δy 3 , respectively.
[0102] Here, it is assumed that the belt supporting rollers of the intermediary transfer belt unit 500 are misaligned, and/or the drive roller 604 is uneven in external diameter, and therefore, the belt deviation occurred, and the amount of the deviatory force P is P 1 shown in FIG. 14 . If the belt deviation amount is Δy 1 , PT 1 is below the dotted line, and therefore, counter deviation force Q is insufficient. Therefore, in order to make counter deviation force Q sufficient, the belt deviation amount is increased to amount Δy 2 to compensate for insufficient amount Pε 1 . In a case where the amount of the deviatory force P is P 1 , which is relatively small, it is unnecessary to generate the steering torque. That is, the belt returning (centering) force caused by the tapering (angle φ) of the friction ring 3 a is sufficient to automatically center the intermediary transfer belt 606 .
[0103] This corresponds to Mode 1, in FIG. 18 , which is the first operational stage of the belt centering system in accordance with the present invention.
[0104] Next, assuming that a belt deviation similar to the above described one occurs, and the amount of deviatory force P is P 2 , shown in FIG. 14 . If the belt deviation amount Δy is greater than the above mentioned amount Δy 2 , PT 2 is below the dotted line, and therefore, the returning (centering) force Q is insufficient. Therefore, it is attempted to compensate for the insufficient amount of the returning force Q by increasing the amount of belt deviation. While the belt deviation amount is increased, it reaches the belt deviation amount Δy 3 . Therefore, although the belt returning force Q, which is caused by the tapering (angle φ) of the friction ring 3 a , can be increased only to Pε 2 , it becomes possible to obtain the counter deviatory force P′, which involves the steering of the steering roller, instead of the tapering.
[0105] This corresponds to Mode 2, in FIG. 18 , which is the second stage of the belt centering operation in accordance with the present invention. The amount of the belt deviation which occurs while the belt is circularly driven under the normal condition is no more than Δy 3 . Therefore, in the normal condition, the belt deviation can be dealt with in the belt centering operation in the first mode. However, as a case where the deviation amount exceeds Δy 3 , it is assumed to be such an operation in which changes in load are large, for example, an operation in which cardboard or the like is conveyed as recording medium, or immediately after an intermediary transfer belt replacement.
[0106] The belt centering first mode (stage), which relies on the tapering (angle φ) of the friction ring 3 a , is not a mode (stage) that truly eliminates the deviatory force P. However, the belt centering second mode (stage) is a mode that truly eliminates the difference in angle γ which is the cause of the generation of the deviatory force P. In other words, the occurrence of steering is what compensates for the distortion of the intermediary transfer belt 606 . Thus, the occurrence of steering reduces the deviatory force P to P 3 shown in FIG. 14 . As the deviatory force P reduces to P 3 , the amount of deviation becomes smaller than Δy 1 . Then, once the amount of deviation becomes smaller than Δy 1 , the deviation is gradually and automatically eliminated by the belt centering effect of the tapering (angle φ) of the friction ring 3 a , and therefore, the normal operational condition is restored.
[0000] <Setting of Coefficient of Friction μs>
[0107] The present invention reduces the steering angle by providing the belt centering automatic system with two belt centering modes (stages), as described above. What is important here is to what value the coefficient of friction μs of the friction ring 3 a is set.
[0108] More concretely, it is to set the coefficient of the friction μs of the friction ring 3 a to a relatively low value. In this embodiment, it is set to roughly 0.3 (μs 0.3), and the angle φ of the tapering is set to roughly 8° (φ≈8°)
[0109] However, the coefficient of friction of the peripheral surface of the friction ring 3 a is made larger than that of the peripheral surface of the follower roller 2 . Incidentally, as for the material for the friction ring 3 a , a resinous substance such as polyacetal (POM) which is slidable is used. Further, in consideration of electrostatic problems attributable to the electrical charge resulting from the friction between the friction ring 3 a and intermediary transfer belt 606 , the friction ring 3 a is given electrical conductivity. Next, the reason why the friction ring 3 a has to be tapered (at angle φ), and also, why the friction ring 3 a has to be given a relatively smaller amount of friction (certain amount of friction) will be described in detail.
[0110] It was already described that the amount of the steering force generated to automatically centering the intermediary transfer belt 606 by using the unbalance between the amount of friction between the friction ring 3 a located at one end of the steering roller 1 and intermediary transfer belt 606 , and the amount of friction between the friction ring 3 a located at the other end of the steering roller 1 and the intermediary transfer belt 606 , can be obtained by multiplying Equation (6) with the amount of difference between the width of contact between the friction ring 3 a at one of the lengthwise ends of the steering roller 1 and intermediary transfer belt 606 , and the width of contact between the friction ring 3 a at other end and the intermediary transfer belt 606 . In the case of a belt centering automatic system, such as the one in this embodiment, which uses the unbalance in the friction, along with the tapering of the friction ring 3 a , the amount of steering force FSTR can be obtained by replacing the amount of belt tension T 1 in Equation (6) with a belt tension T, and taking into consideration the amount of difference in width of contact between the two edges of the intermediary transfer belt 606 .
[0000]
T
=
T
1
+
E
r
tan
φ
(
16
)
[0111] Then, the steering force FSTR can be expressed as follows:
[0000]
F
STR
=
2
Δ
y
μ
s
(
T
1
+
E
r
tan
φ
)
∫
0
θ
s
-
μ
r
θ
sin
(
θ
+
α
)
θ
(
17
)
[0112] The reason why the difference between the width of contact between the friction ring 3 a at one of the lengthwise ends of the steering roller 1 and the intermediary transfer belt 606 , and the width of contact between the friction ring 3 a at the other end of the steering roller 1 and the intermediary transfer belt 606 , becomes 2Δy is that the width of the intermediary transfer belt 606 is greater than that of the follower roller 2 , and is less than the width of the steering roller 1 (combination of follower roller 2 and two friction rings 3 a ), as shown in FIG. 11 . Regarding this relationship, when the intermediary transfer belt 606 is in the idealistic state in terms of position (normal), the width of contact between the friction ring 3 a and intermediary transfer belt 606 is w (hatched portion in drawing) at both ends of the steering roller 1 . Thus, if the intermediary transfer belt 606 deviates by Δy in its width direction, the difference between the width of contact between the friction ring 3 a and intermediary transfer belt 606 at one of the lengthwise ends of the steering roller 1 , and that at the other lengthwise end of the steering roller 1 , becomes 2Δy, as shown in FIG. 11 . That is, even if the belt deviation occurs, the intermediary transfer belt 606 always remains in contact with one of the friction rings 3 a , and therefore, rubs the friction ring 3 a . Therefore, the unbalance in friction between one end of the steering roller 1 and the other can be always detected. Therefore, sudden changes do not occur to the steering angle β.
[0113] It was described referring to FIG. 14 that if a relatively large deviatory force P 2 , that is, a deviatory force P which is too large for the tapering (angle φ) of the friction ring 3 a to deal with, occurs, compensation is made for the insufficiency by generating the counter deviatory force P′ by rotationally moving the steering roller 1 . Basically, the counter deviatory force P′ is generated by changing the difference in angle between the moving direction of the intermediary transfer belt 606 and the attitudinal direction of the intermediary transfer belt 606 . Thus, steering angle β 1 , which is equivalent to the amount of change made to this difference in angle between the moving direction of the intermediary transfer belt 606 , can be simply determined.
[0114] FIG. 15 is a graph which shows the relationship between the amount of the steering torque Tr and the steering angle β. Basically, as the deviation amount Δy increases, the difference in width of contact between the friction ring 3 a and intermediary transfer belt 606 at one end of the steering roller 1 , and that at the other end of the steering roller 1 , increases, and therefore, the steering torque Tr increases, which in turn increases the steering angle β. However, as the steering angle β is increased, the force which the intermediary transfer belt 606 generates to resist its twisting, also increases. Therefore, there is a limit to the size of the steering angle β. Here, the amount of the steering torque Tr can be expressed by the following equation.
[0000]
Tr
=
F
STR
L
=
2
Δ
yL
μ
s
(
T
1
+
E
r
tan
φ
)
∫
0
θ
S
-
μ
γ
θ
sin
(
θ
+
α
)
θ
(
18
)
[0115] A letter L in the equation is the radius of the rotational movement of the steering roller 1 , and stands for the distance shown in FIG. 10( b ).
[0116] Referring to FIG. 15 , the amount of steering torque Tr necessary to generate a steering angle β 1 is Tr 1 , which can be calculated using Equation (18). Equation (18) has multiple parameters that affect the amount of the steering torque Tr. In reality, however, in many cases, the parameters other than the coefficient of friction μs inevitably settle to certain values because of the required intermediary transfer belt driving performance, transfer performance, etc., of which the intermediary transfer belt unit is required. Thus, the parameters, the value of which is to be set for the automatic centering of the intermediary transfer belt 606 , are the angle φ of the tapering of the friction ring 3 a , and the coefficient of friction μs. In the case of this embodiment, in which the angle φ of the tapering of the friction ring 3 a is eight degrees (φ=8°), the coefficient of friction μs, which is for generating the steering torque Tr 1 need to be roughly 0.3 (μs≈0.3). If the friction ring 3 a is made of such a material as silicon rubber that is high in coefficient of friction (μs=1.0), the steering torque Tr 2 , the amount of which is determined by Equation (18), becomes larger than the steering torque Tr 1 , as shown in FIG. 15 , and the steering angle β 2 , which is determined by the steering torque Tr 1 , becomes greater than the steering angle β 1 . In other words, the steering angle β 2 , which is greater than necessary, brings forth a wasteful amount of change to the attitude of the intermediary transfer belt 606 . Thus, the overshoots occur during the automatic centering of the intermediary transfer belt 606 , which results in the deviation in the dot position in the primary scan direction. That is, all that is necessary is not that the steering torque Tr 1 which provides the steering angle β 1 is included. Unless the coefficient of friction μs is set in consideration of the effects of the excessive amount (β 2 −β 1 ) of steering angle β generated by the excessive amount of torque (Tr 2 −Tr 1 ), the effects (which reduces changes which occur to belt attitude with elapse of time) of the belt centering automatic system having two modes (stages), which uses the tapered (at angle φ) friction ring 3 a , cannot be obtained. Incidentally, regarding how large or small the coefficient of friction μs, according to the basic theory of the automatic centering of belt, the larger the coefficient of friction μs, the greater the steering torque. Therefore, if solving the belt deviation problem is the only object as in the past, a substance, such as rubber, the coefficient of friction μs of which is in a range of 1.0-1.5 (μs=1.0-1.5) is to be chosen as the material for the friction ring 3 a . This range is defined as the high range for the coefficient of friction μs.
[0117] On the other hand, the object of the present invention is to solve two problems, which are the belt deviation and the image deviation in the primary scan direction. It was already explained that the above-described automatic centering system having two stages (modes) is effective. The friction ring 3 a for achieving this object is structured so that it is tapered at angle φ, and its peripheral surface is made frictional (coefficient of friction μs). A value 0.3 to which the coefficient of friction μs is set to achieve the object can be defined as being clearly low compared to that in the past.
<Coefficient of Friction μSTR and Belt Material>
[0118] Up to this point, the automatic belt centering mode, which is carried out in two stages, and is one of the characteristic features of the present invention, has been descried while emphasizing the importance of the parameters which determine the characteristics of the friction ring 3 a . However, the requirements for improving the belt centering automatic system are present also for the coefficient of friction μSTR of the follower roller 2 and the material of the intermediary transfer belt 606 .
[0119] In Equation (15′), coefficient of friction μSTR is related to the resistive force which works when the intermediary transfer belt 606 is restored in position. Coefficient of friction μSTR itself is not one of the parameters which is related to the driving performance and transfer performance of the intermediary transfer belt unit. Therefore, it can be set from the standpoint of the automatic centering of the belt. Further, among the first to third items in Equation (15′), which are related to the taper angle φ, the third item includes the coefficient of tensional elasticity, being therefore highest in terms of the contribution to the belt returning (centering) force Q. It is evident therefore that the counter deviatory force P′, which has to be generated by rotationally moving the steering roller 1 , can be kept small by making the third item as large as possible, and the fourth item as small as possible.
[0120] In this embodiment, therefore, aluminum is used as the material for the follower roller 2 to provide the peripheral surface of the follower roller 2 with a coefficient of friction of roughly 0.1 (μSTR≈0.1), which is smaller than the coefficient of friction μS of the friction ring 3 a (μs≈0.3).
[0121] The intermediary transfer belt 606 is a resinous belt, the substrate layer of which is polyimide, and its coefficient of tensional elasticity E is approximately 18,000 N/cm 2 . Thus, the large tensional stress, which occurs in a substance which is large in coefficient of tensional elasticity E and is unlikely to stretch, can be effectively converted into belt returning (centering) force by making the follower roller 2 smaller in its coefficient of friction jSTR.
[0122] This continuously eliminates the warping which occurs to the intermediary transfer belt 606 . Therefore, it does not occur that the intermediary transfer belt 606 is continuously driven while remaining subjected to a harmful amount of load.
[0123] Therefore, not only is it possible to realize an automatic belt centering system which is significantly smaller in the counter deviatory force P′, and also, smaller in attitude change of the steering roller 1 , than a conventional system, but also, to prevent the breaking of the intermediary transfer belt 606 , or the like problems. Incidentally, the material for the intermediary transfer belt 606 does not need to be limited to polyimide. That is, it may be a resinous material other than the polyimide, or a metallic material, as long as the material can provide an intermediary transfer belt, the substrate layer of which is formed of a material which is similar in coefficient of elasticity to polyimide and does not easily stretch. Further, the material of the follower roller 2 may be a material other than the one in this embodiment, as long as its coefficient of friction μSTR is smaller than the coefficient of friction μs of the friction ring 3 a.
[0124] Here, the method for measuring the coefficient of friction of the above described friction ring 3 a , follower roller 2 , drive roller 604 , etc., will be described. In this embodiment, the coefficient of friction testing method for plastic film and sheet (JIS K7125) is used. More concretely, a sheet which makes up the inward surface of a belt, which in this embodiment is the polyimide sheet which makes up the inward surface of the intermediary transfer belt 606 , is used as a test piece.
[0000] <Effects of Belt Centering Automatic System in Accordance with Present Invention>
[0125] FIG. 17 shows the action of the above described belt centering automatic system in this embodiment. FIG. 17( a ) is a graph which shows the progression of the response of the belt centering automatic system, which occurred when an external disturbance which caused the belt deviation occurred at t=0 (sec). FIG. 17( b ) is a graph which shows the amount of difference between the data which were obtained at two belt edge detection positions M 1 and M 2 ( FIGS. 12 and 13) located at different positions in terms of the belt movement direction. It shows the changes in the positional deviation, in terms of the primary scan direction, which occurred when the intermediary transfer belt 606 was automatically centered. As will be evident from FIG. 17( a ), as the belt centering automatic system in this embodiment is used, the belt edge is returned to the normal position without overshooting. Thus, as will be evident from FIG. 17( b ), it is possible to center the intermediary transfer belt 606 without conspicuous positional deviation in the primary scan direction, except for the positional deviation z 1 in the primary scan direction, which is the effect of the external disturbance inputted at t=0 (sec). As will be evident from FIG. 17( a ), by using the belt centering automatic system in this embodiment, the belt edge is returned to the normal position without involving the overshoot. As a result, as will be understood from FIG. 17( b ), the intermediary transfer belt 606 can be centered without involving the conspicuous positional deviation in terms of the primary scan direction, except for the positional deviation z 1 effected by the external disturbance inputted at t=0.
[0126] As described above, by using the present invention, the positional deviation of the intermediary transfer belt 606 , which is likely to occur as the intermediary transfer belt 606 is circularly moved, can be automatically corrected using only the frictional unbalance, while using as small a steering angle possible, that is, while suppressing the changes of the suspension attitude of the belt, which occur with elapse of time. Therefore, it is possible to provide an intermediary transfer belt unit which is capable of solving not only the belt deviation problem, but also, the color deviation problem in terms of the primary scan direction. Further, the belt centering automatic unit in this embodiment is not a belt centering automatic unit that depends on only the coefficient of friction. Therefore, the friction ring can be molded of an inexpensive resinous substance. Therefore, the belt centering automatic unit in this embodiment is unlikely to be affected by the nonuniformity in the coefficient of friction, and also, is not easily affected by the changes which occur with elapse of time. With the employment of an intermediary transfer belt unit, such as the one in this embodiment, it is possible to provide an image forming apparatus which is very robust, inexpensive, and superior in image quality.
[0127] Incidentally, the image forming apparatus in this embodiment was a color image forming apparatus ( FIG. 6 ). However, the present invention is also applicable to a monochromatic image forming apparatus which yields only black images. In a case where the present invention is applied to a monochromatic image forming apparatus, the positional deviation in the primary scan direction is not color deviation. Instead, it is the decline in the registration accuracy in terms of the primary scan direction, which is attributable to the progressive deterioration of the lateral edges of an image. Further, the parameter setting for the friction ring 3 a in this embodiment is nothing but an example. In other words, the values for the tapering angle φ and coefficient of friction for the friction ring 3 a may be different from those given in this embodiment, as long as the automatic belt centering mode having two stages, which is the primary characteristic feature of the present invention, holds.
Embodiment 2
[0128] In addition to the intermediary transfer belt in the above described first preferred embodiment, the transfer belt 71 , with which an image forming apparatus 70 , shown in FIG. 7 , is provided can be listed as another belt involved in image formation. The image forming apparatus 70 shown in FIG. 7 is basically the same in recording medium feeding process and recording medium conveyance process as the image forming apparatus 60 shown in FIG. 6 . Therefore, the image forming apparatus 70 will be described only about its image formation process which is different from that of the image forming apparatus 60 .
[0129] The image forming apparatus 70 in this embodiment has: an image forming portion 613 Y which forms an image with the use of yellow (Y) toner; an image forming portion 613 M which forms an image with the use of magenta (M) toner; an image forming portion 613 C which forms an image with the use of cyan (C) toner; and an image forming portion 613 BK which forms an image with the use of black (BK) toner. The image forming portions 613 Y, 613 M, 613 C, and 613 BK are the same in structure, although they are different in toner color. Therefore, an image forming portion 613 Y is described as their representative. Incidentally, the image forming portions 613 are the same in structure as those the image forming apparatus in the above described first preferred embodiment.
[0130] The image forming portion 613 Y, which is a toner image forming means, is made up of: a photosensitive member 608 , which is an image bearing member; a charging device 612 for charging the photosensitive member 608 ; an exposing apparatus 611 a ; a developing apparatus 607 , and a photosensitive member cleaner 609 . The photosensitive member 608 is rotated in the direction indicated by the arrow mark m 2 in the drawing. As the photosensitive member 608 is rotated, its peripheral surface is uniformly charged by the charging device 612 . The exposing apparatus 611 a is driven by the inputted signals of image formation information, and the charged portion of the photosensitive member 608 is exposed to the beam of light projected upon the charged portion through a diffractive member 611 b . By this exposure, an electrostatic latent image is formed on the photosensitive member 608 . The electrostatic latent image on the photosensitive member 608 is developed by the developing apparatus 610 . As a result, a visible image (which hereafter may be referred to as toner image) is effected on the photosensitive member 608 .
[0131] Meanwhile, a recording medium sheet S is sent into the main assembly of the image forming apparatus in synchronism with the progression of the yellow (Y) image formation process, which is positioned most upstream in terms of the rotational direction of the transfer belt 71 . Then, the recording medium sheet S is held electrostatically adhered to the portion of the transfer belt 71 , which is in the image formation area. While the recording medium sheet S is conveyed by the transfer belt 71 , remaining adhered to the sheet S, a toner image is transferred onto the recording medium sheet S. The image formation process and transfer process, which are similar to those carried out in the yellow image forming portion 613 Y, are also carried out in sequence in the image forming portions 613 M, 613 C, and 613 BK, which are on the downstream side of the image forming portion 613 Y, with such a timing that the toner images formed in the downstream image forming portions are transferred in layers onto the recording medium sheet S, which is being conveyed by the transfer belt 71 . As a result, a full-color toner image is effected on the recording medium sheet S. Then, the recording medium sheet S is separated from the portion of the transfer belt 71 , which is in contact with the drive roller 604 , by the curvature of the drive roller 604 (static electricity is removed as necessary). Then, the recording medium sheet S is conveyed to a fixing apparatus 68 , which is on the downstream side in terms of the recording medium conveyance direction, through a pre-fixation conveyance portion 67 . Incidentally, the transfer residual toner, that is, the toner remaining on the photosensitive member 608 after the toner image transfer, is recovered by the photosensitive member cleaner 609 , to prepare the photosensitive member 609 for the next image formation cycle. In the case of the image forming apparatus in this embodiment, there are four image forming stations 613 , that is, the image forming portions Y, M, C, and BK. However, the number of colors, and the order in which the image forming portions 613 are arranged, do not need to be limited to the above described ones.
[0132] Next, the transfer belt unit, which is the unit for circularly moving the transfer belt 71 , will be described about its structure. The transfer belt 71 is a member in the form of an endless belt, which is held stretched by a drive roller 604 , a steering roller 1 , a pair of auxiliary rollers 72 and 617 , and is circularly moved in the direction indicated by an arrow mark V in the drawing. The function of providing the transfer belt 71 with a preset amount of tension is also provided, along with the function of driving the transfer belt 71 , by the steering roller 1 . The automatic belt centering mechanism is the same in structure as the automatic belt centering mechanism in the first preferred embodiment described with reference to FIGS. 1 and 2 . Basically, the friction ring portions 3 in this embodiment are the same as those in the first preferred embodiment, which depend on both the tapering (at angle φ) and steering roller 1 , as shown in FIGS. 3( a ) and 4 .
[0133] In the case of an image forming apparatus of the direct transfer type, such as the image forming apparatus 70 shown in FIG. 7 , the change in the attitude in which the transfer belt 71 is held stretched, becomes the changes in the attitude of the recording medium sheet S on the transfer belt 71 . Therefore, if the change in the steering roller angle, which is caused while the transfer belt 71 is automatically centered, is large, the overshoot, shown in FIG. 16 , which occurs during the progression of centering of the transfer belt 71 , and the positional deviation in the primary scan direction, which is attributable to the overshoot, occur. Therefore, not only the friction ring 3 is tapered (at angle φ), but also, is made relatively small in coefficient of friction μs, and the automatic belt centering operation which is carried out in two stages, which is shown in FIGS. 14 and 18 , is carried out as in the case of the first preferred embodiment. Basically, the coefficient of friction μSTR of the follower roller 2 , coefficient of tensional elasticity E in this embodiment are made similar to those in the first preferred embodiment. More concretely, the friction rings 3 are formed of electrically conductive polyacetal (POM), and are eight degrees in the angle φ of the tapering (φ=8°), and 0.3 in the coefficient of friction (μs=0.3). The follower roller 2 is formed of aluminum, and is 0.1 in coefficient of friction (μSTR=0.1). The transfer belt 71 is formed of polyimide, and its coefficient of tensional elasticity E is 18,000 N/cm 2 (E=18,000 N/cm 2 ).
[0134] Thus, when the deviatory force P is so small that the deviation amount Δy does not reach the deviation amount Δy 3 , which is large enough for the steering roller 1 to be steered (at angle β), the transfer belt 71 can be automatically centered by the tapering (at angle φ) of the friction ring 3 alone. When the deviatory force P is large enough for the deviation amount Δy to be Δy 3 , the transfer belt 71 can be automatically centered by utilizing the counter deviatory force P′, which is generated by rotationally moving the steering roller 1 , and therefore, can be automatically centered by rotationally moving the steering roller 1 at a relatively small steering angle β. Therefore, the transfer belt 71 can be centered without the overshooting, such as that shown in FIG. 17 , and therefore, it is possible to minimize the image deviation in the primary scan direction, which occurs when the transfer belt 71 is automatically centered. In other words, not only can this preferred embodiment solve the belt deviation problem, but also, can improve an image forming apparatus in terms of the color deviation in the primary scan direction. Ultimately, the employment of this transfer belt unit makes it possible to provide an image forming apparatus, which is inexpensive, but, is high in image quality.
[0135] Incidentally, the parameter setting for the friction ring 3 a in this embodiment is nothing but an example. That is, the value for the angle φ of the tapering of the friction ring 3 , and the value for the coefficient of friction μs, may be other values than those in this embodiment, as long as the their relationship allows the image forming apparatus in this embodiment to be operated in the automatic belt centering two-stage mode ( FIG. 18 ). Further, the image forming portion 613 , shown in FIG. 7 , uses an electrophotographic image forming method. However, the present invention is also applicable to an image forming apparatus, the image forming portions of which uses inkjet recording method, as long as the apparatus uses the transfer belt 71 .
Embodiment 3
[0136] Further, as one of the components involved in image formation, an image formation belt 81 , with which the image forming apparatus 80 , shown in FIG. 8 , is equipped, can be listed. Basically, The image forming apparatus 80 shown in FIG. 8 is basically the same in recording medium feeding process and recording medium conveyance process as the image forming apparatus 60 shown in FIG. 6 . Therefore, the image forming apparatus 80 will be described only about its image formation process which is different from that of the image forming apparatus 60 .
[0137] The image forming apparatus 80 in this embodiment has: an image forming portion 6130 Y which uses yellow (Y) toner for development; an image forming portion 6130 M which magenta (M) toner for development; an image forming portion 6130 C which uses cyan (C) toner for development; and an image forming portion 6130 BK which uses black (BK) toner for development. The image forming portions 6130 Y, 6130 M, 6130 C, and 6130 BK are the same in structure, although they are different in toner color. Therefore, an image forming portion 6130 Y is described as their representative. The image forming portion 6130 Y is primarily made up of a photosensitive belt 81 , a charging apparatus 84 , an exposing apparatus 611 a ; a developing apparatus 6100 , etc. The components in this embodiment which are the same in referential code as those in the first preferred embodiment are the same in structure as those in the first preferred embodiment.
[0138] The photosensitive belt 81 is an endless belt, the surface layer of which is a photosensitive layer. It is held stretched by a drive roller 604 , a steering roller 1 , an inward transfer roller 82 , a pair of auxiliary rollers 72 and 617 , and is circularly moved in the direction indicated by an arrow mark V in the drawing. The number of the photosensitive belt supporting rollers does not need to be limited to that in this embodiment. As the photosensitive belt 81 is rotated, its outward surface is uniformly charged by the charging device 84 . Then, the charged portion of the photosensitive belt 81 is scanned by the exposing apparatus 611 a . As a result, an electrostatic latent image is formed on the photosensitive belt 81 . The exposing apparatus 611 a is driven by the inputted signals of image formation information, and projects a beam of light across the charged portion of the photosensitive belt 81 through a diffractive member 611 b . The electrostatic latent image on the photosensitive belt 81 is developed by the developing apparatus 6100 , with the use of toner. The above described sequence of the image formation process are sequentially carried out in the image forming portions Y, M, C, and BK, starting from the image forming portion Y, which is the most upstream one, while being controlled with such a timing that the toner images formed in the downstream image forming portions are placed in layers on the photosensitive belt 81 . As a result, a full-color toner image is effected on the photosensitive belt 81 , and conveyed to the transfer nip, which is formed by an inward transfer roller 82 and an outward transfer roller 83 . The process carried out in the transfer nip to transfer the full-color toner image from the photosensitive belt 81 onto the recording medium sheet S, the timing control for the process, etc., are basically the same as those for the intermediary transfer method described with reference to FIG. 6 . Incidentally, the transfer residual toner, that is, the toner remaining on the photosensitive belt 81 after the toner image transfer, is recovered by the belt cleaner 85 , to prepare the photosensitive belt 81 for the next image formation cycle. In the case of the image forming apparatus in this embodiment, there are four image forming stations 6130 , that is, the image forming portions Y, M, C, and BK. However, the number of colors, and the order in which the image forming portions 6130 are arranged, do not need to be limited to the above described ones.
[0139] Next, the structure of the unit which circularly moves the photosensitive belt 81 will be described. The photosensitive belt 81 is a member in the form of an endless belt, which is held stretched by a drive roller 604 , a steering roller 1 , and a pair of auxiliary rollers 72 and 617 . It is circularly moved in the direction indicated by an arrow mark V in the drawing. The function of providing the photosensitive belt 81 with a preset amount of tension is also provided, along with the function of driving the photosensitive belt 81 , by the steering roller 1 .
[0140] The automatic belt centering mechanism in this embodiment is the same in structure as the automatic belt centering mechanism in the first preferred embodiment described with reference to FIGS. 1 and 2 . The friction ring portions 3 in this embodiment are tapered at an angle of φ as those in the first preferred embodiment, as shown in FIGS. 3( a ) and 4 . Basically it is the same as that in the first preferred embodiment. In the case of an image forming apparatus of the photosensitive belt type, such as the image forming apparatus 80 shown in FIG. 8 , if the change in the steering roller angle, which is caused while the photosensitive belt 81 is automatically centered, is large, the change in the attitude in which the photosensitive belt 81 is held stretched also becomes large, and therefore, the overshoot, shown in FIG. 16 , which occurs while the photosensitive belt 81 is centered, and the positional deviation in the primary scan direction, which is attributable to the overshoot, occur. Therefore, not only the friction ring 3 is tapered (at angle φ), but also, is made relatively small in coefficient of friction μs, so that the belt centering automatic operation is carried out in two stages, which is shown in FIGS. 14 and 18 , as in the case of the first preferred embodiment.
[0141] Basically, the coefficient of friction μSTR of the follower roller 2 , coefficient of tensional elasticity E of the photosensitive belt 81 in this embodiment are similar to those in the first preferred embodiment. More concretely, the friction rings 3 are formed of electrically conductive polyacetal (POM), and are eight degrees in the angle φ of the tapering (φ=8°), and 0.3 in the coefficient of friction (μs=0.3). The follower roller 2 is formed of aluminum, and is 0.1 in coefficient of friction μSTR (μSTR=0.1). The photosensitive belt 81 is formed of polyimide, and its coefficient of tensional elasticity E is 18,000 N/cm 2 (E=18,000 N/cm 2 ).
[0142] Thus, when the deviatory force P is so small that the deviation amount Δy does not reach the amount Δy 3 , which is large enough for the steering roller 1 to be steered (at angle β), the photosensitive belt 81 can be automatically centered by the tapering (at angle φ) of the friction ring 3 alone. When the deviatory force P is large enough for the deviation amount Δy to be Δy 3 , the photosensitive member 81 is automatically centered by utilizing the counter deviatory force P′, which is generated by rotationally moving the steering roller 1 , and therefore, can be automatically centered by rotationally moving the steering roller 1 at a relatively small steering angle β. Therefore, the photosensitive belt 81 can be centered without overshooting, such as that shown in FIG. 17 , and therefore, it is possible to minimize the positional image deviation in the primary scan direction, which occurs when the photosensitive belt 81 is automatically centered. In other words, not only can the photosensitive belt unit in this preferred embodiment solve the belt deviation problem, but also, can improve an image forming apparatus in terms of the color deviation in the primary scan direction. Ultimately, the employment of this photosensitive belt unit makes it possible to provide an image forming apparatus, which is inexpensive, but, is high in image quality.
[0143] Incidentally, the parameter setting for the friction ring 3 a in this embodiment is nothing but an example. That is, the value for the angle φ of the tapering of the friction ring 3 , and the value for the coefficient of friction μs, may be other values than those in this embodiment, as long as the their relationship allows the image forming apparatus in this embodiment to be operated in the automatic belt centering mode which is operated in two stages ( FIG. 18 ).
[0144] The present invention makes it possible to provide such a belt centering automatic system characterized in that when an external disturbance is relatively small so that the amount of belt deviation remains below a preset value, the photosensitive belt 81 is centered by the tapering of the frictional rings 3 alone, whereas the steering roller 1 is rotationally moved only if an external disturbance which is large enough to cause the amount of belt deviation to exceed a preset value is inputted. Therefore, it becomes possible to automatically center the component in the form of an endless belt as it is circularly moved, while minimizing the change in the belt attitude, which occurs with the elapse of time. Therefore, it becomes possible to correct both of the two problems, that is, “belt deviation”, and “color deviation in terms of the primary scan direction”, which the belts involved in image formation have, with the employment of an inexpensive structural arrangement.
[0145] The belt driving apparatus, which employs the automatic belt centering system in accordance with the present invention, can be applied to a fixation belt, in addition to the intermediary transfer belt, transfer belt, and photosensitive belt, which were described above. More concretely, it can be applied to a fixing apparatus as an image heating apparatus for fixing a toner image to recording medium. Referring to FIG. 19 , the fixing apparatus is of the belt type, which is made up of a fixation roller 615 as a fixing member, and a pressure belt 614 . The recording medium is conveyed while remaining pinched by the fixation roller 615 and pressure belt 614 . A fixing apparatus of the belt type is wider in nip, being therefore greater in the amount by which heat is given to the recording medium sheet S. Therefore, it is effective to provide an image forming apparatus which is significantly better in image quality when cardboard, coated paper, and the like, are used as recording medium, than a conventional image forming apparatus, and also, to provide an image forming apparatus which is significantly faster in image formation speed.
[0146] Next, referring to FIG. 19 , a fixing apparatus 190 in this embodiment will be described. The fixing apparatus 190 has a hollow fixation roller 615 , in which it has a heater 191 as a heat generating member. The electric power to the heater 191 is controlled by a control portion (CPU), with the use of a thermistor 195 , which is a temperature detection member of the noncontact type, so that the temperature of the fixation roller 615 is raised to a preset level, and kept at the preset level. The fixation roller 615 is laminated; the peripheral surface of its hollow metallic core is coated with rubber. It is driven by an unshown driving force source, in the direction indicated by an arrow mark a in the drawing. The pressure belt 614 , which opposes the fixation roller 615 , is suspended stretched by a drive roller 192 , a steering roller 1 , an upstream tension roller 617 , and a downstream tension roller 618 , and is circularly moved in the direction indicated by an arrow mark b in the drawing. There is provided a wide fixation nip between the fixation roller 615 and pressure belt 614 , by keeping the fixation roller 615 and pressure belt 614 pressed upon each other in such a manner that the pressure belt 614 is wrapped around the fixation roller 615 by a small angle, while being backed up from within the inward side of the pressure belt 614 , by a pressure pad 616 as a pressure applying member, so that a preset amount of pressure is maintained between the pressure belt 614 and pressure pad 616 . A recording medium sheet S having been conveyed in the direction indicated by an arrow mark F in the drawing is guided into the fixation nip by a fixation nip entrance guide 196 , and is conveyed through the fixation nip while remaining pinched by the fixation roller 615 and pressure belt 614 . Then, the recording medium sheet S is separated from the fixation roller 615 and pressure belt 614 with the use of the curvature of the fixation roller 615 , while being assisted by a separation claw 194 . Then, it is transferred to the downstream conveyance passage of the image forming apparatus, by a pair of discharge guides 197 and a pair of discharge rollers 193 .
[0147] The effects similar to those obtained in the first preferred embodiment can be obtained by using the steering roller 1 in the first preferred embodiment as the steering roller for the fixing apparatus.
[0148] Incidentally, the above described effects obtainable by the present invention can be obtained by increasing the frictional portions in the preceding preferred embodiment, in the angle of the tapered portion, while reducing the frictional portions in coefficient of friction.
[0149] Further, in the case of each of the preceding embodiments, the image forming apparatus is structured so that the steering operation was carried out after the width of contact between the belt and frictional portion reached a preset value. However, the image forming apparatus structure does not need to be limited to those described above. That is, the image forming apparatuses may be structured so that the belt centering operation by the friction portions and the belt centering operation by the steering operation are carried out at about the same time.
[0150] As described above, the present invention makes it possible to reduce the change in the belt attitude, which occurs with the elapse of time, by reducing the frictional portions in coefficient of friction, and also, to generate a proper amount of belt centering force.
[0151] While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth, and this application is intended to cover such modifications or changes as may come within the purposes of the improvements or the scope of the following claims.
[0152] This application claims priority from Japanese Patent Application No. 325793/2008 filed Dec. 22, 2008 which is hereby incorporated by reference.
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An image forming apparatus has a rotatable belt, a stretching unit for stretching the belt, a steering unit for stretching and steering the belt, wherein the steering unit includes a rotatable portion rotatable with rotation of the belt, a frictional portion, provided at each of opposite axial end of the rotation portion, for slidable contact with the belt, and a support for the rotatable portion and the frictional portion. A rotation shaft rotatably supports the support, and the steering unit is capable of steering the belt by rotation thereof from sliding between the belt and the frictional portion, wherein each of the frictional portions is provided with an inclined surface which is inclined to be further from a rotational axis of the rotation portion axially toward an outside, and wherein the belt is contacted to at least one of the inclined portions.
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This application is a continuation in part of a former application by the inventor, Ser. No. 08/756,240, filed Nov. 26, 1996, and now abandoned.
BACKGROUND AND SUMMARY OF THE INVENTION
This invention pertains to forms for holding poured concrete being used as basement or other concrete walls, and more particularly to a system for providing such forms quickly, conveniently and at relatively low cost.
Poured concrete walls have been used for many years. Forms into which to pour the concrete to form the walls have undergone many changes during that time. At first, with inexpensive carpenter labor, it was easiest to simply build wooden walls forming a trench between those walls into which the newly-mixed concrete could be poured. Later, re-usable sheet metal forms were developed. These forms could be placed, the concrete poured, and the forms removed so they could be reused.
More recently, systems have been proposed by which slabs of foamed plastic material are held in parallel spaced relation while the concrete is poured into the space between the slabs. With such walls, the plastic forms remain as insulation.
This invention pertains to the latter type of system and provides a much quicker, simpler way of putting the forms together for the preparation of the form for the pouring of the concrete, and a wall more rigid and supportive than previous walls of its type.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross sectional view of a poured concrete wall using as a base the new system of forms,
FIG. 2 is a perspective view of one rail of the form used to hold the foamed plastic form member,
FIG. 3 is a view similar to FIG. 2 of a base or top rail,
FIG. 4 is a perspective view of a tie used to hold the rails in proper relationship,
FIG. 5 is a partial sectional view of an alternate end fastening for the ties,
FIG. 6 is a sectional view of the rail in an alternative form usable as a intermediate rail, and
FIG. 7 is a sectional view of the rail in an alternate form, usable as a top and bottom rail.
DESCRIPTION
Briefly, this invention comprises a system of forms for holding poured concrete to form a wall. The basic form is not new, but the invention provides a convenient and quick system of putting the forms together for use, and provides a rare rigid and supportive wall.
In the construction of insulating forms for the pouring of concrete, it is current practice to use a series of sheets of foamed plastic material to provide the walls for the form. Each wall is formed of such panels held in spaced parallel arrangement by series of ties or spacers, generally being placed in slots at the edges of the sheets of plastic material. A system of this general type is shown in U.S. Pat. No. 4,765,109, issued Aug. 23, 1988; and U.S. Pat. No. 4,889,310, issued Dec. 26, 1989.
By this present invention, the applicant provides a simplified and improved system for building each wall and tying the walls together to shape the form for pouring the concrete. The use of panels 10 of foamed plastic material is common to both systems. However, in applicant's new system, plain edges not requiring tongue and grooves are used on the panel. These panels are set into tracks 11 of roughly H-shape having outer flanges 12 and inner flanges 12 ′ joined by a web 13 . It will be noticed that the formation provides a track or channel unit 11 having an upward opening channel and a downward opening channel, each of which has an inner flange 12 and an outer flange 12 ′ adapted to receive an edge of a panel 10 between said flanges. The flanges are spaced apart to embrace the thickness of the panels 10 so that each panel fits smoothly into the track and is held in line thereby.
At the top and bottom of each side wall, a capping track 15 may be used. This track is channel-shaped having a web 16 exactly like that of the main tracks 11 . The outer flanges 17 and inner flanges 17 ′, however, extend only one way from the web, thus forming a familiar channel shape. It is apparent how these strips will cover the top and bottom edges of the walls of the form. The tracks have an extended length which preferably extends the full width of the panel. However, they may be shortened to no less than one-half that width so long as the track crosses the abutting ends of adjacent panels.
Variations in these tracks are shown. For example, in both the H-shaped track 11 and the capping track 15 , the flanges 12 ′ and 17 ′ are shown as somewhat narrower than the outer flanges 12 and 17 . The reason is principally based on the function of the outer flange. As the concrete is poured, there is considerable pressure pushing outwardly on the forms. Thus, the flanges 12 and 17 on the outside need to be somewhat more resistant than the inner flanges 12 ′ and 17 ′. Thus these inner flanges may be made somewhat less strong than the outer.
Another variation is shown in FIG. 3 where the flanges 17 and 17 ′ are shown having a barbed holding strip 20 of generally triangular cross section running the length of the flange on the side of the flange adjacent the web. These strips 20 when in contact with the panels 10 tend to hold the panels in place so that slight bumps will not displace the panel and destroy the wall. This form greatly stiffens the wall, both by stiffening the flange on which it is formed and by holding the panel more rigidly when that panel is inserted between the flanges.
In order to be useful, the walls formed by the panels 10 and the tracks 11 and 15 must be held in spaced parallel relationship. This is accomplished by the use of ties 22 attached to the tracks by a simplified structure. The ties essentially hold the walls of the forms in a fixed parallel relationship both during the setting up of the forms and during the pouring of the concrete.
To provide for the structure, each of the tracks 11 or the capping tracks 15 is provided with a continuous holding protrusion 25 running along the track 11 (or track 15 ). A cross-section of the protrusion is shaped as an arrow-head having a shank 26 attached to the track and an arrow point held by the shank. The arrow point has a pointed tip 27 running as an edge parallel to the track, and a pair of barb-shaped portions 28 forming the rear of the point-shape. Thus, the barbs 28 have a surface sloping outward and away from the surface to which the protrusion 25 is attached. This shape is desirable because a mating surface will tend to be held more securely against forces tending to pull the attaching devices apart because of the acute angle at which the surface intersects with the shank 26 .
The tie 22 which holds the forms together is best shown in FIG. 4 . These ties, when fastened, extend a relatively short distance along the tracks 25 . Each end of the tie 22 is formed with a mating (female in the illustrated device) slotted hollow 30 which fits over the arrow head protrusion 25 on the tracks 11 and 15 . The body 31 of the tie may be a simple bar of proper length to hold the walls of the form in proper relationship as indicated in FIG. 1 . Notice that the mating hollow and barb have mirror image cross sections. This mirror image is required for resistance to withdrawal of one from the other.
The alternative form shown in FIG. 5 is simply a changed cross sectional form of the protrusion, shown in this figure at 25 ′ and the mating hollow 30 ′. The changed form uses dual barbs 32 in order to provide a stronger grasp between the male and female formations, when it becomes necessary to hold the walls of the form against greater pressure from the poured concrete. This might happen with walls thicker or higher than usual. The dual barbed tie might also be strong enough so that fewer ties could be used than when the single barbed form is used.
Still another variation in the cross-sectional shape of the tracks 11 and 15 is shown in FIGS. 6 and 7. These figures show the preferred H-shape and U-shape having interior barbs 20 . However, the interior flanges 35 and 36 respectively corresponding to the originally described flanges 17 ′ and 12 ′ respectively are formed with an inner leaning edge portion 37 on the interior flange 35 of the H-shaped cross-section and a similar portion 38 on the flange 36 in the U-shaped cross-sectional track.
The sloped edged portions 37 and 38 are useful in setting up the forms because the panels can be more easily inserted between the walls. Again the object is to ease the operation so that time and energy can be saved and so that the level of necessary skill can be reduced.
It will be recognized that while the ties are shown and described as having the female formation and the protruding strips 25 are described as male formation, that these formations could be reversed without in any way changing the usefulness of the formation of the assembly. Applicant prefers the illustrated arrangement where the tracks 11 and 15 can be made of a relatively rigid plastic and the ties 22 a somewhat more flexible material such as a nylon type plastic so that the entrance to the hollows 30 is somewhat easier to expand. In this way, the ties are somewhat easier to install.
In use, the first tracks - ordinarily base tracks 15 —would be placed in parallel spaced relation. Ties 22 along the length of the track would be fastened simply by pressing the male formed part into the hollow 30 of the female form and snapping it into place. By using a continuous strip on the tracks 15 , the ties can be placed at either regular or irregular intervals along the track as opposed to systems requiring openings in the panels. This flexibility is a real time-saving expedient when setting up the walls. The panels 10 are then placed in the channel form of the base track 15 and are topped by an H-shaped track 11 . Successive panels can then be built up till the form is as high as desired and then capped with a cap track 15 . In each layer, ties 22 should be fastened horizontally between the adjacent tracks to hold the walls in place. When the capping tracks have been placed and tied together, the concrete can be poured between the panel-walls and allowed to set, thus forming a poured concrete wall having insulating panels both inside and outside.
By using the continuous tracks 11 and 15 , the joints between the styrofoam panels are considerable strengthened and are made much more rigid. Where walls of forms in former types of assembly are held by ties and therefore allow flexing between walls unless extra care is used in the placement of ties, applicant's wall is relatively rigid. Walls formed by use of the tracks 11 and 15 will withstand much greater wind than previously formed walls before pouring. This is of particular benefit where it is necessary to prepare a form in one day for use in receiving poured concrete the following day—a common occurrence in many jobs because of the time required for the pour.
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A system of preparing a form for the pouring of concrete for foundations and the like. The system includes a series of tracks for holding of forming insulation material or the like. The tracks are held by ties having ends readily attachable to ribs on the tracks for rapid and convenient assembly. The tracks are formed to hold insulating panels in a spaced parallel relationship. The ties and tracks mate together in a holding relation easily engageable.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improved delay arming and safety mechanism for a fuze for a spinning projectile.
2. Prior Art
The fuze of this invention is an improvement on the conventional ball rotor safing and arming mechanical fuze used for medium caliber ammunition, an example of which is the M505A3 point detonating fuze employed in M56 20 mm High Explosive Incendiary ammunition, shown in FIG. 1.
The M505 fuze ball rotor employes a single safety device which is a "C" spring clip and which retains the explosive train, i.e. the detonator and the booster, in an out-of-line position prior to gun launch. This spring clip is defeated when the projectile exits the gun muzzle at the very high spin rate imparted to the projectile by the rifling within the gun barrel. Once the spring clip releases its grip on the out-of-line ball rotor, the rotor, due to spin dynamics, aligns itself so that the detonator within the rotor becomes oriented to the same axis as the firing pin and the booster. At this disposition, the fuze detonator is "armed" and capable of being "initiated" by the firing pin.
A shortcoming of such a ball rotor fuze is that only a single gun launch induced environment, i.e., projectile spin, suffices to arm the fuze. Desirably, a second gun launch induced environment, i.e., setback, should also be required to arm the fuze, and these should be two independent devices to respond respectively to each environment. Thus, if there are two safety devices, then if one device has been omitted in the assembly procedure, the other device may be there to keep the fuze safe.
Typically, these fuzes have a third semi-safing feature comprising a flange on the firing pin, which flange must be sheared off upon impact to free the pin to stab the detonator. Such a shearing process absorbs much kinetic energy and reduces the sensitivity of the fuze to low angle grazing impacts.
There have been many improvements proposed, including Ziemba, U.S. Pat. No. 3,595,169 and Rossman et al, U.S. Pat. No. 4,440,085, which each show a single spring clip which must respond to both setback and spin to release the ball rotor. If this single spring clip has been omitted in assembly, however, the rotor is free and may allow arming of the fuze. Other variations of interest are shown in Thompson, U.S. Pat. No. 2,715,873; Ziemba et al, U.S. Pat. No. 3,397,640; Bayard et al, U.S. Pat. No. 3,871,297; Ziemba, U.S. Pat. No. 4,242,963; Warren et al, U.S. Pat. No. 4,242,964; Weber et al, U.S. Pat. No. 4,458,594; Ziemba, U.S. Pat. No. 4,494,459; and Nicolas et al, U.S. Pat. No. 4,510,869.
Accordingly, it is an object of this invention to precondition arming of a fuze on contemporaneously but independently sensing the presence of adequate spin and setback forces.
A further object is to provide such a fuze with improved sensitivity to a grazing impact.
SUMMARY OF THE INVENTION
A feature of this invention is a safing and arming mechanism for a fuze for a spinning projectile including a ball rotor journaled for rotation within a cavity in the fuze. A firing pin, said cavity and a booster charge lie along the longitudinal axis of the fuze. The rotor carries a stab sensitive detonator in its diametral bore. A first spring mounted on a first seat cut into the ball normally fixes the ball with the detonator, out of alignment with the longitudinal axis of the fuze. A second spring mounted on a second seat cut into the ball also fixes the ball out of alignment. To release the ball, the first spring must be shifted aftwardly by setback force to a third seat cut into the ball, and the second spring must be enlarged by centrifugal force and removed from said second seat.
Additionally a third spring mounted on a seat on the firing pin must be enlarged by centrifugal force to free the firing pin prior to impact.
BRIEF DESCRIPTION OF THE DRAWING
These and other objects, advantages and features of this invention will be apparent from the following specification thereof taken in conjunction with the accompanying drawing in which:
FIG. 1 is a longitudinal cross-section of the prior art M505 fuze;
FIG. 2 is a longitudinal cross-section of a first embodiment of this invention in the fuze "safe" disposition;
FIG. 2A is a top view of the "C" spring clip for the rotor which is similar to the M505 clip;
FIG. 2B is a top view of the split ring for the rotor;
FIG. 2C is a top view of the split ring for the firing pin;
FIG. 3 is a longitudinal view of the fuze of FIG. 2 in the "setback" disposition;
FIG. 4 is a longitudinal view of the fuze of FIG. 2 in the "muzzle exit" or "spun up" disposition;
FIG. 5 is a longitudinal view of the fuze of FIG. 2 in the "armed" disposition;
FIG. 6 is a longitudinal view of the fuze of FIG. 2 in the "percussed" disposition;
FIG. 7 is a chart showing the kinetic energy absorbed by a conventional firing pin;
FIG. 8 is a longitudinal view of a second embodiment of this invention in the fuze "safe" disposition;
FIG. 9 is a longitudinal view of the fuze of FIG. 8 in the "setback" disposition;
FIG. 10 is a longitudinal view of the fuze of FIG. 8 in the "muzzle exit" disposition;
FIG. 11 is a longitudinal view of the fuze of FIG. 8 in the "post muzzle exit" disposition;
FIG. 12 is a longitudinal view of the fuze of FIG. 8 in the "armed" disposition; and
FIG. 13 is a longitudinal view of the fuze of FIG. 8 in the "percussed" disposition.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the prior art standard M505 fuze comprising a fuze body 10, a rotor 12, a detonator capable of being initiated at only one end 12A thereof; a rotor detent "C" spring 14, for retaining the rotor against rotation with the 12A end of the axis of the detonator (12B) at less than 90°, e.g. 85°, of the longitudinal axis 10A of the fuze, a firing pin 16 having a flange 16A, a nose cap 18, a booster charge 20, and a booster holder 22. The projectile is spun up during its passage through the barrel, the "C" spring fails due to spin forces at its narrow section releasing the rotor, which precesses to align the detonator axis 12B with the projectile spin axis 10A with the end 12A adjacent to the firing pin 16. Upon impact, the nose cap 18 must be crushed and the flange 16A sheared before the firing pin may be accelerated toward the detonator. If the "C" spring 14 is omitted during assembly, the rotor is subsequently free to wander and perhaps align its axis 12B with the axis 10A.
FIG. 2 shows the preferred embodiment of this invention. This fuze 30 comprises a fuze body 32, a rotor 34, a detonator 36 fixed in a bore 38 on an axis 40 of mass symmetry in the rotor, a booster holder 42 is secured by mating threads in an aft cavity 44 in the body and jointly with the body provides a central substantially spherical cavity 46 in which the rotor is journaled. A booster charge 48 is fixed in a blind bore 50 in the holder, and is spaced from the rotor by a thin web 52. A firing pin 54 is partially disposed in a forward bore 56 in the body 32 and has an aftwardly directed spike 58. The pin 54 has an annular groove 60 in which is disposed a split ring 62, also shown in FIG. 2C, and which has a notch 64 diametrically opposite the split 66. The ring 62 engages the forward, truncating face 68 of the body and precludes aftward movement of the pin 54 in the bore 56 towards the rotor. A crushable cap 70 is secured over the forward face 68 of the body and the head 72 of the pin and captures the pin in the bore 56.
An annular groove 74 is formed in the aft face of the rotor, on a diametrical axis 75, coaxial with body axis 76, considering the rotor axis 40 to be at 85° to the axis 76 of the body, and is opposite an annular groove 78 formed in the body. A "C" spring rotor detent 80, also shown in FIG. 2A, is disposed in the annular groove 74, abutting the annular front face 81 of the holder 42, and aligned with the groove 78.
A pair of adjacent annular grooves, 82 distal and 83 proximal, are formed on the front face of the rotor, both coaxial with the groove 74. The distal groove 82 is opposite an annular groove 84 formed in the body. A split ring 86, also shown in FIG. 2B, is disposed in the distal groove 82.
It will be seen that both the "C" spring 80 by its abutment against the booster holder front face 81 and the split ring 86 by its abutment with the body groove 84 preclude any rotation of the rotor 34 from its 85° misalignment with the projectile axis 76. The split ring 62 by its abutment against the face 68 precludes any aftward movement of the firing pin 54 towards the rotor 34.
During storage and transportation the fuze is in the disposition shown in FIG. 2. Upon firing of the round of ammunition, i.e. "launch" of the projectile, the fuze is accelerated into its "setback" disposition as shown in FIG. 3, wherein as the fuze is accelerated, at e.g., at 105,000 gs, the inertia of the split ring 86 causes it to snap over the ridge between the pair of grooves, from the distal groove 82 into the proximal groove 83, and out of abutment with the groove 84 in the body. Thus the safety of the rotor provided by the split ring 86 has been defeated independently of the "C" spring 80 which continues to lock the rotor in its "safe" disposition.
As the projectile is accelerated along the length of the gun barrel towards the muzzle, the interaction of the rifling in the bore of the gun barrel with the rotating band of the projectile causes the projectile to be spun up about its longitudinal axis 76 to a maximum rotational velocity as it exits the muzzle. This rotational velocity, as shown in FIG. 4, at, e.g., 65,000 rpm, causes the arms of the "C" spring 80 to spread apart into the groove 78 and break apart, out of abutment with the face 81 of the booster holder. Thus the safety of the rotor provided by the "C" spring has been defeated independently of split ring 86. The rotational velocity also causes the arms of the split ring 62 to spread apart out of the groove 60 and to break apart at the notch 64 to permit the firing pin 54 to "float" in the bore 56.
After the "C" spring 80 has broken, due to dynamic mass unbalance the rotor precesses within the spinning projectile to bring the detonator into alignment with the firing pin and the booster (on axis 76) to the "armed" disposition as shown in FIG. 5.
Upon target impact, the nose is crushed and the firing pin is accelerated to stab the detonator as shown in FIG. 6.
It will be seen that the substitution of the split ring 62 for the conventional flange on the firing pin greatly increases the sensitivity of the fuze to a low energy grazing impact. The absorption of kinetic energy by the conventional flange in shear is shown in FIG. 7. In the present invention, the split ring, resting in the groove 60, supports the firing pin 54 against setback force, but at the time the projectile has left the gun barrel, centrifugal force causes the split ring to open and free the pin to "float" beneath the nose cap of the fuze 80, and that the only resistance offered to its travel into the detonator at target impact is that force which is required to crush the nose cap, thus making the fuze more sensitive to targets at reduced projectile strike velocity.
An alternative embodiment of this invention is shown in FIG. 8. In this embodiment an unwinding ribbon 100 is substituted for the "C" spring of the first embodiment. This unwinding ribbon performs two functions: First, it serves as the spin safety of the fuze, i.e., the rotor cannot precess to the armed disposition until the ribbon has spun free of the rotor. Second, the time required to unwind the ribbon represents the larger part of the delay in the arming of the fuze. The smaller part of the delay is the time required for the rotor to precess to its "armed" disposition after the ribbon has unwound free of the rotor.
Use of an unwinding ribbon as a combination spin safety and arming delay mechanism is made feasible by the use of a double ended detonator.
This embodiment employs a unique detonator 102 which makes possible the use of an unwinding ribbon as both a spin safety and an arming delay mechanism. This detonator contains a single primary explosive charge of Mercury 5 Trinitrotetrozole which is a high output explosive which is also stab sensitive. Since this detonator can be stab initiated at either end thereof, it does not matter through which direction the rotor 104 precesses to its "armed" disposition. Therefore, the detonator 102 in the "safe" disposition can be held with its axis 106 at 90° to the longitudinal axis 108 of the projectile. Since the driving torque causing the rotor to precess from the 90° initial position is essentially zero and increases, as a function of the detonator axis, to a maximum at 45°, it is possible for the ribbon to retain the rotor in its 90° position until the ribbon is fully unwound without the ribbon binding due to excessive rotor torque loads. The length of the delay is a function of the length of the ribbon, which after setback as shown in FIG. 9, unwinds into the groove 78 as shown in FIG. 10 and 11, and hence to permit the rotor to precess into the "armed" disposition shown in FIG. 12. Either end of the detonator may be presented to the firing pin which stabs the detonator on impact with the target as shown in FIG. 13. The length of the delay provided by the unwinding ribbon of the second embodiment may be made much longer than the delay provided by the 85° rotor design shown in FIG. 2.
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This invention provides a safing and arming mechanism for a fuze for a spinning projectile including a ball rotor journaled for rotation within a cavity in the fuze. A firing pin, said cavity and a booster charge lie along the longitudinal axis of the fuze. The rotor carries a stab sensitive detonator in its diametral bore. A first spring mounted on a first seat cut into the ball normally fixes the ball with the detonator, out of alignment with the longitudinal axis of the fuze. A second spring mounted on a second seat cut into the ball also fixes the ball out of alignment. To release the ball, the first spring must be shifted aftwardly by setback force to a third seat cut into the ball, and the second spring must be enlarged by centrifugal force and removed from said second seat.
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RELATED APPLICATIONS
The present application claims the benefit of U.S. Provisional Patent Application No. 61/116,131, filed Nov. 19, 2008, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The invention relates generally to a merchandising display and dispensing system for display and dispensing articles. In particular, the invention relates to a modular display and dispensing system having a plurality of modules fitted with one another. The invention also relates to a module device for constructing a merchandising display and dispensing system.
BACKGROUND OF THE INVENTION
Products in relatively small individual packages are often displayed in and sold from merchandise dispensers that dispense the packages to customers one at a time. Such dispensers are especially useful for small cylindrical product packages that would otherwise be difficult to display on a typical store shelf. The manner in which a product is displayed and dispensed can have a significant impact on sales. This is particularly true in “product-rich” environments, such as grocery and drug stores.
Conventional merchandise dispensers may suffer from certain shortcomings. For example, such dispensers may not display the product in a visually-appealing manner that promotes sales. Conventional dispensers may be difficult and/or inconvenient to reload. Such dispensers may not be amenable to the creation of larger displays by combining a number of separate dispensers.
SUMMARY OF THE INVENTION
The invention relates to a merchandising display and dispensing system for displaying and dispensing articles, including cylindrical shaped products, such as rolls of tablets, or disk-like confections. The display and dispensing system can be formed with a plurality of modules, which can be fitted together to construct a modular display and dispensing system.
Each module comprises a left side panel and a right side panel which are fitted together and form a serpentine chute which feeds rolls by gravity to an access tray where a roll can be removed by hand, thus permitting another roll to enter the tray. The front of the module receives a front cover which covers the chute and provides a surface for indicia of contents inside the module. The front cover is preferably hinged at either its bottom or top to permit reloading product in the chute.
Each module has a rear surface provided with openings for receiving suction cups or hanging on a nail, hook or other mounting device. However it is preferred to mount the modules side-by-side on a base plate by dovetail connections provided on the base plate and the bottoms of the modules. The modules can also be connected to one another vertically by dovetail connections on top of each module, and/or laterally by dovetail connections on the lateral walls of the adjacent modules. Additionally or alternatively, a header can be fitted by dovetail connection across the top row of modules to provide additional retention of the array or rows and columns, as well as additional space for identifying information.
Each module is fitted together by pins and sockets in a press fit, and may also be glued. However, positive mechanical retention is preferably provided by the various dovetail connections when the modules are assembled in an array of rows and columns on the base plate.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and features of the present invention will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for purposes of illustration and not as a definition of the limits of the invention, for which reference should be made to the appended claims. It should be further understood that the drawings are not necessarily drawn to scale and that, unless otherwise indicated, they are merely intended to conceptually illustrate the structures and procedures described herein. In the drawings:
FIG. 1 shows perspective views of a single module and a group of modules assembled in a 2×3 array of rows and columns formed according to a first embodiment;
FIGS. 2A-2H show various views of a left side panel of the module shown in FIG. 1 ;
FIGS. 3A-3H show various views of a right side panel of the module shown in FIG. 1 ;
FIGS. 4A-4H show various views of the base of the module shown in FIG. 1 ;
FIGS. 5A-5H show various views of the cover of the module shown in FIG. 1 ;
FIGS. 6A-6H show various views of the header of the module shown in FIG. 1 ;
FIG. 7 shows a perspective view of a single module formed according to a second embodiment;
FIGS. 8A-8G show various views of a left side panel of the module shown in FIG. 7 ;
FIGS. 9A-9G show various views of a right side panel of the module shown in FIG. 7 ;
FIGS. 10A-10H show various views of the cover of the module shown in FIG. 7 ;
FIGS. 11A-11J show various views of the base of the module shown in FIG. 7 ;
FIGS. 12A-12J shows various views of the header of the module shown in FIG. 7 ;
FIG. 13 shows a flowchart of the process steps of assembling a 2×3 array of modules; and
FIG. 14 shows a flowchart of the process steps of loading the assembled modular array.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 1 shows a merchandising display and dispensing system 1 for display and dispensing articles. The display and dispensing system 1 can be formed with a plurality of modules 10 , which are interconnected with one another to form a modular system 1 . In one embodiment, the multiple modules 10 can be formed to be identical so as to provide interchangeability for the modular system 1 . In the example shown in FIG. 1 , the display and dispensing system 1 is shown to have a 2×3 array (two rows and three columns) of modules 10 . One of such modules 10 is separated from the display and dispensing system 1 and shown side-by-side with the same. Detailed description of such modules 10 will be provided below.
The modules 10 each comprise a left side panel 12 L and a right side panel 12 R, which are formed so that each of them is substantially a mirror image of the other. FIGS. 2 and 3 show various views of the respective left and right side panels 12 L, 12 R. As the left and right side panels 12 L, 12 R are formed to be substantially mirror images, one the left side panel 12 L will be described in great details.
The left side panel 12 L include first and second guide rails 14 L, 16 L extending from an inside surface of the left panel 12 L and substantially perpendicularly thereto. The first and second guide rails 14 L, 16 L form a serpentine passage 18 L therebetween. Each lap of the serpentine passage 18 L is inclined downward, allowing articles to be dispensed in the assembled module 10 by gravity when the assembled module 10 is in a working position as shown in both perspective and right-side plane views of FIGS. 2A-2H .
In the example shown in FIGS. 2A-2H , the serpentine passage 18 opens at the front top portion of the left side panel 12 L, declines towards the rear portion of the left panel 12 L, turns and declines toward the front portion, turns and declines toward the rear portion a second time, and then turns towards the front bottom portion of the left panel 12 L. In such a case, the two ends 20 in , 20 out of the serpentine passage 18 L both open at the front side of the left panel 12 L. In the alternative, the serpentine passage 18 L can open at both the front and rear portions of the panel 12 L. In one example not shown, one end of the serpentine passage 18 L can open at the rear top portion of the panel 12 L. In such an example, articles are to be loaded into the module 10 from the rear thereof.
The first and second guide rails 14 L, 16 L can incline at different inclination angles. For example, each leg of the first and second guide rails 14 L, 16 L is inclined at an angle from about 10° to about 15° in relation to a horizontal direction. In one example, the inclination angle is about 11°. The inclination angle can be determined by a number factors including the weight of the articles to be dispensed, the material of the articles, the material of the guide rails 14 L, 16 L, and other factors.
Additionally or alternatively, the serpentine passage 18 L can be formed to have various numbers of turns. In the example of FIGS. 2A-2H , the serpentine passage 18 L is shown to have three turns. The first and second guide rails 14 L, 16 L of the left panel 12 L can also be formed to provide a different number of turns.
The left panel 12 L can be formed with one or more of top, rear, and bottom panels 22 L, 24 L, 26 L. In the example shown in FIGS. 2A-2H , the top, rear, and bottom panels 22 L, 24 L, 26 L and the left side panel 12 L define a substantially rectangular shape of a module 10 , after the left side panel 12 L is assembled with a corresponding right side panel 12 R (see, FIGS. 3A-3H ). In an example not shown, the top, rear, and bottom panels 22 L, 24 L, 26 L can assume various shapes for enhanced display effects.
The left and right side panels 12 L, 12 R each can be formed with various additional structures for various purposes. For example, the side panels 12 L, 12 R can be formed with fasteners 28 L, 28 R so that the side panels 12 L, 12 R can be joined with each other to form a module 10 (see, FIG. 1 ). For example, complementary fasteners, such as press-fit fasteners, can be formed on the left and right side panels 12 L, 12 R as are shown in their perspective views in FIGS. 2 and 3 . When the complementary fastener are made to engage with one another, they connect the left and right side panels 12 L, 12 R to each other to result in a module 10 . In an example, the fasteners 28 L, 28 R can be releasably connected to one another, allowing the left and right side panels 12 L, 12 R to be assembled and disassembled repeatedly.
In another example, the bottom panels 26 L, 26 R of the side panels 12 L, 12 R can be formed with forward extending lips 30 L, 30 R, respectively, to form an access tray 32 for receiving a dispensed product. The forward extending lips 30 L, 30 R each continue to extend upward and form a barrier 34 L, 34 R to retain the dispensed product in position and prevent the same from accidentally falling off the receiving tray 32 . The dispensed product can thus be readily accessed by a user.
Additionally or alternatively, various connecting structures can be formed on the side panels 12 L, 12 R and adapted to join the module 10 to a front cover (see FIGS. 4A-4H ), to another adjacent module 10 , to a module base (see FIGS. 5A-5H ), and/or to a module header (see FIGS. 6A-6H ) as will be described below in connection with these additional components of the display and dispensing system 1 .
The module 10 shown in FIGS. 2A-2H can be assembled by bringing and fastening the left and right side panels 12 L, 12 R to each other. For example, the side panels 12 L, 12 R are joined with each other by the fasteners 28 L, 28 R formed on such side panels 12 L, 12 R. In the resulting module 10 , the respective guiding rails of the left and right side panels 12 L, 12 R are aligned to form a serpentine chute 18 inside the module 10 . For example, the first guide rails 14 L, 14 R are aligned to each other and form a continuous front guide 14 . The second guide rails 16 L, 16 R are aligned with each other to form a continuous rear guide 16 . A serpentine chute 36 is formed between the front and rear guides 14 , 16 and extends similarly to the serpentine passage 18 L described above.
In one example, the first guide rails 14 L, 14 R are spaced from each other as the height of such guide rails 14 L, 14 R is less than that of the top, rear, bottom panels 22 L, 22 R, 24 L, 24 R, 26 L, 26 R as illustrated in the perspective views of the side panels 12 L, 12 R in FIGS. 2 and 3 . The space between the first guide rails 14 L, 14 R is designed to be less than the lesser dimension of the article to be dispensed to avoid such article to fall through the space.
When the module 10 is set up for operation in a working position as shown in FIG. 1 , the serpentine chute 36 (see FIGS. 2A-2H ) can assist to feed rolls by gravity to the access tray 32 . The dispensed articles can then be removed by a user. When the dispensed article is removed, another article can be dispensed by gravity and enter the access tray 32 .
FIGS. 4A-4H show a front cover 40 provided for covering the front of the module 10 and the front and rear guides 14 , 16 inside the module 10 . The front cover 40 can assume a shape corresponding the shape of the front portions of the left and right side panels 12 L, 12 R. In the example shown in FIGS. 4A-4H , the front cover 40 have a curved profile formed in accordance with the curvature of the front portions of the side panels 12 L, 12 R. One skilled in the art will appreciate that the front cover can assume various other shapes, such as a straight or wavy surface (not shown).
The front cover 40 of each module 10 can be formed to provide indicia of the content in the module 10 . For example, the front cover 40 can be provided with a transparent window or opening 42 to allow viewing of the products contained in the module 10 . Additionally or alternatively, the front cover 40 can provide a surface for indicia of products. In one example, the front cover 40 can be made of a transparent material allowing product indicia, such as a product label, to be placed on the inside of the front cover 40 and face outside toward the user. In the alternative, the front cover 40 can be formed so that product information can be affixed on the outside surface of front cover 40 . One skilled in the art will appreciate that the product information can be affixed to the front cover 40 by various other methods.
The front cover 40 can be attached to the remaining portion of the module 10 by any of various ways. In a preferred embodiment, the front cover 40 is hinged to the bottom portions of the left and right panels 12 L, 12 R in the module 10 to permit the front cover 40 to pivot open, such as when reloading products in the top of the chute 36 . In the example shown in FIGS. 4A-4H , the front cover 40 is formed with a pair of pivoting pins 44 L, 44 R extending from the bottom edges of the front cover 40 . The pivoting pins 44 L, 44 R are adapted to engage and pivot inside corresponding retaining apertures 46 L, 46 R in the left and right side panels 12 L, 12 R, respectively (see FIGS. 2 and 3 ).
The front cover 40 can also be formed with a pair of locking pins 48 L, 48 R extending from the top edges of the front cover 40 . The locking pins 48 L, 48 R are adapted to be received in corresponding latching openings 50 L, 50 R in the left and right side panels 12 L, 12 R. As is shown in FIGS. 2 and 3 , the latching openings 50 L, 50 R in the side panels 12 L, 12 R each are surrounded by a upward extending stopper 52 L, 52 R for maintaining the front cover 40 in a closed position and preventing the front cover 40 from opening by accident.
During operation of the front cover 40 , the front cover 40 is either lifted out of or dropped in the latching openings 50 L, 50 R in the left and right side panels 12 L, 12 R. To facilitate such opening and closing operation of the front cover 40 , the retaining apertures 46 L, 46 R in the left and right side panels 12 L, 12 R can be have an oblong shape, as is shown in FIGS. 2 and 3 . The oblong shaped retaining apertures 46 L, 46 R allow cylindrical pivoting pins 44 L, 44 R and in turn the front cover 40 to move slightly in a vertical direction.
In the embodiment shown in FIG. 1 , multiple modules 10 can be assembled together to form a modular display and dispensing system 1 . For example, the modules 10 can be stacked to form multiple rows or joined side-by-side to form multiple columns. For example, each module 10 can be formed with a convex joint element 54 vex on the top to connect with a concave joint element 54 cav on the bottom of another module 10 . In one example, the modules 10 are each formed with a convex joint element 54 vex on the top surface and a concave joint element 54 cav on the bottom surface. Such modules 10 can be interchanged and interconnected to form a modular system 1 .
Additionally or alternatively, each module 10 can be formed with a convex joint element 56 vex on one side surface to connect with a concave joint element 56 cav on an opposite side of another module 10 . In one example, the modules 10 each can be formed with a dovetail joint element on each of the top, bottom, and side surfaces of the module 10 to join with a complementary dovetail joint element in an adjacent module.
FIGS. 5A-5H show a base plate 60 formed to provide additional retention to modules 10 supported thereon. The base plate 60 has a bottom side 62 to be situated on a supporting structure, such as a shelf, countertop or tabletop at the point of purchase. On the top surface 64 of the base plate 60 , a number of joint elements 66 a , 66 b , 66 c are formed, which are complementary to the joint members on the bottom of the modules 10 . In one example, the joint elements 66 a , 66 b , 66 c on the base plate 60 are dovetail joint elements. As one of the perspective views in FIGS. 5A-5H shows, the base plate 60 can be formed with a hollow interior 68 on the bottom side 62 . In one example, a rib 70 is formed inside the hollow interior 68 to provide stability for the base plate 60 .
The base plate 60 can have an extension 72 extending beyond the assembled modules 10 in the front side. Such an extension 72 can prevent the stacked modules 10 from tipping forward and thus afford additional stability to the display and dispensing system 1 . In one example, the extension 72 is provided with indicia 74 (see FIG. 1 ) for the products contained in the modules 10 and/or the entire display and dispensing system 1 .
FIGS. 6A-6H shows a header 80 , which can be used together with the modules 10 in a display and dispensing system 1 . In the example shown in FIGS. 6A-6H , the header 80 has an elongated shape with an L-shaped cross-section. The header 80 has a joining plate 82 formed to be connected to the joint elements on the top of modules 10 . In one example, the joining plate 82 is formed with a plurality of cut-outs 84 each to be connected to a complementary dovetail joint element formed on top of the module 10 .
The front plate 86 of the header 80 extends upward from the joining plate 82 . Similar to the front covers 40 , the front plate 86 can provide a surface 88 for indicia of products in the modules 10 and/or the entire display and dispensing system 1 . In another example not shown, the front plate can be formed in various configurations to promote the products contained in the modules. For example, the front plate can be formed to have the same shape of the products, such as one or more two-dimensional or three-dimensional soda cans for a soda display and dispensing system.
The various components of the module 10 can be formed of any of various materials. For example, one or more of the side panels 12 L, 12 R including top, rear, and bottom panels 22 L, 22 R, 24 L, 24 R, 26 L, 26 R, the front cover 40 , the base plate 60 , and the header 80 can be made of a plastic material through a molding process.
FIGS. 7 to 10 show a second embodiment of a module 110 similar the module 10 described above. Similar components and elements of the modules 10 , 110 are formed of similar reference numerals with the same last two digits. Only differences between the two modules 110 , 10 are elaborated below.
As FIGS. 8A-8G and 9 A- 9 G show, the left and right side panels 112 L, 112 R are each formed with a third guide rail 117 L, 117 R continuously following along the serpentine passage 118 L. The third guide rails 117 L, 117 R have a smaller height dimension compared to that of the first and second guide rails 114 L, 116 L, as is shown in the front side views of FIGS. 8A-8G and 9 A- 9 G. The third guide rail 117 L, 117 R provide additional guidance to the products being dispensed along the serpentine passage 118 L. Additionally or alternatively, the third guide rail 117 L, 117 R space the products away from the inside surfaces of the left and right side panels 112 L, 112 R and thus minimize the possibility of the products being jammed inside the serpentine chute 118 .
In another example shown in FIGS. 8A-8G and 9 A- 9 G, the first guide rails 114 L, 114 R are each provided with a supporting pin 190 L, 190 R located near the inlet of the serpentine chute 118 and facing toward each other. The supporting pins 190 L, 190 R operate to support a loading guide when loading articles into the module 110 , as will be described below.
FIGS. 10A-10H show the front cover 140 of the second embodiment, in which a loading guide 192 is provided extending from the inside of the front cover 140 . When the front cover 140 is in an opened position, the loading guide 192 exits from inside of the module 10 and extends in a substantially the same inclined direction as the upper leg of the front guide 114 . The loading guide 192 is thus accessible by a user to load items onto the loading guide 192 . When the front cover 140 is moved toward the closed position, as is shown in the side view in FIGS. 10A-10H , the loading guide 192 retreats into the module 10 . During the retreat, the loading guide 192 inclines further downward to unload the items onto the serpentine front guide 114 by gravity.
In one embodiment, the loading guide 192 is formed with a tip portion 194 , which is narrower than the remaining portion of the loading guide 192 . During a loading operation, the narrowed tip portion 194 can fit between the first guide rails 114 L, 114 R formed in the left and right side panels 112 L, 112 R, respectively, and form a substantially continuous loading surface extending from the loading guide 192 to the front guide 114 (see FIG. 14 ). In a preferred embodiment, the tip portion 194 has a hook-like structure 196 formed on the lower surface of the tip portion 194 . The hook-like structure 196 is adapted to engage with a pair of supporting pins 190 L, 190 R formed on the first guide rails 114 L, 114 R so as to support the front cover 140 in an open position during a loading operation.
The front cover 140 can also be provided with a pulling tab 198 to assist a user in opening the front cover 140 . In the example shown in FIGS. 10A-10H , the pulling tab 198 can be formed to extend from the top of the front cover 140 and opposite from the loading guide 192 .
FIGS. 11A-11J show the base plate 160 of the second embodiment. The base plate 160 can be formed to support two, three, or more modules 10 , 110 . In the example of the two-module base plate 160 (see right side of the drawing), the base plate 160 can have one or more joint elements 167 vex formed on one of the side surface to connect with complementary joint elements 167 cav formed on an opposite side surface of another base plate 160 . For example, convex and concave joint elements 167 vex , 167 cav are formed respectively at the left and right side surfaces of the base plate 160 . Such a base plate 160 can be joined to another base plate 160 to form an expanded modular display and dispensing system 101 (see FIG. 13 ). In one example, the joint elements 167 vex , 167 cav on the side surfaces of the base plate are dovetail joint elements. In another example, the concave joint elements 167 cav can be in the form of cut-outs formed in the side walls of the base plate 160 .
FIGS. 12A-12J show a header 180 similar to that shown in FIGS. 6A-6H .
FIG. 13 shows a flowchart of the process of assembling a 2×3 array of modules 110 . Steps 1 and 2 in FIG. 13 indicate that the bottom row of modules 120 are attached to a base plate 160 . During steps 1 and 2 , each of the modules 110 in the bottom row is dovetailed to the base plate 160 and to the adjacent module(s) 110 . Step 3 indicates that the top row modules are then attached to the bottom row modules by the dovetail joint elements on the respective modules 110 . In Step 4 , the header 180 is assembled, resulting in a final modular display and dispensing system 101 .
The above assembling steps can be carried out at the point of purchase, such as a store. In such a case, the assembled modular display and dispensing system 101 is ready for loading the products as described below in connection with FIG. 14 . Alternative, the assembling steps 1 - 4 can be carried out by the manufacturer. In such a case, the assembled modular display and dispensing system 101 can be packed in a shipping carton, as indicated in step 5 , to be delivered to customers. Optionally, the products to be dispensed can be packed and shipped to the customers at the same time.
FIG. 14 shows a flowchart of the process of loading the modular array of FIG. 13 . To open the front cover 140 , lift the front cover 140 to unlatch the locking pins 148 L, 148 R on the front cover 140 as indicated in step 1 of the opening operation. Then, engage the hook-like structure 196 on the loading guide 192 with the supporting pins 190 L, 190 R on the left and right first guide rails 114 L, 114 R, as indicated in step 2 of the opening operation. The loading guide 192 thus extends the front guide 114 outside the module 110 for easier access by a user. For example, products can be placed onto the loading guide 192 , which leads the products onto the front guide 114 .
After the loading operation is completed, the loading guide 192 is unhooked from the supporting pins 190 L, 190 R. The front cover 140 can then be closed. When the locking pin 148 L, 148 R on the front cover 140 reaches the latching opening 150 L, 150 R on the side panels 112 L, 112 R, the front cover 140 is lifted to allow the locking pins 148 L, 148 R to be retained in position in the latching opening 150 L, 150 R.
The loaded display and dispensing system 101 is ready for use. In one example, the display and dispensing system 101 can be placed in a highly visible location in the store, such as by a cash register.
While there have shown and described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, can be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention can be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.
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A merchandising display and dispensing system for displaying and dispensing articles, including cylindrical shaped articles or rolls of disk-shaped articles. In particular, the invention relates to a modular display and dispensing system having a plurality of modules fitted with one another. Each module comprises a left side panel and a right side panel which are fitted together and form a serpentine chute which feeds articles by gravity to an access tray where an article can be removed by hand, thus permitting another article to enter the tray. The front of the module receives a front cover for covering the chute and provides a surface for indicia of contents inside the module. The front cover is preferably hinged at the bottom to permit reloading product in the top of the chute. Various connecting structures can be formed on the side panels and adapted to join the module to a front cover, to another adjacent module, to a module base, and/or to a module header to form a modular display and dispensing system.
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This is a continuation of application Ser. No. 07/766,824, filed Sep. 26, 1991 now abandoned, which in turn is a divisional application of Ser. No. 07/758,464, filed Sep. 6, 1991 now U.S. Pat. No. 5,166,840; which in turn is a continuation application of Ser. No. 07/630,375, filed Dec. 18, 1990 now abandoned; which in turn is a continuation application of Ser. No. 07/512,531, filed Apr. 18, 1990 now abandoned; which in turn is a continuation application of Ser. No. 07/187,219, filed Apr. 28, 1988 now abandoned; which in turn is a continuation application of Ser. No. 06/731,157, filed May 6, 1985, which is now U.S. Pat. No. 4,783,707, issued Nov. 8, 1988; which in turn is a continuation application of Ser. No. 06/331,795, filed Dec. 17, 1981, now abandoned; which in turn is a continuation application of Ser. No. 06/030,930, filed Apr. 17, 1979 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a picture image recording device and more particularly to a device using a recording medium which permits setting a plurality of recording tracks separately from each other for recording picture image signals on each of them.
2. Description of the Prior Art
Picture image recording devices of the type using a recording medium which permits setting a plurality of recording tracks separately from each other for recording signals of still picture images on each of the set tracks have already been proposed.
Since the recording device of this type is designed for recording still picture images, the basic function thereof is arranged, for example, to perform recording of one picture image each time a camera is triggered. Considering applications of the device of this type, if it is only possible to record more than just one picture image by each trigger operation, the function of the device is not always satisfactory and is thus applicable only to a limited range of purposes.
If the device of this type is arranged to be capable of continuously recording images on recording tracks as long as the camera trigger is persistently effected, it would be convenient for recording the images of a moving object such as recording for motion analysis or something like a so-called time-lapse filming. Such arrangement can be very advantageously usable, for example, for analyzing a golf swing, batting, a pitching motion and the like and, accordingly would find a wider range of applications by virtue or functional improvement.
On the other hand, the most advantageous point of the picture image recording device of this type lies in that, unlike a photographic camera that uses a silver salt film, it permits, for example: Even when recording has been made only halfway on the recording medium, the record can be taken out and put on a suitable reproducing device for appreciation of just the recorded part as desired; and, after appreciation, the recording medium can be returned to the recording device and then other picture images can be recorded on the rest of the recording medium. Or, with the fully recorded medium put on the reproducing device, some of the recorded tracks may be erased by means of an eraser and then other picture images may be recorded as replacement on the erased tracks.
For such usage, it is very important to provide some facility that permits accurate discernment of a recorded track and a track not recorded from each other. Without such discernment, if another picture image is recorded on the recorded track, two picture image signals would be mixed and a reproduced picture image would be hardly acceptable because, in the device of this type, it is extremely difficult to precisely align the heads of two picture image signals for synchronization and synchronism tends to be lost.
It is, therefore, highly advantageous for a device of this type to be provided with arrangement to accurately discern a recorded track from a track not recorded and to give a warning when a recording track on which recording is going to be performed has been already recorded; or to automatically prohibit double recording on a recorded track; or, with further advanced arrangement, to shift a track of a recording head to another track, when the track to be used for recording has been already recorded, either by mechanically shifting the head or by electrically shifting the head through change-over between head channels. Such arrangement would automatically ensure that recording can be always performed on a recording track which has not been recorded.
Further, a device of this type is required to have a facility for indicating the number of recorded tracks. If such indication is arranged to be made by directly detecting up to which of the recording tracks recording has been performed and to show the number of recorded tracks according to the result of such detecting, the device must have a complex structure, which then would hinder an effort to make the device compact. In another conceivable arrangement, the recording medium may be placed in a cartridge; a code marking may be attached to a part of the housing thereof every time recording is performed on a recording track; and then the number of recorded tracks may be indicated by detecting the code markings. In this case, it is an advantage that the number of recording tracks that have been recorded can be indicated when the cartridge is once taken out from the recording device halfway during a recording operation thereon and thereafter again put in the device. However, this method is not completely satisfactory because it still unnecessarily complicates the structural arrangement and also might cause an erroneous action when the device is reloaded with the cartridge.
As mentioned in the foregoing, the picture image recording device of the prior arts still require improvement in various points.
SUMMARY OF THE INVENTION
This invention is directed to the solution of the above stated problems and the subject matter of the invention lies in the provision of an improved picture image recording device which is of the type using a recording medium permitting to set a plurality of recording tracks separately from each other for recording picture images on each of these tracks and which is capable of meeting all of the above stated various requirements.
More specifically stated, it is a first object of this invention to provide a picture image recording device for recording still picture images which can be operated to record moving objects and is thus advantageously usable for many purposes.
To attain this object, in accordance with this invention, the picture image recording device is operable at least in two different modes including a first mode in which recording is performed on only one recording track and a second mode in which recording is performed continuously or sequentially on a plurality of recording tracks, the device being arranged to be shiftable between the two modes.
In a preferred embodiment of this invention which will be further described hereinafter, the device is arranged to be shiftable between two different speeds in the above stated second mode. In another embodiment, the device can be used for video recording at an ordinary video recording speed through a combined use of it with a video recording device. These arrangements further enhance the functional capability of a device of this type.
It is a second object of this invention to provide a picture image recording device of the above stated type having an improved feature that double recording on a recording medium, i.e. recording on a recorded track, can be effectively prevented.
To attain this object of the invention, the picture image recording device is provided with a detecting means which, at the time of recording a picture image signal, automatically detects whether or not the recording track of a recording medium on which the picture image signal is going to be recorded has already been recorded.
In this arrangement of the device, the inconvenience of having double recording is prevented by giving a warning against double recording and automatically prohibiting it with an output of the detecting means utilized therefor. Further, in the case of a preferred embodiment of the invention which will be described hereinafter, there is provided a control means which controls shifting of the track of a recording means (change-over from one recording track to another) in response to the output of the detecting means; and the recording track of the recording means is automatically shifted by the control means to a track which has not been recorded. This is very advantageous for a device of this type.
It is a third object of this invention to provide a picture image recording device equipped with a simple, reliable and inexpensive arrangement to automatically indicate the number of tracks of a recording medium which have been already recorded.
In accordance with this invention, this object is attained in the following manner: The recording device is provided with a switching means which shifts image signal recording means for one recording track to another and an indication means which indicates the number of recorded tracks in response to the shifting of the recording means.
In the preferred embodiments of this invention which will be described hereinafter, the switching means mechanically shifts the recording means in relation to the recording tracks while the indication means is mechanically associated with the shifting section of the recording means to indicate the number of recorded tracks; or the above stated recording means is arranged to be a multi-channel recording means which is electrically shiftable between many channels while the above stated switching means is arranged to be an electrical channel switching means and the number of recorded tracks is indicated by causing the above stated indication means to electrically respond to the output of the switching means.
The above and other objects and features of the invention will appear more fully hereinafter from the following description taken in connection with the accompanying drawings wherein embodiments are illustrated by way of example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the structural arrangement of an essential part of a camera incorporating a picture image recording device as embodiment of this invention.
FIG. 2 is a section view taken on line II-II of FIG. 1 .
FIG. 3 is a plan view taken on the side indicated by line III-III of FIG. 1 .
FIG. 4 is a plan view showing interrelation between a mode selection dial and a mode selection slide shown in FIG. 3 .
FIG. 5 is a block circuit diagram showing the basic structural arrangement of an image pickup-video signal generation magnetic recording circuitry system which is applicable to the device of the invention.
FIG. 6 is a schematic view showing a CCD image sensor used as solid-state image pickup element in the circuit shown in FIG. 5 .
FIG. 7 is a circuit diagram showing the arrangement of an electrical circuitry employed in one embodiment of the invented device. FIG. 7A is a logic circuit diagram showing the logic arrangement of a flip-flop circuit used in the circuit shown in FIG. 7 . FIG. 7B shows an input-to-output relation of the flip-flop circuit shown in FIG. 7A .
FIG. 8 is an enlarged oblique view showing the details of structural arrangement of a magnetic head suitable for use in the circuit shown in FIG. 7 .
FIG. 9 is a perspective view showing the structural arrangement of an essential part for indicating the number of recorded tracks suitable for the circuit shown in FIG. 7 .
FIG. 10 is a timing chart showing an input-to-output relation of a counter and an ADD gate used in the circuit shown in FIG. 7 for producing control signals.
FIG. 11 is a timing chart showing the operation of the essential parts of the circuit shown in FIG. 7 in a mode S (singly image shot) when a cartridge that has not been recorded at all is used.
FIG. 12 is a timing chart showing the operation of the essential parts of the circuit shown in FIG. 7 in the mode S when a cartridge that has been partly recorded is used.
FIG. 13 is a timing chart showing the operation of the essential parts of the circuit shown in FIG. 7 in a mode C 1 or C 2 (continuous or sequential image shot).
FIG. 14 is a circuit diagram showing the arrangement of an essential part in a modification example of the embodiment shown in FIG. 7 .
FIG. 15 is a circuit diagram showing the arrangement of an essential part in another modification example of the embodiment shown in FIG. 7 .
FIG. 16 is a circuit diagram showing the arrangement of an essential part in a further modification example of the embodiment shown in FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the accompanying drawings, preferred embodiments of the invention are described by way of example as shown below:
The embodiment described here are examples where the present invention is applied to a handy camera. Referring first to FIGS. 1-3 , a reference symbol CA indicates the camera; TL indicates a picture taking lens; a reference numeral 1 indicates a focusing ring; 2 indicates a zooming operation rod; 3 indicates a semi-transparent mirror which is provided for taking out a view finder light and is disposed obliquely within a camera body in the rear of the picture taking lens L; and 4 indicates a semi-transparent mirror provided in the path of a reflection light coming from the mirror 3 for the purpose of taking out a photometric light. A light measuring element 5 is positioned to receive a reflection light of the mirror 4 . Behind a total reflection mirror, there is arranged a view finder optical system of a known structure. A reference numeral 7 indicates an eye cup which is provided for the view finder. Behind the above stated mirror 3 , there is provided a picture taking diaphragm which is arranged to permit complete stopping in this particular embodiment. A numeral 9 indicates a CCD image sensor employed as solid-state image pickup element. In this embodiment, the image sensor is a two dimensional image pickup CCD of the known frame transfer type is employed as shown in FIG. 6 . Further, as will be described hereinafter, in front of an image pickup part of the CCD image sensor 9 , there are disposed a lenticular lens and a color stripe filter in a known manner. There is provided a cartridge loading chamber 10 which is arranged to place therein a magnetic recording cartridge 12 containing therein a magnetic recording disc 11 in a freely rotatable manner. As shown in FIG. 2 , the shaft 12 a of the cartridge 12 is arranged to rotatably carry the disc 11 . In the housing of the cartridge, there are provided a central opening 12 b which is provided for receiving a disc driving spindle 14 of the camera CA and a slot 12 c which is arranged to receive a magnetic head 15 provided on the side of the camera CA. As shown in FIG. 1 , the disc 11 is provided with a center hole 11 a at which the disc is rotatable carried by the shaft 12 a. The disc 11 is further provided with an arcuate slot 11 b which is arranged concentrically with the center hole 11 a. With this arrangement, the disc 11 is urged toward the central opening 12 b by a plate spring 13 which is provided within the cartridge 12 as shown in FIG. 2 . Further, as indicated by a numeral 10 a in FIG. 2 , the rear part of the cartridge loading chamber 10 is recessed to permit insertion of the cartridge 12 into the cartridge loading chamber 10 with a lid 16 of the chamber opened in an oblique the cartridge, the cartridge is lodged in place in a normal posture with the spindle 14 inserted into the central opening 12 b and the magnetic head 15 into the slot 12 c respectively.
Then, the tip of the head 15 is in contact with a magnetic recording part 11 c of the disc 11 . The recording part 11 c can be set by arranging thereon a plurality of, say, 40 recording tracks in a state of being separated from each other. Each of the recording tracks is arranged to permit recording thereon magnetic signals for one frame of a still picture as will be further described hereinafter. The disc 11 itself has a flexibility to receive the head pressure of the head 15 with the resilience of the disc 11 . With the loading chamber lid 16 closed, the cartridge 12 is fixedly and correctly set in place by the plate springs 17 and 18 shown in FIG. 12 . The disc driving spindle 14 is provided with a driving pin 14 a which is engageable with the arcuate slot 11 b provided in the disc 11 and the spindle 14 is connected to the shaft 19 a of a fly wheel 19 . The fly wheel shaft 19 a is borne by a bearing metal member 20 at a boss part 21 of the camera frame to have no rotational chattering nor thrust chattering. This arrangement is important because the image recording performance of the device would be greatly affected by such chattering of this shaft 19 a. There is provided a motor Mo which is arranged to rotate the fly wheel 19 . Because an output pulley 22 of the motor Mo and the fly wheel 19 , there is provided a rubber belt 23 . With a driving system arranged in this manner, the disc 11 is driven to rotate in the direction of an arrow C indicated in FIG. 1 . A numeral 25 indicates a head carrying member which is arranged to hold the above started head 15 at its bent arm part 25 a provided at the fore end thereof. The head carrying member 25 is carried by a supporting rod 24 to be slidable along the rod 24 , which is attached to a part of the camera frame along the slot 12 c of the cartridge 12 . A spring 26 urges the head carrying member 25 in the direction of an arrow D indicated in FIG. 2 . The head carrying member 25 is provided, at a part thereof, with ratchet teeth 25 b which are formed to define spacing between the magnetic recording tracks in the recording part 11 c of the magnetic recording disc 11 . Further, with the head carrying member 25 displaced to an extreme and position thereof in the direction of the arrow D indicated in FIG. 2 by the spring 26 , the magnetic head is arranged to be in a position corresponding to the outermost peripheral track of the recording part 11 c of the disc 11 . The number of teeth of the ratchet 25 b is determined in accordance with the number of tracks set on the disc 11 and, in this embodiment, the number of the ratchet teeth is 41 for the 40 tracks of the disc. Accordingly, the head 15 has a total of 41 setting positions. A numeral 27 indicates a ratchet feeding claw which is arranged to shift the head carrying member 25 tooth by tooth against the force of the spring 26 in the direction reverse to the direction of the arrow D. The ratchet feeding claw 27 is urged in the direction of engaging with the ratchet teeth 25 b by a spring 28 and is also is linked with a movable armature Am of a plunger Pl. When the plunger is energized, the armature Am is arranged to thrust forward by one stroke which shifts the above stated head carrying member 25 exactly as much as one tooth against the force of a spring 29 in the direction opposite to the arrow D. The head carrying member 25 is arranged to be retained in the shifted position by a lock claw 30 , which is pivotally carried to be freely rotatable on a shaft 31 attached to a part of the camera frame and is urged by a spring 32 in the direction of engaging the ratchet teeth 25 b. When the loading chamber lid 16 is opened, the head carrying member 25 is caused by a reset member 33 to automatically return to an initial position in which the head 15 is facing the outermost track of the disc 11 . The head portion of the reset member 33 is formed into a tapered or circular shape into a hook part and the reset member 33 is attached to a part of the chamber lid 16 to have its hook part engage with the tail end 30 b of the lock claw 30 . Therefore, when the lid 16 is opened, the reset member 33 causes the lock claw 30 to rotate counterclockwise as viewed on the drawing against the force of a spring 32 . At that time, the head part 30 a of the force end of the lock claw 30 pushes a protrusion 27 a of the fore end of the feed claw 27 to rotate the feed claw 27 clockwise as viewed on the drawing on a point at which the feed claw 27 is linked with the armature Am. Thus, both the lock claw and the feed claw are disengaged from the ratchet teeth 25 b. By this, the head carrying member 25 is automatically returned into its initial position as mentioned in the foregoing. This reset member 33 has some flexibility and, when the lid 16 is opened to a degree more than a given angle, the reset member 33 is disengaged from the lock claw 33 and, when the lid 16 is closed, the head part of the reset member 33 comes to contact and override the tail end 30 b of the lock claw 30 to bring the hook part thereof into engagement with the tail end 30 b. It is therefore advantageous to have the edge of the tail end 30 b of the lock claw 30 rounded as shown in FIG. 2 . Further, although it is not clearly shown in the drawing, the lock claw 30 is prevented from abutting upon the fore end face of the feed claw 27 by disposing it a little away from the feed claw 27 in the direction perpendicular to the surface of paper on which FIG. 2 is drawn. Meanwhile, the protrusion 27 a of the fore end of the feed claw 27 is somewhat extended in the direction perpendicular to the paper surface to have this extended part engageable with the head part 30 a of the lock claw 30 .
Further, in FIGS. 1 and 3 , a numeral 34 indicates a camera trigger button which is of the so-called two step trigger type; and 35 indicates a grip part which is arranged to contain a power source battery E therein. In FIG. 1 , a symbol EU indicates an electrical circuit unit the details of which will be described hereinafter. In FIG. 3 , a numeral 36 indicates a mode selection dial which is arranged to be shiftable between positions of indices “S”, “C 1 ”, “C 2 ” and “MV”. The index “S” indicates a single picture frame shot; C 1 indicates continuous picture frame shots which are performed, for example, at a rate of about 3.3 picture frames per second; and MV indicates picture taking performed at a rate of 30 picture frames per second, which corresponds to motion picture shots at a normal video recording speed. The term “shot” as used herein means a picture taking operation. Further, as will be further described hereinafter, one picture frame is composed of two field signals. A numeral 37 indicates a slide which is slidable for selection between automatic shifting and manual shifting of the head 15 in relation to the recording tracks for the single picture frame shot and which is thus shiftable between indices “A” and “M”. The index “A” A numeral 38 indicates a push button which is provided for manual shifting of the head 15 when the manual shift mode M has been selected. The push button 33 permits manual operation of the plunger Pl through circuit arrangement as described hereinafter. In the mode C 1 , C 2 or MV, it is evidently absurd to manually shift the head 15 . Therefore, in this embodiment, the slide 37 is inhibited from shifting from “A” to “M” in the mode C 1 , C 2 or MV and is allowed to shift to “M” in the mode S only. When the mode is shifted from “S” to “C 1 ”, “C 2 ” or “MV” while the slide 37 is in the position “M”, the slide 37 is automatically reset into the position “A” by a can 39 which is interlocked with the dial 36 . This cam 39 is disposed to face a follower part 40 a of a plate 40 which is arranged for pin-slot engagement and on which the slide 37 is provided. A numeral 41 indicates a click stop spring. The mode symbols marked on the cam 39 in parentheses indicate the region of the cam corresponding to each mode.
Again referring to FIG. 3 , there is provided a jack 42 for taking out a video signal (NTSC signal) to the outside. The jack 42 permits to connect an ordinary VTR device thereto and is usable particularly in the mode MV. As mentioned in the foregoing, the number of picture frames recordable on the disc 11 is limited to 40 or thereabout. If a motion picture is recorded on the disc 11 at a standard video recording speed, the recording will not last more than one second or thereabout. The number of recording tracks may be increased. However, such increase is evidently limited. It is absurd to record a motion picture on a disc to begin with. With the jack 42 provided in combination with the mode MV, therefore, motion picture recording can be performed over a long period of time in combination with an ordinary known VTR (video tape recording) device. This arrangement further broadens the functional capability of the camera. There is also provided a jack 43 for remote control. A remote controller is connected to this jack 43 .
The structural arrangement of the essential parts related to this invention in the camera CA is as described in the foregoing. The details of the circuit arrangement in the above stated electrical circuit until HU will be understood from the following description:
In FIG. 5 which shows the arrangement of an image pickup—video (NTSC) signal generation—magnetic recording system, a reference numeral 44 indicates an oscillator circuit which generates clock pulses of a relatively high frequency of the order of MHz. A numeral 45 indicates a synchronization control circuit which produces various synchronization control signals required for synchronization control over the image sensor 9 and the circuitry shown here in accordance with the clock pulses from the oscillator circuit 44 . As shown in FIG. 6 in a modelizing manner, the CCD image sensor 9 comprises an image pickup part (a photo sensitive part) 9 a which is composed of many photo sensor elements arranged in a matrix like manner: a memory part 9 b which takes in an electric charge cor-esponding to the brightness of each of the picture elements accumulated at the image pickup part 9 a and which thus stores the electric charge in a memory cell at an address corresponding to the address of each element; and an analog shift register 9 c which is provided for transferring the stored electric charges in a time serial manner. As well known, with the exception of the image pickup part 9 a, all components of the image sensor 9 are part 9 a, there are arranged a color stripe filter 48 and a lenticular lens 49 . The synchronization control circuit 45 supplies the CCD image sensor 9 with driving signals Pa including a signal for controlling the accumulation of electric charges at the image pickup part 9 a; clock pulses for transferring the accumulated electric charges of the image pickup part 9 a to the memory part 9 b within an extremely short period of time at a predetermined timing, for example every 1/60 sec. (which corresponds to the timing of a vertical synchronization signal); and clock pulses for time serially producing all of the electric charges taken in the memory part 9 b through the shift register 9 c within a period of 1/60 second which corresponds to the time of 1 V—1 vertical scanning period of television (i.e. for read-out of the stored electric charges). Further, although it is not shown in FIG. 6 , it goes without saying that the electric charges that are transferred by the shift register 9 c are eventually obtained in a state of having been converted into voltages or currents or the like. Further detailed description is omitted herein as the frame transfer type CCD image sensor of this type has already been well known.
Returning now to FIG. 5 , numerals 50 and 51 indicate sample-hold circuits which sample-hold the output of the CCD image sensor 9 . These sample-hold circuits are arranged to be controlled by control signals Pb (sampling signals) from the synchronization control circuit 45 . A numeral 52 indicates a video signal (NTSC signal) generating circuit which is composed of: A brightness signal producing circuit 53 which produces a brightness signal Y in accordance with the output of the sample-hold circuit 50 ; a color signal producing circuit 54 which produces primary color signals R and B in accordance with the output of the sample-hold circuit 51 ; and an encoder 55 which produces a NTSC signal (a color video signal of NTSC system) based on the signals Y, R and B received from these circuits 53 and 54 . As well known, the synchronization control circuit 45 supplies synchronization control signals Pc and Pd to the color signal producing circuit 54 and the encoder 55 . The video signal generating circuit of this type has been thoroughly known through prior art disclosure such as a Japanese patent application laying open publication No. SHO 53-34417. Therefore, illustration of the circuit herein is limited to functional blocks. A numeral 56 indicates a magnetic recording circuit for recording video signals. The magnetic recording circuit 56 is composed of a low pass filter 57 , a pre-emphasis circuit 58 , a frequency modulation circuit 59 , a high pass filter 60 , a band pass filter 61 , a frequency converter circuit 62 , a low pass filter, a mixer circuit 64 and a recording amplifier 65 . The magnetic recording circuit 56 is thus arranged to be also-called chrominance subcarrier low conversion multiplex recording system. The operation of the circuit of this system is well known and does not require detailed description here. Briefly stated, when the NTSC signal, i.e. a combined color video signal, is obtained from the above stated video signal generating circuit 52 , a brightness signal Y and a chrominance subcarrier signal fc of 3.58 MHz are separated from the video signal through the low pass filter 57 and the band pass filter 61 respectively. The separated brightness signal Y is pre-emphasized by the pre-emphasis circuit 58 and, after it is frequency modulated by the frequency modulation circuit 59 , the signal Y is supplied to the mixer circuit 64 as frequency modulated brightness signal with a part of its lower-side band wave removed through the high pass filter 60 . On the other hand, the chrominance subcarrier signal fc is balance modulated at the frequency converter circuit 62 by a signal Pe (fn) coming from the synchronization control circuit 45 . Then, through the low pass filter 63 , a difference signal thereof, i.e. a low conversion chrominance subcarrier signal f s =f n −f c is taken out and supplied to the mixer circuit 64 . The mixer circuit 64 then mixes the color signal carried by this low conversion chrominance subcarrier f s with the frequency modulated (FM) brightness signal from which a part of its lower-side band wave has been removed to obtain a mixed signal (a VTR signal). The mixed signal is applied to the head 15 through the amplifier 65 to perform magnetic recording of it on a recording track of the disc 11 .
Next, referring to FIG. 7 , the structural arrangement described in the foregoing will be more fully understood from the following description of a concrete example of the electrical circuit system:
In the first example given here, a combination type magnetic head is employed as the above stated magnetic head 15 . The combination magnetic head is composed of a detection head 15 A which is provided solely for the purpose of detecting whether or not a magnetic recording track of the disc 11 on which a picture image signal is going to be recorded (hereinafter will be called “picture recording”) has already been recorded with a picture and a recording head 15 B which is provided solely for the purpose of recording. When the disc 11 rotates in the direction of the arrow C shown in FIG. 1 , the detection head 15 A is arranged to be always positioned ahead of the recording head 15 B. In recording, when the track has been already recorded, double recording is prevented by this arrangement to ensure correct recording on a track that has not been recorded.
In FIG. 7 , a reference symbol E indicates the circuit power source mentioned in the foregoing; and SWE indicate a normally closed type end switch which is arranged to be opened upon completion of picture recording on all of the tracks of the disc 11 . The switch SWE is connected in series with the circuit power source E. As for the arrangement required for opening this end switch SWE, the use of the arrangement shown in FIG. 9 or something like that will be advantageous. In the case of FIG. 9 , there is provided a track count member 72 which is arranged to sway in response to the feeding action of the head carrying member 25 with its tail end pivotally connected to a part of the camera frame and with a pin 71 on the head carrying member 25 engaged with a slot 72 a provided in the middle part of the count member 72 . A pointer 73 which is attached to the fore end of the count member 72 indicates the number of recorded tracks on a track number indicating graduation plate 75 which is disposed inside a window 74 . Further, when the head carrying member 25 is shifted to the left as viewed on the drawing to an extent as much as the total number of the teeth of the ratchet teeth 25 b, i.e. when it comes away from the innermost circular track of the recording part 11 c of the disc 11 and is shifted further inward by one tooth, the end switch SWE is opened by a switch opening protrusion 76 provided on the fore end of the count member 72 .
A PHP switching transistor Tr 1 has its emitter side connected to the end switch SWE. A symbol SWR 1 indicates a normally open type first step trigger switch which is arranged to be turned on by the first step stroke of the above stated trigger button 34 and which is connected to the base of the transistor Tr 1 . A symbol SW 1 indicates a change-over switch which is shiftable between fixed terminals S, C 1 , C 2 and MV in response to the above stated mode selection dial 36 . The movable contact piece of the switch SW 1 is connected to the collector side of the transistor Tr 1 . The fixed terminals S, C 1 and C 2 are connected in common. A symbol PUC indicates a power up clear circuit which produces a single pulse (a power up clear signal) when the power source is turned on; DFC indicates a differentiation circuit which produces a negative single pulse when its terminal a is connected to the minus side of the power source E; SW 2 indicates a change-over switch which is shifted between fixed terminals S, C 1 , C 2 and MV in response to the mode selection dial 36 , the terminals S and MV being neutral terminals, the terminals C 1 and C 2 being connected to the output terminal b of the above stated differentiation circuit DFC and the movable contact piece thereof being connected to the terminal a of the differentiation circuit PFC; and FF 4 indicates a SR-flip-flop which receives the output of the power up clear circuit PUC at its react input terminal R and receives, at its set input terminal S, the output of an inverter IV 1 which is provided for producing the output of a Schmidt circuit SMC (will be described hereinafter) by inverted logic. The Q output of the SR-flip-flop is arranged to be supplied to the base of an NPN switching transistor Tr 4 the collector side of which is connected to the movable contact piece of the above stated change-over switch SW 2 . A symbol SWR 2 indicates a second step trigger switch which is arranged to be turned on by the second step stroke of the above stated trigger button and is connected to the emitter of the transistor Tr 4 ; and FF 1 indicates a SR-flip-flop which is arranged to receive, at its set input terminal S, the output of the inverter IV 2 provided for producing the output of the above stated differentiation circuit DFC by inverted logic and is arranged to receive, at its reset terminal P, the output of an OR gate OG 1 which obtains a logical sum of the output of the above stated power up clear circuit PUC and the output of the Schmidt circuit SMC which will be described hereinafter, the SR-flip-flop FF 1 thus being arranged to maintain power supply. The Q output terminal of the flip-flop is connected to the base of the above stated transistor Tr 1 . When the second step trigger switch SWR 2 is turned on under a condition in which the output of the OR gate OG 1 is low and the Q output of the flip-flop FF 4 is high (i.e. a condition in which the transistor Tr 4 is rendered conductive with the second step trigger switch SWR 2 turned on), the flip-flop FF 1 is set by a high level output of the inverter IV 2 and the Q output of the flip-flop FF 1 becomes low. Then, since the Q output terminal is connected to the base of the transistor Tr 1 , the transistor Tr 1 is held conductive by the depression of the trigger button 34 to the second step stroke and does not become nonconductive when the trigger button 34 is instantly released from depression. The transistor Tr 1 is released from this state of being held conductive when the detection head 15 A detects a recorded track as will be described hereinafter. Therefore, at this time, if the first step trigger switch SWR 1 is off, the transistor Tr 1 becomes nonconductive to cut off power supply to the circuit system.
There is provided a SR-flip-flop FF 2 for recording control. The set input terminal S of the flip-flop FF 2 receives the output of an OR gate OG 2 which obtains a logical sum of the output of the above stated power up clear circuit PUC and the output of the Schmidt circuit SMC while the reset input terminal R of the flip-flop FF 2 is arranged to receive the output of an AND gate AG 1 which obtains a logical product of the output of a delay circuit DLC which will be described hereinafter and the Q output of a flip-flop FF 3 which will also be described hereinafter. A symbol CNT 1 indicates a 4-bit binary counter of a pulse fall synchronization type. The counter CNT 1 counts the output pulses ( FIG. 10 , ( b )) of an inverter IV 3 which produces, by inverted logic, the pulses Ff ( FIG. 10 , ( a )) at a timing ( 1/60 sec.) corresponding to the vertical synchronization signal from the synchronization control circuit 45 shown in FIG. 5 . With this counting performed, the output terminals A, B, C and D of the counter CNT 1 respectively produce pulse signals as represented at ( c ), ( d ), ( e ) and ( f ) in FIG. 10 . A symbol AG 5 indicates an AND gate which obtains a logical product of the outputs B and C of the above stated counter CNT 1 . The output of the AND gate AG 5 is as represented by ( g ) in FIG. 10 . Another AND gate AG 6 is arranged to obtain a logical product of the outputs B, C and D of the counter CNT 1 . The output of the AND gate AG 6 is as represented by ( h ) in FIG. 10 . Therefore, assuming that the period of the output pulse Pf of the above stated synchronization control circuit 45 represented by ( a ) in FIG. 10 is 1/60 sec., the period of the output A of the counter CNT 1 is 1/30 sec., that of the output B of the counter is 1/15, that of the output C of the counter is 1/7.5 and that of the output D of the counter is 1/3.75. Then, since the time, at a high level, of each of the output B of the counter CNT 1 and outputs of the AND gates AG 5 and AG 6 is 1/30 sec., these outputs are usable as recording control signal in the modes S, C 1 and C 2 respectively. The output B of the counter CNT 1 and the outputs of the AND gates AG 5 and AG 6 are arranged to be selectable in the modes S, C 1 and C 2 by the change-over switch SW 3 which is responsive to the mode selection dial 36 . Although the period of the output of the AND gate AG 5 which is selected in the mode C 1 is 1/7.5 sec. and the period of the output of the AND gate AG 6 which is selected in the mode C 2 is 1/3.75 sec., these periods are arranged in the circuit of this embodiment to be about 6 picture images/sec. in the mode C 1 and about 3.3 picture images/sec. in the mode C 2 for effecting continuous shots.
Further, each of the output B of the counter CNT 1 and outputs of the AND gates AG 5 and AG 6 selected by the switch SW 3 is supplied to the output stage (i.e. the amplifier circuit 65 shown in FIG. 5 ) of the image pickup—video signal generation—magnetic recording system circuit 69 which is arranged as shown in FIG. 5 and also to the recording control analog switch ASW which is provided between the recording head 15 B and the circuit 69 to perform recording control thereby. The clear terminal CLR of the above stated counter CNT 1 is arranged to receive the Q output of the above stated flip-flop FF 2 . Accordingly, when the Q output of the counter CNT 1 is high, the counter CNT 1 is kept in a state of being cleared. The counter CNT 1 thus counts the output pulses of the inverter IV 3 only when the Q output of the flip-flop FF 2 is low.
A symbol La 2 indicates a display lamp which is caused to light up by the PNP switching transistor Tr 2 arranged to receive the Q output of the flip-flop FF 2 at its base. In other words, the display lamp La 2 is caused to light up to indicate that recording is being performed when the counter CNT 1 is performing a counting operation with the Q output of the flip-flop FF 2 being low. A symbol AP indicates an amplifier which amplifies the output of the above stated detection head 15 A; C indicates a DC out capacitor; HIC indicates a rectifying integration circuit HIC which rectifies and integrates an AC signal component, i.e. a video signal component in the output of the amplifier AF; and SNC indicates a Schmidt circuit which is responsive to the output of the rectifying integration circuit HIC. The output of the Schmidt circuit becomes high when the track on which recording is going to be performed has been already recorded and become low when the track has not been recorded. The output of the Schmidt circuit SMC is supplied to the AND gate AG 3 and the OR gates OG 1 , OG 2 and OG 3 and, through the inverter IV 1 , is supplied by inverted logic also to the AND gate AG 2 and the set input terminal S of the flip-flop FF 4 . A symbol CNT 2 indicates a 2-bit binary counter of a pulse fall synchronization type which receives and counts the output pulses from the above stated inverter IV 3 . The higher bit output, i.e. the output B, of the counter CNT 2 is arranged to be used for driving the above stated plunger Pl and is supplied to the other input terminal of the above stated AND gate AG 3 . The output of the AND gate AG 3 is supplied to the base of the NPN switching transistor Tr 3 . The output B of the counter CNT 2 has a high level duration period of 1/30 sec. in the same manner as the output B of the other counter CNT 1 . Therefore, with a minimum energization period required for driving the plunger Pl arranged to be 15 to 20 msec. or thereabout, the output B of the counter CNT 2 gives a sufficient pulse for driving the plunger Pl. Further, the time constant of the above stated integration circuit HIC is set at a sufficient value of time, say, 30 msec. or thereabout for driving the plunger Pl. There is provided a display lamp La 3 which lights up when the track going to be recorded has been already recorded in the mode S-M, i.e. in the mode of single picture image shot with manual shifting of the head. In the mode M, the display lamp La 3 is connected to the collector of the transistor Tr 3 by the switch SWM 1 which is responsive to the above stated slide 37 . In the mode A, the switch SWM 1 connects the plunger Pl to the collector of the transistor Tr 3 . A symbol SWP indicates a push switch which is turned on by the above stated push button 33 ; and SWM 2 indicates a switch which, in the mode M, connects the switch SWP to the plunger Pl in response to the above stated slide 37 .
A motor control circuit MCC is provided for constant speed control of the motor Mo. In this embodiment, the rotation speed of the motor Mo is controlled by the control circuit MCC to have the disc 11 rotate at a speed of 1,800 r.p.m. so that signals for one frame, i.e. for two fields, are recorded on a track by every rotation of the disc 11 . A delay circuit DLC is provided for having a delay time corresponding to a period of time (50-100 msec.) required for building up of the speed of the motor Mo. The output of the delay circuit is supplied to the AND gate AG 1 . A symbol FF 3 indicates a SR-flip-flop. The set input terminal S of the flip-flop FF 3 receives the output of the AND gate AG 2 which obtains a logical product of the Q output of the flip-flop FF 1 and the output of the inverter IV 1 . The reset input terminal R of the flip-flop FF 3 receives the output of the OR gate OG 3 which obtains a logical sum of the output of the above stated power up clear circuit PUC and the output of the Schmidt circuit SMC. The Q output of the flip-flop FF 3 is supplied to the AND gate AG 1 . A symbol PMC indicates a light measuring circuit which determines a correct diaphragm aperture value based on the output of a light measuring element 5 and electric charge accumulation time (i.e. integrated time of picture element signals) obtained at the image pickup part 9 a of the image sensor 9 . The light measuring circuit PMC is arranged to receive power supply together with the above stated circuit 69 through the diode D 3 or D 4 irrespective of the mode selection of the mode selection dial 36 , i.e. irrespective as to which of the mode terminals is in connection with the switch SW 1 . In this embodiment, the electric charge accumulation time is defined solely by the timing of the read-out starting pulse (start pulse) included in the sensor driving signal Pa which is produced by the synchronization control circuit 45 . According to the example described in the foregoing, for example, the electric charge accumulation time is fixed to 1/60 sec. or thereabout. In this case, therefore, fixed information on this time is given to the light measuring circuit PMC. Incidentally, this time corresponds to film exposure time in an ordinary camera that uses a silver salt film. Accordingly, the same structural arrangement as a known light measuring circuit of a film camera is usable as this light measuring circuit PMC. A reference numeral 66 indicates a diaphragm driving means such as a meter or motor which adjusts a diaphragm 8 to a correct aperture value in response to the output of the light measuring circuit PMC. The output shaft of the diaphragm driving means is connected to the diaphragm 8 . The diaphragm 8 is arranged to permit so-called complete stopping for the purpose of preventing so-called “sticking” of the CCD image sensor 9 . As for arrangement required for such complete stopping, in the case of using a meter as diaphragm driving means 66 , a spring may be arranged to act on the moving coil thereof such that the diaphragm 8 is kept in a completely stopped state when the coil is not energized. Where a motor is employed as the driving means 66 , a condensing means such as a capacitor may be connected to the motor to completely stop the diaphragm 8 by forcedly driving it with the holding power of this condensing means imparted when the output from the light measuring circuit is cut off. A numeral 67 indicates a graduation member for indicating aperture values. The member 67 is arranged to be driven together with the diaphragm 8 by the above stated diaphragm driving means 66 and is prepared, for example, by marking graduations of aperture values on a transparent film or the like. The member 67 is disposed within a view finder of the camera and is arranged to show an adjusted value of aperture of the diaphragm by coincidence of a graduation mark with a fixed index 68 . A symbol La 1 indicates a lamp which is provided for illuminating the above stated graduation member 67 from behind it and is connected to the diodes D 3 and D 4 . The lamp La 1 is arranged to receive power supply to light up with the transistor Tr 1 energized irrespective of the mode selected by the mode selection dial. Therefore, in addition to its function of illuminating the graduation member 67 , the lamp La 1 functions also to indicate that the trigger button 34 is depressed to the first step thereof.
In the arrangement described in the foregoing, the circuit 69 , the light measuring circuit PMC and the lamp La 1 are arranged to receive power supply with the transistor Tr 1 rendered conductive energized irrespective of the mode position in which the mode selection dial 36 is set. On the other hand, with the exception of them, other circuits are arranged to receive power supply, with the transistor Tr 1 rendered conductive, only when the mode selection dial 36 is in the mode position, S, C 1 , or C 2 . Further, each of the SR-flip-flop circuits FF 1 -FF 4 , which are used in the circuit shown in FIG. 7 , has a logic arrangement made by a combination of two NOR gates NOG 1 and NOG 2 as shown in FIG. 7A . The input-to-output relation of the flip-flop circuit is as shown in FIG. 7B .
A jack which is provided for supplying the NTSC signal to the outside is connected to the circuit 69 and, more specifically stated, to the output stage of the video signal generation circuit 52 shown in FIG. 5 . A remote jack 43 is connected through diodes D 1 and D 2 in parallel with the switches SWR 1 and SWR 2 .
The camera which has the structural arrangement as described in the foregoing operates—in the following manner: As mentioned in the foregoing, the camera permits selection of any of the five operation modes including the mode S-A (single picture image shot—automatic head shifting), the mode S-M (single picture image shot—manual heading shifting), the mode C 1 (continuous shots at a rate of 7.5 picture images/second), the mode C 2 (3.75 picture image/sec. continuous shots) and the mode MV (motion picture shots at a VTR speed using a VTR device). To facilitate understanding, the mode S-A is first described with reference to the timing chart of FIG. 11 as follows: Let us assume that the camera CA is loaded with a recording disc 11 with none of the recording tracks thereof having been recorded. The head 15 is set in its initial position as mentioned in the foregoing. The end switch SWE is therefore on. Under this condition, when the dial 36 is set in the mode position S, the switch SW 1 is turned on; the switch SW 2 comes to be in an open state while the switch SW 3 comes to be connected to the output terminal B of the counter CNT 1 . Then, when the slide 37 is set in the position of the mode A, the switch SWM 1 is connected to the side of the plunger Pl while the switch SWM 2 comes to be in an open state and the camera CA is set in the mode S-A. Under this condition, the operator directs the camera CA toward a desired object while peeping into the view finder and, when he depresses the trigger button 34 to the first stroke, the first step trigger switch SWR 1 is turned on to render the transistor Tr 1 conductive thereby. Accordingly, the light measuring circuit PMC comes to work and the diaphragm 8 is adjusted from its completely stopped state to a correct aperture value. Meanwhile, the lamp La 1 lights up to illuminate the graduation plate 67 and the motor Mo starts to cause the disc 11 to rotate. This shown in FIGS. 11( a ), ( b ), ( d ), ( e ) and ( f ). Further, when the transistor Tr 1 is rendered conductive, the power up clear circuit PUC produces pulses as shown in FIG. 11( g ) to reset thereby the flip-flop circuits FF 1 , FF 3 and FF 4 and to set the flip-flop FF 2 . Then, the Q output of the flip-flop FF 1 and the Q output of the flip-flop FF 2 become high as shown in FIGS. 11( k ) and ( l ). On the other hand, with the transistor Tr 1 rendered conductive, the circuit 69 receives power supply and begins to drive the CCD image sensor 9 , which then begins the image pickup—video signal generation—VTR signal producing operation. At this time, the synchronization control circuit 45 produces pulses Pf of timing which corresponds to the vertical synchronization signal as represented by FIG. 11( o ). The pulses Pf are applied to the counters CNT 1 and CNT 2 through the inverter IV 3 . However, since the Q output of the flip-flop FF 2 at this time is high, the counter CNT 1 is in a cleared state, i.e. kept in a state of being incapable of counting. Thus, the pulses are not counted by the counter CNT 1 . Accordingly, the output B of the counter CNT 1 is low as shown in FIG. 11( p ). The analog switch ASW is, therefore, remains off. On the other hand, the counter CNT 2 then begins to count the output pulses from the inverter IV 3 . Further, with the transistor Tr 1 rendered conductive when a period of time anticipated to correspond to time required for the motor Mo before it comes to build up to a normal speed has elapsed, the output of the delay circuit DLC becomes high as shown in FIG. 11( h ) and, accordingly, one input to the AND gate AG 1 then becomes high.
At this time, in the output of the detection head 15 A, there appears no AC signal component because the disc 11 has not been recorded at all. Therefore, the output level of the integration circuit HIC is below a predetermined level and, accordingly, the output of the Schmidt circuit SMC is low as shown in FIG. 11( g ). Therefore, the plunger Pl is not energized. The heads 15 A and 15 B are in their initial positions where they are in contact with the outermost track of the recording part 11 c of the disc 11 . Further, since the output of the inverter IV 1 becomes high at this point of time, one input to the AND gate AG 2 becomes high. The flip-flop FF 4 is set and the Q output of it becomes high.
Under this condition, when the trigger button 34 is depressed to the second step ( FIG. 11( a )), the second trigger switch SWR 2 is turned on, as shown in FIG. 11( c ), to render the transistor Tr 4 conductive. This causes the differentiation circuit DFC to produce a negative pulse as shown in FIG. 11( h ). Accordingly, as shown in FIG. 11( i ), the inverter IV 2 comes to produce high pulses. By this, the flip-flop FF 1 is set and, as shown in FIG. 11( j ), the Q output of the flip-flop FF 1 becomes high. The output of the AND gate AG 2 thus becomes high at this point of time to set the flip-flop FF 3 and the Q output of the flip-flop FF 3 becomes high as shown in FIG. 11( m ). This causes both of the two inputs to the AND gate AG 1 to become high thus to make the output thereof high at this point of time. Accordingly, the flip-flop FF 2 is reset and the Q output of it is inverted to become low. The counter CNT 1 is then released from its cleared state and begins to count input pulses.
Further, when the flip-flop FF 1 is set by the high pulse from the inverter IV 2 , the Q output of the flip-flop FF 1 becomes low as shown in FIG. 11( k ). Since this causes the transistor Tr 1 to be kept in a conductive state, the circuit system continues its operation because power supply thereto is not cut off even if the trigger button 34 is released from its state of being depressed at this point of time.
When the counter CNT 1 begins to count input pulses under this condition and when the B output of it becomes high as shown in FIG. 11( p ), the analog switch ASW is turned on thereby and the output of the amplifier circuit 65 shown in FIG. 5 is supplied to the recording head 15 B to cause it to perform magnetic recording of signals for one frame of the picture image of an object on the outermost track of the disc 11 . The B output of the counter CNT 1 arranged in this embodiment is obtained by frequency dividing by two the pulses Pf of timing corresponding to the vertical synchronization signal ( FIG. 10( a )) from the synchronization control circuit 45 as has already been described with reference to FIG. 10 . The high level period of time of the B output of the counter CNT 1 is two periods of the pulses Pf, i.e. 1/30 sec. Meanwhile, in the circuit system shown in FIG. 5 , the output of the image sensor is read out, and accordingly the field signal is produced, continuously twice in a repeated manner within this length of time 1/30 sec. Therefore, a signal of 2 fields=1 frame is magnetically recorded on the track of the disc 11 . As already mentioned, therefore, the motor control circuit MCC is arranged to control the rotating speed of the motor Mo in such a way as to have the disc 11 rotated at the rate of 1,800 r.p.m.
When 1/30 second has elapsed after the B output of the counter CNT 1 became high as shown in FIG. 11( p ), the B output again becomes low to turn off the analog switch ASW. During this period, a signal for one frame is magnetically recorded on the track of the disc 11 in the 2 fields—1 frame manner. Since the detection head 15 A is disposed ahead of the recording head 15 A as mentioned in the foregoing, when recording of 1 frame has been completed, the magnetic signal recorded by the recording head 15 B is picked up by the detection head 15 A. Accordingly, in the output up by the detection head 15 A, there appears an AC signal component, i.e. a video signal component, and this causes the output level of the integration circuit HIC to become higher than a predetermined level. This in turn makes the output of the Schmidt circuit SMC high as shown in FIG. 11( g ). Then, the flip-flop FF 3 is reset thereby and the Q output of the flip-flop FF 3 becomes low as shown in FIG. 11( m ). Accordingly, the reset input R of the flip-flop FF 2 becomes low and the flip-flop FF 2 is set by the high level output of the Schmidt circuit SMC. The Q output of the flip-flop FF 2 then becomes high as shown in FIG. 11( l ). The counter CNT 1 is cleared by this and becomes incapable of counting. The B output of the counter CNT 1 thus becomes as shown in FIG. 11( p ) and is low after completion of recording. Accordingly, the analog switch ASW is turned off. With the output of the Schmidt circuit SMC having become high, the B output of the counter CNT 2 is applied to the base of the transistor Tr 3 through the AND gates AG 3 as shown in FIG. 11( s ). The transistor Tr 3 is rendered conductive thereby to energize the plunger Pl. Accordingly, the head carrying member 25 is moved forward by the feed claw 27 as much as one tooth of the ratchet teeth 25 b. The heads 15 A and 15 B are shifted by this to a second track. Since the second track has not been recorded in this case, the AC signal component disappears from the output of the detection head 15 A as the shifting of the heads 15 A and 15 B is effected to the second track. After a predetermined period of time, therefore, the output level of the integration circuit becomes lower than the predetermined level and, accordingly, the output of the Schmidt circuit SMC then becomes low as shown in FIG. 11( g ).
When the output of the Schmidt circuit SMC becomes high, the flip-flop FF 1 is reset and the Q output of it becomes low as shown in FIG. 11( j ). Since the flip-flop FF 1 will not be set thereafter as long as a high pulse is not produced from the inverter IV 2 , the flip-flop FF 3 is not set thereafter. Accordingly, the operation of the camera CA is stopped or suspended in a state of having completed the shifting of the heads 15 A and 15 B to the next non-recorded track. Under this condition, if the depression of the trigger button 34 is eased back to its first stroke to open only the second step trigger switch SWR 2 and if, after that, the trigger button 34 is again depressed to the second step stroke to turn on the second step trigger switch SWR 2 , the differentiation circuit DFC again comes to produce negative pulses. Then, the flip-flop FF 1 is again set by the high pulse coming from the inverter IV 2 to allow recording on the non-recorded track. Upon completion of recording on this non-recorded track, the heads 15 A and 15 B are shifted further to another non-recorded track and the camera is again stopped or suspended in this condition.
When the operation of the camera CA is stopped or suspended by the resetting of the flip-flop FF 1 , the Q output of the flip-flop FF 1 has been high. Therefore, at this point of time, the transistor Tr 1 is released from its state being kept conductive. If the trigger button 34 has been released from the state of being depressed and if the trigger switches SWR 1 and SWR 2 thus have been turned of at this point of time, the transistor Tr 1 becomes non-conductive to cut off power supply to the whole circuits system. The timing for releasing the trigger button 34 from depression is arranged as follows: As indicated by {circle around (A)} in FIG. 11( a ), if the switch SWR 2 has once been turned on by depression of the button 34 to the second step stroke, the transistor Tr 1 is caused to be retained in a state of being conductive by the action of the flip-flop FF 1 as mentioned in the foregoing. The camera, therefore, automatically performs the operation described in the foregoing and the heads 15 A and 15 B come to a stop upon completion of shifting to the second recording track. On the other hand, as indicated by {circle around (B)} also in FIG. 11( a ), if the trigger button 34 is depressed only to the first step stroke and then released without going to the second step stroke, the conductivity holding arrangement is not applied to the transistor Tr 1 . Therefore, the camera is instantaneously stopped when the trigger button is released from the depression made in this manner.
Further, while the Q output of the flip-flop FF 2 is low, i.e. during recording, the lamp La 2 is caused to light up with the transistor Tr 2 rendered conductive to indicate that recording is in process. It is advantageous to have this lamp La 2 positioned to permit observation of it within the view finder.
In this mode S-A, upon completion of recording for one frame, the heads 15 A and 15 B are either stopped or suspended in a state having been automatically shifted to the next recording track. After that, the operation described in the foregoing is repeated to record picture image signals for one frame on each of recording tracks one after another every time the trigger button 34 is depressed to the second step stroke.
Then, the number of recording tracks that have been recorded in this manner is indicated on the track number indicating graduation plate 75 by the pointer 73 which is attached to the fore end of the counting member 72 which is shown in FIG. 9 . Upon completion of recording on the innermost track of the disc 11 , when the heads 15 A and 15 B are automatically shifted, the protrusion 76 provided on the form end of the counting member 72 comes to open the end switch SWE and power supply to the whole circuit system is cut off.
The foregoing description has covered a recording operation on a recording disc 11 which has not been recorded at all. In cases where the camera is loaded with a cartridge containing a disc that has some of its recording tracks already recorded, the camera operates in the following manner: Assuming that the first track of the disc 11 has already been recorded, the flip-flop circuits FF 1 , FF 3 and FF 4 are reset and the flip-flop circuit FF 2 is set by the pulse produced from the power up clear circuit PUC when the first step trigger switch SWR 1 is turned on. The output level of the integration circuit HIC becomes higher than a predetermined level when the motor starts. Therefore, as shown in FIG. 12( m ), the output of the Schmidt circuit SMC becomes high. Accordingly, as will be understood from FIG. 7B , the Q outputs of the flip-flop circuit FF 1 and FF 3 remain low as shown in FIGS. 12( e ) and ( h ), because at least their reset inputs R remain high. Therefore, the flip-flop FF 2 is not reset and the Q output of the flip-flop FF 2 remains high as shown in FIG. 12( g ). Thus, there obtains a condition of inhibiting recording. Further, since the output of the inverter IV 1 becomes low when the output of the Schmidt circuit SMC is high, the flip-flop FF 4 is not set and its Q output remains low as shown in FIG. 12( i ). Therefore, even if the second step trigger switch SWR 2 is turned on by further depression of the trigger button 34 at this point of time, the transistor Tr 4 is not rendered conductive thereby. Therefore, the differentiation circuit DFC does not produce a negative pulse. On the other hand, when the output of the Schmidt circuit SMC becomes high, the B output of the counter CNT 2 is applied to the base of the transistor Tr 3 through the AND gate AG 3 as shown in FIG. 12( o ). Accordingly, when the transistor Tr 3 is rendered conductive, the plunger Pl is energized to shift the heads 15 A and 15 B to the next track. If the next track has not been recorded before, the output level of the integration circuit HIC becomes lower than the predetermined level. Accordingly, as shown in FIG. 12( m ), the output of the Schmidt circuit SMC becomes low after a predetermined period of time to make the output of the inverter IV 1 high. By this, the flip-flop FF 4 is set and the Q output of it becomes high as shown in FIG. 12( i ). Therefore, if at this point of time the second step trigger switch has been turned on, the transistor Tr 4 becomes conductive to cause the differentiation circuit DFC to produce a negative pulse as shown in FIG. 12( c ). Then, the high pulse from the inverter IV 2 ( FIG. 12( d ) (comes to set the flip-flop FF 1 and the Q output of the flip-flop FF 1 becomes high as shown in FIG. 12( e ). The flip-flop FF 3 is set by this and the Q output thereof becomes high as shown in FIG. 12( h ). Accordingly, when the output of the delay circuit DLC becomes high ( FIG. 12( j )), the flip-flop FF 2 is reset and its Q output becomes low as shown in FIG. 12( g ). Then, as mentioned in the foregoing, signals for one frame are recorded on the new recording track. If this new track has already been recorded, the output of the Schmidt circuit SMC remains high as shown by a broken line in FIG. 12( m ). Therefore, with the recording inhibiting condition being kept unchanged as shown by broken lines in FIG. 12( c )-( i ), ( l ) and ( o ), the heads 15 A and 15 B are further shifted to the next track. After that, when the output of the Schmidt circuit SMC becomes low as shown by a broken line in FIG. 12( m ), i.e. when these heads arrive at a non-recorded track, the above mentioned actions are performed, as shown by broken lines in FIGS. 12( c )-( i ) and ( l ), to have signals for one frame recorded on this non-recorded track.
In cases where a cartridge having some of tis tracks already recorded is used, therefore, double recording on the recorded tracks is inhibited and the heads 15 A and 15 B are arranged to be automatically shifted without performing recording on the recorded tracks until a non-recorded track is detected. Upon completion of recording on the non-recorded track, the heads are shifted to a next non-recorded track. After completion of shifting, the camera CA is either stopped or suspended.
The operation in the mode S-A has been described in the foregoing, operation in the next mode S-M, i.e. single picture image shot—manual head shifting mode, will be understood from the following description: When the slide 37 is shifted to the position M, the switch SWM 1 is shifted thereby from the side of the plunger Pl to the side of the lamp La 3 while the push switch SWP is connected to the plunger Pl through the switch SWM 2 . Therefore, even when a track which is facing the heads 15 A and 15 B are not automatically shifted to a next track. Instead of that, the lamp La 3 flickers in response to the output of the AND gate AG 3 , or the B output of the counter CNT 2 , to give a warning that the track facing these heads 15 A and 15 B has already been recorded. See FIG. 12( p ). In this case, the push button 38 is depressed to turn on the switch SWP for shifting the heads 15 A and 15 B to a next track.
In this mode S-M, if the track facing the heads 15 A and 15 B has not been recorded, recording can be performed by operating the trigger button in the same manner as described in the foregoing. Upon completion of recording on this track, however, the heads 15 A and 15 B are not shifted to a next track while the lamp La 3 just flickers even when the output of the Schmidt circuit SMC becomes high—see broken lines in FIGS. 11( g ) and ( s ) and FIG. 11( t ). The heads 15 A and 15 B are shifted, in this case, by turning on the push switch SWP. On the other hand, if the track facing the heads 15 A and 15 B has already been recorded, the lamp La 3 flickers as shown in FIG. 12( p ). The heads 15 A and 15 B, therefore, can be shifted to a next track by turning on the switch SWP. Then, if this track has not been recorded, recording can be performed thereon. If this track has been recorded, the lamp La 3 continues to flicker to give a further warning. In this manner, the warning by the lamp La 3 is repeated until the heads 15 A and 15 B arrive at a non-recorded track; and, with the push button 38 thus being repeatedly depressed, recording is performed on a non-recorded track when the heads 15 A and 15 B come to the non-recorded track.
The details of the functions of the above stated flip-flop FF 4 and the transistor Tr 4 are as follows: If the flip-flop FF 4 and the transistor Tr 4 are not provided in the circuit system shown in FIG. 7 , in cases where the trigger button 34 is rapidly depressed to the second step stroke to almost concurrently turn on the trigger switches SWR 1 and SWR 2 when a recording track facing the heads 15 A and 15 B is detected already recorded in the above stated mode S-A and some subsequent tracks are also found recorded, or when, in the mode S-M, a track facing the heads 15 A and 15 B is detected already recorded, even if the turning on of the trigger switch SWR 2 causes the differentiation circuit DFC to produce the negative pulse and thus to have a high pulse produced from the inverter IV 2 , the output of the Schmidt circuit SMC might have not become high. Then, as will be understood from FIG. 7B , the flip-flop FF 1 would not be set at least the Q output thereof would remain low. In such a case, even if the heads 15 A and 15 B are brought to a non-recorded track by automatic shifting in the mode S-A or by operating the push button 38 in the mode S-M, the output of the Schmidt circuit SMC is low at this point of time while the flip-flop FF 1 is still not set and its Q output also remains low. Therefore, the camera CA is either stopped or suspended in a state of having the heads 15 A and 15 B brought to the non-recorded track, so that recording cannot be performed on the non-recorded track. On the other hand, with the flip-flop FF 4 and the transistor Tr 4 provided, the flip-flop FF 4 is set only when the output of the inverter IV 1 is high, i.e. when the output of the Schmidt circuit SMC is low indicating that a track facing the heads 15 A and 15 B has not been recorded. Therefore, as will be understood from FIGS. 12( a ), ( c ), ( i ) and ( m ), the transistor Tr 4 does not become conductive as long as the output of the Schmidt circuit is high, that is as long as the heads 15 A and 15 B are facing a recorded track, even if the switch SWR 2 has been turned on. Therefore, the differentiation circuit DFC does not produce the negative pulse. Then, when the heads 15 A and 15 B come to face a non-recorded track and when the output of the Schmidt circuit thus become low, the flip-flop FF 4 is set to make the transistor Tr 4 conductive. Then, the differentiation circuit DFC comes to produce the negative pulse and the flip-flop FF 1 is set thereby. With this arrangement, therefore, the above stated trouble of inoperativeness can be effectively avoided.
Operation in the mode of continuous picture image shots will be understood from the following description: For continuous picture image shots, the selection dial 36 is shifted to the mode C 1 or C 2 . This causes each of the switches SW 1 -SW 3 to shift to the terminal C 1 or C 2 . Further, in this case, even if the slide 37 is in the mode position M, the cam 39 which is responsive to the mode selection dial 36 shifts the slide 37 to the mode position A. Accordingly, each of the switches SWM 1 and SWM 2 comes to be connected to the terminal A. Then, with the switch SW 2 connected to the terminal C 1 or C 2 , the differentiation circuit DFC is caused to short-circuit between its terminals a and b. Once the flip-flop FF 4 is set, therefore, the output of the differentiation circuit DFC remains low as long as the second step trigger switch SWR 2 is on. The set input S of the flip-flop FF 1 , therefore, is high as long as the switch SWR 2 is on and, as will be understood from FIG. 7B , the Q output of the flip-flop FF 1 is high as long as its reset input R is low. Further, the Q output of the flip-flop FF 1 is low as long as its set input S is high. Therefore, while the trigger button 34 is being depressed to the second step stroke, picture image recording is not inhibited and recording shots are performed continuously as long as the heads 15 A and 15 B are facing a non-recorded track. Further, if a recorded track is detected during the recording operation, the output of the Schmidt circuit SMC becomes high upon detection of it. The flip-flop FF 2 is set by this and the counter CNT 1 is cleared (i.e. recording is inhibited). At the same time, the plunger is energized to carry out automatic shifting of the heads 15 A and 15 B to a next track. In this instance, when the output of the Schmidt circuit SMC becomes high, both the set input S and the reset input R of the flip-flop FF 1 become high. Therefore, as will be understood from FIG. 7B , the Q output of the flip-flop FF 1 becomes low while, on the other hand, the flip-flop FF 3 is reset. This condition remains unchanged as long as the heads 15 A and 15 B are facing a recorded track. When the heads 15 A and 15 B arrive at a non-recorded track, the output of the Schmidt circuit SMC becomes low to make the Q output of the flip-flop FF 1 high. Accordingly, the flip-flop FF 3 is set and the Q output thereof becomes high. This in turn resets the flip-flop FF 2 to remove the recording inhibition and to permit resumption of recording. This action is continuously performed as long as the trigger button 34 is in a state of being depressed to the second step stroke. Further, the holding of continuity of the transistor Tr 1 is effected in the same manner as described in the foregoing. The switch SW 3 selects the output of the AND gate AG 5 in the mode C 1 and selects that of the AND gate AG 6 in the case of the mode C 2 . A continuous shot operation is performed at a rate of about 6 picture images/sec. in the case of the mode C 1 and about 3.3 picture images/sec. in the mode C 2 .
FIG. 13 shows the operation of the circuit system in the mode C 1 or C 2 . In this drawing, the mode C 1 is shown by full lines and the mode C 2 by broken lines.
The camera CA is provided with an external output jack 42 . With an ordinary VTR device connected to this jack and by setting the mode selection dial 36 set in the mode position MV, a motion picture shot operation in the 2 fields—1 frame manner can be carried out at a rate of 30 frames/sec. With the dial 36 set in the mode position MV, each of the switches SW 1 -SW 3 is shifted to a terminal MV thereof. When the trigger button 34 is depressed at least to the first step stroke to just turn on the switch SWR 1 , the circuit 69 and the light measuring circuit PMC are actuated. A combined color video signal of NTSC system is then produced out of the jack 42 to be recorded on a magnetic tape in the VTR device.
Further, the actions of the camera CA described in the foregoing can be started by operating a remote controller connected to the remote control jack 43 instead of by operating the trigger button. In this case, since the circuit shown in FIG. 7 is provided with a safety circuit consisting of the flip-flop FF 4 and the transistor Tr 4 as mentioned in the foregoing, the remote controller is required to have just a single switch.
Referring now to FIG. 14 , one example of modification of the above mentioned embodiment of the invention is described as shown below:
In this modification example, a single magnetic head is used for the combined purposes of detecting non-recorded or recorded track and performing a recording operation. The operation mode of the device is shiftable as desired by utilizing the output of the above stated counter CNT 1 in the same manner as the control system shown in FIG. 7 . FIG. 14 shows only the parts that are different from the arrangement shown in FIG. 7 . Other parts that are omitted from the illustration are arranged in exactly the same manner as in FIG. 7 . Description given here is, therefore, limited to the parts differing from the arrangement shown in FIG. 7 .
In FIG. 14 , a reference numeral 15 ′ indicates a magnetic head which is employed for the combined pusposes of detecting and recording. The head 15 ′ is connected to the above stated analog switch ASW and to an analog switch ASW′ is connected to the DC cut capacitor C provided in the input stage of the above stated non-recorded or recorded track detection circuit (i.e. the amplifier AP, the integration circuit HIC and the Schmidt circuit SMC). The analog switch ASW′ is arranged to receive from the inverter IV 4 an inverted output of the signal to be supplied to the above stated analog switch ASW. In this arrangement, when the recording control signal (i.e. the B output of the counter CNT 1 or the output of the AND gate AG 5 or AG 6 ) which is selected by the switch SW 3 is low, the analog switch ASW′ is turned on to use the head 15 ′ for the purpose of detecting a non-recorded or recorded track. Then, if a non-recorded track is detected by this and the recording control signal from the switch SW 3 becomes high to permit recording, the analog switch ASW is turned on to use the head 15 ′ for the purpose of recording on the non-recorded track. Other details of operation are exactly the same as in the case of the circuit shown in FIG. 7 and are omitted from description here.
In the embodiments described in the foregoing, the head is arranged to be mechanically shifted relative to the tracks of the disc 11 . In addition to these embodiments, other embodiments are shown in FIG. 15 and FIG. 16 . In each of the embodiment, the magnetic head is arranged to be a multi-channel head having a number of channels corresponding to the number of tracks of the disc 11 and is fixedly disposed to perform the function of discerning a recorded or non-recorded track and the function of recording on a non-recorded track by shifting it from one channel to another. FIGS. 15 and 16 show only the essential parts required for carrying out the above stated functions and, unless specifically stated otherwise, other parts that are not shown in these drawings are exactly the same as the arrangement shown in FIG. 7 .
Referring first to FIG. 15 which corresponds to FIG. 7 , a reference symbol CNT 3 indicates a binary counter of a pulse fall synchronization type incorporating a decoder, or a counter-decoder, which is provided for channel shifting. The clear terminal CLR of the counter CNT 3 is arranged to receive the output of the power up clear circuit PUC. A symbol IV 5 indicates an inverter arranged for obtaining an inverted signal of the output of the power up clear circuit PUC; OC indicates a one shot circuit which is arranged to be triggered by building up of the output of the inverter IV 5 ; and OG 4 indicates an OR gate which is provided for obtaining a logical sum of the output of the one shot circuit OC and the output of an inverter IV 7 the input terminal of which is connected to a resistor R provided in place of the above stated plunger Pl. The output of the OR gate OG 4 is arranged to be supplied to the clock input terminal CK of the counter CNT 3 as count up clock. Reference numerals 15 A 1 - 15 A n indicate non-recorded- or recorded-track detecting heads which are fixedly arranged to correspond to the tracks provided on the disc 11 ; and 15 B 1 - 15 B n indicate recording heads which are also fixedly arranged to correspond to these tracks. These heads constitute a so-called multi-channel head. In the same manner as in the case of the head 15 shown in FIG. 8 , the detection heads 15 A 1 - 15 A n are positioned ahead of the recording heads 15 B 1 - 15 B n in relation to the rotation of the disc 11 . In this particular embodiment, the number of heads “n” means 40 and these heads are unified into one body. Symbols ASW′ 1 -ASW′n indicate analog switches respectively connected to the heads 15 A 1 - 15 A n and are connected to the input stage of the above stated non-recorded- or recorded-track detection circuit, i.e. to a DC cut capacitor on the input side of the amplifier AP. Symbols ASW 1 -ASWn indicate analog switches connected to the heads 15 B 1 - 15 B n and also to the output stage of the image pickup—video signal generating—magnetic recording circuit 69 . Symbols AND 1 -ANDn indicate AND gates which are arranged to obtain logical products of the recording control signal selected by the above stated switch SW 3 , i.e. the B output of the counter CNT 1 or the output of AND gate AG 5 or AG 6 and the decoded outputs 1 -n of the above stated counter CNT 3 . The outputs of these AND gates AND 1 -ANDn are supplied to the analog gates ASW 1 -ASWn. Further, the decoded outputs 1 -n of the counter CNT 3 are supplied to the analog switches ASW′ 1 -ASW′n respectively.
The arrangement described above operates as follows: With the trigger button 34 depressed to the first step stroke, the power up clear circuit PUC produces pulses as shown in FIG. 11( g ). Then, this causes all of the decoded outputs 1 -n of the counter CNT 3 to become low. Following this, when the one shot circuit OC is triggered by building up of the output of the inverter IV 5 and when the one shot pulse of the one shot circuit OC is produced, this causes the counter CNT 3 counts up by one and first the decoded output 1 thereof becomes high. The analog switch ASW′ 1 is turned on and the output of the detection head 15 A 1 is applied to the amplifier AP through the capacitor C. Then, if the first track facing the heads 15 A 1 and 15 B 1 has not been recorded, the flip-flop FF 1 is reset with flip-flop FF 3 set as mentioned in the foregoing, and the recording head 15 B 1 performing recording on the first track. After recording, when the completion of the recording on this track is detected by the detection head 15 A 1 , a high pulse output of the AND gate AG 3 renders the transistor Tr 3 momentarily conductive. Therefore, in cases where the switches SWM 1 and SWM 2 have been shifted to the mode A (i.e. in the case of the mode S-A, C 1 or C 2 ), this causes the inverter IV 7 to produce a high pulse output. Then, building-up of this output pulse of the inverter IV 7 causes the counter CNT 3 to count up by one to make the decoded output 2 thereof high. Then, the analog switch ASW′ 2 is turned on this time. The detection head 15 A 2 detects whether the second track is not recorded. In the mode C 1 or C 2 , if the second track is not recorded, the recording head 15 B 2 performs recording on the second track when the recording control signal from the switch SW 3 becomes high in the same manner as described in the foregoing. Conversely, if the second track is found already recorded, a high pulse output of the AND gate AG 3 renders the transistor Tr 3 momentarily conductive. Then, building-up of the inverter IV 7 causes the counter CNT 3 to count up by one and the decoded output 3 of the counter becomes high. Accordingly, the above mentioned detection is performed on a third track. Thus, in the case of the mode C 1 or C 2 , recording on non-recorded tracks is repeated as long as the trigger button 34 is kept in a state of being depressed in the same manner as in the preceding embodiment.
In the mode S-A, after completion of recording on a non-recorded track, the pulse-fall of the output pulse of the inverter IV 7 causes the counter CNP 3 to count up by one; under this condition, the camera is either stopped or suspended; after the trigger button 34 is released from depression, when it is depressed again, detection is performed by shifting from one to another the detection heads 15 A 1 - 15 A n starting with the head 15 A 1 until a non-recorded track is detected thereby; and, upon detection of a non-recorded track, recording is performed thereon by a recording head that corresponds to this track. Further, in the mode S-M, the channel shifting of the heads 15 A 1 - 15 A n and 15 B 1 - 15 B n is carried out by operating the push switch SWP in the same manner as in the embodiment shown in FIG. 7 . In other words, the input to the inverter IV 7 becomes low with the switch SWP turned on. Therefore, by the building-up of the output of the inverter IV 7 , the counter CNT 3 is caused to count up by one to permit the channel shifting of the heads.
In the modification example which is shown in FIG. 16 and which corresponds to the embodiment shown in FIG. 12 , a multi-channel head is composed of heads 15 ′ 1 - 15 ′ n each of which is arranged to serve combined purposes of detecting and recording, unlike the heads 15 A 1 - 15 A n and 15 B 1 - 15 B n which are used in the arrangement shown in FIG. 15 . Each of these heads 15 ′ 1 - 15 ′ n is connected to analog switches ASW′ 1 and ASW 1 , ASW′ 2 and ASW 2 . . . , or ASW′ n and ASW n. There are arranged AND gates AND′ 1 -AND′n to obtain logical products of the recording control signal which is selected by the switch SW 3 (i.e. the B output of the counter CNT 1 or the output of AG 5 or AG 6 ) and is obtained as inverted signal through an inverter IV 6 and the decoded outputs 1 -n of the counter CNT 3 . The outputs of these AND gates AND′ 1 -AND′n are arranged to be supplied to the analog switches ASW′ 1 -ASW′n as applicable respectively.
The device arranged as shown in FIG. 16 operates in a manner which will be readily understood from the foregoing description of the arrangement shown in FIGS. 14 and 15 . Therefore, the operation of the device is omitted here.
According to the arrangements shown in FIGS. 15 and 16 , the mechanical arrangement for shifting the head as shown in FIG. 2 is no longer required. With these arrangements employed, it will be disadvantageous to have the “A”-to-“M” change-over arrangement including the slide 37 , push button 38 and the switches SWM 1 , SW 2 and SWP. In these modification examples, the above stated lamp La 3 may be connected to the collector of the transistor Tr 3 to display the count up action of the counter CNT 3 , i.e. the channel shifting status of the heads 15 A 1 - 15 A n and 15 B 1 - 15 B n. As for displaying the number of recorded tracks in the modification examples shown in FIGS. 15 and 16 , the display may be arranged, for example, in the following manner: The device is provided with a display unit DU consisting of a decoder drive and a display seven segment LED. The outputs 1 —n of the counter CNT 3 are supplied to the decoder disposed within the display unit DU to make digital display. It is also possible to use a LED dot array display unit consisting of n number of light emitting diodes (LED). In such a case, it will be convenient to have the display made within the view finder.
In the modification example shown in FIG. 15 or 16 , the end switch SWE and control for the switch SWE are arranged, for example, as follows: A so-called latching relay switch LRS is employed as shown in the drawing as end switch SWE. The latching relay switch is arranged to have its movable contact piece shifted from a terminal b to a terminal a when its coil CLa is energized. The connection to the terminal a is retained, for example by a holding force of a permanent magnet even when power supply to the coil CLa is cut off. Then, when the power is supplied again to the coil, the movable contact piece MC shifts from the terminal a to the terminal b and again is kept in contact with the terminal b by the holding force of the permanent magnet. One end of the coil CLa is connected to the collector of a NPN switching transistor Tr 5 which is arranged to receive the decoded output n+ 1 of the above stated counter CNT 3 and the one end of the coil CLb is connected to one off the contact pieces of a normally open type switch SW 4 which is arranged to be turned on, for example, by opening the lid 16 of the cartridge loading chamber. The movable contact piece MC and the other end of each of the coils CLa and CLb are connected to the plus side of the power source E while the terminal b is connected to the emitter of the transistor Tr 1 . The emitter of the transistor Tr 5 and the other contact piece of the switch SW 4 are connected to the minus side of the power source E. With arrangement made in this manner, when the loading chamber lid 16 is opened for loading the camera CA with a cartridge 12 , the switch SW 4 is turned on to energize the coil CLb. The movable contact piece MC then connects with the terminal b. Then, with the first step trigger switch SWR 1 turned on by depression of the trigger button, the transistor Tr 1 is made conductive to allow power supply to the circuit system. After completion of recording on all tracks of the disc 11 , when the decoded output n+ 1 of the counter CNT 3 becomes high, the transistor Tr 5 is made conductive thereby and the coil CLa is energized to shift the movable contact piece MC from the terminal b to the terminal a. Therefore, power supply to the circuit system is cut off at this point of this even if the first step trigger switch SWR 1 is on. When the loading chamber lid 16 is opened to take out the recorded cartridge, the switch SW 4 is turned on to energize the coil CLb. Again the movable contact piece MC is shifted from the terminal a to the terminal b and is kept there until the coil CLa is energized through the transistor Tr 5 .
As described in the foregoing, in accordance with this invention, a relatively simple logical arrangement not only permits single picture image recording but also permits continuous recording on a plurality of tracks. It must be emphasized that the invention makes it possible to carry out analytical photographic recording for moving objects, so that unique, interesting picture images can be enjoyed by reproducing such records. The functional improvement attained in accordance with this invention makes the recording device usable for a wide range of purposes.
Further, as also shown in the embodiment examples given herein, the continuous recording can be performed at different selectable speeds. This arrangement gives a further advantageous effect. Further, with the invented device used in combination with an ordinary VTR device, it is possible to accomplish recording of a moving object at a VTR speed without being confined to recording on a recording medium having a limited number of recording tracks.
In accordance with the arrangement made in the embodiment examples, a state of having been already recorded or not recorded of the track on which recording is going to be performed can be accurately detected. This is a highly advantageous feature for a device of this type which must meet the rational requirements mentioned in the beginning of this specification. With a very simple logical arrangement, the device of the invention is capable of performing advantageous functions, such as inhibiting double recording, giving a warning against it, automatic shifting of recording means to a non-recorded track and the like.
The arrangement to display the number of recorded tracks as shown in the embodiment examples is very simple. The display arrangement, therefore, can be easily incorporated in the device, is less likely to come out of order and can be added at low cost, so that it gives a great advantage to the picture image recording device. Further, as also shown in the embodiment examples, the power source of the recording device is arranged to be automatically cut off upon completion of recording on all recording tracks. This is highly rational arrangement for a device of this type.
In the embodiment examples given, the image pickup—video signal generation—magnetic recording system circuitry to be used in accordance with this invention is arranged to use a CCD image sensor as image pickup element. However, it goes without saying that, in place of the CCD image sensor, conventionally known image pickup tubes, such as a vidicon, etc. are also usable as image pickup element. Further, a magnetic disc is used as recording medium in the embodiment examples. However, the invention is not limited to this. Use of other recording media, such as a magnetic drum is also usable with minor modification of the structural arrangement of the device.
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A camera apparatus includes a single release switch member. The single release switch member is for instructing an image capture operation, and selects one of a first operative state and a second operative state. The first operative state is selected when the single release switch member is pushed down to a first depth. The second operative state is selected when the single release switch member is pushed down to a second depth which is deeper than the first depth. The camera apparatus selects a recordable portion of a recording medium in response to selection of the first operative state, and generates a predetermined electrical signal if the camera apparatus selects the recordable portion of the recording medium. The camera apparatus records the image signal on the selected recordable portion if the second operative state is selected by the single release switch member, and the predetermined electrical signal is generated.
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BACKGROUND OF THE INVENTION
The present invention generally relates to optical recording/reproducing apparatus and particularly to an optical recording/reproducing apparatus for recording and/or playing back an information signal on and from an optical disk by means of a laser beam.
Conventionally, there is an optical recording/reproducing apparatus for recording an information signal on a rotary disk in a form of pits by irradiating same with a laser beam and for playing back the information signal from the disk by irradiating same with the laser beam so as to detect the existence or non-existence of the pits.
In such a conventional optical disk recording/reproducing apparatus, the recording is made while rotating or revolving the disk at a predetermined speed which is determined on the basis of a relation between the sensitivity of the recording medium to the laser beam and the output power of the laser diode. In the conventional apparatus, the speed of revolution of the disk is usually set to be equal at the time of recording and at the time of playback.
In such an apparatus, it is necessary to reduce the intensity of the laser beam at the time of playback relative to the case of recording so that no erroneous recording is made on the disk at the time of playback. For this purpose, the output power of the laser diode which is usually set to a first level P1 (FIG. 3) which may be 6 mW for example at the time of recording, is reduced to a second level P2 (FIG. 3) which may be 1.2 mW at the time of playback. By changing the output level of the laser diode as such, the information signal is recorded on and reproduced from the optical disk with a data transfer rate such as 2 Mbit/sec.
As far as the recording is concerned, one can achieve a satisfactory signal-to-noise (S/N) ratio or carrier-to-noise (C/N) ratio in such a conventional apparatus with respect to the noise produced in the laser diode because of the large output power. At the time of playback where the output power of the laser diode is reduced to one fifth as compared to the case of recording, however, there is a problem in that the noise caused in the laser diode which may be at least equal to the noise at the time of recording deteriorates the S/N or C/N ratio. Further, the data transfer rate is limited to a same rate such as 2 Mbit/sec for both of the recording and playback.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide a novel and useful optical recording/reproducing method and apparatus wherein the aforementioned problems are eliminated.
Another object of the present invention is to provide an optical recording/reproducing method and apparatus for recording and/or reproducing an information signal on and/or from a rotary optical disk wherein the S/N ratio or C/N ratio at the time of playback is improved.
Another object of the present invention is to provide an optical disk recording/reproducing method and apparatus for recording an information signal on a rotary optical disk by irradiating same with an optical beam and for playing back the recorded information, signal from the rotary optical disk by irradiating same with the optical beam, wherein the speed of revolution of the optical disk at the time of playback is set to a value which is larger than the speed at the time of recording so that an energy of the optical beam incident to a unit area of the optical disk in a unit time at the time of playback is made smaller than the energy of the optical beam correspondingly incident to the optical disk at the time of recording. According to the present invention, one can use a large output power of the laser diode for both of the recording and playback modes. As a result of the use of the large output power, one can reduce the S/N ratio or C/N ratio for the noise produced in the laser diode at the time of playback. Further, one can increase the rate of data transfer at the time of playback as compared to the conventional apparatus.
Other objects and further features of the present invention will become apparent from the following detailed description when read in conjunction with attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the construction of an embodiment of the optical recording/reproducing apparatus of the present invention;
FIG. 2, consisting of 2A, 2B and 2C, is a diagram for explanation of the principle of astigmatic focusing control used in the apparatus of FIG. 1; and
FIG. 3 is a characteristic curve showing a relationship between a drive current and output power of a laser diode used in the apparatus of FIG. 1.
DETAILED DESCRIPTION
FIG. 1 shows a block diagram of an optical recording/reproducing apparatus according to an embodiment of the present invention.
Referring to FIG. 1, an optical disk 10 rotated by a drive motor 11 is recorded with an information signal by a laser beam which is produced by a laser diode 12 and focused on a recording surface of the disk 10 after passing through a collimator lens 13, beam splitter 14, tracking mirror 15 and an objective lens 16. Further, the optical beam reflected back from the disk 10 is passed through the objective lens 16, tracking mirror 15 and beam splitter 14 in reversed direction and reaches another beam splitter 17 where it is split into two branches. One branch is supplied to a photo sensor 18 for reproducing the information signal from the reflected optical beam and the information signal thus reproduced is supplied to a signal output terminal 19. The reflected light beam of the other branch is reflected by a mirror 20 and conducted to a quadrant photosensor 22 after passing through a cylindrical lens 21.
The quadrant photosensor 22 comprises first, second, third and fourth quadrants 22a, 22b, 22c and 22d respectively producing output signals A, B, C and D which are supplied to a focusing error detection circuit 23 where the signal A from the first quadrant and the signal C from the second quadrant are added to form a first sum signal (A+C) and the signal B from the third quadrant and the signal D from the fourth quadrant are added to form a second sum signal (B+D). Further, first and second sum signals are subtracted from each other, whereby a focusing error signal is obtained as (A+C)-(B+D). It should be noted that one can obtain the reproduced information signal by adding the signals A-D. In this case, one can omit the use of the photo sensor 18.
The apparatus of FIG. 1 carries out the astigmatic focusing servo control. When the optical disk 10 is closer to the objective lens 16 than its focal length, the beam spot formed on the quadrants 22a-22d of the photosensor 22 takes a form of eclipse elongating from the upper left quadrant 22a to the lower right quadrant 22c as shown in FIG. 2(A). When the optical disk 10 is far from the objective lens 16 beyond its focal length, on the other hand, the beam spot on the quadrants 22a-22d takes a form of eclipse elongating from the upper right quadrant 22b to the lower left quadrant 22d as illustrated in FIG. 2(C). When the disk 10 is exactly on the focus of the lens 16, the beam spot on the quadrants 22a-22d takes a form of true circle as shown in FIG. 2(B).
As the quadrants 22a-22d produce an electrical output responsive to the intensity of light falling thereon, the focusing error signal defined previously indicates by its value if the optical disk 10 is on the focus of the objective lens 16 or if it is off-focused. When it is off-focused, one can further discriminate if the disk 10 is too far from the lens 16 or too close to the lens 16 on the basis of the sign or sense of the focusing error signal.
The focusing error signal thus produced by the focusing error detection circuit 23 is supplied to a servo control circuit 25 after passing through a gain adjusting circuit 24. The focusing error signal is then amplified in the circuit 25 and energizes a solenoid 26 on which the objective lens 16 is carried. As a result, the objective lens 16 is moved such that the laser beam is properly focused on the optical disk 10.
The information signal to be recorded on the optical disk 10 is supplied to an input terminal 30. The signal is supplied to the laser diode 12 after passing through a laser drive circuit 31 where the laser beam is modulated with the information signal. The motor 11 is driven by a motor drive circuit 33.
In the optical recording/reproducing apparatus of the present invention, a system controller 34 is used for changing the operational mode between the recording mode and the playback mode responsive to a mode command signal from an input terminal 35. Responsive to the command signal, the system controller 34 supplies a control signal to the gain adjusting circuit 24, laser drive circuit 31 and the motor drive circuit 33.
FIG. 3 shows a relation between the drive current supplied from the laser drive circuit 31 to the laser diode 12 and the output power produced by the laser diode responsive to the drive current. At the time of recording, the system controller 34 produces a control signal indicating the recording mode responsive to the command signal at the input terminal 35. Responsive to the control signal, the laser drive circuit 31 supplies the drive current with a level indicated by I1. Referring to FIG. 3, the laser diode 12 thus driven produces an average output power P1 which may be 6 mW, for example. Of course, this output power P1 may be adjusted suitably according to the recording signal. At the same time, the gain of the gain adjusting circuit 24 is set to one. Further, the motor drive circuit 33 drives the motor 11 at a speed of 1800 rpm responsive to the control signal from the system controller 34.
At the time of playback, the system controller 34 produces a second control signal indicating the playback mode. Responsive to the second control signal, the laser drive circuit 31 supplies a drive current of level I3 to the laser diode 12, whereby an output power of P3 which may be 3.6 mW, for example, is obtained from the laser diode. Further, the gain of the gain adjusting circuit 24 is set to 1.66 responsive to the second control signal. Further, the motor drive circuit 33 drives the motor 11 at a speed of 5400 rpm.
In this example, the output power of the laser diode at the time of playback is three times larger than the usual level of the output power for the playback mode. In spite of such a high laser output power, the energy of the laser beam irradiated on a unit area of the optical disk in a unit time remains the same as in the conventional case, as the speed of revolution of the optical disk is increased to three times larger than the conventional speed for the playback mode. As a result, no pit is formed on the disk at the time of playback.
Further, the change in the level of the focusing error signal between the recording mode and the playback mode is compensated by the gain adjusting circuit 24 so that there is no substantial difference in the level of the focusing control signal. Thus, the focusing control in the playback mode is performed identically to the case of the recording mode.
In this method, the output power level of the laser diode 12 at the time of playback is three times larger than the output power level at the time of playback in the conventional apparatus. As a result, the S/N ratio or C/N ratio due to the noise produced in the laser diode 12 is improved significantly.
Further, the data transfer rate at the time of playback is increased to 6 Mbit/sec which is three times larger than the conventional rate of 2 Mbit/sec. The data transfer rate of 2 Mbit/sec at the time of recording remains the same.
In one modification, one may use a same output power P1 of 6 mW for both the recording and playback. In this case, the gain set by the gain adjusting circuit 24 is set to one for both the recording and playback. Further, the motor 11 is rotated at a speed of 9000 rpm. With this method, one can eliminate the use of the gain adjusting circuit 24 and further increase the S/N ratio or C/N ratio of the reproduced signal. Further, the data transfer rate at the time of playback is increased to 10 Mbit/sec which is five times larger than the conventional rate.
Further, the present invention is not limited to these embodiments but various variations and modifications may be made without departing from the scope of the invention.
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An optical recording/reproducing apparatus records an information signal on a rotary optical disk by irradiating an optical beam having an optical power such that an energy sufficient to cause recording of the information signal is incident to a unit area of the optical disk in a unit time while revolting to optical disk at a first predetermined speed, and plays back the information signal from the optical disk by irradiating the optical beam while revolving the optical disk with a second predetermined speed such that the energy incident to a unit area of the optical beam in a unit time at the time of playback does not cause recording on the optical disk.
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This application is a continuation of pending international patent application PCT/EP2004/001290 filed on Feb. 12, 2004 which designates the United States and claims priority of German Application No. 103 08 383.9 filed on Feb. 27, 2003.
FIELD OF THE INVENTION
The invention relates to a method and optical system for measuring the topography of a test object, having the characteristics disclosed in the generic portion of Patent Claim 1 , and an optical system appropriate to said method, having the characteristics cited in the generic portion of Patent Claim 6 .
Optical measurement systems, which obtain a number of spatial coordinates of the surface of a test object by parallactically projecting complex patterns onto an object, exist in the state of the art. In general in such cases a regular striped pattern is projected onto the test object. The position of the stripes is recorded with a scanner or a video camera. The measuring is based on a triangulation, so that the projection and image-recording angle and the distance between the camera and projector must be known. Because the stripes are not identifiable individually, there results a modulation uncertainty in determining the spatial coordinates, and said uncertainty must be resolved through multiple recordings, each at various stripe distances.
The projection of regular point patterns, which are produced by laser illumination of a diffractive optical element, is also part of the state of the art in automatic object recognition. A paper in Machine Vision News , Vol. 4, (1999) describes the displacement of the elements of a regular point pattern on projection onto an uneven surface. It is stated in general that new possibilities of object recognition would be opened up as a result, without any more precise description of these possibilities such as an identification of the points of the surface.
To exclude modular uncertainties in the optical measurement of spatial structures, unequivocally identifiable measurement data are mainly used, which are applied on the test object. With the help of image-recording and image-evaluating systems, these measurement data can be individually recognized and measured.
Measurement of three-dimensional structures or of surfaces and lengths is also a matter of significance in endoscopic measurement technology.
In medical applications, for instance, the minimally invasive recognition of shapes and volumes of tumors is important as an aid in decision making for the optimal treatment or for monitoring the growth process.
In technical endoscopy, for instance, on the basis of a quantitatively determined material error, it is possible to avoid or postpone the dismantling of the device until a critical mass is determined.
In these applications it is impossible to apply special measurement data on the test object.
Besides other measurement methods, therefore, in measurement endoscopy as well, use was made of the principle of image evaluation of the parallax, that is, of the apparent lateral displacement of an illuminated pattern, depending on the projection distance. In a 3D measurement endoscope described by K. Armbruster and M. Scheffler, of the Institut für angewandte Forschung in der Automation, in FH Reutlingen, structured light, for example a line pattern is projected into the object space that is to be measured and the setting image is photographed with a camera from a second perspective. In this method the position of the light source is defined with respect to the camera so that the 3D coordinates of an object surface can be calculated by means of triangulation. A method for photographing and measuring bodies was presented by K. Armbruster in the Volume of Proceedings of the 3 rd Symposium on Image Processing, Technical Academy, Esslingen (1993).
In U.S. Pat. No. 5,150,254 A1 the principle of shape recognition by evaluation of a projected marker line was described in general terms. Stabilization of the angle of projection and the position of the marker line were cited as a fundamental problem, because both are decisive for the exact determination of the distance to the test object. The angle of projection and the image-recording angle are selected in such a way that the marker line lies in the middle of the image.
U.S. Pat. No. 5,669,871 A1 describes an endoscope with an illuminating system positioned on its distal end, a CCD image-recording system and a projection system for a line of reference. The optical axes of the image-recording system and of the projection system are at a defined distance from one another. A single line of reference is projected onto the object plane, so that the projection system has a means of adjustment in order to produce the straightest possible line of reference. In cylindrically domed object surfaces, the endoscope must be oriented in such a way that the line of reference runs parallel to the cylindrical axis. In addition it is essential in each case to ensure that the line of reference lies on the object part that is to be measured.
Through image evaluation, the spatial coordinates of a straight line are calculated for the lines of reference superimposed on the object image and the straight line is close to the image of the projected line of reference. From the deformations of the line of reference in the object image relative to the calculated straight line, the spatial coordinates of selected object points situated on the straight line of reference can be determined
Patent DE 3516164 C2 descries a system for optical length measurement with an endoscope. On the distal end of the endoscope, a projection system and an image-recording system are positioned at a fixed distance from one another. The optical axes of the two systems are arranged parallel to one another and the angles of aperture of the projection of the projection cone and of the image-recording cone are equal. By means of the projection system, a circular marker, for instance, is projected onto the object and is depicted in the image of the test object. The distance of the circular marker from the uppermost point of the visual field constitutes a reference length whose size is independent of the respective object distance because the parallactic displacement of the boundary of the visual field and of the position of the circular marker run parallel to one another, because of the equal conic angle.
Only one length estimation is possible with this method by means of relative length comparison. The exactitude depends, moreover, on whether the boundary of the visual field and the projection of the circular marker are situated in the same plane. No information can be obtained on heights by means of the test object.
It is therefore the object of the invention to produce a method of measurement and a system of measurement on the basis of illuminated measurement data for parallactic determination of coordinates, so that with the help of an image-evaluation system an unequivocal identification of the measurement data can be achieved entirely from the position of the measurement data in the image of the test object and the measuring system is not required to be situated so that it is adjusted to the shape of the test object.
This object is fulfilled according to the invention through a method of the aforementioned type having the defining characteristics of Patent Claim 1 . Advantageous refinements are obtained from the characteristics of related Claims 2 through 5 .
An optical system of the aforementioned type, appropriate for fulfilling the object, has, according to the invention, the defining characteristics of Claim 6 . Advantageous embodiments are derived from related Claims 7 through 26 .
The optical system, according to Claim 27 , is particularly appropriate for use in an endoscope. An advantageous embodiment results from the defining characteristics of related Claim 28 .
The fundamental concept in the invention consists in the fact that the first axis for positioning the elements of the test pattern is inclined by an angle ac relative to the vertical projection of the base line into a plane of reference. The base line is thus the connecting line between the midpoints of the pupils of the projection and image-recording system. The plane of reference is vertical to the optical axis of the image-recording system in the object space removed from the distal end of the optical system by a reference distance. It is the surface in which the test pattern is defined with the system parameters (x, a, s, t, n, m) explained in further detail hereafter. By establishing the reference distance, the distance-dependent parameters s and t receive a fixed value. The reference distance can be selected to be, for instance, the middle working distance for which the optical system is designed.
In a one-dimensional test pattern, only the inclination at a selected angle of 0 0 degrees ensures that with the parallactic displacement of the elements of the test pattern every element moves on its own line of displacement parallel to the projection of the base line. For an unequivocal proof of every element in the image, however, the size of the element and the dissolution power of the image-recording system must be considered in selecting the angle. At too small an angle oc, otherwise, neighboring elements could partly be covered up because of the resulting strongly differing parallactic displacement, with great local differences of height in the test object. The angle a should therefore be selected so that the distance a between the lines of displacement of every element is great enough so that sufficient space remains to the neighboring element for the surface of every element even with an error value of the position and with a possibly distorted line of displacement.
In a two-dimensional test pattern, the second axis can be inclined for the alignment of the other elements at any desired ankle beta relative to the first axis. Even here, however, care must be exercised so that with the parallactic displacement of the bar elements no mutual covering of the lines of displacement can occur. Depending on the number n and the distance s of the elements along the first axial direction and the distance t of the elements along the second axial direction, the angle a=arc tan 1n˜1s˜1 has proven to be optimal. It corresponds to a distance 1 of the lines of displacement in the size of a=ts(n2s2+t2)˜½ sin β (beta). Hereafter, for simplicity's sake, a right angle is most often assumed between the two axes.
With the regular arrangement of the elements of the test pattern, as defined by the parameters s and t, care must be exercised so that manufacturing tolerances of the generating optical component and illustration errors of the projection system can cause distortions of the test pattern in the plane of reference that can result in slightly distorted connecting lines in the axial directions, rows of lines, and column lines of the elements. In the plane of reference, therefore, the elements of the test pattern can differ from the pre-established regularity by an uncertainty u. To ensure identifiability of the elements of the test pattern according to the invention, the uncertainty u should be less than half the distance a of the lines of displacement of the regular test pattern. Therefore, u<½ts(n2s2+t2)−½ should apply. By respecting this condition, the lines of displacement have no common points despite a distortion.
To produce the test pattern it is useful to use a diffractive optical element (DOE) that is illuminated with a diode laser. A DOE works at relatively low loss rates and is easily handled in installation in the optical system to achieve the necessary orientation of the projected test pattern. With a test pattern with point-shaped elements, they can be produced with high intensity and sharp concentration.
The pre-established limitation of the number of elements along each axial direction ensures that all elements depicted in the image plane can be completely identified. The situation of the identified elements can be compared, in image processing, with the corresponding positions in the calibration images.
Any possible absent elements have no influence on the identifiability of the other elements.
From the image coordinators of the elements in the image of the test object determined through image processing, the related spatial coordinates of the element can be determined in the test pattern on the test object. The elements identified with their spatial coordinates can then be used as supports for calculating a surface adapted to it. Mathematical methods for computing fitted surfaces are known in the state of the art in their own right and in particular also allow a correlation with corresponding data sets from surface shapes acquired elsewhere.
In the illustration, embodiments of the invention are presented schematically and are described in greater detail on the basis of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the parallactic displacement of a point pattern with small changes in distance of a plane surface.
FIG. 2 shows the parallactic displacement of a point pattern between a plane surface and a body with great height differences.
FIG. 3 shows the parallactic displacement with inventive arrangement of a point pattern.
FIG. 4 shows the geometric conditions for the arrangement of the inventive point pattern in a place of reference.
FIG. 5 shows a projection system to produce a point pattern.
FIG. 6 shows a construction for a test system.
FIG. 7 shows a cross-section through the proximally viewed image plane of the test system.
FIG. 8 shows a cross-section through the image plane with a different arrangement of the projection system.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates the principle of parallactic displacement of a point pattern. The filled-in points represent the position of the point pattern on a calibration object in a certain projection plane. If the distance to this plane is modified only slightly, the point pattern in the image at first proximity describes a lateral displacement parallel to a connecting line between the midpoints of the output pupil of a projection system and the entry pupil of an image-recording system.
This connecting line forms the base of the measurement system. With a minor change of distance, the parallactic displacement of the point pattern is also minor; as is made clear from the points represented as rings. In this case each ring can be clearly related to its starting position.
FIG. 2 shows the parallactic displacement of the point pattern with projection onto a test object with a topography that clearly lies above and below the plane of the calibration object. The filled-in points in turn represent the position of the point pattern on the calibration object in a certain projection distance.
The points depicted as rings appear in the image of the test object and are recognizably not related to any particular starting position. An unequivocal determination of the spatial coordinates of the illuminated points is not possible, especially when individual points are still not present in the image.
FIG. 3 shows a point pattern in the inventive position.
The depicted lines run parallel to the base of the measurement system.
The axial directions for the point pattern run at an angle to these lines. The result is a distance between the lines, whereby each of the filled-in points, upon its parallactic displacement, runs along its own line on which no additional points lie. The parallactically displaced points depicted as rings are also still separately recognizable despite partial overlapping and can be related to their respective starting position.
Even absent points in the parallactically displaced image do not disturb the evaluation of the additional points.
FIG. 4 shows a test pattern 1 consisting of elements Pij (i=1, . . . , n; j=1, . . . , m) projected onto a reference plane. In a first axial direction 2 , n=4 elements are arranged at regular intervals to one another. In a second axial direction 3 , m=3 elements are arranged at regular intervals to one another. The axial direction 2 is rotated by an angle alpha relative to the vertical projection of the base 4 . The axial direction 3 in this example is situated vertically on the axial direction 2 ; that is, beta=30 degrees. The angle alpha is selected in such a way that no additional elements Pii lie on the lines of displacement 5 , 6 , 7 of the elements P 21 , P 31 , P 41 . The related distance a between the lines of displacement 5 , 6 , 7 .
The related distance a between the lines of displacement 5 , 6 , 7 is derived from a=ts(n2s2+t2)˜½ sin β. The optimal angle alpha is oc=arc tan t-n-′-s-′, where t/n is the size of the axial segments on the axial direction 3 , which derive from the crossing points of the lines of displacement 5 , 6 , 7 with the axial direction 3 . Unequivocal identification of the elements Pij in the image of the test object is thus ensured. The depicted content is based on an ideal system. In practice the projection system 8 can produce distortions of the position of the Pij.
FIG. 5 shows a projection system 8 to produce the test pattern 1 . The projection system 8 is supplied with light by a glass fiber 9 . The light arrives by way of an aspherical collimation lens 10 , for instance. After collimation, the light consists of even waves, which go through a diffractive optical element (DOB) 11 . This element splits the single collimated, entering light beam into many partial beams, which then produce the previously described test pattern with the elements Pij. Such DOE's are commercially available and can also be manufactured for various element shapes.
In addition to the point pattern, other forms such as a pattern from crossed coordinate lines can also be appropriate, provided the points of intersection move on independent lines of displacement.
Reasons for selecting the regular point pattern are the commercial availability of the DOE, the clear recognizable quality of the pattern because the light capacity is concentrated on small points, and, even with an optical distortion, the still relatively round shape of the points, which can easily be recognized by an automatic image-processing program. The system can essentially also be used with irregular test patterns, as long as every point has its own line of displacement.
Below the DOE a line system 12 can be positioned which adjusts the angle of illumination of the point pattern to the visual field of an image-recording system.
FIG. 6 depicts the components of a complete measurement system into which the inventive optical system is integrated.
The measurement system has a head portion 13 , which includes a projection system 8 , an image-recording system 14 , and a light leader cable 15 to illuminate the test object. The head part can also form the distal end of a video endoscope. The connecting line between the pupil midpoints of the projection system 8 and of the image-recording system 14 forms a test basis 17 . The projection system 8 projects a point pattern Pij onto the surface 16 of the test object.
The head part 13 is connected with the operating element 18 of the measurement system by means of a shaft 19 . The shaft 19 can also be a rigid or flexible endoscope tube. It contains the fibers 9 for illuminating the projection system 8 , the electrical transmission lines 20 from and to the image-recording system 14 , and a light leader cable 15 .
The glass fiber 9 is fed in the operating element 18 by a laser diode 21 .
The fiber type can be selected, depending on the demands, to be multimodal, single-modal, or single-modal-polarization-containing. A removable plug-in connection 22 is provided for greater ease of installation.
The function of the DOE contained in the projection system 8 is based on wavelength-dependent bending effects. The size of the test pattern thus changes in immediate proximity proportionally to the wavelength. To eliminate the resulting measurement uncertainty, the wavelength can either be held constant by thermostatizing the laser diode 21 or the wavelength is recorded by means of a temperature measurement on the laser diode 21 in order to compensate numerically the change in size of the test pattern.
The measurement system described so far is associated with several console appliances. A cold light source 23 , for instance, supplies light energy to illuminate the test object by means of the light leader cable 15 . The image-recording system 14 , for instance, is a video camera with CCD chip which is controlled by a camera controller 24 . A computer 25 with its software essentially controls the image recording, image management, image processing, calibration of the measurement system, the execution of the measurement, the control of the laser diode 21 , and the temperature measurement and stabilization. A first and a second monitor 26 , 27 can be linked up to the camera controller 24 and the computer 25 . The connection of the console devices to the service element 18 is done by means of a plug-in distributor 28 .
To obtain appropriate measurement values, the laser diode 21 is usefully switched on and off image-synchronously in quick succession. This provides the image-processing software, first of all, with state-of-the-art differentiation formation between successive images with and without test pattern. The differentiation then contains mainly just the image information of the test pattern.
In addition, an image without the disturbing test pattern is available for observation purposes.
The laser diode 21 , in addition, can be further modulated in intensity with a noise so that a slight variation in the wavelength arid thus, continuing onward, a fluctuation in the speckle structure is caused. This improves the position determination of the elements of the test pattern and thus the measurement exactitude of the system.
The projection system 8 is positioned beside the image-recording system 14 in the illustrated sectional plane. During installation it is easily rotated so that the orientation of the test pattern to the extent previously described lies slightly diagonal to the projection of the base 17 . During image depiction, this leads to the optical effect of an inclined test pattern.
FIG. 7 shows the section through the image plane in the view with the projected point pattern Pij and the vertical projection 4 of the test basis 17 . The test basis 17 in the illustration is the connecting line between the midpoint 29 of the exit pupil of the projection system 8 and the midpoint 30 of the entrance pupil of the image-recording system 14 .
It is possible, however, to position the projection system 8 in such a way that the projection 4 of the test basis runs at an inclined angle to one image side. This special case is illustrated in FIG. 8 , with the projection of the test basis forms the angle alpha with one image side. The result is that the first axial direction 2 is directed parallel to an image side, corresponding to a more useful view. Here, however, the lines of displacement run at an inclined angle to the image side.
The parallactically displaced test pattern in the image of the test object can be evaluated basically by two different methods.
The basis of an analytic process consists in determining and storing calibration parameters for every measurement system on the work side with the help of test images. The parameters are: image coordinates of all elements Pij in the selected calibration distance, the basis, the focal distances, the distortion, and the individual centering error of the optics.
In measuring, the measurement system must identify the elements Pij; that is, the indices I, j must be unequivocally determined. With basically familiar mathematical formulas, the spatial coordinates x, y, z are computed from the respective image coordinates u, v on the CCD chip of the video camera.
The basis for an interpolation process is the recording of n calibration images in n calibration distances, where a coordinate grid is used as calibration object. In the calibration image k the elements P(k)jj are identified. For every element P(k)ij the image coordinates u(k)ij and v(k)jj are recorded and determined on the calibration object with the help of the coordinate lines and the spatial coordinates x(k)j, x(k)ij, z(k)ij are determined, where z(k) corresponds to the respective calibration distance which is equal for all elements in the kth calibration plane. For all xij, a polynomial of the (n−1)th degree is formed in Ujj with the calibration values and likewise for y, j, and Zij, so that the calibration process that is to be carried out one time is concluded.
In measuring, for every point the indices I, j and the image coordinates ujj are recognized. With the ujj that are obtained, the spatial coordinates x, y, z are computed from the calibration polynomials for all elements into which a surface can then be fitted which approaches the actual surface of the test object. In this copied surface, by superimposition with the image of the test object, visible characteristics such as for instance damaged areas, tears, or corrosion surfaces, can then be designated and their size measured.
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Disclosed is an optical system for measuring the topography of a test object, comprising a system for projecting an optically recognizable test pattern onto the surface of an object area that is to be measured, and an image-recording system and image-evaluation system for determining the parallactically displaced image coordinates of the test pattern in the object area that is to be measured, the distance of the centers of the aperture diaphragms of the projection system and the image-recording system forming a test basis. Said optical system is characterized in that the test pattern consists of a limited number of elements that are placed at regular intervals in at least one first axial direction, said axial direction being rotated by an angle a relative to the vertical projection of the test basis.
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TECHNICAL FIELD
The present disclosure relates generally to methods, systems, and computer-readable media for automated license plate character recognition.
BACKGROUND
Automated license plate recognition (hereinafter, “ALPR”) generally refers to an automated process for applying optical character recognition (hereinafter, “OCR”) techniques to images captured by traffic cameras to recognize vehicle license plate information.
ALPR technology is useful for law enforcement and other purposes, allowing for mass surveillance of vehicle traffic for a variety purposes at very low personnel costs. ALPR technology can be utilized concurrently with a variety of law enforcement procedures, such as techniques for determining vehicle speed, monitoring traffic signals, electronic toll collection, and individual vehicle surveillance.
ALPR methods can involve three steps. The first step can be determining the location of the license plate in the image (hereinafter, “plate localization”). The second step can be separating the individual characters on the license plate from the remainder of the image (hereinafter, “character segmentation”). The third step can be applying OCR techniques to the segmented characters.
Various image processing methods can be utilized as part of the ALPR process, including, for example, binarization. Generally, binarization is a process by which a color or gray-scale image can be analyzed, and a binary value can be assigned to each pixel of the image based on a set of parameters and the original color of the pixel. Such binary values can be visually depicted as black or white to create a monochromatic image. Therefore, a given pixel color can be assigned a “white” value or a “black” value during binarization.
Binarization of an image facilitates many processes that can be performed on the image. For example, a computing device can analyze binarization data and recognize clusters of adjacent pixels with the same binary value and match the clusters with known patterns of characters or objects.
However, the captured images of vehicle license plates are not always optimal for character recognition. For example, objects such as trailer hitches, rust, dirt, stickers, or/and license plate frames can occlude license plate characters from a camera's perspective. Additional factors, such as shadow and state license plate logos, can further slow or prevent the character recognition by hindering various ALPR sub-processes, such as binarization.
Such factors can be alleviated if an optimum set of parameters are utilized with the various ALPR sub-processes. For example, utilizing an optimum threshold value during the binarization process can resolve irregularities caused by factors such as shadowing and non-character objects. However, determining the optimum parameters is complicated by the fact that the optimum parameters can vary based on numerous factors, including time of day, license plate design, occlusion factors, position of the camera, and quality of the image.
Accordingly, APLR technology may be improved by techniques for dynamically determining optimum parameters for APLR sub-processes, such as binarization.
SUMMARY OF THE DISCLOSURE
The present disclosure relates generally to methods, systems, and computer readable media for providing these and other improvements to APLR technology.
Once an image of a license plate has been captured using a camera, a computing device can perform various APLR sub-processes on the image with a first set of parameters to determine license plate information. APLR sub-processes can include, but are not limited to, binarization, plate localization, character segmentation, OCR, image normalization, image smoothing, noise reduction, tone reduction curves, edge filtering, Laplacian filtering, Gaussian smoothing, and pattern detection. Each APLR sub-process can individually require one or more parameters, which can be used as various inputs, including, but not limited to, threshold values, filter selection, and variable substitution.
The APLR sub-processes can result in a set of segmented license plate characters. Each segmented license plate character can be scored based on a number of factors, including, but not limited to, a connected component analysis, a character shape analysis, a character orientation analysis, pattern recognition, straight-line normalization, a character placement analysis, and expected license plate patterns. Once the characters are scored, the APLR sub-processes can be repeated with a new set of parameters, and the resulting segmented characters can similarly be scored. The process can be repeated a set number of times or until a threshold score is obtained.
Generally, the best score obtained is associated with the segmented license plate characters that are optimized for character recognition. Therefore, such dynamic selection of parameters can result in improved accuracy and efficiency in character recognition.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various embodiments of the present disclosure and together, with the description, serve to explain the principles of the present disclosure. In the drawings:
FIG. 1 is a diagram depicting exemplary images of a license plate before and after binarization, consistent with certain disclosed embodiments;
FIG. 2 is a diagram depicting exemplary images of a license plate before and after binarization, consistent with certain disclosed embodiments;
FIG. 3 is a diagram depicting exemplary images of a license plate before and after binarization, consistent with certain disclosed embodiments;
FIG. 4 is a diagram depicting an exemplary traffic camera attached to a computing device that may utilize APLR technology, consistent with certain disclosed embodiments;
FIG. 5 is a flow diagram illustrating an exemplary method of implementing APLR technology on a computing device, consistent with certain disclosed embodiments.
DETAILED DESCRIPTION
The following detailed description refers to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar parts. While several exemplary embodiments and features of the present disclosure are described herein, modifications, adaptations, and other implementations are possible, without departing from the spirit and scope of the present disclosure. Accordingly, the following detailed description does not limit the present disclosure. Instead, the proper scope of the disclosure is defined by the appended claims.
FIG. 1 is a diagram depicting exemplary images of a license plate before and after binarization, consistent with certain disclosed embodiments. As depicted in FIG. 1 , captured license plate image 100 can be a captured image of a license plate with characters XJO 398 captured by an image recording device, such as a traffic camera. Characters XJO 398 can be a solid color, such as blue or black. The background of the license plate can also be a solid color, such as white or yellow. The license plate can also include a state logo, such as graphic element 101 . As depicted in FIG. 1 , graphic element 101 can overlap characters O and 3. Graphic element 101 can be a different color than the license plate characters and the background, such as orange. Further, captured image 100 can include shadow 102 cast over part of the license plate. As depicted in FIG. 1 , shadow 102 can overlap characters XJO and part of the license plate background. The area covered by shadow 102 can appear darker compared to the remainder of the image.
A computing device can perform a binarization technique on captured image 100 using a first set of parameters 110 to produce binarized image 120 . Binarized image 120 is an exemplary visual representation of the binarization process, and, in some embodiments, an actual binarized image may not be necessary to perform the disclosed processes. In some embodiments, each pixel from captured image 100 can be assigned a value of 0 or 1 based on the binarization algorithm and the first set of parameters. In the visual representation of binarized image 120 , pixels assigned a value of 0 can be represented as black and pixels assigned a value of 1 can be represented as white. As depicted in binarized image 120 , characters XJO 398, graphic element 121 , and the area covered by shadow 122 have been assigned a value of 0 or black, and the remainder of the background of the image has been assigned a value of 1 or white.
A computing device can segment the binarized image into characters using a variety of methods, including, but not limited to, segmenting clusters of pixels with the same assigned value. Because the pixels used to depict characters XJO 3, graphic element 121 , and shadow 122 overlap and have all been assigned the same value of 0 or black, a computing device may be unable to separate those objects. However, a computing device can segment the 9 and the 8 from the remainder of the image due to the surrounding background pixels assigned a value of 1 or white. Accordingly, a computing device may segment the image into three characters. The first character can include XJO 3, graphic element 121 , and shadow 122 , the second character can be character 9, and the third character can be character 8.
A computing device can assign scores to each character segment using methods that, include, but are not limited to, a connected component analysis, a character shape analysis, a character orientation analysis, pattern recognition, straight-line normalization, and a character placement analysis. For example, a range of scores can be from one to ten, and a computing device can perform pattern recognition on the 9 and the 8 and output a high score, such as a score of nine out of ten, because the characters have recognized patterns. However, pattern recognition performed on the combined XJO 3, graphic element 121 , and shadow 122 , as shown, can produce a low score, such as a score of one out of ten, as the combined character does not match any recognized patterns. A total score can be given to binarized image 120 based on the individual scores of each character, which can be stored and associated with the first set of parameters and/or the binarized image data. The computing device can then repeat the binarization process with new parameters, as depicted in FIG. 2 .
FIG. 2 is a diagram depicting exemplary images of a license plate before and after binarization, consistent with certain disclosed embodiments. As depicted in FIG. 2 , captured license plate image 200 can represent the same captured license plate image as depicted in FIG. 1 and can include characters XJO 398, graphic element 201 , and shadow 202 , as described above for captured image 100 .
A computing device can perform a binarization technique on captured image 200 using a second set of parameters 210 to produce binarized image 220 . Every pixel from captured image 200 can be assigned a value of 0 or 1 based on the binarization algorithm and the second set of parameters. In the visual representation of binarized image 220 , pixels assigned a value of 0 can be represented as black and pixels assigned a value of 1 can be represented as white. As depicted in binarized image 220 , characters XJO 398 and the area covered by shadow 122 have been assigned a value of 0 or black, similar to binarized image 120 . However, dissimilar to binarized image 120 , in binarized image 220 , graphic element 221 has been assigned a value of 1 or white, similar to the background of the image. Accordingly, graphic element 221 is not visible in binarized image 220 because graphic element 221 is the same color as the background.
A computing device can segment the binarized imaged into characters using a variety of methods, including the methods described above. Because the pixels used to depict characters XJO and shadow 222 have all been assigned the same value of 0 or black, a computing device may be unable to separate those objects. However, a computing device can segment the 3, the 9, and the 8 from the remainder of the image due to the surrounding background pixels assigned to a value of 1 or white. Accordingly, a computing device may segment the image into four characters. The first character can include XJO and shadow 222 , the second character can be character 3, the third character can be character 9, and the fourth character can be character 8.
A computing device can assign scores to each character segment using the methods disclosed above. For example, a computing device can perform pattern recognition on the 3, the 9, and the 8 and output a high score because the characters have recognized patterns. However, pattern recognition performed on the combined XJO and shadow 222 , as shown, can produce a low score, as the combined character does not match any recognized patterns. A total score can be assigned to binarized image 220 based on the individual scores of each character, which can be stored and associated with the second set of parameters and/or the binarized image data. Notably, binarized image 220 can be assigned a score that is better than the score assigned to binarized image 120 because more characters patterns were recognized and given higher scores. The computing device can then repeat the binarization process with new parameters, as depicted in FIG. 3 .
FIG. 3 is a diagram depicting exemplary images of a license plate before and after binarization, consistent with certain disclosed embodiments. As depicted in FIG. 3 , captured license plate image 300 can represent the same captured license plate image as depicted in FIGS. 1 and 2 , and can include characters XJO 398, graphic element 301 , and shadow 302 , as described above for captured image 100 .
A computing device can perform a binarization technique on captured image 300 using a third set of parameters 310 to produce binarized image 320 . Every pixel from captured image 300 can be assigned a value of 0 or 1 based on the binarization algorithm and the third set of parameters. In the visual representation of binarized image 320 , pixels assigned a value of 0 can be represented as black and pixels assigned a value of 1 can be represented as white. As depicted in binarized image 320 , only characters XJO 398 have been assigned a value of 0 or black. Additionally, graphic element 221 and the background area covered by shadow 322 have been assigned a value of 1 or white, similar to the remainder of the background of the image. Accordingly, graphic element 221 and shadow 322 are not visible in binarized image 320 because they are the same color as the background.
A computing device can segment the binarized imaged into characters using a variety of methods, including the methods described above. Accordingly, a computing device can segment the X, the J, the O, the 3, the 9, and the 8 from the remainder of the image due to the surrounding background pixels assigned to a value of 1 or white. Therefore, a computing device may segment the image into six characters: X, J, O, 3, 9, and 8.
A computing device can assign scores to each character segment using the methods disclosed above. For example, a computing device can perform pattern recognition on all six characters and output a high score for each character because all six characters, as shown, have recognized patterns. A total score can be assigned to binarized image 320 based on the individual scores of each character, which can be stored and associated with the third set of parameters and/or the binarized image data. Notably, binarized image 220 can be assigned a score that is better than the scores assigned to both binarized image 120 and binarized image 220 because more characters patterns were recognized and given higher scores. The computing device can then repeat the binarization process with new parameters, determine that a threshold score has been obtained, or determine that a set number of iterations have been performed and terminate the binarization process.
Once the binarization process has been terminated, the computing device can select the segmented characters with the best total score. The computing device can further perform OCR on the segmented characters and store the license plate information.
FIG. 4 is a diagram depicting an exemplary traffic camera attached to a computing device that may utilize APLR technology, consistent with certain disclosed embodiments. Traffic camera 400 may represent any type of camera that is capable of capturing still images or video. Computing device 410 may represent any type of computing device able to receive input from traffic camera 400 . Computing device 410 can be connected to traffic camera 400 , as shown. Additionally, computing device 410 can be integrated with traffic camera 400 as one device, or can be remotely connected, via a network connection, to traffic camera 400 . Further, computing device 410 is not limited to being connected to a single traffic camera and, in some embodiments, can be connected to a fleet of traffic cameras.
Computing device 410 may include, for example, one or more microprocessors 411 of varying core configurations and clock frequencies; one or more memory devices or computer-readable media 412 of varying physical dimensions and storage capacities, such as flash drives, hard drives, random access memory, etc., for storing data, such as images, files, and program instructions for execution by one or more microprocessors 411 ; one or more transmitters for communicating over network protocols, such as Ethernet, code divisional multiple access (CDMA), time division multiple access (TDMA), etc. Components 411 and 412 may be part of a single device, as disclosed in FIG. 4 , or may be contained within multiple devices. Those skilled in the art will appreciate that the above-described componentry is exemplary only, as computing device 410 may comprise any type of hardware componentry, including any necessary accompanying firmware or software, for performing the disclosed embodiments.
FIG. 5 is a flow diagram illustrating an exemplary method of implementing APLR technology on a computing device, consistent with certain disclosed embodiments. In, 500 , the process can begin when a traffic camera captures an image that includes a depiction of a license plate of a vehicle. An image may refer to a single image, multiple images, or a video captured by a traffic camera. The image can additionally include part of the vehicle and/or additional background objects. A computing device integrated with or connected to the traffic camera can then receive and store the image.
In 510 , the computing device can perform plate localization to determine the license plate location within the image using various methods known in the art, including, but not limited to, edge detection and binarization. In some embodiments, the computing device can crop the image around the detected license plate. In other embodiments, the computing device can calculate and store the license plate location in association with the image or as metadata included with the image. The license plate location can be stored as, for example, pixel locations of the edges of the license plate. Hereinafter, reference will be made to an image, which can include either the cropped and/or the uncropped form of the image.
In 520 , the computing device can determine a set of parameters for one or more ALPR sub-processes. Such parameters can include, but are not limited to, binarization threshold values, tone reproduction curve parameters, filter selection parameters, filtering parameters, and variable values.
In the first iteration of 520 for a given image, an initial set of parameters can be determined. In some embodiments, the computing device can determine the initial set of parameters by utilizing a predetermined set of initial parameters. In such embodiments, the predetermined set of initial parameters can be preprogrammed into the ALPR software. Alternatively, the predetermined set of initial parameters can be manually entered by an operator or can be variable depending on certain factors, such as time of day, traffic levels, image quality, etc. The predetermined set of initial parameters can be unique to the specific computing device and/or camera, or can be universal to a fleet of cameras and/or computing devices.
In further iterations of 520 for a given image, new sets of parameters can be determined. In some embodiments, the new set of parameters for a particular iteration can be predetermined based on the number of the iteration. For example, the computing device can use a predetermined second set of parameters for the second iteration and a predetermined third set of parameters of the third iteration, etc.
In other embodiments, the new set of parameters can be determined dynamically based on various factors, including, but not limited to, previously used parameter sets that have yielded high character scores for segmented characters, parameter sets adjusted for the time of day, and parameter sets selected based on determined information about the license plate, such as jurisdiction information.
In further embodiments, a combination of the static and dynamic parameter sets may be used on the same license plate.
The various parameter sets may or may not contain parameters that are completely unique between sets. Accordingly, a first parameter set can contain no parameters in common with a second parameter set. Alternatively, a first parameter set can contain one or more parameters in common with a second parameter set as long as the second parameter set contains at least one unique parameter compared to the first parameter set.
As discussed below, 530 through 560 utilizes a single set of parameters per iteration, and the single set of parameters can represent the initial set of parameters or one of the subsequent sets of parameters, depending on the iteration.
In 530 , the computing device can perform one or more image preprocessing steps on the image. Image preprocessing steps can include, but are not limited to, image normalization and image smoothing. In some embodiments, image normalization is a process by which contrast is increased in the image through the use of, for example, a tone reproduction curve. The set of determined parameters from 520 can include parameters for a tone reproduction curve, such as tone mean and tone variation. The computing device can utilize the tone reproduction curve with the tone reproduction curve parameters to obtain a normalized image.
Additionally, image smoothing can be applied to the image. Image smoothing is a process by which noise can be removed from an image and important patterns can be captured. In some embodiments, image smoothing can be implemented by applying a Gaussian smoothing filter to the image. The set of determined parameters from 520 can include parameters for the Gaussian smoothing filter, such as filter size and standard deviation. The computing device can apply the Gaussian smoothing filter with the Gaussian smoothing filter parameters to obtain an image more suitable for additional filters or binarization.
Additional preprocessing steps can include, but are not limited to, applying an edge filter and/or a Laplacian filter to the image.
In 540 , the computing device can perform binarization on the image, for example, as described above for FIGS. 1-3 . The set of determined parameters from 520 can include parameters for the binarization process, such as the binarization threshold. The computing device can perform binarization on the image using the binarization threshold from the determined parameters. The binarization process can result in a binarized image and/or binarized image data.
In some embodiments, binarization can be performed individually on subsets of the image, including subsets of the license plate. Further, the parameters used during the binarization process can vary from subset to subset. The subsets can be predetermined or can be selected by the computing device before the binarization process beings. For example, the computing device can determine that a subset of the image is a darker shade than the remainder of the image and select a particular binarization threshold value from the determined set of parameters accordingly. Or, the determined set of parameters can include binarization threshold values for predetermined subsets of the image.
In 550 , the computing device can segment the characters on the license plate in the binarized image. In some embodiments, the computing device can analyze the binarized image and determine the license plate characters by clusters of similarly number pixels, as described above. The computing device can segment the characters based on such clusters. The set of determined parameters from 520 can include parameters for determining segmentation thresholds, such as minimum pixel size of characters.
In 560 , the computing device can score the segmented characters. In some embodiments characters can be scored using a connected component analysis to analyze properties of the segmented characters. For example, segmented character properties that can be analyzed include, but are not limited to, orientation of the major axis of the character, area of the character, dimensions of the character, percentage of the character filled, center of the character, distance of the character from an edge, and distance of the character from the center of the license plate. The segmented characters can then be assigned a score based on such factors as similarities to known characters and goodness-of-fitting to a straight line.
In some embodiments, the segmented character score can be partially or fully based on known properties of characters used on license plates in a particular jurisdiction, such as character fonts and character sizes. In additional embodiments, the segmented character score can be partially or fully based on determined properties of previously processed license plates by the same computing device or by one or more computing devices connected to the computing devices via a network connection. In further embodiments, the segmented character score can additionally be based on the expected number of characters on a license plate.
After a score is given to the segmented characters, a total score for the iteration can be calculated. The total score can be calculated using a variety of methods, such as summing the scores of individual characters and/or taking a weighted or un-weighted average of the scores of individual characters. Further, the total score can be adjusted based on the number of segmented characters determined compared to the expected number of characters on a license plate.
In 570 , the computing device can determine whether to process the image again by repeating 520 through 560 or proceed to 580 for character recognition of the segmented characters. In some embodiments, the computing device can determine whether a threshold total score for the segmented characters has been reached for the current set of segmented characters. If the threshold total has been reached, the computing device can proceed to perform character recognition on the segmented characters from 550 . If the threshold total has not been reached, the computing device can determine a new set of parameters and repeat the image processing. The threshold total can be entered by an operator, hardcoded into the software, or vary depending on various factors, including time of day, traffic levels, image quality, and number of previous iterations on the same image.
In other embodiments, the computing device can determine whether a set number of iterations of the image processing have completed. For example, a computing device can process an image ten times with ten unique sets of parameters before proceeding to 580 . If the computing device determines that the set number of iterations have not been performed, the computing device can store the segmented characters with the associated scores and repeat the image processing with a new set of parameters. If the threshold total has been reached, in some embodiments, the computing device can select the segmented characters with the best total score and proceed to 580 using the best scoring segmented characters.
In other embodiments, the computing device can select segmented characters from more than one image processing iteration. For example, a first iteration can result in a first character with a high score and other characters with low scores. Subsequently, a second iteration can result in a first character with a low score and several characters with high scores. After determining that the first character from the first iteration and the first character from the second iteration likely represent the same license plate character, the computing device can select the first character from the first iteration and the remaining characters from the second iteration and proceed to 580 using the selected characters.
In 580 , the computing device can perform known methods of character recognition, such as OCR, on the segmented characters with the highest individual scores or highest total score. The image, the segmented characters, the scores, and the recognized character information can then be stored in memory.
While the steps depicted in FIG. 5 have been described as performed in a particular order, the order described is merely exemplary, and various different sequences of steps can be performed, consistent with certain disclosed embodiments. Further, the steps described are not intended to be an exhaustive or absolute, and various steps can be inserted or removed. For example, in some embodiments, the computing device can perform image preprocessing steps on the image before and/or after plate localization. Additionally, in other embodiments, image preprocessing may not be performed.
Further, the computing device can perform various sequences of the above-described steps during different iterations of the same image. For example, the computing device may not perform image preprocessing on the initial iteration, but may perform image preprocessing on a subsequent iteration of the same image.
In some embodiments, image binarization can be performed before plate localization. In other embodiments, plate localization may not be performed and characters are segmented from the full image. In further embodiments, character segmentation may not be performed and a score can be calculated for the license plate as a whole.
The foregoing description of the present disclosure, along with its associated embodiments, has been presented for purposes of illustration only. It is not exhaustive and does not limit the present disclosure to the precise form disclosed. Those skilled in the art will appreciate from the foregoing description that modifications and variations are possible in light of the above teachings or may be acquired from practicing the disclosed embodiments. The steps described need not be performed in the same sequence discussed or with the same degree of separation. Likewise, various steps may be omitted, repeated, or combined, as necessary, to achieve the same or similar objectives or enhancements. Accordingly, the present disclosure is not limited to the above-described embodiments, but instead is defined by the appended claims in light of their full scope of equivalents.
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A system and method for automatically recognizing license plate information, the method comprising receiving an image of a license plate, and generating a plurality of image processing data sets, wherein each image processing data set of the plurality of image processing data sets is associated with a score of a plurality of scores by a scoring process comprising determining one or more image processing parameters, generating the image processing data set by processing the image using the one or more image processing parameters, generating the score based on the image processing data, and associating the image processing data set with the score.
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TECHNICAL FIELD
The present invention relates to electronic registers, and particularly relates to an electronic register that collects and provides sensor data.
BACKGROUND
“Electronic registers” find wide application across a broad range of industries, including the utility industries, where electronic registers provide critical metering capabilities for gas, electric, water, or other consumables provided on a metered basis. Electronic registers provide a ready mechanism for logging consumption data and, more generally, various types of sensor data, such as fluid level measurements, etc.
With their flexibility and wide usage, however, comes a number of challenges. For example, the designers, manufacturers, and distributors of electronic registers have a keen interest in reducing production costs, maintenance, and support issues, and simplifying the models that need to be stocked, serviced, etc. Customers, on the other hand, require electronic registers that are, in at least some respects, fine-tuned to their particular applications or installations. Difficulties, therefore, arise when attempting to field a base register design that accommodates a wide range of applications, while offering needed features and particularized operation suiting specific applications.
To appreciate some of these difficulties, consider the example components of a typical electronic register. In an exemplary but non-limiting case, an electronic register includes processing circuitry, communication circuitry, and sensor interface circuitry. However, the processing details and, in particular, the processing and logging of the sensor data, depends on the type of sensors and sensor data involved. The various aspects of data handling, such as resolution, scaling, etc., must be preprogrammed or otherwise provisioned in the electronic register before field deployment, which complicates production, distribution, inventory management, installation management, etc.
SUMMARY
According to a method and apparatus disclosed herein, an electronic register advantageously logs raw sensor data without converting the raw sensor data into physical-domain measurements, and without the need for being configured to understand or process such data, or account or compensate for any sensor installation particulars. Instead, the electronic register advantageously stores conversion data in association with each sensor interface circuit being used to collect raw sensor data from a corresponding external sensor, and it provides the conversion data to an external device, in association with the read-out of the raw sensor data logged by the electronic unit. The conversion data provides the mathematical expression, along with any compensation or adjustment values needed, to convert the raw sensor data into corresponding physical-domain measurements.
In an example method, the electronic register receives conversion data from a first external device, via communication interface circuitry of the electronic register, for a sensor interface circuit of the electronic register. The conversion data comprises information for converting raw sensor data obtained from an external sensor coupled to the sensor interface circuit into corresponding physical-domain measurements, and the electronic register stores the conversion data in the electronic register, in logical association with the sensor interface circuit.
Further, according to the method, the electronic register obtains the raw sensor data from the external sensor, via the sensor interface circuit, and logs the raw sensor data in the electronic register, in logical association with the stored conversion data, and without converting the logged raw sensor data into the corresponding physical-domain measurements. Still further, the electronic register outputs the stored conversion data and the logged raw sensor data logically associated with the stored conversion data, to the same or another external device, via communication interface circuitry of the electronic register. The electronic register performs the outputting operation responsive to a trigger, e.g., detection of the external device, or receipt of a request for such information, etc.
In a related example, an electronic register comprises communication interface circuitry configured for communicating with one or more external devices, a sensor interface circuit configured to interface with an external sensor, and processing circuitry including or operatively associated with the communication interface circuitry, the sensor interface circuit, and storage. The processing circuitry is configured to receive conversion data from a first external device, for the sensor interface circuit, the conversion data comprising information for converting raw sensor data obtained from the external sensor into corresponding physical-domain measurements.
The processing circuitry is further configured to store the conversion data in the storage, in logical association with the sensor interface circuit, obtain the raw sensor data from the external sensor, via the sensor interface circuit, and log the raw sensor data in the storage, in logical association with the stored conversion data, and without converting the logged raw sensor data into the corresponding physical-domain measurements. Further, in response to a trigger, the processing circuitry is configured to output the stored conversion data and the logged raw sensor data logically associated with the stored conversion data, to the first external device, or to a second external device.
In yet another example, an electronic register implements a method that includes receiving conversion data for each of two or more sensor interface circuits of the electronic register, wherein the conversion data received for each sensor interface circuit comprises information for converting raw sensor data obtained from the sensor interface circuit into corresponding physical-domain measurements. The method includes storing the conversion data received for each sensor interface circuit in logical association with the sensor interface circuit, logging the raw sensor data obtained from each sensor interface circuit in logical association with the conversion data received and stored for the sensor interface circuit, and without converting the raw sensor data into the corresponding physical-domain measurements. Further, the method includes outputting the logged raw sensor data for any one of the sensor interface circuits to an external device, along with the conversion data received and stored for the sensor interface circuit, thereby enabling the external device to convert the logged raw sensor data into the corresponding physical-domain measurements.
Of course, the present invention is not limited to the above features and advantages. Those of ordinary skill in the art will recognize additional features and advantages upon reading the following detailed description, and upon viewing the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of one embodiment of an electronic register configured to interface with one or more external sensors and to log raw sensor data obtained therefrom.
FIG. 2 is a diagram of one embodiment of the logical associations contemplated herein for the storage of logged raw sensor data and corresponding conversion data.
FIG. 3 is a logic flow diagram of one embodiment of a method of operation at an electronic register.
FIG. 4 is a logic flow diagram of another embodiment of a method of operation at an electronic register.
FIG. 5 is a schematic diagram of one embodiment of a sensor interface circuit configured for obtaining raw sensor data from an external sensor.
DETAILED DESCRIPTION
By way of non-limiting example, FIG. 1 illustrates an embodiment of an electronic register 12 . According to the example, the electronic register 12 includes communication interface circuitry 14 , which in turn includes a radio frequency (RF) transceiver circuit 16 , and a “local” wired or wireless communication interface circuit 18 . Further included are one or more sensor interface circuits 20 , shown by way of example as sensor interface circuits 20 - 1 through 20 -N, processing circuitry 22 , storage 24 , and a power supply 26 .
Each sensor interface circuit 20 is configured to interface with an external sensor 30 . e.g., the sensor interface circuit 20 - 1 interfaces with an external sensor 30 - 1 , and the sensor interface circuit 20 - 2 interfaces with an external sensor 30 - 2 . The number “ 20 ” is used without suffixing to refer to single sensor interface circuits, and to refer to multiple sensor interface circuits. Suffixing appears only where needed for clarity and use of the reference number 20 in this generalized fashion does not mean that each sensor interface circuit 20 is identical to the next one. The reference number “ 30 ” is used the same way, and such usage does not mean that each external sensor 30 is identical to the next one.
In some embodiments, the electronic register 12 does include two or more sensor circuits 20 that are “like” sensor circuits, i.e., of the same type, design, and implementation. For example, the at least two like sensor interface circuits 20 comprise two or more analog current loop interfaces or two or more analog voltage interfaces having like nominal current or voltage ranges. In the same embodiment, or in other embodiments, however, at least two of the sensor interface circuits 20 are different in type, design, and implementation. One type of sensor interface circuit 20 comprises a digital counter or pulse input, another type of sensor interface circuit 20 comprises a current signal interface, and yet another type of sensor interface circuit 20 comprises a voltage signal interface.
The electronic register 12 provides advantageous mechanisms for interfacing with individual sensors 30 , with respect to their particular sensor types, their particular operational characteristics, and their particular installation details. These mechanisms may be exercised or accessed. e.g., through the communication interface circuit 18 and/or through the RF transceiver circuit 16 , if present and configured for such use.
In an example implementation, the communication interface circuit 18 is configured for communicating with one or more external devices 32 that are used to read sensor data and associated information from the electronic register 12 . In at least one embodiment, the communication interface 18 allows an external device 32 to configure the electronic register 12 with respect to individual ones of the sensor interface circuits 30 . Two external devices 32 - 1 and 32 - 2 are shown by way of example, e.g., the device 32 - 1 may be operative as a “configurator” for setting up the electronic register 12 with respect to one or more external sensors 30 , while the device 32 - 2 may be operative as a “reader” or “interrogator” for reading out logged sensor data and other information from the electronic register 12 . Of course, the same device 32 may provide both capabilities, based on user authorization, etc. In an example case, a laptop computer is configured to operate as the external device 32 - 1 and/or 32 - 2 , but proprietary or dedicated devices 32 may also be used.
Other means of accessing or communicating with the electronic register are available in embodiments that include the RF transceiver circuit 16 . That circuitry comprises, for example, a cellular radio modem or other wide-area radio interface that is configured to communicatively couple the electronic register 12 to an Advanced Metering Infrastructure (AMI), such as represented by the depicted radio network 34 and the associated radio network node 36 .
Other embodiments of the electronic register 12 may omit the RF transceiver circuit 16 , in favor of relying on the local communication interface 18 for the collection of logged data, etc., by one or more external devices 32 . Non-limiting examples of the local communication interface circuit 18 include Near Field Communication (NFC) circuitry, a Wi-Fi interface, a Bluetooth interface, an Ethernet interface, or an RS-232 or other wired serial interface. In general, the local communication interface circuit 18 is configured for bi-directional communication between the electronic register 12 and one or more external device(s) 32 .
With the above in mind, in at least one embodiment, the electronic register 12 comprises communication interface circuitry 14 configured for communicating with one or more external devices 32 , a sensor interface circuit 20 configured to interface with an external sensor 30 , and processing circuitry 22 including or operatively associated with the communication interface circuitry 14 , the sensor interface circuit 20 , and storage 24 . The processing circuitry 22 is configured to receive conversion data from a first external device 32 - 1 , for the sensor interface circuit 20 . The conversion data comprises information for converting raw sensor data obtained from the external sensor 30 into corresponding physical-domain measurements, and the processing circuitry 22 is configured to store the conversion data in the storage 24 , in logical association with the sensor interface circuit 20 .
The processing circuitry 22 is further configured to obtain the raw sensor data from the external sensor 30 , via the sensor interface circuit 20 , and log the raw sensor data in the storage 24 , in logical association with the stored conversion data, and without converting the logged raw sensor data into the corresponding physical-domain measurements. That approach enables the processing circuitry 22 to log data from an arbitrary sensor chosen by the user, but unknown to the manufacturer of the electronic register 12 a priori. No firmware modification is required to support a different type of sensor, yet multiple interrogation devices can use the conversion data and display physical-domain measurement values to the user.
The processing circuitry 22 also increases its efficiency and avoids complexity by logging the raw sensor data, rather than “converting” the raw sensor data into units of measurement associated with the physical parameter being measured by the involved external sensor 30 . The capability of making such conversions is, however, advantageously preserved by maintaining the logged raw sensor data in logical association with the stored conversion data needed to convert the logged raw sensor data into corresponding physical-domain measurement values.
In particular, the processing circuitry 22 is configured to, in response to a trigger, output the stored conversion data and the logged raw sensor data logically associated with the stored conversion data, to the first external device 32 - 1 , or to a second external device 32 - 2 . The trigger may be external—such as a reading event—or may be internal, such as the expiration of a timer internal to the electronic register 12 . The processing circuitry 22 in at least some embodiments is configured to output the stored conversion data and the associated logged raw sensor data to a metering network—i.e., the AMI infrastructure—via the RF transceiver circuit 16 .
As an example, the “trigger” in question is the detection by the electronic register 12 the presence of an external device 32 . Such detection may be more nuanced. For example, “detection” in one or more embodiments comprises detecting the presence of the external device 32 , and determining that the external device 32 is authorized to receive logged raw sensor data, etc., from the electronic register 12 . Authorization may be determined based on simple protocol handshaking, or may be more involved, e.g., password or other credential verification, or key-based authentication. In another example, the “trigger” in question is the receipt of request or command from an external device 32 .
In one or more embodiments, the processing circuitry 22 is configured to obtain the raw sensor data from any given external sensor 30 by reading a sensor signal output from the external sensor 30 and normalizing the readings according to a defined numeric representation. Here, it will be understood that the processing circuitry 22 uses the corresponding sensor interface circuit 20 to “read” the sensor signal output from the external sensor 30 . In at least one such embodiment, the processing circuitry 22 is configured to normalize the readings according to the defined numeric representation. For example, the processing circuitry 22 normalizes the readings by formatting them according to a defined fixed-point or floating-point data type used by the electronic register 12 . The data normalization allows the electronic register to handle readings from disparate sensor types and/or configurations in a uniform manner, and it simplifies logging, memory management, etc. In turn, these simplifications correspond to simplifications in the design, programming, and operation of the electronic register 12 .
As an example of the advantages flowing from the normalization of raw sensor data, the processing circuitry 22 in one or more embodiments is configured to obtain the raw sensor data from a given external sensor 30 as digital readings obtained from the sensor interface circuit 20 associated with the given external sensor 30 . In this example, the sensor interface circuit 20 is configured to digitize an analog sensor signal output by the given external sensor 30 . Additionally, or alternatively, the electronic register 12 includes a sensor interface circuit 20 that is configured to receive an analog or digital signal from an external sensor 30 that is indicative of count values, and the processing circuitry 22 is configured to log the indicated count values in a normalized form.
In another illustrative example, the electronic register 12 includes at least two sensor interface circuits 20 . e.g., a first sensor interface circuit 20 - 1 and a second sensor interface circuit 20 - 2 . The processing circuitry 22 is configured to receive and store respective conversion data for each of the sensor interface circuits 20 , log the raw sensor data obtained for each sensor interface circuit 20 in logical association with the respective stored conversion data, and, when outputting the logged raw sensor data for any given one of the sensor interface circuits 20 , to output the respective stored conversion data.
In more detail, the processing circuitry 22 is configured to store conversion data for a sensor interface circuit 20 - 1 /external sensor 30 - 1 , log raw sensor data obtained from the sensor interface circuit 20 - 1 in logical association with the corresponding conversion data, and output that corresponding conversion data for the logged raw sensor data. The same operations are performed with respect to a sensor interface circuit 20 - 2 /external sensor 30 - 2 . Consequently, regardless of whether the two external sensors 30 - 1 and 30 - 2 are nominally the same, the particulars of each sensor installation can be accounted for without modifying the basis operation of the electronic register 12 , simply by loading appropriately configured conversion data into the electronic register 12 , for each external sensor 30 .
In this regard, the conversion data stored by the processing circuitry 22 in the storage 24 for any particular sensor interface circuit 20 and its corresponding external sensor 30 comprises, for example, the calculation or formula used for converting the corresponding logged raw sensor data into physical-domain measurements. For example, an external sensor 30 outputs an analog voltage or current signal corresponding to sensed gas pressure in PSI, the associated sensor interface circuit 20 digitizes the sensor signal into corresponding analog-to-digital converter (ADC) count values, e.g., values between 0 and 1023 for a ten-bit ADC.
These count values, which may be normalized, e.g., to a 32-bit format, correspond to a range of gas pressure and the conversion data would be, for example:
P measured = court logged 1023 × P max ,
where P max is the top of the sensing pressure range, and count logged is the raw ADC count value (in normalized form).
However, it is contemplated herein that the conversion data in one or more embodiments provides for a much richer pairing of given external sensors 30 to the electronic register 12 , without adding any complication to the operation of the electronic register 12 . For example, the conversion data loaded into the electronic register 12 for a given external sensor 30 may include one or more calibration values, e.g., coefficients for scaling errors, sensor offsets, etc. The “intelligence” for parsing and applying the conversion data resides in the external devices 32 (and/or remote network nodes), rather than in the electronic register 12 . Moreover, the electronic register 12 need only reserve sufficient storage for holding the conversion data for each of its sensor interfaces 20 , e.g., 512 bytes, 1024 bytes, etc., to serve as a blank slate for loading whatever type of conversion data is needed or desired.
Such an approach obviates the need for preconfiguring the electronic register 12 for the particulars of any installation, as the only real requirement is that the electronic register 12 includes sensor interface circuits 20 that are compatible with the type(s) of external sensor(s) 30 deployed at a given installation. Moreover, the electronic register 12 from one location can be moved to another location and immediately be “tuned” or adapted to the particulars of the external sensors 30 at the new location, merely by loading the appropriate conversion data into the electronic register 12 .
As another advantage, it is contemplated herein that one or more embodiments of the electronic register 12 are configured to provide alarm functionality with respect to the external sensors 30 . e.g., to alarm on high or low signals, signal ranges, etc., corresponding to critical physical-domain measurement thresholds or ranges. Because the electronic register 12 foregoes any conversion of the logged raw sensor data into the physical domain, it advantageously ties its alarm functionality to an alarm threshold provided to it for any given sensor interface circuit 20 . The alarm threshold is expressed as a unit-less numeric value in a same numeric range as used for the logged raw sensor data obtained from the involved external sensor 30 . For example, the alarm threshold is expressed in normalized ADC counts.
The processing circuitry 22 is configured to receive such alarm thresholds from an external device 32 and/or through the radio network 34 , and to store the alarm thresholds in logical association with the respective sensor interface circuits. The processing circuitry 22 is further configured to output an alarm signal responsive to determining that the logged raw sensor data from a given external sensor 30 violates the alarm threshold loaded in the electronic register 12 for that sensor 30 .
Still further, in one or more embodiments, the processing circuitry 22 is configured to receive, store, and subsequently output reverse conversion data for any given sensor interface circuit 20 . The reverse conversion data comprises information for converting the involved physical domain measurements into corresponding raw sensor data values, thereby enabling an external device 32 to use the reverse conversion data to convert physical-domain alarm thresholds expressed in physical-domain measurement units into corresponding unit-less alarm thresholds for the electronic register 12 . In other words, an operator of the external device 32 sets an alarm threshold in the physical domain, e.g., sets a high or low gas pressure alarm in PSI, and the external device 32 calculates the corresponding raw sensor data values and returns those values to the electronic register 12 as alarm thresholds.
The outputting of alarm signals comprises, for example, outputting alarm signaling via the local communication interface 18 and/or via the RF transceiver circuit 16 , for network-based alarm reporting.
More generally, in at least one embodiment, the electronic register 12 is configured to output its stored conversion data and the logged raw sensor data logically associated with the stored conversion data, based on transmitting the stored conversion data and the logged raw sensor data to the radio network node 36 , as a first or second external device 32 . That is, in some embodiments, the external device 32 is a remote node or server communicatively coupled to the electronic register 12 via the radio network 34 . As noted, however, the first or second external device 32 may comprise a portable communication unit for reading or configuring the electronic register 12 . In such cases, the electronic register 12 is configured to communicate with the portable communication unit via a local wired or wireless connection.
FIG. 2 illustrates an example of the storage 24 , which in one or more embodiments provides volatile and non-volatile storage, e.g., working or data memory, along with program and data storage. While the storage 24 may comprise more than one type of storage—e.g., more than one type of memory or storage circuit—it shall be broadly understood as comprising a computer-readable medium, that includes storage for the aforementioned conversion data, the reverse conversion data, the alarm thresholds, and the logged raw sensor data. As suggested in the illustrated example, such storage is at least logically partitioned on a per-sensor interface circuit basis, so that such data is stored for each sensor interface circuit 20 . Of course, depending on the memory management implemented in the electronic register 12 , the storage 24 need not be pre-partitioned, and such partitioning may be purely logical and performed dynamically, or on an ad hoc basis, by the processing circuitry 22 .
The storage 24 in one or more embodiments also stores a computer program 38 comprising program instructions that, when executed by one or more processing circuits of the electronic register 12 , specially adapts such processing circuits to operate as the aforementioned processing circuitry 22 . For such operation, the storage 24 provides non-transitory storage for the computer program 38 , where “non-transitory” does not necessarily mean permanent or unchanging but does connote storage of at least some persistence, e.g., the program instructions are held in memory for execution.
As such, the storage 24 comprises, for example, SRAM, DRAM, or other working memory, along with FLASH, EEPROM, SSD, or other non-volatile storage circuitry, and the processing circuitry 22 in one or more embodiments comprises one or more microprocessor-based circuits, DSP-based circuits, ASIC- or FPGA-based circuits, or other digital processing circuitry. More broadly, the processing circuitry 22 comprises fixed circuitry, programmed circuitry, or a mix of fixed and programmed circuitry. Here, “fixed” circuitry denotes circuitry that is preconfigured to carry out particular operations or functions, while programmed circuitry takes on such configuration as a consequence of program instruction execution.
FIG. 3 illustrates a method 300 that may be implemented via the electronic register 12 of FIG. 1 , or by another suitable register configuration. The method 300 includes receiving (Block 302 ) conversion data from an external device 32 , via communication interface circuitry 14 of the electronic register 12 , for a sensor interface circuit 20 of the electronic register 12 . The conversion data comprises information for converting raw sensor data obtained from an external sensor 30 coupled to the sensor interface circuit 20 into corresponding physical-domain measurements.
The method 300 further includes storing (Block 304 ) the conversion data in the electronic register 12 , in logical association with the sensor interface circuit 20 , obtaining (Block 306 ) the raw sensor data from the external sensor 30 , via the sensor interface circuit 20 , and logging (Block 308 ) the raw sensor data in the electronic register 12 , in logical association with the stored conversion data, and without converting the logged raw sensor data into the corresponding physical-domain measurements. Still further, the method 300 includes, responsive to a trigger, outputting (Block 310 ) the stored conversion data and the logged raw sensor data logically-associated with the stored conversion data, to the external device 32 (e.g., to any of devices 32 - 1 or 32 - 2 , or the radio network node 36 ), via the communication interface circuitry 14 of the electronic register 12 .
FIG. 4 illustrates a method 400 , which may be understood as a more detailed example or variation of the method 300 . The method 400 includes receiving (Block 402 ) conversion data for each of two or more sensor interface circuits 20 of the electronic register 12 , wherein the conversion data received for each sensor interface circuit 20 comprises information for converting raw sensor data obtained from the sensor interface circuit 20 into corresponding physical-domain measurements.
The method 400 further includes storing (Block 404 ) the conversion data received for each sensor interface circuit 20 in logical association with the sensor interface circuit 20 , and logging (Block 406 ) the raw sensor data obtained from each sensor interface circuit 20 in logical association with the conversion data received and stored for the sensor interface circuit 20 , and without converting the raw sensor data into the corresponding physical-domain measurements. Still further, the method 400 includes outputting (Block 408 ) the logged raw sensor data for any one of the sensor interface circuits 20 to an external device 32 , along with the conversion data received and stored for the sensor interface circuit 20 , thereby enabling the external device 32 to convert the logged raw sensor data into the corresponding physical-domain measurements.
FIG. 5 depicts an example sensor interface circuit 20 . By way of non-limiting example, the illustrated sensor interface circuit 20 is configured to receive a 4-20 mA current signal and includes terminals 40 - 1 and 40 - 2 , for connecting with the current-carrying wiring from an external sensor 30 , along with a resistor 42 (“R” in the diagram) used to develop a voltage signal proportional to the input current signal. An amplifier 44 (“AMP”) outputs a voltage-mode signal corresponding to the voltage developed across the resistor 42 , and an ADC 46 digitizes the output signal from the amplifier 44 . The processor circuitry 22 logs the ADC counts as the raw sensor data for the attached external sensor 30 . It will be appreciated that the amplifier 44 may be configured to provide buffering, filtering, gain, or other signal-conditioning, and that the sensor interface circuit 20 may include circuitry not shown, e.g., ESD protection circuitry, etc.
Notably, modifications and other embodiments of the disclosed invention(s) will come to mind to one skilled in the art having the benefit of the teachings presented in the preceding descriptions and the associated drawings. Therefore, it is to be understood that the invention(s) is/are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of this disclosure. Although specific terms may be employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
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According to a method and apparatus disclosed herein, an electronic register advantageously logs raw sensor data without converting the raw sensor data into physical-domain measurements, and without need for being configured to understand or process such data, or account or compensate for any sensor installation particulars. Instead, the electronic register advantageously stores conversion data in association with each sensor interface circuit being used to collect raw sensor data from a corresponding external sensor, and it provides the conversion data to an external device, in association with read-out of the raw sensor data logged by the electronic unit. The conversion data provides the mathematical expression, along with any compensation or adjustment values needed, to convert the raw sensor data into corresponding physical-domain measurements.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an air conditioner, and more particularly to drive means for rotating wind direction louver boards in an air outlet of said air conditioner and a diffuser installed below said air outlet.
2. Description of the Related Art
At the air outlet of the air conditioner, up-down wind direction boards (flaps) are provided for adjusting heat-exchanged air uniformly toward a room or, in some case, for locally adjusting the wind direction. FIG. 7 is a sectional view indicating an overall construction of the conventional air conditioner, and FIG. 8 is an enlarged cross-sectional view of the air outlet portion. Also, the air conditioner comprises an indoor unit and an outdoor unit, and the air conditioner described herein means the indoor unit of a wall mounted type.
That is, this air conditioner as an indoor unit is equipped with a housing 1 designed as an indoor wall mounted type; in this example, air inlets 2 are provided respectively at the front face and the top face of the housing 1, and an air outlet 5 is provided at the lower portion of the front face of the housing 1. A heat exchanger 3 and an air blowing fan 4 are provided in an air passage from the air inlet 2 to air outlet 5 inside the housing 1.
Inside the air outlet 5, provided are two up-down wind direction boards such as flaps 7 and 8 for adjusting the up-down wind direction and a plurality of lateral air direction boards such as slats of louver 6 for adjusting wind motion in lateral direction. Generally, the flaps 7 and 8 are arranged at the front side of the lateral wind direction boards (louver) 6 when seen from the external side of the air conditioning unit (within the room). And the flaps are supported by support pieces 7b and 8b suspended from an upper wall portion of the air outlet 5 in such a manner that their rotation axes 7a and 8b become almost horizontal. That is, the up-down flaps 7 and 8 are rotatable around the horizontal rotation axes 7a and 8a as the centers between the initial stop position closing the air outlet 5 and the maximum open position at which the flaps are almost in vertically downward direction as shown in FIG. 7 and FIG. 8.
Though only one louver slat 6 is shown in FIG. 7 and FIG. 8, actually a plurality of slats are provided in the direction orthogonal to the paper surface of the drawings. Each slat 6 of the lateral wind direction board (louver) is supported through a bush 6a by the upper wall portion of the air outlet 5 in such a manner that each slat 6 will rotate laterally around the axis of rotation which is almost orthogonal to the axis of rotation of the flaps 7 and 8. Also, an arm 6b is connected to each bush 6a, and a clip 6c for synchronously rotating each slat 6 is attached to said arm 6b.
As the air blowing fan 4 is operated, air is sucked from the air inlet 2, heat-exchanged by a heat exchanger 3 and then blown to the inside of room from the air outlet 5 and, at that time, the lateral wind direction is adjusted by the lateral wind direction boards (louver) and, at the same time, the up-down wind direction is adjusted by up-down direction boards (flaps) 7 and 8.
In this way, the various wind directions can be adjusted. However, if the flaps 7 and 8 are set almost downward vertically to the maximum open position as shown in FIG. 7 and FIG. 8 during a heating operation or a rapid cooling operation, for example, then the wind blows hard against the flaps 7 and 8, and the gap between the lower flap 8 and the bottom edge of the air outlet 5 becomes narrower, so that the air blowing efficiency is decreased.
Therefore at the bottom of the air outlet 5, a diffuser 9 constituting a part of said air outlet 5 is installed rotatably around an almost horizontal rotation axis 9a. And if the opening angle of the flaps 7 and 8 is made larger as stated above, then the diffuser 9 is rotated counter-clockwise in FIG. 7 and FIG. 8 and the air outlet 5 is made wider.
In this way, in rotating the flaps 7 and 8 and the diffuser 9, conventionally an exclusive motor 11 for driving the flaps and a motor 19 for driving the diffuser are installed respectively.
The motor 11 for driving the flaps is installed on one side of the side wall portion 5a of the air outlet 5 as shown by a chain line in FIG. 8, and a drive gear 20 is attached to a drive shaft 11a of the motor. Driven gears 22 and 23 are attached respectively to the rotation axes 7a and 8a of the flaps 7 and 8, and these driven gears 22 and 23 are interlocked with a drive gear 20 through an intermediate gear 21. By doing this, the flaps 7 and 8 are synchronously driven by the motor 11 and can be set to an arbitrary angle of tilt between the initial stop position closing the air outlet 5 and the maximum open position almost vertically downward as shown in FIG. 7 and FIG. 8.
The motor 19 for driving the diffuser is arranged at a position on lower rear side of a main body casing 1a determining a boundary line of an air passage inside the housing 1 and rotates the diffuser 9 to the position shown in FIG. 7 and FIG. 8 when the flaps 7 and 8 are rotated to the side of the maximum open position, and the frontage of the air outlet 5 is widened. In this way, the motor 19 rotates the diffuser 9 in response to the movement of the flaps 7 and 8, and the motor control is performed by control means such as CPU (central processing unit, not shown in the drawings).
By the use of the diffuser 9, the wind direction adjustment can be performed more effectively without lowering the efficiency of air blowing. However, in the conventional way, there are certain problems because the diffuser driving motor 19 and its motor drive circuit are required, and thus an increase in the production cost is unavoidable. In addition, a space for mounting the motor 19 is required and this is troublesome in making the housing 1 compact.
The present invention has been made for solving the conventional problems stated above. And its object is to provide an air conditioner capable of driving the up-down direction boards (flaps) and the diffuser by a single motor without requiring a motor exclusively for the diffuser.
SUMMARY OF THE INVENTION
To achieve the objects of the present invention described above, a first present invention has a housing with an air inlet and an air outlet formed therein, a heat exchanger and an air blowing fan are provided within an air passage from said air inlet to said air outlet inside the housing, also provided in said air outlet are at least one up-down wind direction board (flap) which rotates in an up-down direction around an almost horizontal axis of rotation as well as a plurality of lateral wind direction boards (louvers) rotating in a lateral direction around the axis of rotation which is almost orthogonal to the axis of rotation of said up-down wind direction board, a diffuser constituting a part of said air outlet is provided in a rotatable manner around an almost horizontal axis of rotation at the lower portion of said air outlet and; a motor for driving said up-down wind direction board is located on the side of one side wall portion of said air outlet. In the air conditioner, said up-down wind direction board can be set to an arbitrary angle of tilt by said motor between the initial stop position closing said air outlet and the maximum open position directed to almost vertically downward, and also a driving force transmitting means is provided for transmitting the movement of said up-down wind direction board to said diffuser when said up-down wind direction board is located in a range from a particular position of an angle of tilt to said maximum opening position for said up-down wind direction boards and said diffuser.
In this first invention, the driving force transmitting means is equipped with a first link having a base end portion for coaxially coupling the drive shaft of the motor to the rotation axis of the up-down wind direction boards (flap), a second link having a base end portion coaxially coupled to the rotation axis of the diffuser and a second coupling pin provided at the position being eccentric from the axis of said base end portion, and a first rod coupling the first coupling pin to the second coupling pin; if the up-down wind direction board is in the range of a position of the particular angle of tilt and the initial stop position between the second coupling pin and the first rod, then movement of the up-down wind direction board is not transmitted to the diffuser; and if the up-down wind direction board is in the range from the position of the particular angle of slope to the maximum open position, then a lost motion mechanism is provided for transmitting the movement of the up-down wind direction board to the diffuser.
In this case, the lost motion mechanism comprises the second coupling pin and an ellipse hole at the first rod side which is fitted to the second coupling pin.
Also in the first invention, the position of the particular angle of tilt of the up-down wind direction board is almost in a horizontal position; when the up-down wind direction board is at the initial stop position, the first coupling pin is located below a virtual reference line connecting the base end portion of the first link to the second coupling pin of the second link; when the up-down wind direction board is rotated from the initial stop position to almost horizontal position, the first coupling pin moves to the upper portion of the virtual reference line.
To achieve the objects stated above, in the second invention, a housing formed by the air inlet and air outlet is provided, a heat exchanger and an air blowing fan are provided in the air passage from the air inlet to the air outlet within the housing; within the air outlet, two up-down wind direction boards each rotating in an up-down direction around an almost horizontal axis of rotation are provided at the positions separated up and down and back and forth; also a plurality of lateral wind direction boards rotating in lateral directions around the axis of rotations almost orthogonal to the axis of rotation of the up-down wind direction boards are provided; in the lower portion of the air outlet, a diffuser constituting a part of the air outlet is provided in a rotatable manner around an almost horizontal axis of rotation; also, a motor for driving the up-down wind direction boards is provided on the side of one side wall portion of the air outlet; in the air conditioner set to an arbitrary angle of tilt between the initial stop position closing the air outlet by the up-down wind direction boards by means of the motor and the maximum open position directed almost vertically downward, one of the up-down wind direction boards is coupled to the motor by actuation; between one of the up-down wind direction boards and the other up-down wind direction board, first driving force transmitting means is coupled for coupling in such a manner that both the up-down wind direction boards will be rotated synchronously; between the other up-down wind direction board and the diffuser, second driving force transmitting means is provided for transmitting the movement of the other up-down wind direction board when each up-down wind direction board is in the range from the position of a particular angle of tilt to the maximum open position.
In this second invention, the first driving force transmitting means is equipped with a first link having a base end portion coaxially coupling a drive shaft of said motor to the axis of rotation of the one up-down wind direction board and a first coupling pin provided at the position eccentric from the axis of the base end portion, a third link having a base end portion coaxially coupled to the rotation axis of said other up-down wind direction board and a third coupling pin and a fourth coupling pin respectively provided at the different positions eccentric from the axis of the base end portion, and a second rod coupling the first coupling pin to the third coupling pin. The second driving force transmitting means is equipped with a second link having a base end portion coupled coaxially to a rotation angle of said diffuser and a second coupling pin provided at the position eccentric from the axis of the same base end portion; and if said other up-down wind direction board is in the range of the initial stop position and the position of the particular angle of tilt between the second coupling pin and the first rod, then the movement of the same other up-down wind direction board is not transmitted to said diffuser; and if the same other up-down wind direction board is in the range from said particular position of the angle of tilt to the maximum open position, then a lost motion mechanism transmits the movement of the same other up-down wind direction to the diffuser.
In this case, the lost motion mechanism comprises the second coupling pin and an ellipse hole at the first rod side which is to be fitted to the same second coupling pin.
Also according to the second invention, when each up-down wind-direction board is at the initial stop position, the fourth coupling pin is located below the virtual reference line connecting the base end portion of the third link to the second coupling pin of said second link, and when said respective up-down wind direction boards have been rotated from the initial stop position to almost horizontal positions, the fourth coupling pin moves above the virtual reference line.
Moreover, both the first and second inventions are equipped with spring means for energizing the diffuser toward the upper initial position for reducing the width of the opening (frontage) of the air outlet; and when the diffuser is energized to the initial position by the same spring means, the rear end portion of the upper surface of the same diffuser comes into contact with the front end portion of the main body casing determining the boundary line for the air passage within the housing, and then positioning of its initial position can be performed.
In addition, both the first and second inventions have characteristics in that the driving force transmitting means is mounted between a hinge plate constituting the one side wall portion of the air outlet and a motor base supporting the motor.
These and other objects, features and advantages of the present inventions will become clear from the following description of the preferred embodiment taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the overall internal construction of the air conditioner as a first embodiment according to the present invention.
FIG. 2 is an exploded perspective view for explaining the drive force transmitting means of the first embodiment.
FIG. 3A to FIG. 3C show the operations for the first embodiment of the invention.
FIG. 4 is a section showing the overall internal construction of the air conditioner as the second embodiment of this invention.
FIG. 5 is an exploded perspective view for explaining the drive force transmitting means of the second embodiment.
FIG. 6A to FIG. 6C show the operations of the second embodiment.
FIG. 7 is a section of the internal construction of an air conditioner as the prior art.
FIG. 8 is a section showing the configuration of the air outlet portion of said prior art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The first embodiment of the air conditioner according to the present invention will be described hereinafter with reference to FIG. 1 and FIG. 2 of the accompanying drawings. In this first embodiment, any portions that are the same or deemed to be the same as the conventional ones will be marked with the same reference codes thereby omitting the explanation thereof.
In this first embodiment, one up-down wind direction board 7 is provided inside the air outlet 5. That is, its rotation axis 7a is supported almost horizontally by a supporting piece 7b suspended from an upper wall portion of the air outlet 5.
Also, at the lower portion of the air outlet 5, a diffuser 9 constituting a part of the air outlet 5 is provided in a rotatable manner around an almost horizontal rotation axis 9a.
The air outlet 5 is surrounded by a lower wall portion including an upper wall portion and the diffuser 9 and a pair of right and left side walls and, in this embodiment, one of the side wall portions is formed by a hinge plate 5A shown in FIG. 2.
At the rear side (opposite side of air blower 5) of this hinge plate 5A, a motor base 12 for mounting a motor 11 is arranged at a predetermined gap with the hinge plate 5A, and a drive force transmitting means 10A for transmitting the drive force of the motor 11 to the up-down wind direction board 7 and the diffuser 9 is housed in the gap.
The drive force transmitting means 10A is equipped with a first link 13 for coaxially coupling a drive shaft 11a of the motor 11 and the rotation axis 7a of the up-down wind direction board 7, a second link 17 coaxially coupled with the rotation axis 9a of the diffuser 9, and a first rod 16 bridged between the first link 13 and the second link 17.
The first link 13 has a cylindrical base end portion 131, though other end side of the base end portion 131 is not shown in the drawings, thereby forming a coupling hole to be fitted in the drive shaft 11a of the motor 11, and a coupling shaft 132 to be inserted into a shaft hole of the rotation axis 7a of the up-down wind direction board 7 is provided coaxially with the coupling hole at one side on the other end side of the base end portion 131.
At the base end portion 131 of the first link 13, an arm 133 extending in the direction normal to the rotation axis is provided integrally, and a first coupling pin 134 is provided at the tip portion of the same arm 133. That is, the first coupling pin 134 is located eccentrically from the base end portion 131.
The second link 17 has a cylindrical base end portion 171, and its one end side has a rotation shaft 172 supported by a shaft receiving hole 12c formed at the motor base 12. Also, at the other end side of the base end portion 171, a coupling shaft 173 to be inserted into a shaft hole of the rotation axis 9a of the diffuser 9 is provided coaxially with the rotation shaft 172.
At the base end portion 171 of the second link 17, an arm 174 extending in the direction orthogonal to the rotation axis is provided integrally, and the tip portion of the same arm 174 is provided with a second coupling pin 175. That is, the second coupling pin 175 is provided at a position eccentric from the base end portion 171.
At the hinge plate 5A, a bearing hole 5b for supporting the base end portion 131 of the first link 13 and a bearing hole 5d for supporting the base end portion 171 of the second link 17 are formed. Also, at the motor base 12, a hole 12a for inserting the drive shaft 11a of the motor 11 is formed in addition to the bearing hole 12c. The first rod 16 has a first coupling hole 161 to be fitted to the first coupling pin 134 on its one end side, and the second coupling hole 162 to be fitted to the second coupling pin 175 is provided on other end side.
In this case, a second coupling hole 162 is an ellipse hole (slit-shaped hole) having the minor axis almost equal to the diameter of the second coupling pin 175 and the major axis formed like a slit in the length direction of the same first rod 16.
That is, there is a play (a clearance which does not couple mechanically) along the length direction of a first rod 16 between the second coupling pin 175 and the second coupling hole 162, and this play constitutes the lost motion mechanism described later.
The second link 17 is provided with spring means for energizing the diffuser 9 upward (clockwise direction in FIG. 1). In this embodiment, a coil spring 18 is used as the spring means. One end 181 of this coil spring 18 is attached to a hook 12d formed to a motor base 12. An attaching hole 176 is formed to the arm 174 of the second link, and the other end of the coil spring 18 is attached to the attaching hole 176.
The diffuser 9 is energized upward by this coil spring 18 and is held to the initial position shown in FIG. 3A in normal state. In this case, the upper rear end portion 9f of the diffuser 9 is utilized as positioning means for its initial position. That is, it is so designed that the upper rear end portion 9f of the diffuser 9 comes into contact with the front end portion 1e of the main body casing 1a when the diffuser 9 is in the initial position.
According to this, there is no need to separately provide positioning means such as stopper, it is more advantageous costwise, and also no gap is created with the main body casing 1a when the diffuser is in initial position, so that noise such as wind-blowing sound is not generated.
Next, the operation of the first embodiment will be explained based on FIG. 3A to FIG. 3C. FIG. 3A shows a stop state of the air conditioner or an early stage of the initial state such as warning-up of the operation start in which the air outlet 5 is closed by the up-down wind direction boards 7, that is, the up-down wind direction board 7 is in initial state position, and also the diffuser 9 is held to the initial position by the coil spring 18.
In FIG. 3B, the up-down wind direction board 7 is rotated by the motor 11 from the initial stop position to the counter-clockwise direction, and the board is set almost in horizontal position. In this first embodiment, within the rotation range of the initial stop position of the up-down wind direction boards 7 to the almost horizontal position, the movement of the first rod 16 is absorbed by the play between the second coupling pin 175 to the second coupling hole 162; by this lost motion mechanism, the drive force of the motor 11 is not transmitted to the diffuser 9.
In succession, when the up-down wind direction board 7 is further rotated counter-clockwise by the motor 11, to the vertically downward direction to the maximum opening position side as shown in FIG. 3C, the play between the second coupling pin 175 and the second coupling hole 162 disappears, and the drive force of the motor 11 is transmitted to the diffuser 9 through the first link 13, the first rod 16 and the second link 17. In this way, the diffuser 9 is rotated counter-clockwise against the energizing force of the coil spring 18, and the frontage of the air outlet 5 is widened.
As described above, where the up-down wind direction board 7 is set almost at a horizontal position, the diffuser 9 is not open, therefore, the cold air can be sent out almost in a horizontal direction during cooling operation without directly sending cold air to the users.
Also, when the up-down wind direction board 7 is turned toward the maximum open position side in the vertical downward direction during a heating operation, for example, the diffuser 9 is opened in response to its movement thereby performing effective heating operation creating no drop in the efficiency of air supply.
In this first embodiment, when up-down wind direction board 7 is in an initial state of FIG. 3A relative to a line as reference line d which is connecting the center point b of the base end portion 131 of the first link 13 to the center point c of the second coupling pin 175 of the second link 17, the coupling portion a between the first coupling pin 134 and the first coupling hole 161 is located in such a manner that the coupling portion a comes below the reference line d; and when the up-down wind direction board 7 is turned almost up to the horizontal position of FIG. 3B, the coupling portion a is moved above the reference line d.
According to the above, when the up-down wind direction board 7 is rotated in the range between the initial state position of FIG. 3A and an almost horizontal position of FIG. 3B, the coupling portion a will pass above the dead point of the reference line d, so that the play between the second coupling pin 175 and the second coupling 162 can be made to a minimum, therefore, play is hardly felt even if a user pushes the diffuser 9 with the hand and thus a high grade can be maintained for the products.
Now the second embodiment of FIG. 4 to FIG. 6 will be explained. If the up-down wind direction board 7 of the first embodiment is a first up-down wind direction board, then a second up-down wind direction board 8 is added to the air outlet 5 in the second embodiment and, accordingly, drive force transmitting means changed. Also, the diffuser 9 is has a configuration as same as that of the first embodiment, and for the portions not different from those of the first embodiment, the same reference codes or numbers used in the first embodiment are adopted thereby omitting the explanation.
The first up-down wind direction board 7 and the second up-down wind direction board 8 are supported by support pieces 7b and 8b suspended from the upper wall portion of the air outlet 5 in such a manner that the rotation axes 7a and 8a become almost horizontal as same as the conventional example of FIG. 7 as explained previously. Also, with respect to the positional relation between both the up-down wind direction boards 7 and 8, the first up-down wind direction board 7 is located at an upper position at the front side of the air outlet 5 and the second up-down wind direction board 8 is in a lower position at the diagonally rear of the first up-down wind direction board 7 when the air outlet 5 is seen from the room side. That is, the second up-down wind direction board 8 is arranged between the first up-down wind direction board 7 and diffuser 9. Both the up-down wind direction boards 7 and 8 are synchronously rotated by the motor 11 between the initial stop position closing the air outlet 5 and the maximum open position almost downward vertically as same as the case of the first embodiment.
As shown in FIG. 5, the drive force transmitting means 10B of the second embodiment is equipped with the first drive force transmitting means coupling the first up-down wind direction board 7 and the second up-down wind direction board 8 and with the second drive force transmitting means coupling the second up-down wind direction board 8 to the diffuser 9 because the second up-down wind direction board 8 is arranged between the first up-down wind direction board 7 and the diffuser 9.
The first drive force transmitting means contains the first link 13 for coaxially coupling the drive shaft 11a of the motor 11 to the rotation axis of the first up-down wind direction board 7, the third link 15 to be attached to the rotation axis 8a of the second up-down wind direction board 8, and a second rod 14 for coupling the first link 13 to the third link 15.
The third link 15 has a cylindrical base end portion 151 and, at its one end side, a rotation shaft 152 is provided which is borne by the bearing hole 12b formed in a motor base 12. Also, at the other end side of the base end portion 151, a coupling shaft 153 to be inserted into the shaft hole of the rotation axis 8a of the second up-down wind direction board 8 is provided coaxially with the rotation shaft 152.
At the base end portion 151 of the third link 15, an arm 154 extending in a direction orthogonal to its rotation axis is provided integrally, and the third coupling pin 155 and fourth coupling pin 156 forming a pair up and down are provided at the tip portion of the same arm 154. In this case, the arm 154 has a fan shape widening around the base end portion 151 as a center, and the third coupling pin 155 is arranged at a position above the fourth coupling pin 156 (refer to FIG. 6A).
The second rod 14 is equipped with coupling holes 141 and 142 at both the ends, and one of the first coupling hole 141 is fitted to the first coupling pin 134 of the first link 13, and the other second coupling hole 142 is fitted to the third coupling pin 155 of the third link 15. Also, in the hinge plate 5A, the bearing hole 5c for bearing the base end portion 151 of the third link 15 is additionally formed.
The second drive force transmitting means contains the fourth coupling pin 156 of the third link 15, the second link 17 attached to the diffuser 9, and the first rod 16 coupling the second coupling pin 175 of the same second link 17 to the fourth coupling pin 156 of the third link 15.
The first coupling hole 161 of the first rod 16 is fitted to the fourth coupling pin 156 of the third link 15, and other second coupling hole 162 is fitted to the second coupling pin 175 of the second link 17; even in this second embodiment, the second coupling hole 162 of the first rod 16 is an ellipse hole (slit-shaped hole) having a predetermined play for the second coupling pin 175.
Next, the operation of the second embodiment will be explained based on FIG. 6A to FIG. 6C. FIG. 6A is for the initial state where the air conditioner is in stop state or in worming-up time in an early stage of the operation start in which the air outlet 5 is closed by the first and second up-down wind direction boards 7 and 8, that is, both up-down wind direction boards 7 and 8 are in an initial stop position, and the diffuser 9 is also held in the initial position by the coil spring 18.
In FIG. 6B, the first and second up-down wind direction boards 7 and 8 are rotated counter-clockwise by the motor 11 from the initial stop state and are set to almost horizontal position. The drive force of the motor 11 is transmitted to the first rod 16 through the first link 13, the second rod 14 and the third link 15 and, even in this second embodiment, the movement of the first rod 16 is absorbed by the play within the rotation range between the initial stop position of the up-down wind direction boards 7 and 8 to almost horizontal position, and the drive force of the motor 11 is not transmitted to the diffuser 9 by the lost motion mechanism stated above.
In succession, when the up-down wind direction boards 7 and 8 are rotated in the counter-clockwise direction by the motor 11 toward the maximum open position side in the vertical downward direction as shown in FIG. 6C, a play between the second coupling pin 175 and the second coupling hole 162 is lost and the drive force of the motor 11 is transmitted to the diffuser 9 through the first link 13, second rod 14, third link 15, first rod 16 and second link 17. In this way, the diffuser 9 is rotated counter-clockwise against the energized force of the coil spring 18, and the frontage of the air outlet 5 is widened.
Even in the second embodiment as described above, if the up-down wind direction boards 7 and 8 are set almost in a horizontal position, the diffuser 9 is not opened, so that the cold air can be effectively sent out almost in horizontal direction without directly sending the cold air to the users during cooling operation.
Also, when the up-down wind direction boards 7 and 8 are rotated toward the maximum open position side in the vertically downward direction during heating operation, for example, the diffuser 9 is opened in response to that movement, so that effective heating operation can be performed without any decrease in air supply efficiency.
In this second embodiment, a line connecting the center point b of the base end portion 151 of the third link 15 to the center point c of the second coupling pin 175 of the second link 17 being a reference line d when the up-down wind direction boards 7 and 8 are in the initial state of FIG. 6A, the coupling portion a between the fourth coupling pin 156 and the first coupling hole 161 of the first rid 16 is located below said reference line d; and when the up-down wind direction boards 7 and 8 have been rotated almost to the horizontal position of FIG. 6B, the coupling portion a is moved above the reference line d.
According to the above, as explained also in the first embodiment, the coupling portion a will pass on the dead point of the reference line d when the up-down wind direction boards 7 and 8 are rotated between the initial state position of FIG. 6A and almost the horizontal position of FIG. 6B, so that the play between the second coupling pin 175 and the second coupling hole 162 can be made to a minimum, so that rattling is hardly felt even though the user pushes the diffuser 9 by the hand, and a high grade can be assured for the products.
Also in the second embodiment, the first up-down wind direction board 7 is coupled to the drive shaft lb of the motor 11 through the first link 13 but the coupling of the second up-down wind direction board 8 to the drive shaft 11b of the motor 11 may be made through the third link 15 by changing the mounting position of the motor 11 for the motor base 12.
Also, a plurality of parts such as links, rods and coupling pins are respectively contained in the drive force transmitting means 10A and 10B, codes such as first and second are given to the part names but it should be understood that this was done for the convenience of identifying each part merely for the explanation.
In any case, this invention is not limited by said preferred embodiments explained above, and contains the items varied within the range of engineering philosophy.
As being apparent from the above description, according to the present invention, the motor for driving the up-down wind direction boards can be used also as a drive source for the diffuser. Therefore, the motor for driving the diffuser and its motor drive circuit becomes unnecessary, by which cost reduction can be realized, a compact housing can be provided, and these are specially desired for wall mounted type air conditioners.
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In an air conditioner, at least one up-down wind direction board rotates in an up-down direction around almost horizontal rotation axis within an air outlet, and a plurality of lateral wind direction boards rotating laterally are provided around rotation axes as the center which are almost orthogonal to the rotation axis of said up-down wind direction board. Also a diffuser constituting a part of the air outlet is provided rotationally around an almost horizontal rotation axis as the center at the lower portion of the air outlet. A motor for driving the up-down wind direction board is provided at the side of one side wall portion of the air outlet. The up-down wind direction board is set by said motor to any arbitrary angle of tilt between the initial stop position closing said air outlet and maximum open position almost vertically downward. When the said up-down wind direction board is in a range from the position of a particular angle of tilt to said maximum open position between said up-down wind direction board and said diffuser, a drive force transmitting device provided is capable of transmitting the movement of said up-down wind direction board to said diffuser thereby permitting the driving of both the up-down wind direction board and diffuser by a single motor.
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FIELD OF INVENTION
[0001] This invention relates to internal combustion engines and more particularly to modifications of conventional in line six engines capable of increasing the miles per gallon of the modified engines when embodied in motor vehicles.
BACKGROUND OF THE INVENTION
[0002] Conventional in line six cylinder engines if modified to make them 20% more efficient in terms of mpg can meet the requirements mandated by the US government starting in 2014. The conventional in line six cylinder engine is currently the engine of choice for most semi rigs and many other heavy trucks that come within the government mandate.
SUMMARY OF THE INVENTION
[0003] One non-limiting object of the present invention is to provide modifications to conventional in line 6 cylinder engines capable of increasing their efficiency in operation, preferably by at least 20%, thus making them suitable to satisfy the market in large trucks and semi tractors which must be created by 2014 in order to meet the government mandates as to mpg. This objective increase is achieved by the present invention by modifying the central two adjacent piston and cylinder assemblies of the engines so that they operate in accordance with the principles of my pending patent application Ser. No. 13/475,253, the disclosure of which is hereby incorporated by reference into the present application. The modifications involved (1) changing the camshaft so that the central two adjacent piston and cylinder assemblies have their four stroke cycles in phase rather than 180° out of phase, (2) providing a communicating passage between the combustion chambers of the central two piston and cylinder assemblies and (3) modifying either the hardware or programming for the control of the fuel injectors of the central two piston and cylinder assemblies so that they can be selectively controlled not to inject fuel during the operation cycle thereof. The modifications contemplates providing a new cam shaft in which not only the cams relating to the central two adjacent piston and cylinder assemblies are modified to change 180° out of phase to in phase, but the cams relating to other piston and cylinder assemblies in order to provide a somewhat balanced application of the driving forces during each cycle.
[0004] It is preferable in accordance with the principles of the present invention to provide a maximum fuel saving mode wherein alternately one of the two cylinders firing is cut off from fuel. It is also an object of the present invention to provide new engines wherein two cylinders fire over 120° of crankshaft rotation constructed to embody the modifications herein provided hereinbefore indicated.
[0005] Various options within the invention are as follows.
[0006] The camshaft may be constructed and arranged so that the firing strokes of the two outer and intermediate assemblies are simultaneous, the fuel injecting and firing system being operable to selectively control the injectors of the two outer and intermediate assemblies in a third mode wherein one injector associated with each of the two outer and two intermediate assemblies is controlled to inject zero amount of fuel.
[0007] The fuel injecting and firing system may be operable to control an injector to inject fuel into a cylinder during an associated piston stroke when the compressed air in the associated combustion chamber has reached an auto ignition pressure so that the igniting of the mixture occurs as a result of the injection.
[0008] The fuel injecting and firing system may be operable to control an injector to inject fuel into a cylinder during an associated piston intake stroke and the mixture of fuel and compressed air in the associated combustion chamber is ignited by energizing a spark plug in communicating relation to the mixture.
[0009] An aspect of the invention also includes a method of increasing the efficiency of a six cylinder in line engine having six piston and cylinder assemblies mounted in line formation within a frame, the assemblies having pistons connected to a crankshaft so that the pistons of two inner adjacent assemblies, two outer assemblies and two intermediate assemblies move through repetitive cycles of reciprocating movement offset with respect to one another by 120° of crankshaft rotation in which each cycle has four strokes of movement alternately in opposite directions which take place during successive 180° rotational movements of the crankshaft, a crankshaft for controlling inlet and outlet valves to allow air to be taken into a cylinder during an intake stroke of each assembly and to be compressed into a combustion chamber within a cylinder of each assembly during and immediately following compression stroke of each assembly and a fuel injecting and firing system including an injector for each assembly operable to supply fuel during a stroke of the assembly so that when a charge of air under pressure mixed with fuel is ignited within a combustion chamber the resultant increase in pressure in the associated cylinder affects a power stroke of an associated piston immediately following the compression stroke of the assembly, the method comprising:
[0010] replacing the camshaft of the engine which controls the valves of the inner assemblies with a replacement camshaft constructed and arranged so that the cycles of piston movement of the two inner assemblies are in phase,
[0011] providing a communicating passage between the combustion chambers of the two inner assemblies, and
[0012] modifying the fuel injecting and firing system so that the injectors for the two inner assemblies are selectively operable to operate (1) in a normal mode wherein the injectors associated with both inner assemblies operate to supply fuel during a stroke of both assemblies so that when a charge of air under pressure mixed with fuel is ignited within both combustion chambers the resultant increase in pressure in both cylinders affects a power stroke in both cylinders or (2) in a fuel saving mode wherein the injector associated with one of the inner assemblies operates to supply fuel during a stroke of the associated piston so that when a charge of air under pressure mixed with fuel within the combustion chamber of the one of the inner assemblies is ignited, the resultant increase in pressure in the combustion chamber of the one of the inner assemblies is communicated through the passage with the air under pressure in the combustion chamber of the other of the inner assemblies to affect the power stroke of both assemblies.
[0013] Other various options of the method may include the following.
[0014] The compression stroke of each assembly may create an auto-ignition compression pressure and wherein the mixture is ignited by injecting fuel into the air under auto-ignition pressure within the associated combustion chamber.
[0015] The mixture of air and fuel in the associate combustion chamber by injecting fuel with the intake of air during each intake stroke and the mixture may be ignited by the energization of a spark plug in communication with the mixture.
[0016] The new camshaft may control the valves of the two outer and two intermediate assemblies so that cycles of the two outer and two intermediate assemblies are in phase, and the injectors of the fuel injecting and firing system associated with the two outer and two intermediate assemblies are controlled in a third mode wherein one of the injectors of the two outer and two intermediate assemblies inject a zero amount of fuel.
[0017] The passage may be provided by grinding inwardly of a seal engaging surface of the frame between the cylinders of the two inner assemblies.
[0018] The fuel injecting and firing system may be controlled by a computer and the modification of the system is achieved by reprogramming the computer.
[0019] The fuel injecting and firing system may be controlled by pumping fuel under pressure through individual lines to each injector in timed relation and the modification of the system is achieved by modifying the lines to the injectors.
[0020] Other objects, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a perspective view of a conventional in line six cylinder engine with parts broken away for purposes of clearer illustration.
[0022] FIG. 2 is a perspective view of a first modification in accordance with the principles of the present invention in the form of a new crankshaft.
[0023] FIG. 3 is a fragmentary perspective view of a second modification in accordance with the principles of the present invention in the form of a passage in the engine block between cylinders 3 and 4 .
[0024] FIG. 4 is a schematic and block diagrammatic view of a third modification in accordance with the principles of the present invention in the form of a modified fuel injecting and firing system.
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIG. 1 shows a prior art six cylinder in line diesel engine 10 which includes a main frame 12 having a pan 13 detachably fixed to the lower end of a crankcase portion 14 thereof. Mounted within the crank case portion 14 is a crankshaft 16 journaled in main bearings 18 . The crankshaft 16 includes six crankpin bearings 20 on which the bolt secured split ends of six connecting rods 22 are journaled. The opposite ends of the six connecting rods 22 are journaled in six wristpin bearings 24 mounted within six pistons 26 respectively. The six pistons 26 are in-line oriented slidably sealingly mounted in six in-line oriented cylinders 28 formed by six in-line oriented cylinder liners 30 removably fixed within the frame 12 .
[0026] The connecting rods 22 are journaled at one end on the crankshaft 16 and at the other end on the pistons 26 which causes the pistons 26 to be reciprocated within the cylinder liners 30 through a cycle of four reciprocating strokes while the crankshaft is rotated through two rotations.
[0027] The four events which occur within the cylinders 28 during each four stroke cycle include, in order, intake compression, fire, and exhaust. The events are accomplished in response to a camshaft 32 which is suitably journed on the frame 12 . The camshaft 32 is mounted in a position to be driven by the crankshaft 16 . The drive is accomplished by a gear 34 fixed on the crankshaft 16 to rotate therewith and a meshing gear 36 of twice the size of gear 34 fixed on the camshaft 32 so that the camshaft 32 rotates at half the speed of the crankshaft 16 .
[0028] The four events are accomplished by reciprocating inlet valves 38 spring biased to close inlet openings leading into the cylinders 28 above the pistons 26 and outlet or exhaust valves 40 spring biased to close outlet openings leading from the cylinders 28 to an exhaust manifold (not shown) forming a part of an exhaust system including an exhaust pipe (not shown).
[0029] The inlet and outlet valves 38 and 40 are moved into opening relation to the inlet and outlet openings against their spring bias by inlet and outlet cam lobes 42 and 44 on the camshaft 32 which move inlet and outlet lifter rods 46 . The inlet and outlet valves 38 and 40 are actively moved by one ends of inlet and outlet rocker arms 47 , the other ends of which are moved by the inlet and outlet lifter rods 46 .
[0030] The position of the cam lobes 44 on the camshaft 32 cause (1) the inlet valve 38 associated with each cylinder to be open at an appropriate time so that the inlet opening is open during the inlet stroke event of the cylinder cycle (2) cause the outlet valve 40 associated with each cylinder to be opened at an appropriate time so that the outlet opening is open during the outlet or exhaust stroke event. The inlet and outlet valves 38 and 40 are allowed to remain in their spring biased closed position during the compression stroke event of each cycle wherein the air in the cylinder taken in during the intake stroke event is compressed to an auto ignition pressor. The inlet and outlet valves 28 and 30 also remain closed during the firing stroke during which diesel fuel is injected into the cylinder by a computer controlled fuel injecting and firing system, generally indicated at 48 ; modification of which is shown in FIG. 4 and will be described in detail hereinafter.
[0031] It will be understood that the conventional in-line six cylinder engine also has accessories such as an alternator, fuel and air filters, an oil pump, a turbo charger, a super charger, etc., which remain unmodified in accordance with the principles of the present invention and hence are either not shown in the drawings or described in detail herein.
[0032] It can be seen that the conventional engine 10 includes six in-line crankshaft driven piston and cylinder assemblies, which can be conveniently identified from left to right as 1 through 6 respectively. Each of the piston and cylinder assemblies 1 - 6 includes a cylinder liner 30 , a piston 26 and a connecting rod 22 , which can be referred to as cylinder 1 , piston 1 or connecting rod 1 , cylinder 2 , piston 2 or connecting rod 2 , etc., for purposes of clearly identifying each one of six.
[0033] The six crank portions of the crankshaft 16 are arranged so that pistons 1 and 6 move together in cylinders 1 and 6 , pistons 2 and 5 move together in cylinders 2 and 5 and pistons 3 and 4 move together in cylinders 3 and 4 . A conventional firing order is 153624 which means that the firing stroke event takes place in successive strokes first in cylinder 1 ; second, in cylinder 5 ; third, in cylinder 3 ; fourth, in cylinder 6 ; fifth, in cylinder 2 ; and sixth, in cylinder 4 . A cycle must take place in each cylinder in two rotations of the crankshaft (four 180° strokes) or one rotation of the camshaft (four 90° strokes). In order for six firing stroke events to take place in four incremental movements of the camshaft (90° each) or four incremental movements of the crankshaft (180° each) it is conventional that these firing stroke events be initiated 120° apart with respect to the crankshaft rotation. To accomplish the initiation of six successive firing stroke events every 120° (1) the firing stroke event in cylinder 5 is initiated 120° after the initiation of the firing stroke in cylinder 1 , (2) the firing stroke event in cylinder 3 is initiated 120° after the initiation of the firing stroke event in cylinder 5 , (3) the firing stroke events of cylinders 6 , 2 and 4 follow in the same sequence. Also in order to achieve six successive stroke initiations within two revolutions of the crankshaft 32 the cycles of commonly used pistons 1 and 6 , 2 and 5 and 3 and 4 are 180° out of phase with respect to one another.
[0034] Referring now more particularly to FIG. 2 , there is shown therein a first modification for the conventional engine 10 in accordance with the principles of the present invention. The modification shown in FIG. 2 is a new camshaft 50 to replace the conventional camshaft 32 . The camshaft 50 is constructed to allow the two adjacent piston and cylinder assemblies 3 and 4 to be done in phase rather than 180° out of phase. Compared with a conventional camshaft 32 , new camshaft 50 has cam lobes 4 positioned on the camshaft in angular alignment rather than with cam lobe 3 , as shown, being 180° out of alignment therewith. This alignment of cam lobes 3 and 4 allows pistons 3 and 4 to complete their combustion strokes simultaneously so that selectively both cylinder 3 and 4 will receive an injection of diesel fuel appropriate to fire both during the following simultaneous power strokes thereof or to alternatively inject only one cylinder 3 or 4 with an appropriate amount of fuel for one of cylinders 3 and 4 to fire alternatively in only one cylinder so that the increased pressure conditions resulting from the one fire can be communicated to the other cylinder. That is, the passage allows pressure generated by fuel injected and ignited in cylinder 3 or 4 to be communicated to the other of cylinders 3 or 4 receiving no fuel, so the pressure drives both pistons 3 and 4 simultaneously. This generates power of both pistons with one less injection charge.
[0035] FIG. 3 shows the modification used to accomplish the communication. As shown, the modification is simply to remove from the seal engaging surface of the frame 12 extending between cylinders 3 and 4 sufficient material, as by grinding or other means, to form a passage 52 of a minimum size suitable to enable the communication to take place. Alternatively, a portion of the seal extending from cylinder 3 to cylinder 4 can be removed.
[0036] FIG. 4 shows the modifications sufficient to enable the mode selection to take place. FIG. 4 shows one computerized fuel injecting and firing system, generally indicated at 54 , for an in line six cylinder engine operating as a diesel engine. The system 54 includes a fuel injector 56 for each cylinder 1 - 6 . Each injector 56 has a source of fuel under pressure communicating therewith, which, as shown, includes a power driven pump 58 capable of delivering fuel from a fuel tank 60 to a manifold 62 having a maximum pressure condition determined by a pressure relief valve 64 in a line between the manifold 62 and tank 60 . The manifold 62 communicates the fuel pressure therein directly to the six injectors 56 .
[0037] Each injector 56 has a solenoid operated valve 66 formed therein for controlling the flow of fuel under pressure communicated therewith outwardly of a nozzle end thereof. In the cases of diesel operation, the nozzle end of each injector 56 is positioned to inject fuel directly into the combustion chamber of the associated cylinder 1 - 6 . The solenoid operated valves 66 are controlled by electrical signals coming from a computer 68 which signals determine the time and amount of fuel injected by the associated injector 66 .
[0038] Referring again to FIG. 2 , there is shown therein a preferred further camshaft modification embodied in the new camshaft 50 enabling a preferred, more balanced application of the forces created by the firing events in the cylinders to the crankshaft 32 . Specifically, the further modification is to change the movement of inlet and outlet valves 1 and 6 and the inlet and outlet valves 2 and 5 so that the cycles in cylinders 1 - 6 and 2 - 5 are in phase rather than being 180° out of phase. Compared with camshaft 32 , new camshaft 50 preferably in addition to the angular alignment of cam lobes 3 and 4 has cam lobes 6 angularly aligned with cam lobes 1 and cam lobe 2 are angularly aligned with cam lobes 5 . With these further modifications the firing stroke event is initiated in two cylinders simultaneously every 240° of rotation of the crankshaft 82 .
[0039] As best shown in FIG. 4 , preferably, the fuel injecting and firing system 48 includes modifications which allow a selected third mode of operation wherein alternating one of injectors 1 and 6 and alternating one of injectors 2 and 5 is controlled to inject zero amount of fuel. That is, injectors 2 and 5 are being used in a known “skip-fire” style where no fuel or pressure from another source is being introduced into the associated cylinder. This third mode where cylinders 3 and 4 are also operating alternately with one injector injecting zero amount of fuel but receiving pressure from the other cylinder receiving fuel, can be identified as a maximum fuel saving mode (50% saving) whereas the previously identified fuel saving mode can be identified as an intermediate fuel saving mode (16⅔%).
[0040] In the system 54 shown in FIG. 4 the selection of which of the three modes is to operate is left up to the driver of the vehicle. FIG. 4 illustrates a box 70 having three buttons 72 , 74 and 76 which when pushed provide three different signals to the computer 48 .
[0041] Preferably, the signal which activates the computer 68 to emit signals commensurate with the maximum power mode is made by pressing a manual control button 72 although it could be under the control of a sensor that activates when the vehicle is going up a steep grade or the gas pedal has been floor-boarded. Preferably, the signal which activates the computer to emit signals commensurate with the maximum fuel savings mode is the separate manual control button 74 although it could be activated when the cruise control button is turned on. It is noted that cylinders 3 and 4 will both fire in the maximum power mode, while only one will fire in the maximum fuel saving mode. And, when neither maximum mode is operating, the cylinders 3 and 4 will fire one alternately (the intermediate mode).
[0042] Consequently, the preferred operation of the fuel injecting and firing system 48 is to select the intermediate mode at all times (16⅔% less fuel than max power), as by a third manual control button 76 except when added power is desired or needed (max power mode) or when the cruise control button is turned on (max fuel saving mode 50% less fuel than max power).
[0043] When the computer 48 receives a signal as a result of pushing button 72 , the computer 48 is programed to activate all of the injectors 50 at the appropriate time. When the computer 48 receives a signal as a result of pushing button 74 , the computer in proper timed relation (1) alternate one of injectors 3 and 4 (2) alternate one of injectors 1 and 6 and (3) alternate one of injectors 2 and 5 . When the computer 48 receives a signal as a result of pushing button 76 , the computer 48 is programmed to activate in properly timed relation alternately one of injectors 3 and 4 and both injectors 1 and 6 and both injectors 2 and 5 .
[0044] The modifications to be made in accordance with the principles of the present inventions are the same whether the engine is diesel ignited or spark plug ignited. In the case of a spark ignited engine the nozzle ends of the injectors 56 are directed along with a variable air supply into the cylinders through the open inlet valve during the intake stroke. While a spark plug is provided in each combustion chamber and a distributor assembly is also provided it is preferable to modify the distributor system so that when both cylinders 3 and 4 are to be fired together only one is fired and the fire in that one is used to fire the other through the communicating passage.
[0045] It should be appreciated that the foregoing embodiment(s) have been illustrated solely for the purposes of illustrating the structural and functional advantages of the present invention and is not intended to be limiting. To the contrary, the present invention includes all modifications, alterations, substitutions and equivalents within the spirit and scope of the appended claims.
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One non-limiting object of the present invention is to provide modifications to conventional in line 6 cylinder engines capable of increasing their efficiency in operation. This includes modifying the central two adjacent piston and cylinder assemblies of the engines. The modifications involve (1) changing the camshaft so that the central two adjacent piston and cylinder assemblies have their four stroke cycles in phase rather than 180° out of phase, (2) providing a communicating passage between the combustion chambers of the central two piston and cylinder assemblies and (3) modifying either the hardware or programming for the control of the fuel injectors of the central two piston and cylinder assemblies so that they can be selectively controlled not to inject fuel during the operation cycle thereof. The modifications contemplates providing a new cam shaft in which not only the cams relating to the central two adjacent piston and cylinder assemblies are modified to change 180° out of phase to in phase, but the cams relating to other piston and cylinder assemblies in order to provide a somewhat balanced application of the driving forces during each cycle.
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The present application is a continuation-in-part of co-pending application Ser. No. 08/984,695 entitled "Polyamide Binders for Ceramics Manufacture" filed on Dec. 3, 1997, the disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
A method for binding ceramic materials in aqueous media is disclosed. The method utilizes water-soluble polyamides prepared by condensation polymerization for binding various classes of ceramic materials.
BACKGROUND OF THE INVENTION
Ceramic materials are commonly prepared by mixing powdered ceramic oxides such as magnesia, alumina, titania and zirconia, in a slurry along with additives, such as dispersants and binders. The slurry may be spray dried to produce ceramic particles. The particles are formed into an aggregate structure, called a "green ceramic," having a desired shape and subsequently subjected to a severe heat treatment known as sintering. The sintering process converts the green ceramic into a cohesive "fired ceramic", having a nearly monolithic polycrystalline ceramic phase.
The binder serves to hold the ceramic particles of the green ceramic in the desired shape after forming. The binder can also provide lubrication while the particles are pressed. Preferably, the binder combusts or vaporizes completely during the sintering process leaving no trace of the binder in the fired ceramic. In performing these functions, binders significantly affect the properties of the fired ceramics which are ultimately produced.
In commercial practice, poly(vinyl alcohols) are widely used as ceramic binders. Additionally, poly(ethylene oxide) and ethylene-vinyl acetate copolymers reportedly have been used as binders for particulate material, such as granular silica gel.
For example, polymeric binders containing substantially hydrolyzed copolymers made from monomers having ester or amide functional groups, poly(vinylformamide) or a copolymer of vinyl alcohol and vinyl amine are disclosed in U.S. Pat. Nos. 5,358,911; 5,487,855 and 5,525,665.
Spray drying is an evaporative process in which liquid is removed from a slurry containing a liquid and a substantially non-volatile solid. The liquid is vaporized by direct contact with a drying medium, usually air, in an extremely short retention time, on the order of about 3 to about 30 seconds. The primary controlling factors in a spray drying process are particle size, particle size distribution, particle shape, slurry density, slurry viscosity, temperature, residence time, and product moisture.
The viscosity of the slurry must be suitable for handling and spray-drying. Although spray-drying equipment conditions may be adjusted to handle a variety of viscosities, larger particles will usually result from higher viscosity slurries.
Those of ordinary skill in the art are familiar with the spray-drying process used in the production of ceramic materials, and will be able to optimize the control factors of spray-drying to best advantage. Alternatively, the spray drying or dry pressing processes may be replaced by other well known forming methods, such as granulation, tape casting and slip casting.
Spray drying of the slurry produces substantially dry, free-flowing powder particles which contain the ceramic, the binder and the optional materials described above. The dry particles are granules which are generally spheroidal in shape and have an effective diameter of about 50 to about 300 micrometers. Typically, about 0.5 percent to about 8 percent of the binder, based on the dry weight of the ceramic powder, is present in the dry particles.
In granulation, a mixture of dry powder or powders is mixed or rolled, commonly in a barrel shaped apparatus. Water and/or a binder solution is sprayed into the mixing powder causing aggregation of the small particles into larger granules. The size of the granules is controlled by the amount of material sprayed into the powders and the speed with which it is sprayed. Granulated powders may be screened to a desired size and pressed to shape in a pressing operation prior to sintering. Alternatively, the granules themselves may be the desired product and may be sintered directly.
Tape casting is commonly used to produce thin substrates for the electronics industry. In the process, a thick ceramic slurry containing ceramic powder, dispersant and binders is prepared. This slurry is cast onto a smooth surface such as a Mylar or plastic sheet and the thickness is controlled by passing the sheet under a blade which smoothes the slurry surface and scrapes off excess material. The slurry tape is dried to a plastic state and cut and shaped to specification. The amount of binders present in tape casting is very high, typically on the order of 15 to 20 wt. % of the ceramic powder mass.
In fluidized bed spray drying, small "seed" particles are placed in a column and hot air is blown into the seed powder from below suspending the particles in the column. A ceramic slurry is sprayed onto the seed particles from above, causing them to grow. When the particles reach a large enough size, they are siphoned out of the dryer while more seed particles are introduced. This process can produce powder for further forming processes, or the powder itself may represent the desired product, in which case it would be sintered to produce the final ceramic.
The dry particles are compacted to produce an aggregate, green ceramic structure. Preferably, the particles are compacted by pressing in dies having an internal volume which approximates the shape desired for the final fired ceramic product. Alternatively, the particles are compacted by roll compacting or other well-known compacting methods. The spray dried blend of powder, binder, and optional surfactants and lubricants is relatively free flowing so that it can enter and closely conform to the shape of the pressing dies.
Inside the dies, the dry particles are subjected to a pressure which is typically in the range of about 2000 to about 50,000 psi. Pressing the particles produces an aggregate structure, called a green ceramic, which retains its shape after removal from the die.
One forming technique used for spray dried or granulated material is roll compaction, also referred to as roll pressing. This technique takes a dry powder and crushes it between two rollers in a continuous process. This process produces sheets of ceramic of various widths and thicknesses. These sheets can be cut to shape and sintered to produce the final ceramic body. The process is commonly used to produce ceramic substrates for the electronics industry.
Dry pressing involves filling a shaped die with spray dried or granulated powder and pressing it at high pressures. The pressing occurs through movable pistons at the top and/or bottom of the die cavity. The process can be used to produce fairly complex geometries in a single forming step. The ceramic body that results is ejected from the die and sintered to produce a final ceramic product.
Isostatic pressing is similar to dry pressing in that a ceramic powder is pressed in a die cavity. In isostatic pressing, however, all or part of the die wall consists of a flexible material. After filling the die cavity with powder, the die is submerged in a liquid pressure chamber and pressure is applied to squeeze the die and compact the powder. Unlike dry pressing, no movable parts are involved. Isostatic pressing is commonly used on large or very long parts to minimize cracking or lamination of the final ceramic green body.
Extrusion involves the pushing of a concentrated, plastic, slurry through an orifice. The orifice is of the size and shape of the desired ceramic body. This process is commonly used to produce ceramic tubes or similarly shaped pieces. The slurry used is prepared from dry powders which are mixed with water, organic binders and lubricants, and a coagulant. This slurry is usually predried in a filter press or similar apparatus to remove excess water and thicken the slurry to a plastic material. The material is then extruded through a press which is either piston or screw driven. The extruded material is cut to length, dried, and sintered.
Jiggering is commonly used in the whiteware industry to shape an extruded or filter pressed ceramic slurry. Typically, a portion of the plastic slurry is placed on a rotating wheel and shaped by rollers and/or knife blades to a desired geometry. This body is then dried and sintered.
Another ceramic forming method, that is used for parts of complex shape, is slip casting. In slip casting, a concentrated ceramic slurry (slip) is poured into a mold with an internal shape of the desired ceramic body. The slurry used must be highly concentrated to prevent settling of particles and/or excessive shrinkage during drying. At the same time, the slip must be fluid enough to completely fill the mold and allow escape of air bubbles. The presence of a polymeric binder adds strength to the cast body preventing breakage during mold removal and handling of the body prior to sintering.
Heating the aggregate structure drives off volatile materials such as water, and burns off organic materials, such as binders, plasticizers, dispersants or surfactants. When a sufficiently high temperature is reached, the particles of the aggregate structure begin to fuse, but do not fuse completely, and become fastened to one another to produce a relatively strong fired ceramic material having essentially the desired shape.
The slurry is, for example, spray dried to produce substantially dry particles which include the polymer. The particles are preferably pressed to produce an aggregate, green ceramic structure and heated to produce a fired ceramic material. Alternatively, the particles can be formed into an aggregate, green ceramic structure by roll compaction or other well-known methods.
Many references describe the use of polymers as aids in the manufacture of ceramics. However, such polymers are generally formed by radical-induced polymerization of vinylic monomers. Substantially hydrolyzed copolymers formed from vinylic esters and amides are disclosed in U.S. Pat. Nos. 5,358,911; 5,525,665 and 5,487,855 for ceramics production. A hydrolyzed terpolymer formed from maleic anhydride, N-vinyl pyrrolidinone and a third vinyl monomer for preparing ceramic oxide materials is disclosed in U.S. Pat. No. 5,266,243. A method for dispersing one or more ceramic materials in an aqueous medium utilizing a polymer formed from hydroxy functional monomers and acid-containing monomers is disclosed in U.S. Pat. Nos. 5,532,307 and 5,567,353. A method for preparing sintered shapes utilizing the reaction product of an amine other than an alkanolamine with a hydrocarbyl-substituted carboxylic acylating agent is described in U.S. Pat. No. 5,268,233, and a method for increasing green fracture strength of a ceramic part utilizing polymers of vinylic monomers is disclosed in U.S. Pat. No. 4,968,460.
However, none of these references disclose the poly(aminoamide) condensation polymers described herein.
Water soluble polyamide syntheses are disclosed in U.S. Pat. Nos. 5,053,484 and 5,324,812.
The condensation polymers have been cross-linked and utilized as Yankee Dryer Adhesives as disclosed in U.S. Pat. No. 5,382,323.
Nylon-type resinous products have also been utilized for improving wet strength in papermaking in U.S. Pat. No. 3,250,664. However, the condensation polymers have not been utilized for the manufacture of ceramics.
Although commercially available binders are satisfactory for many applications, a need exists for improved binders which provide still greater strength and/or green density in green ceramic materials. Greater green strength reduces breakage during handling of the green ceramics and, generally, is associated with higher quality fired ceramics. The value of an increase in density is that it results in decreased shrinkage, decreased warpage, and overall improvement of the uniformity of physical properties.
SUMMARY OF THE INVENTION
A method for binding ceramic materials in aqueous media is disclosed. The method utilizes water-soluble polyamides prepared by condensation polymerization for binding various classes of ceramic materials.
DESCRIPTION OF THE INVENTION
The present invention relates to polymeric binders for preparing ceramic materials. Other possible uses for the condensation polymers described herein include using the polymers as binders in investment casting shells, as water-reducing aids for gypsum wallboard manufacture or as dispersants for metal oxides and/or carbon black. The method can be used to produce fired ceramic materials from ceramic powders. Suitable powders include but are not limited to: aluminum oxide, silicon nitride, aluminum nitride, silicon carbide, silicon oxide, magnesium oxide, lead oxide, zirconium oxide, titanium oxide and neodymium oxide. The powder can have a weight-averaged median particle size in the range of a few nanometers to about 1/2 millimeter. Powders having a median size in the range of about 0.5 to about 10 micrometers are preferred.
One aspect of this invention is an unfired, ceramic precursor material comprising a mixture of:
a) a ceramic powder selected from the group consisting of aluminum oxide, silicon nitride, aluminum nitride, silicon carbide, silicon oxide, magnesium oxide, lead oxide, zirconium oxide, titanium oxide, steatite, barium titanate, lead zirconate titanate, clays, ferrite, yttrium oxide, zinc oxide, tungsten carbide, sialon, neodymium oxide and combinations thereof and
b) a water soluble condensation polymer formed from the polymerization of
i) at least one compound having at least two functional groups of the formula ##STR1## wherein Z is selected from the group consisting of --OH; --OR 1 wherein R 1 is selected from the group consisting of linear, cyclic or branched alkylene groups having from one to eight carbon atoms, aromatic groups, polycyclic groups and heteroaromatic groups; --Cl; --Br and --F, with
ii) at least one polyamine having at least two amine groups selected from the group consisting of:
polyamines of the formula
H.sub.2 N--R.sub.2 --NH--R.sub.3 --NH.sub.2
wherein R 2 and R 3 may be the same or different and are selected from the group consisting of linear, cyclic or branched alkylene groups having from two to eight carbon atoms, aromatic groups, heteroaromatic groups and polycyclic groups;
polyamines of the formula ##STR2## wherein R is selected from the group consisting of hydrogen, methyl groups and mixtures thereof, and p is an integer ranging from 0-8; and
polyamines of the formula ##STR3## wherein the sum of a+c ranges from about 0 to 8, b ranges from about 2 to about 50 and R' is an alkyl group of one to four carbon atoms; and
(iii) at least one epoxy resin having at least two epoxide groups.
Another aspect of this invention is a method for preparing a ceramic material, which comprises the steps of:
a) mixing a ceramic powder with an aqueous solution containing a water-soluble condensation polymer to produce a slurry, said water-soluble condensation polymer formed from the polymerization of
i) at least one compound having at least two functional groups of the formula ##STR4## wherein Z is selected from the group consisting of --OH; OR 1 wherein R 1 is selected from the group consisting of linear, cyclic or branched alkylene groups having from one to eight carbon atoms, aromatic groups, polycyclic groups and heteroaromatic groups; --Cl; --Br and --F, with
ii) at least one polyamine having at least two amine groups selected from the group consisting of:
polyamines of the formula
H.sub.2 N--R.sub.2 --NH--R.sub.3 --NH.sub.2
wherein R 2 and R 3 may be the same or different and are selected from the group consisting of linear, cyclic or banched alkylene groups having from two to eight carbon atoms, aromatic groups, heteroaromatic groups and polycyclic groups;
polyamines of the formula ##STR5## wherein R is selected from the group consisting of hydrogen, methyl groups and mixtures thereof, and p is an integer ranging from 0-8; and
polyamines of the formula ##STR6## wherein the sum of a+c ranges from about 0 to 8, b ranges from about 2 to about 50 and R' is an alkyl group of one to four carbon atoms;
iii) at least one aromatic epoxy resin having epoxide groups;
b) drying the slurry by a process selected from the group consisting of filter pressing, fluidized bed spray drying, roll compaction, spray drying and tape casting to produce particles which include said block copolymer;
c) compacting the particles by a process selected from the group consisting of dry pressing, extrusion, isostatic pressing, jiggering and slip casting to produce an aggregate structure; and
d) heating the aggregate structure to produce a fired ceramic material. In the method described above, the particles may be produced by granulation and the step of compacting the particles to produce an aggregate structure may be selected from the group consisting of dry pressing, roll compaction and isostatic pressing.
For the practice of any aspect of this invention, one example included in the general class of compounds described above is a dicarboxylic acid which may be of the formula ##STR7## wherein R 1 is selected from the group consisting of linear, cyclic or branched alkylene groups having from one to eight carbon atoms, aromatic groups, polycyclic groups and heteroaromatic groups. Moreover, the dicarboxylic acid may have at least four carbon atoms. The dicarboxylic acid may be adipic acid, sebacic acid, terephthalic acid, or said dicarboxylic acids may be mixtures of sebacic acid and adipic acid, or terephthalic acid and adipic acid, among others.
For the practice of any aspect of this invention, the polyamine may be of the formula
H.sub.2 N--R.sub.2 --NH--R.sub.3 --NH.sub.2
For example, the diamine may be diethylene triamine. The polyamine may also be of the formula ##STR8## wherein R may be selected from the group consisting of hydrogen, methyl groups and mixtures thereof, and p is an integer ranging from 0-8. Additionally, the polyamine may be a polyoxyalkylene diamine of the formula ##STR9## wherein the sum of a+c ranges from about 0 to 8, b ranges from about 2 to about 50 and R' is an alkyl group of one to four carbon atoms. Moreover, the polyamine may be 4,7,10-trioxa-1,13-tridecane diamine.
The aromatic epoxy resin may be any aromatic compound containt two or more epoxide groups. Preferably, the aromatic epoxy resin may be selected from the group consisting of: 2,2-bis(4-hydroxyphenyl) propane diglycidyl ether; 2,2'- (1-methylethylidene)bis(4,1-phenyleneoxymethylene)!bisoxirane homopolymer; resorcinol diglycidyl ether and hydroquinone digylcidyl ether.
The following materials may also be added to any aspect of this invention: a second water-soluble condensation polymer (as described herein), a polyethylene glycol, a poly(vinyl alcohol), polyethylene oxide, a poly(ethylene oxide/propylene oxide), glycerol or other processing additives known to those skilled in the art.
For the practice of any aspect of this invention, the water-soluble condensation polymer described herein may be from about 0.1% to about 15% by weight of total ceramic material. Moreover, the water-soluble condensation polymer may be from about 1% to about 5% by weight of total ceramic material.
In one aspect, the ceramic powder is mixed with an aqueous solution containing a polymer to produce a slurry. Preferably, the solution is prepared using deionized water. The slurry may also contain lubricants and surfactants, such as dispersants and anti-foaming agents.
It is also recognized that the properties of a ceramic such as, but not limited to, green density, surface quality or milling characteristics, may be varied as desired by adjusting the ratio of the different monomers in a copolymer or the molecular weight of the polymer used in the binder composition.
The condensation polymer is made by condensing one or more carboxylic acids, ester or anhydride with one or more polyamine and an aromatic epoxy resin. Preferably, the condensation polymer is prepared by condensing one or more polycarboxylic acids, esters or anhydrides with one or more polyamines and the reaction product of an aromatic epoxy resin with one or more polyamines. As is generally understood, the term amines encompasses any compound having a trisubstituted nitrogen group. Therefore, said amines may be multifunctional.
One example of compounds having the general structure described above is a dicarboxylic acid having the structure: ##STR10## wherein R 1 is a linear, cyclic, or branched alkylene group having from one to eight carbon atoms, an aromatic group, a polycyclic group or a heteroaromatic group (as utilized herein the terms carboxylic acid, ester or anhydride are meant to also encompass multifunctional compounds which are carboxylic acids, esters or anhydrides also containing other functional groups; or more than two acid, ester or anhydride groups) may be reacted with a polyamine having the structure:
H.sub.2 N--R.sub.2 --NH--R.sub.3 --NH.sub.2 III
wherein R 2 and R 3 may be the same or different and are linear, cyclic or branched alkylene groups containing from 2-8 carbon atoms, aromatic groups, polycyclic groups or heteroaromatic groups. Polyamines having heteroaromatic groups include aziridines, azetidines, azolidines, tetra- and dihydropyridines, pyrroles, indoles, piperidines, imidazoles, di- and tetrahydroimidazoles, piperazines, isoindoles, purines, morpholines, thiomorpholines, N-aminoalkylmorpholines, N-aminoalkylthiomorpholines, N-aminoalkylpiperazines, N,N'diaminoalkylpiperazines, azepines, azocines, azonines, azecines and tetra-, di- and perhydro derivatives of each of the above and mixtures of two or more of these heterocyclic amines.
The aromatic group can be a single aromatic nucleus, such as a benzene nucleus, a pyridine nucleus, a thiophene nucleus, a 1,2,3,4-tetrahydronaphthalene nucleus, or a polynuclear aromatic moiety. Such polynuclear moieties can be of the fused type, that is wherein at least two aromatic nucleii are fused at two points to another nucleus such as found in naphthalene, anthracene, and the azanaphthalenes among others. Such polynuclear aromatic moieties can also be of the linked type wherein at least two nuclei (either mono or polynuclear) are linked through bridging linkages to each other. Such bridging linkages can be selected from the group consisting of carbon-to-carbon single bonds, ether linkages, keto linkages, sulfide linkages, polysulfide linkages of 2 to 6 sulfur atoms, sulfinyl linkages, sulfonyl linkages, methylene linkages, alkylene linkages, di-(lower alkyl)-methylene linkages, lower alkylene ether linkages, alkylene keto linkages, lower alkylene sulfur linkages, lower alkylene polysulfide linkages of 2 to 6 carbon atoms, amino linkages, polyamino linkages and mixtures of such divalent bridging linkages.
The condensation polymer is made up of dimeric repeating units, such as in the structure: ##STR11##
Wherein n is an integer providing a weight average molecular weight of at least 1,000, and preferably at least 7,500, or higher.
The above dicarboxylic acid is preferably a diacid containing at least four carbon atoms, and is most preferably adipic acid, i.e. ##STR12## most preferably, ##STR13##
The diamine above is preferably those polyamines obtained from condensation reactions of ethylene and propylene amine, or mixtures thereof, which polyamines have the structure: ##STR14##
wherein R is chosen at each occurrence, from the group consisting of H, CH 3 , or mixtures thereof; and p is an integer ranging from 0-8, preferably from 0-4, and most preferably 1-2.
Since the reaction product can contain mixtures both in terms of different acids and/or different amines, and also with different molecular weights, both with the same or different difunctional acids and/or polyamine, one may have mixtures of condensation polymers.
The polyamine may also be of the formula: ##STR15## wherein R and R" may be C 1 -C 4 alkyl, preferably ethyl, propyl or isopropyl; R' may be hydrogen or C 1 -C 4 alkyl, preferably hydrogen or methyl; and x is an integer of from about 1 to about 10.
The polyamine may also be a relatively low molecular weight poly(alkylene glycol) diamine of the formula: ##STR16## where x is from about 2 to 5, R is hydrogen or an alkyl of one to four carbon atoms and the polyethylene glycol diamine has M w of at least 100 with a mixture of ethylene oxide and propylene oxide. In a preferred embodiment of the invention, R is hydrogen. Also, x preferably averages from about 2 to about 3. When R is hydrogen and x is 2, the material is triethylene glycol diamine (JEFFAMINE® EDR-148 amine). When R is hydrogen and x is 3, the reactant is tetraethylene glycol diamine (JEFFAMINE® EDR-192 AMINE). It will be appreciated that throughout this description x is understood to be an average value of the distribution of polymers present, rather than an absolute number indicating a completely pure material.
The polyoxyalkylene diamine reactants useful in this invention have the structure: ##STR17## where the sum of a+c ranges from about 0 to about 8, b ranges from about 2 to about 50 and R' is an alkyl group of one to four carbon atoms. Again, a, b and c are to be understood as average values in many instances. In a preferred embodiment, the ethylene oxide moieties denoted by b represent at least 50% of the molecule. Stated in another way, this could be represented as: ##EQU1##
The JEFFAMINE ED series diamines fall within this definition:
______________________________________ a + c= b=______________________________________JEFFAMINE ED-600 3.5 13.5JEFFAMINE ED-900 3.5 20.5JEFFAMINE ED-2001 3.5 45.5______________________________________
These Jeffamines are available from Texaco.
More than one polyoxyalkylene diamine within this definition may be used as desired to affect the properties of the final polyamide. Preferably, R' is methyl and the sum of a+c ranges from about 3 to 4. Alternatively, a and c are independently 1 or 2 and some, but not all, of the ethoxy moiety subscripted by b could be propoxy.
The aromatic epoxy resin compounds suitable for use in preparing the polymeric condensation products of this invention are organic compounds having at least two reactive epoxy groups. These compounds are aromatic and can contain substituent groups such as alkyl, aryl, organic ester, phosphate ester, halogen, cyano group among others without interfering with the condensation. The aromatic epoxy resin compounds may also have olefinic unsaturation on substituents. The preferred aromatic epoxy resin compounds are the aryl substituted compounds having as the sole reactive groups under the conditions of the reaction, at least two epoxy groups and wherein oxygen is present only in oxirane, ether and ester arrangement. Particularly preferred are the compounds consisting only of carbon, hydrogen and oxygen wherein oxygen is present only in oxirane, ether and ester arrangement, and wherein the epoxy groups are terminal groups of an aryl substituted compound.
It is to be understood that the invention is not limited to the foregoing compounds alone and a variety of aromatic epoxy resin compounds can be used.
A mixture of two or more aromatic epoxy resins can be used for the practice of this invention, or if desired, the polyamine can be reacted successively with different aromatic epoxy resins to obtain the condensation polymers.
Examples of aromatic epoxy resins useful for the practice of this invention include bisphenol A epichlorohydrin (condensate, resin, copolymer or epoxy resin) also known as 2,2-bis(4-hydroxyphenyl) propane epichlorohydrin (copolymer, polymer or condensate) and 4,4'-(1-methylethylidene)bisphenol polymer with (chloromethyl) oxirane; and the diglycidyl ether of 2,2-bis(4-hydroxyphenyl)-propane among others.
The aromatic epoxide having at least two epoxide groups may first be reacted with a polyamine having at least two amine groups selected from the group consisting of:
polyamines of the formula
H.sub.2 N--NH--R.sub.3 --NH.sub.2
wherein R 2 and R 3 may be the same or different and are selected from the group consisting of linear, cyclic or branched alkylene groups having from two to eight carbon atoms, aromatic groups, heteroaromatic groups and polycyclic groups;
polyamines of the formula ##STR18## wherein R is selected from the group consisting of hydrogen, methyl groups and mixtures thereof, and p is an integer ranging from 0-8; and
polyamines of the formula ##STR19## wherein the sum of a+c ranges from about 0 to 8, b ranges from about 2 to about 50 and R' is an alkyl group of one to four carbon atoms prior to condensation with said compound of step i) and said polyamine of step ii).
Many modifications may be made in the process of this invention without departing from the spirit and scope thereof which are defined only in the appended claims. For example, one skilled in the art may discover that particular reaction conditions, sequences, polyamines and dicarboxylic acids which may not be explicitly recited herein, but which are nevertheless anticipated, would give optimal or otherwise desirable results. In some instances, for example, it may be preferable to react the aromatic epoxy resin with a pre-formed polyaminoamide or simultaneously polymerize the polyacid, polyamine and aromatic epoxy resin.
As used herein, the term JEFFAMINE D-190 describes Polyoxypropylene diamine having the structure: ##STR20##
As used herein, the term JEFFAMINE D-230 describes Polyoxypropylene diamine having the structure: ##STR21##
As used herein, the term JEFFAMINE D-400 describes Polyoxypropylene diamine having the structure: ##STR22##
The reaction conditions and variants to obtain the condensation polymers are described below, and also have been described in the following references:
Gen. Offen. D. E. 2,456,638
U.S Pat. No.2,926,116
U.S. Pat. No. 2,926,154
U.S. Pat. No. 3,607,622
Each reference above is incorporated herein by reference.
It has been found particularly preferable to use in the reaction mixture wherein for said acid, ester or anhydride the ester, acid or anhydride functionality is in a molar ratio of approximately 1:1 with the amine functionality of the amine utilized.
According to one embodiment of the invention, the condensation polymers of the invention are prepared as follows: A poly(aminoamide) condensation polymer may be prepared from a 0.85/1-1/0.85 molar ratio of polyamine/diacid (dicarboxylate) where the polyamine consists of a mixture of a polyamine and the reaction product of an aromatic epoxy resin and either the same or a different polyamine. Prior to use, the polymer may be first diluted to 5-60% polymer in solution and/or acidified to pH=5.0-10.0 as is convention in the art. The preferred polyamine and diacid (dicarboxylate) of the invention are diethylenetriamine and adipic acid (or its esters), respectively. Additional preferred polyamines and diacids are disclosed herein. Sulfuric acid is typically used to adjust the pH of the backbone solution, but the identity of the acid is not critical to the invention. Acetic acid, phosphoric acid, and hydrochloric acid can also be used. The use of hydrochloric acid would, however, be less desirable since it would introduce chloride ions into the product.
The only upper limitation on the molecular weight of the copolymers is that they are of any molecular weight which allows water-solubility.
The following examples are presented to describe preferred embodiments and utilities of the invention and are not meant to limit the invention unless otherwise stated in the claims appended hereto.
EXAMPLE 1
The following procedure was utilized to form a terpolymer of adipic acid, diethylene triamine and diethylene triamine/Epon 828 reaction product.
17.52 g of Epon 828, a Bisphenol A epoxy resin available from Shell, was mixed with 75.52 g of diethylenetriamine under a nitrogen blanket at 130° C. for 2 hours. After cooling to about 50° C., 106.96 g of adipic acid and 100 g of DI water were added to the reactor. The mixture was heated to 185° C. while distilling off water. After 3 hours at 185° C., the solution was cooled to about 150° C. and 180 g of DI water was added carefully. The solution was heated at boiling for 1 hour and cooled to room temperature. The BFV (Brookfield Viscosity) of the resulting product was 1700 cps (spindle 1, 1.5 rpm).
EXAMPLE 2
The following procedure was utilized to form a terpolymer of adipic acid, diethylene triamine and diethylene triamine/Epon 828 reaction product.
3.8 g of Epon 828 and 78.5 g of diethylenetriamine were heated under a nitrogen blanket at 130° C. for 2 hours. After cooling to about 50° C., 117.7 g of adipic acid and 100 g of DI water were added. The mixture was heated to 185° C. while distilling off water. After 3 hours at 185° C., the solution was cooled to about 150° C. and 180 g of DI water was added carefully. The solution was heated at boiling for 1 hour and cooled to room temperature. The BFV of the resulting product was 648 cps (spindle 1, 1.5 rpm).
EXAMPLE 3
The polyamides were made by condensation polymerization in the following manner. 191.6 g of amine was weighed directly into the flask. That flask was equipped with resin head, stirrer, thermometer, thermocouple, distillation trap, and condenser; then stirred and cooled. Then, about half of the DI water (i.e., half of 132.6 g) was added to the reactor, followed by adding 292 g adipic acid to the reactor while maintaining the reaction temperature at less than 90° C. Immediately after adding all of the adipic acid, external cooling was ceased. Heating to approximately 185° C. was begun. When the mixture reached about 123° C., water began to distill, and was removed continuously through the trap and collected in a graduated cylinder.
Heating was continued until the solution reached 185° C. Next, the solution was maintained at that temperature for three hours blanketed in N 2 . At the end of 3 hours, the solution was air cooled to about 140-150° C., followed by careful addition of 417.2 g DI water. Next the solution was reheated to boiling and maintained at boiling for 60 minutes, then cooled to room temperature.
Condensation polymers 2-6 of Table I were prepared according to this technique, and have the physical characteristics as described below.
TABLE I______________________________________Polymer Amine Acids Ratio Amine/Acid M.sub.w M.sub.n______________________________________2 A C 0.9/1.0 215000 70503 A C 0.95/1.0 23600 61004 A D/C 0.95/.33/.67 4400 27005 A E/C 0.95/.33/.67 3000 20006 A D/C 0.98/.33/.67 15200 5000______________________________________ A = Diethylene Triamine, available from Aldrich Chemical Co. of Milwaukee Wisconsin C = HO.sub.2 C(CH.sub.2).sub.4 CO.sub.2 H (adipic acid), available from Aldrich Chemical Co. of Milwaukee, Wisconsin D = HO.sub.2 C(CH.sub.2).sub.8 CH.sub.2 H (sebacic Acid), available from Aldrich Chemical Co. of Milwaukee, Wisconsin E = Terephthalic acid, available from Aldrich Chemical Co. of Milwaukee, Wisconsin
EXAMPLE 4
Condensation polymers were tested as binders for alumina particles of the type that are commonly used for producing ceramic materials according to the following procedure.
The slip was prepared as follows: 1500 g slips were prepared to 80 weight percent alumina powder (92% alumina based blend from a Northeastern ceramics manufacturer) in water using 0.12 weight percent (polymer/powder) of the polymer dispersant. To each slip so prepared, the polymeric treatment to be tested was added, to be a total of 2.0 weight percent (polymer/powder) level. Next, each binder-containing slip was propeller mixed at 800 rpm for one hour. For any necessary dilution, deionized water was added to attain the tabulated powder solids level.
The milled slurry was spray dried in a Yamato DL-41 laboratory spray dryer. Dryer operating conditions were: 250° C. air inlet temperature, atomizing air setting of 1.2, slurry feed pump setting of 5, and drying air feed rate of 0.7 cubic meters per minute. A dry powder was produced which was recovered, screened and stored overnight in a 20 percent relative humidity chamber.
The screened powder was pressed into nine pellets in a Carver laboratory press, three at 10,000 pounds per square inch pressing force, three at 15,000 pounds per square inch pressing force, and three at 25,000 pounds per square inch pressing force. The pellets were approximately 28.7 millimeters in diameter and 5 to 6 millimeters in height. The dimensions and weights of the pellets were measured and the pellets were crushed to determine the force required to break them. Diametral compression strength (DCS) for each of the pellets was determined from the breaking force and the pellet dimensions. The average diametral compression strength in megapascals for each set of three pellets is presented below in Table II.
Green body diametral compressional strength is important in ceramics applications for the following reasons. The principal function of the binder is to hold the compacted form together after pressing. The method utilized for determination of suitable "green strength" is the diametral compression strength or DCS of a cylindrical section across its diameter. DCS is actually a measure of tensile strength. The unit of measurement of pressure tolerance is the megapascal (Mpa). Typical values for DCS of "green" parts are in the range of 0.3-3.0 Mpa. A higher DCS value indicates a more efficient binder. Table II shows that the polymers of the instant invention act as effective ceramic binders.
Since a greater density is more desirable, the results of Table II illustrate that the polymers of the instant invention are advantageous in this respect also.
TABLE II______________________________________Pressure (psi) Treatment 1.sup.1 Treatment 2.sup.2 Treatment 3.sup.3 Treatment 4.sup.4______________________________________Green Strength10000 0.25 0.545 0.51 0.30715000 0.358 0.621 0.576 0.4525000 0.76 1.082 0.913 0.614Green Density10000 2.0837 2.2592 2.2397 2.226115000 2.1504 2.3001 2.545 2.283525000 2.288 2.4262 2.3507 2.3627______________________________________ .sup.1 = PVA, polyvinyl alcohol, available from Air Products. .sup.2 = Condensation polymer prepared according to the procedure described in Example 2. .sup.3 = Condensation polymer prepared according to the procedure described in Example 1. .sup.4 = Condensation polymer of adipic acid/diethylene triamine/terephthalic acid, prepared according to the procedure described in Example 3.
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A method for binding ceramic materials in aqueous media is disclose. The method utilizes water-soluble polyamides prepared by condensation polymerization for binding various classes of ceramic materials.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the priority of application Ser. No. P 39 22 862.2, filed Jul. 12, 1989 in the Federal Republic of Germany, the subject matter of which is incorporated herein by reference. Furthermore the subject matter of this application is related to that of U.S. application Ser. No. 07/239,583, filed Sep. 1, 1988 (now U.S. Pat. No. 4,903,473) the subject matter of which is also incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a cage-type stranding machine of the type which includes a rotor equipped with a throughgoing supporting pipe rotatably mounted at both ends and supporting, concentrically with the rotor axis, several spool carriers holding spools for the filaments to be stranded in a manner so as to be rotatable and drivable.
In cage-type stranding machines of the above-mentioned type at least two circular plates, depending on the number of spool carriers required, are disposed at the supporting pipe. The spool carriers are held in these plates so as to. rotate about their longitudinal axes. The longitudinal axes of the spool carriers are oriented parallel to the rotor axis while the axes of rotation of the spools held by the spool carriers extend perpendicularly thereto. Between the two carrier plates, several spool carriers are arranged in uniform distribution about the circumference. These spool carriers are coupled with one another by way of a drive system so that they revolve relative to the rotor if the rotor rotates. This generally occurs in such a way that, with the rotor rotating, the axes of the spools remain oriented parallel to one another and parallel to the plane of the floor.
Due to the dimensions of the spools, the axes of rotation of the spool carriers must be placed at a considerable distance from the supporting pipe so as to even permit the above-described position relative to the rotor. This results in a considerable total diameter for the rotor as a whole, which ultimately leads to limitations regarding size and stability of the stranding machine.
Since the free space required for the rotary movement of the spool carriers, and the limitation on the total diameter of the rotor, require that certain limits be maintained, the diameter of the supporting pipe (which is decisive for the stability of the rotor) cannot be enlarged at will. The entire system becomes sensitive to bending vibrations, so that there are limitations with respect to the highest permissible rpm.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a cage-type stranding machine of the above-mentioned type which has a much stiffer rotor and thus permits higher operating speeds.
This is accomplished according to the invention in that the supporting pipe is provided with at least three radially outwardly oriented longitudinal webs which extend in the longitudinal direction and are uniformly distributed over the circumference of the pipe. Seen in the longitudinal direction, the supporting pipe is provided with at least two spaced supporting shields which extend in at least two planes of rotation (that is, there are at least two supporting shields fixed to the supporting pipe and spaced apart to one another, are fixed to the longitudinal webs, and provide a support for the spool carriers. By using such longitudinal webs and the supporting shields fixed to them, it is possible to employ a supporting pipe having a relatively small diameter and simultaneously increase the bending strength of the rotor as a whole. The bending encountered during operation, caused by the weight of the rotor and/or residual imbalances which cannot be entirely compensated, is thus reduced so that a significantly higher rpm can be achieved with such a stiffened rotor, and thus the production output of the machine can be increased.
The term "plane of rotation," as used herein, means a plane which is perpendicular to the axis of the supporting pipe and which passes through the path swept out by a designated object attached to the supporting pipe, directly or indirectly, as the supporting pipe rotates.
As a particularly advantageous feature of the invention, it is further provided that the axes of rotation of the individual spool carriers mounted between two supporting shields that are adjacent one another in the longitudinal direction of the supporting pipe are oriented at an angle to the rotation axis of the supporting pipe, with the bearings of the spool carriers in one of the supporting shields being disposed at a relatively great distance from the supporting pipe and with the bearings of the spool carriers in the other supporting shield being disposed at a relatively small distance from the supporting pipe. The resulting oblique position of the spool carriers reduces the diameter of the rotation circle of the rotor without adversely influencing the free rotatability of the spool carriers relative to the rotor (since spools of a given size can be located closer to the supporting pipe without bumping into it as the spool carriers rotate, particularly for spools that are long in comparison with their diameters, if the spool carriers are positioned obliquely rather than parallel to the supporting pipe), so that the centrifugal forces acting on the rotor are reduced and thus the operating conditions are improved at high rotor rpm.
Another special advantage of such a cage-type stranding machine resulting from the reduced rotation circle diameter is that the machine can be set up at any desired location in the production sequence. While the prior art systems necessitated placement in a ditch of about 70 cm due to their large diameter, this requirement is eliminated by the invention because of the reduction of the rotation circle diameter. Advisably, the ends of the spool carriers facing the stranding point are mounted at a small distance from the supporting pipe. Thus, the filaments to be stranded and coming from the spools can be guided to the stranding point through respective openings in the supporting shields in the immediate vicinity of the supporting pipe. The filaments can be brought past the subsequent spool carrier without problems.
A further feature of the invention is that, with respect to each plane of rotation, a supporting shield is disposed between two adjacent longitudinal webs; the individual supporting shields are oriented at an angle to the supporting pipe axis; and the edges of the supporting shields on the side of the supporting pipe extend along a circumferential path and the outer edges of the supporting shields extend along another circumferential path. This arrangement has the advantage that the spool carrier bearings provided on the supporting shields, and elements of the drives required for rotation of the spool carriers relative to the rotor, are all oriented perpendicularly to the plane of the supporting shields, thus simplifying manufacture. Moreover, the sloping position of each individual supporting shield associated with a spool carrier permits a further, although slight, reduction of the diameter.
Another advantageous feature of the invention is that, in the region of at least one spool carrier, a measuring sensor is provided for picking up the centrifugal force generated by the spool of the spool carrier in question. This sensor communicates with a system for controlling the rpm of the stranding machine and of the removal system for the stranded filaments. With the aid of this feature, it is possible to run the machine at a lower number of revolutions at the beginning of a stranding job, when the spools are relatively full, and then, with decreasing coil diameter on the spools, to increase the rpm of the rotor. The centrifugal force acting on the spool bodies is a measure of the reduction of the coil diameter and constitutes a parameter according to which the rpm of the rotor and the removal velocity can be regulated. In this connection, it is sufficient to measure the centrifugal force at only one spool since, in principle, all spools receive the same amount of stranded filament, if possible. However, it is advisable to employ that spool which has the greatest starting weight in the spool carrier at the measuring location. In this way it is possible to always operate the stranding machine in the optimum rpm range. The stranding machine is initially started up at a starting rpm determined by a predetermined centrifugal force. Then the rpm increases progressively until the permissible maximum rpm is reached, which may be maintained until the end of the stranding job so that, as a whole, a considerable increase in production results with improved quality of the product. Wire brakes are practically eliminated. The centrifugal force measurement can be made without any moving parts if a so-called electrical pressure pickup is incorporated as the measuring sensor in the bearing of one of the spool carriers. The measured signal can be transmitted either by way of a slip ring or without contact by way of a transmitter. Depending on the type of drive employed for the stranding machine and the removal or wind-up devices, the measurement and change of rotor rpm and removal speed can be effected continuously or can be adjusted at given time intervals.
A further advantage of the invention is that the machine does not require any additional selector circuits with which it would have to be set up for different materials to be stranded. Thus, the stranding machine can be loaded, without any switching measures whatsoever, first with filaments of a heavy material such as copper, and thereafter with filaments of a lighter material such as aluminum. This is insignificant for the control process since the use of a predetermined centrifugal force as the guiding parameter automatically produces the appropriate rotor rpm. Due to the constant centrifugal stresses, the machine (along with the spools and spool bearings) will be stressed much less as a whole, so that much less wear occurs. Moreover, since the machine moves at a slower rpm at the beginning of the stranding job, smaller drive motors can also be used. Consequently, the brakes for the stranding basket may also have smaller dimensions. An advisable feature of the invention is that the measuring sensor is provided at a spool carrier bearing which is located at a relatively great distance from the supporting pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view schematically illustrating a stranding machine in accordance with the present invention.
FIG. 2 is a sectional view along line II--II of FIG. 1.
FIG. 3 schematically shows the complete stranding unit with a removal device for the stranded material.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the illustrated embodiment, the ends of a rotor 1 are rotatably mounted in bearing blocks 2 and 3. Bearing block 2 includes a transmission mechanism (not illustrated) which communicates with a drive motor 4. Although not shown, bearing block 3 has apertures for passage of filaments 20. On the side of bearing block 3 facing away from rotor 1, there is a stranding point 5 where the filaments to be stranded are twisted into a cable.
Rotor 1 includes a supporting pipe 6 and four longitudinally extending, radially outwardly oriented webs 7, which are distributed at 90° intervals over the circumference of the pipe 6. The end of rotor 1 facing bearing block 2 is provided with a gear head 8 which includes transmission mechanisms (not illustrated) required for cage-type stranding machines employing reverse movement. A planetary gear arrangement such as that disclosed in U.S. Pat. No. 4,574,574 (which is incorporated herein by reference) may be employed. The individual spool carriers 9 and their spools 10 are driven by the transmission mechanisms of gear head 8 in such a manner that, during rotation of pipe 6, the axes of rotation of spools 10 remain in a parallel orientation relative to one another and to the floor 11 of the building.
Supporting shields 12 are disposed between longitudinal webs 7. The supporting shields 12 are oriented at an oblique angle to the axis of supporting pipe 6 and are fixed to longitudinal webs 7. The supporting shields 12 may be flat plates, as shown, or frustoconical members.
In the illustrated embodiment, only the spool carriers 9 and their spools 10 at the top and bottom are shown. The spool carriers facing the observer are omitted for the sake of easier illustration, and one of the webs 7 is partially broken away as indicated at 21. As can be seen in FIG. 1, spool carriers 9 and their axes of rotation 13 are oriented at an angle relative to the axis of the supporting pipe 6, with the axes of rotation -3 of the spool carriers 9 being oriented perpendicular to supporting shields 12.
The driving energy for spool carriers 9 is received from gear head 8 via cardan shafts 14 (which include simple universal joints). The driving energy is transferred, by way of chain or toothed-belt drives 15, here shown only schematically, from each supporting shield 12 to the next following spool carrier 9.
In the illustrated embodiment, four spool carriers 9 are arranged in one rotational plane, so that a total of twelve spool carriers 9 are provided on the rotor 1. Although not shown, the filament 20 taken from each spool 10 is guided inward toward the periphery of pipe 6 and is there diverted by a roller and guided parallel to supporting pipe 6 through an aperture in bearing block 3 to stranding point 5.
As indicated schematically in FIG. 2, a measuring sensor 16, for example in the form of a so-called pressure pickup, is arranged in the bearing of a spool carrier 9 and senses centrifugal force from the spool carrier 9 and its spool 10 that act on the bearing if rotor 1 rotates. As in the above-noted related application (now U.S. Pat. No. 4,903,473), a strain gauge which supports the bearing outwardly, in the radial direction, may be used to sense the centrifugal force. The measurement signal is conveyed by means not illustrated (including, for example, a slip ring transmitter in the region of bearing block 2) to an electronic evaluation system 17 which is, in turn, connected to a motor control circuit 18 for regulating the revolutions of drive motor 4. The evaluation system 17 is set to a fixed desired value for the centrifugal force and the rpm of the drive motor 4 is varied, on the basis of the deviation between the actual value measured by the measuring sensor 16 and the predetermined desired value, so as to reduce the deviation to zero and thereby maintain the centrifugal force at the desired value. Since the weight of a spool 10 decreases the longer a stranding job has lasted, the rpm of drive motor 4 must be increased to keep the centrifugal force at the desired value. The lay of the stranded filaments 20 forming the cable should remain practically constant over the entire length of the cable, so it is necessary to increase the rate at which the filaments 20 are pulled through the system by increasing the rpm of the drive motor (not illustrated) for the removal system (not illustrated). The linkage to the drive motor for the removal system is provided by an output signal from evaluation system 17, as indicated by the arrow 19. Such an arrangement makes it possible, after an initially low rpm of about 120 rpm at the beginning of the stranding job and a removal rate of about 68 m/min, to constantly increase the rpm of the machine so that finally a maximum speed of about 180 rpm (permissible for the machine in question) is realized. As a whole, this results in an average removal velocity for the finished cable of about 85 m/min, and a maximum removal velocity of about 100 m/min.
While a stranding machine according to the invention and employing the described regulation is subjected to a centrifugal force of only 65% of the allowed maximum centrifugal force, operation without the described rotation (that is, with an essentially constant rotor rpm) would require the absorption of the allowed maximum centrifugal force that is 100% for the same production output. This comparison of numbers alone shows that, with the described regulating process, the driving power to be installed and the construction costs for all bearings and for the cage brake (not shown) can be reduced considerably.
As shown in FIG. 3 the output signal (arrow 19) of the evaluation system 17 is connected to a motor control circuit 22 for regulating the revolutions of drive motor 23 of a removal device 24, by which the stranded material is wound up with an increasing speed, depended to the increasing speed of production of the stranding machine.
It will be understood that the above description of the present invention is susceptible to various modifications, changes, and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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A cage-type stranding machine includes a rotatably mounted supporting pipe (6) and radially outwardly oriented longitudinal webs (7) attached to the supporting pipe and distributed uniformly around its circumference, resulting in greater stiffness which permits higher rpm. Spool carriers (9) are rotatably supported by supporting shields (12), which are attached to the longitudinal webs. The supporting shields and the rotation axes (13) of the spool carriers are arranged at an angle to the supporting pipe to reduce the rotation circle diameter, which again permits an increased rpm in operation so that the production output can be increased.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to food applicators and more particularly pertains to a new portable, hand held condiment dispenser for dispensing a condiment onto an item of food.
2. Description of the Prior Art
The use of food applicators is known in the prior art. More specifically, food applicators heretofore devised and utilized are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements.
Known prior art food applicators include U.S. Pat. No. 5,328,509. Additionally, U.S. Pat. No. 5,213,431; U.S. Pat. No. 5,051017; U.S. Pat. No. Des. 346,112; U.S. Pat. No. 4,021,125 and U.S. Pat. No. 4,030,844 teach roll-on dispensers for dispensing personal care products, such as deodorant. However, these references only dispense personal care products, and therefore do not include releasable dispensing heads or refillable containers.
While these devices fulfill their respective, particular objectives and requirements, the aforementioned patents do not disclose a condiment dispenser. The inventive device includes a container holding a condiment, a valve controlling the flow of condiment from the container, and a releasably attached dispensing head, permitting use of different types of dispensing heads. The container includes a removable filling cap permitting the container to be refilled with a condiment. Alternatively, the container can be a pliant tube which can be squeezed in order to discharge the condiment from the container.
In these respects, the condiment dispenser according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of dispensing condiments onto items of food.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of food applicators now present in the prior art, the present invention provides a condiment dispenser construction wherein the same can be utilized for dispensing condiments onto items of food.
The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new condiment dispenser apparatus and method which has many of the advantages of the food applicators mentioned heretofore and many novel features that result in a new condiment dispenser which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art food applicators, either alone or in any combination thereof.
To attain this, the present invention generally comprises a container holding a condiment, a valve controlling the flow of condiment from the container, and a releasably attached dispensing head, permitting use of different types of dispensing heads. The container includes a removable filling cap permitting the container to be refilled with a condiment. Alternatively, the container can be a pliant tube which can be squeezed in order to discharge the condiment from the container.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
It is therefore an object of the present invention to provide a condiment dispenser apparatus and method which has many of the advantages of the food applicators mentioned heretofore and many novel features that result in a condiment dispenser which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art food applicators, either alone or in any combination thereof.
It is another object of the present invention to provide a condiment dispenser which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a condiment dispenser which is of a durable and reliable construction.
An even further object of the present invention is to provide a condiment dispenser which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such condiment dispenser economically available to the buying public.
Still yet another object of the present invention is to provide a condiment dispenser which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a condiment dispenser for dispensing condiments onto items of food.
Yet another object of the present invention is to provide a condiment dispenser which includes a container holding a condiment, a valve controlling the flow of condiment from the container, and a releasably attached dispensing head, permitting use of different types of dispensing heads. The container includes a removable filling cap permitting the container to be refilled with a condiment. Alternatively, the container can be a pliant tube which can be squeezed in order to discharge the condiment from the container.
Still yet another object of the present invention is to provide a condiment dispenser that comes in kit form for use on a wide range of food applications.
Even still another object of the present invention is to provide a condiment dispenser that is easy to use and reduces mess.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a perspective view of a condiment dispenser according to the present invention.
FIG. 2 is a view taken along line 2--2 of FIG. 1.
FIG. 3 is a cross sectional view taken along line 3--3 of FIG. 2.
FIG. 4 is a partial cross sectional view of the dispenser showing the valve in a closed position.
FIG. 5 is a view of an alternate embodiment of a dispensing head.
FIG. 6 is a view showing another embodiment of a dispensing head.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 through 6 thereof, a condiment dispenser embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, it will be noted that the condiment dispenser 10 comprises a container 20 with a valve mechanism 30 and a dispensing head 40 releasably connected to the container. The term condiment, as used throughout, is meant to include, but is not limited to, ketchup, mustard, mayonnaise, jams, jellies, and the like.
As best illustrated in FIGS. 1 through 6, it can be shown that the container 20 is a generally cylindrical, hollow rigid tube having a first, filling end 21, and a second, dispensing end 22. The end 21 includes an exterior thread 23 which mates with an interior thread 25 of a filling cap 24, in order to releasably secure the filling cap 24 to the container. The container contains a condiment, which can be refilled by removing the cap 24 as the need arises. The main portion of the container 20 forms a gripping portion which permits a user to grasp and hold the container in his hand.
Alternatively, the container 20 could be made of a pliant, closed tube (similar to a tube of toothpaste) which can be squeezed in order to dispense the condiment from the container. The pliant container would be prefilled with a condiment and would be disposed of when the condiment is used up.
The dispensing end 22 of the container includes an end wall 26 with an outlet aperture 27. The aperture 27 permits the condiment to flow from the container. A flange 28 having an exterior thread 29 extends from the wall 26, for mating engagement with the dispensing head 40.
In order to control flow through the aperture 27, a valve 30 is provided. The valve 30 includes a valve plate 31 which selectively covers/uncovers the aperture, a stem 32 connected to the plate and extending through the container wall, and a control knob 33 connected to the stem. By grasping the knob 33 and pushing in, or pulling out, the stem 32, the plate 31 is moved to cover/uncover the aperture and thus control the flow of condiment.
The dispensing head 40 includes a base plate 41 with a flange 42 extending therefrom. The flange 42 includes an interior thread 43 which mates with the exterior thread 29 for releasably attaching the head 40 to the container. A space 44 is thus defined between the base plate 41 and the end wall 26. A plurality of apertures 45 are formed through the base plate 41, permitting the flow of the condiment from the aperture 27 and the space 44. Compliant bristles 46 are attached to the base plate 41 and extend therefrom. The dispensing head 40 thus resembles a brush head, where the condiment is disposed on the food item by brushing the bristles across the food item.
With the container held in the position shown in FIG. 1, gravity causes the condiment in the container to flow through the aperture 27 with the valve opened. The condiment then goes into the space 44 and out through the apertures 45. The condiment then flows onto the bristles 46 for disposition onto the food item.
Instead of the brush head 40, different dispensing heads can be used instead. For instance, FIG. 5 shows a spray head 50 which is attached to the container 20 using a threaded flange 51. A pump mechanism 52 is disposed inside of the spray head for pumping the condiment from the container. A suction tube 53 is in communication with the inlet of the pump 52 and has a sufficient length such that it would extend through the aperture 27 and into the inside of the container 20. Outlet tube 54 leads from the pump outlet to a spray nozzle 55. The pump is actuated by a trigger 56 which is pulled and released to cause reciprocation of an actuation shaft 57 in a manner well known in the art. The condiment is thus sprayed out the nozzle 55 by pulling the trigger 56.
FIG. 6 shows another embodiment of a dispensing head 60. Again, the head 60 is attached to the container by a threaded flange 61. The head 60 includes a roller ball 62 which is rotationally supported within the head in a manner well known in the art. The ball 62 is in communication with the condiment, such that when the ball is rolled on a food item, the condiment is spread onto the item of food. The head 60 can also include an exterior thread 63 for mating with threads on a cap 64.
Thus it should be realized that the dispensing heads 40,50,60 are all interchangeably used on the container for providing different means for dispensing a condiment onto a food item. It should also be recognized that condiment container(s) and the different dispensing heads could be sold together in a kit form. Therefore the user has a choice of dispensing heads and condiment containers to use. The container(s) could either come prepackaged with a condiment or the user would fill with his favorite condiment, and the container(s) could either be refillable or disposable.
In use, a particular dispensing head is chosen and attached to the container. The brush head and roll-on head utilize gravity to cause the condiment to flow from the container, or if the container is squeezable, the squeezing action causes the flow. The spray head uses a pump to pump the condiment onto the food item, whether the container is rigid or pliant.
As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A portable, hand held condiment dispenser for dispensing condiments onto items of food includes a container for holding a condiment, a valve controlling the flow of condiment from the container, and a releasably attached dispensing head, permitting use of different types of dispensing heads. The container includes a removable filling cap permitting the container to be refilled with a condiment. Alternatively, the container can be a pliant tube which can be squeezed in order to discharge the condiment from the container.
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RELATED APPLICATIONS OR PATENTS
This is a continuation-in-part of application Ser. No. 726,491, filed Jul. 8, 1991, now U.S. Pat. No. 5,131,790.
BACKGROUND OF THE INVENTION
This invention relates to a method of installing a structural support piling in a subsoil setting passing through a zone of contamination. This piling, or group of pilings, can be used to support an at or above ground structure without adversely affecting or impacting the environment.
One conventional method of achieving support for a structure over non-contaminated ground would include the installation of a concrete spread footing of sufficient dimensions and strength, in the cured state, to support the structure at or above ground level. Another conventional method would include pile driving a metal or wood piling down to a dense underground layer structure. In the situation where below ground contamination has been determined to exist, usually by soil analyses of materials taken from different depths into the subsoil, and particularly where an aquifer could be involved, a concrete spread footing could settle and preclude or interfere with the excavation or other type of penetration of a contaminated zone below the footing at a future date. Settling of a concrete spread footing could also cause tilting problems for structures that have to be rigidly held in place. The conventional pile driving method is not advisable because of the possibility of forcing contaminants toward an aquifer.
SUMMARY OF THE INVENTION
The invention contemplates a method of installing an outer-cased piling, in an earth formation, to support a structure at or above ground level over a zone or zones of underground contamination, particularly where an aquifer is situated at some level below the contamination, without adversely impacting the environment or promoting contamination migration; and the resulting outer-cased piling. This method overcomes the potential problem of forcing or displacing contaminants towards an aquifer as may occur in either installing a concrete spread footing or in driving a pile utilizing conventional techniques. This method also overcomes the potential problem of the structure tilting caused by settling of a concrete spread footing.
In this invention the underground formation, whether soil or rock or a combination, is sampled to determine the location and types of any contamination using conventional coring techniques. Geological measurements are also taken to locate the depth of any water tables in the zone. A borehole or shaft is then sunk to a level such that the bottom of the borehole is below the level of contamination, and in proximal contact to the first relatively impervious clay layer below the zone of contamination. A metal casing is then installed in the borehole and the annular space formed between the outer casing and the wall of the borehole is filled by pumping a cementitious material down the inside of the casing and then upwardly through the annular space. Without this outer casing and the cementitious seal, seepage of contaminants into the borehole, from the contaminated zone, would occur with a layer of contamination collecting at the lowest end of the borehole. This contamination might then, undesirably, be forced downward through a dense underground layer or migrate to water levels during a subsequent pile driving step.
In my prior copending application, it was indicated that the metal pile form should be driven to a point above and not penetrating a dense layer containing the aquifier. It has now been surprisingly and unexpectedly found that driving the pile into the dense layer does not provide any additional risk of contamination and provides more support than when the pile is stopped at or above the dense layer. This point is generally called the point of refusal because the pile does not proceed further into the supporting stratum in spite of further pile driving efforts.
In accordance with the present invention, a piling, typically made from sturdy wood, metal, or metal pipe, is placed inside the cemented-in casing and driven down towards a point of refusal above or in any drinking water aquifer. The piling is then cemented in place within the casing. In the case where the piling is a metal pipe, it is filled with a concrete mixture designed to have a high breaking strength in the cured state. Preferably anchors or hairpins or other attachment means are affixed to the top of the pile form and encased in a concrete pad to assist in anchoring the structure to be cast or otherwise placed on the piling.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view, mostly schematic, which illustrates a metal casing placed in an excavated cavity.
FIG. 2 is a view in vertical section, mostly schematic, which illustrates the cementitious material as a hydraulic seal, the water-filled casing during the cementing step, and the cap, and the tube used during cementing.
FIG. 3 is a view in vertical section, mostly in schematic, which illustrates the annular space between a borehole in an existing earth formation and a metal casing filled with pressure grout as cementitious material.
FIG. 4 is a view in vertical section, mostly in schematic, which illustrates a metal pile form extending through the casing to a point of refusal in a dense sand layer.
FIG. 5 is a view in vertical section, mostly schematic, to illustrate the cementitious material between the inside of the metal casing and the outside of the metal pile form. This schematic also shows the location of anchors and the pile form.
FIG. 6 is a schematic of the pile top cap in elevation along with the valving used during cementing-in of the casing.
FIG. 7 is a fragmentary view in section of anchor loops at the top of the pile form as used to anchor a structure in the form of concrete a slab cast across the top of the pile form and enveloping the, partly broken away and mainly schematic, hairpins protruding therefrom.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As indicated above, this invention relates to a method for installing an outer-cased structural support piling in a subsoil setting passing through a zone of contamination and the apparatus resulting from operation of the method. The following description illustrates the manner in which the principles of the present invention are applied, but the invention is not to be construed, in any sense, as limiting the scope of the invention precisely to the structure shown in the drawings.
In the case where it is desired to build a structure at or above ground level, it is common practice to conduct geologic and hydrogeologic tests of the ground in the vicinity of the proposed construction. This typically entails core boring, analysis of soil removed for contaminants, such as organic chemicals, chlorides and heavy metals, location of water tables, and types of soil or rock layers such as pervious and impervious layers. These data, along with other considerations, such as the weight of the structure to be supported, are used in determining the type of support system for the application according to calculations or estimates well understood in the art. These types of support systems can range from a concrete spread footing to a friction pile to a deep pile with pilings driven downward to an identified dense layer. After the analyses of the geologic area are completed, if contamination is determined to be present, then decisions are made with regard to the environment and the structure as to the best method for supporting the proposed structure.
Referring to the drawings, particularly FIG. 1, in the case of the instant invention using an outer-cased piling to support an at or above ground structure in an area of subsoil contamination, a borehole or shaft is excavated to a depth below the zone of contamination 4 and preferably in proximal contact to form a substantially cylindrical cavity 1 surrounded by a substantially cylindrical wall 3 of soil or rock and a closed bottom 5. A cylindrical metal casing 7, having open upper end 7A and open lower end 7B, an inside surface 7C and an outside surface 8, with the upper end 7A being capable of being sealed by an attachable cap assembly 25, seen in fragmentary enlarged view in FIG. 6, is then placed in the borehole 1 and past the contaminated zone 4. The diameter of the metal casing 7 is smaller than that of the borehole 1 so as to leave an annular space 9 between the casing 7 and the borehole wall 3. The cap assembly 25, as more particularly shown in FIG. 6, is attached to the upper end 7A of the casing 7 as shown in FIG. 2 and a length of tubing 24, having a block and bleed valve assembly 28, is connected to a source 29 of pumpable cementitious material 11, and is inserted through the cap assembly 25. The cap assembly 25 is conveniently assembled by welding or otherwise affixing, preferably with a threaded coupling 26 onto the casing 7 and attaching a threaded cap 27 containing an aperture for sealing passage therethrough of a length of tubing 24. The tubing 24 has connected thereto adjacent to cap 27 a block and bleed valve assembly 28 to facilitate the pumping of cementitious material. After putting together the casing cap assembly 25, an amount of pumpable cementitious material 11 is pumped into the bottom of the borehole 1 to a depth sufficient to form an hydraulic seal at the lower end 7B of the casing 7.
Referring to FIG. 2, while the cementitious material 11 such as a slurry mixture of cement and clay, is still fluid at the bottom of the hole 1, water is added to fill the casing 7 from the topmost portion of the hydraulic seal to at least a level in the upper end 7A of the casing 7. Additional cementitious material 11 is then pumped into the casing 7 through the cap assembly 25 while the assembly is attached resulting in forcing cementitious material up the annular space 9 with water filling the casing and the tubing 24 extending to the hydraulic seal and this is continued until cementitious material exits the top of the annular space 9 formed by the borehole wall 3 and the outside surface 8 of the casing 7. The sealed annular space 9 is shown in FIGS. 3 and 4 filled with cementitious material 11. Any contamination that may have seeped into the borehole 1 during the drilling or the casing installation steps is forced out through the annular space 9 at this time.
After allowing the cementitious material 11 to cure to a hardened state to support the casing 7 in a generally upright position, the cap 27 of the cap assembly 25 is removed and a substantially cylindrical metal pile form 13, with a diameter smaller than that of the metal casing 7, and having a closed bottom end or pile base cap 15, as shown in FIGS. 4 and 5, is inserted into the casing 7 and driven beyond the bore of the lower end 7B of the casing 7 in substantial axial alignment with the longitudinal axis of the casing 7. As shown in FIG. 4, the metal pile form 13 is driven to a point of refusal in the subsoil sufficient to provide support for a structure at or above ground level and forming a second or inner annular space 17 as shown in FIG. 5, between the outer wall of the metal pile form 13 and the inner wall 7C of the casing 7. The metal pile form 13 is then filled with a pumpable structurally supporting cementitious material 18 having a cured breaking strength of at least 1000 psi. The pile bottom closure 15 in this embodiment serves a dual purpose. In the first instance it prevents soil or other drilling debris from entering the inside of the metal pile form 13 while it is being driven and in the second instance it prevents the concrete mixture being poured into the metal pile form 13 from escaping at the base of the metal pile form 13.
Referring to FIG. 5, the second annular space 17 between the metal pile form 13 and the inside surface 7C of the casing 7 is then filled with a pumpable cementitious material 12, which can be the same as or different from the pumpable cementitious material 11 in annular space 9, and is allowed to cure to a hardened state. In order to anchor the structure to the support apparatus 23 as in FIG. 7 one or more anchor loops 19 can be installed in the uncured cementitious material at the top of the support apparatus 23. The one or more anchor loops 19 can then be encased in a concrete cap 35 as shown in FIG. 7.
The metal pile form 13 used in this invention is a metal pipe and preferably is a carbon steel pipe. The cementitious material 18 used to fill the pile form in this invention is preferably concrete and more preferably concrete with a minimum breaking strength of at least 1000 psi after curing for 28 days. To achieve this value typically requires a 5 1/2 bag mix. Another aspect of this invention relates to the cementitious materials, 11 and 12 respectively, used to fill the annular spaces between a) the borehole wall 3 and the outside surface 8 of the casing 7, and b) the inside wall 7C of the casing 7 and the outside of the metal pile form 13. Preferably, this cementitious material is grout and more preferably is pressure grout.
Referring now to FIG. 5, another embodiment of this invention takes the form of an apparatus, preferably a support apparatus 23, for a structure to be supported at or above ground level on or over an earth formation having underground environmental contaminants in a zone at a predetermined depth. This support apparatus 23 includes a metal casing 7 having an upper end, a lower end, and inner and outer surfaces. The metal casing 7 is of sufficient length to have its upper end at or above ground level and its lower end below the predetermined lowest level of contamination and ending adjacent to a point of refusal below the zone of contamination. The casing has an outer substantially cylindrical wall 8 and is installed in an excavated cavity 1 in the ground in a generally upright position. Installed between the casing 7 and the borehole wall 3 is a hardened cementitious material 11 that is in intimate contact with both. A hollow metal pile form 13, having an upper end and a lower end and an upper portion and a lower portion and a bottom pile base cap or closure 15, is substantially housed within the casing 7 and extends downwardly beyond the casing into an underground dense layer stratum 21. The upper end 14 of the metal pile form 13 extends to approximately the same level as the upper end 7A of the casing 7. The metal pile form 13 fully contains a cured structurally supporting cementitious material 18, having a cured breaking strength of at least 1000 psi. The second annular space 17 between the outside surface of the metal pile form 13 and the inside surface 7C of the casing 7 fully contains a hardened cementitious material 12.
As a further aspect of the support apparatus 23 of this invention the metal pile form 13 used in the apparatus is ordinarily a metal pipe and preferably is a carbon steel pipe. Also, the cured concrete material used to fill the pile form has preferably a minimum breaking strength of 1000 psi. As another aspect of the invention the cementitious materials 11 and 12 are grout and are preferably pressure grout. The apparatus of the invention having at least one anchor loop 19 at the top of the support apparatus 23 to anchor the supported structure is yet another embodiment of the invention.
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The invention is a method of installing an outer-cased piling through a zone of subsoil contamination which includes boring a hole to a predetermined depth below the contamination, placing a smaller diameter casing in the full length of the hole, pumping a cementitious material between the outer casing wall and the soil, installing the piling through the casing and down to a point of refusal below the contaminated zone, filling the piling form with cement and then filling the void between the piling and casing with a cementitious material.
The outer-cased piling design allows the piling installation through zones of contamination without adversely impacting the environment or spreading the contamination to other subsurface layers.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a Continuation of International Applications PCT/DE03/00553 and PCT/DE03/00555 both with an international filing date of Feb. 21, 2003, which were both published under PCT Article 21(2) in German, and the disclosures of which are incorporated into this application by reference.
FIELD OF AND BACKGROUND OF THE INVENTION
[0002] The present invention is related to a local network, particularly an Ethernet network, having redundancy properties and a coupling device for such a network.
[0003] A local Ethernet network with redundancy properties is known from WO 99/46908. In the network described therein, coupling devices and a redundancy manager, each having at least two ports and being configured as layer 2 components, are interconnected in a ring-shaped topology by connecting two ports of adjacent devices. The term “layer 2 components” means that at least the layers 1 and 2 of the ISO OSI 7-layer model are implemented in the devices. The devices thus perform an address evaluation and message routing. In normal operation, i.e., if no errors have occurred in the network, the redundancy manager opens the ring. This means that messages received by the redundancy manager at its one port located in the ring are not forwarded via its other port located in the ring, but are blocked. This status is symbolized by an open switch. Thus, logically, the network has a linear topology in which the two line ends of the network are connected to a redundancy manager, which in the error-free case separates the two line ends from one another. In the event of an error, i.e., if an interruption occurs at some point in the network outside the redundancy manager, the redundancy manager connects the two line ends to again form a linear topology.
[0004] Physically, however, this is a ring-shaped network topology in which the devices form a ring by connecting two ports of adjacent devices. The redundancy manager ensures that at any given time the ring is interrupted only at a single location. To check whether there is already an interruption of the ring outside the redundancy manager, i.e., to check whether the network is operating error free, the redundancy manager sends test messages into the ring at defined time intervals via the two ports with which it is connected to the ring, and it opens the ring to form a linear topology with respect to the transmission logic if the test messages are received at its other port within an additional predefined time interval. Otherwise, i.e., if at least one test message has been received at the other port within the additional time interval, the redundancy manager closes the connection, such that the network has again a logically linear topology consisting of a continuous line. With respect to further embodiments and advantages of such a local network and a redundancy manager, reference is made to the above-cited publication WO 99/46908.
[0005] Networks in which messages are distributed from node to node and in which the response to the failure of a communication link between two nodes is to add a redundant communication path, have the risk that messages are copied or circulate within the network. Such errors can be triggered when a redundant communication path is mistakenly added. Thus, as a result of a malfunction of the conventional redundancy manager, the two line ends could inadvertently be connected and a logically ring-shaped network topology could be created. As a result, messages can circulate within the ring. In the worst case, the maximum bandwidth of the network available for the data traffic is occupied, such that further payload traffic among the users connected to the network can no longer be transmitted. When such an error occurs, the network is not available, or at least not fully available, for the connected users.
SUMMARY OF THE INVENTION
[0006] One object of the invention is to provide a local network, particularly an Ethernet network having redundancy properties, which is distinguished by an increased availability of the network for the transmission of payload data of the connected users. A further object is to provide a coupling device to attain this object in a network.
[0007] To attain these objects, in accordance with a first exemplary embodiment a local network, preferably an Ethernet network with redundancy properties, is proposed that includes at least two coupling devices and a redundancy manager, each of which has at least two ports and wherein the coupling devices and the redundancy manager are configured as layer 2 components with respect to the ISO OSI 7-layer model and are interconnected in a ring by a connection of two ports of respective adjacent devices. Additionally the redundancy manager is configured to send initial test messages into the ring at predefined intervals via two of the at least two ports of the redundancy manager with which it is connected to the ring and if the initial test messages sent by each one of the two ports are received by the other one of the two ports of the redundancy manager within a predefined time interval, to open the ring to create a linear topology and otherwise to close the connection. Further, in accordance with the present embodiment, the redundancy manager is configured to indicate a corresponding ring opened or connection closed status in the initial test messages and at least one of the other coupling devices adjacent to the redundancy manager in the ring is configured as a redundancy manager observer to evaluate messages that it receives at one of its ports which is connected to the redundancy manager and to open the ring to create a linear topology if more than only the initial test messages have been received at the one port and the redundancy manager has indicated the ring opened status in the immediately preceding received initial test message.
[0008] According to a further exemplary embodiment, a local network, preferably an Ethernet network with redundancy properties, is provided that includes at least two coupling devices and a redundancy manager, each of which has at least two ports and wherein the coupling devices and the redundancy manager are configured as layer 2 components with respect to the ISO OSI 7-layer model and are interconnected in a ring by a connection of two ports of respective adjacent devices. Additionally, the redundancy manager is configured to send initial test messages into the ring at predefined intervals via two of the at least two ports of the redundancy manager with which it is connected to the ring and if the initial test messages sent by each one of the two ports are received by the other one of the two ports of the redundancy manager within a predefined time interval, to open the ring to create a linear topology and otherwise to close the connection.
[0009] Also, in accordance with the present exemplary embodiment, at least one of the coupling devices is configured as a redundancy manager observer to send second test messages into the ring at predefined time intervals via two of its at least two ports by which it is connected to the ring in order to monitor the redundancy manager and to open the ring to create a linear topology if the second test messages are received at the other of the two respective ports within a predefined time interval and otherwise to close the connection between the ports.
[0010] The present invention is further defined by a coupling device consistent with the coupling devices included in the above-described two exemplary embodiments.
[0011] The invention has the advantage that the monitoring for the correct functioning of the redundancy manager is independent of the redundancy manager. Thus, errors within the redundancy manager cannot interfere with the monitoring or make it impossible. Any accidental closing of the network connection by the redundancy manager is quickly detected by the so-called redundancy manager observer by means of its own test messages, which the redundancy manager observer sends out and evaluates. Any errors that occur are corrected by opening the ring without relatively long delays. This increases the availability of the local network. In addition, any errors during startup, e.g., an incorrect configuration of the redundancy manager, are detected.
[0012] A signaling of such an error by the redundancy manager observer has the advantage that suitable error correction measures can be taken, e.g., the redundancy manager can be repaired or replaced. In addition, any errors during startup, e.g., an incorrect configuration of the redundancy manager, are detected.
[0013] The monitoring principle has the advantage of managing without additional test messages that burden the network. In the initial test messages, the redundancy manager indicates the corresponding status, “ring opened” or “connection closed”, and a coupling device, which is adjacent to the redundancy manager in the ring, opens the ring if more than only initial test messages are received at the port to which the redundancy manager is connected and the redundancy manager has indicated the status “ring opened” in the last receipt of the initial test messages.
[0014] This monitoring principle can advantageously be supplemented by the monitoring of the redundancy manager by the redundancy manager observer using its own second test messages to further reduce the failure probability of the network.
[0015] In the normal case, i.e., in error-free operation, the redundancy manager observer transparently forwards initial test messages of the redundancy manager and takes second test messages, which the redundancy manager observer has fed into the ring, off the ring when it receives them, i.e., it does not forward them. Correspondingly, the redundancy manager transparently forwards second test messages if the redundancy manager has closed the connection. The redundancy manager blocks second test massages, however, i.e., it does not forward them, if the redundancy manager has opened the ring. Configuring the second test messages differently from the initial test messages has the advantage that these functions of the redundancy manager and the redundancy manager observer can be correspondingly executed immediately after the respective message type has been detected. This eliminates the need for a complex matching of the instants of transmission of the initial and the second, test messages between the redundancy manager and the redundancy manager observer and a distinction based on the time position of the test messages, which could be an alternative to the distinction by message types based on the messages themselves.
[0016] Advantageously, the failure probability is further reduced if all the coupling devices interconnected in the ring-shaped topology are configured as redundancy manager observers. This also ensures a monitoring of the functioning of a redundancy manager observer by the other redundancy manager observers. For this purpose, the redundancy manager observers can use a protocol among each other to determine the valid network topology. In the simplest case, however, an exchange of synchronization messages among the redundancy manager observers is sufficient.
[0017] A further monitoring principle, which moreover has the advantage of managing without additional test messages that burden the network, is that the redundancy manager indicates the corresponding status “ring opened” or “connection closed” in the initial test messages and that a coupling device, which is adjacent to the redundancy manager in the ring, opens the ring if more than only initial test messages are received at the port to which the redundancy manager is connected and the redundancy manager has indicated the status “ring opened” in the last received of the initial test messages. This monitoring principle advantageously supplements the monitoring of the redundancy manager by the redundancy manager observer with its own second test messages and thus further reduces the failure probability of the network.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention and its embodiments and advantages will now be explained in greater detail with reference to the drawing, which depicts an exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] In a network, four coupling devices K 1 , K 2 , K 3 and RM are interconnected, and the coupling device RM is operated as a redundancy manager. The coupling devices each have four ports, P 11 -P 14 , P 21 -P 24 , P 31 -P 34 and P 41 -P 44 , respectively, to which connecting lines for the reception and transmission of messages can be connected. The coupling devices K 1 to K 3 and RM are configured as layer 2 components, i.e., they route messages in accordance with an internally stored address table. They are interconnected into a ring-shaped topology such that two ports of adjacent devices are connected. For this purpose, the ports P 12 and P 21 are interconnected by fibers F 12 and F 21 of a glass fiber cable. Copper cable can of course be used as an alternative. The fiber F 12 serves to transmit messages from port P 12 of the coupling device K 1 to the port P 21 of the coupling device K 2 . In the opposite direction, messages are transmitted from the port P 21 of the coupling device K 2 to the port P 12 of the coupling device K 1 via the fiber F 21 . Accordingly, so-called full duplex transmission is possible, in which messages can be simultaneously transmitted in both directions. Correspondingly, the ports P 22 and P 31 are interconnected by fibers F 23 and F 32 , the ports P 32 and P 41 by fibers F 34 and F 43 and the ports P 42 and P 1 by fibers F 41 and F 14 . A user TN 1 is connected to the port P 13 of the coupling device K 1 , a user TN 2 to the port P 23 of the coupling device K 2 , a user TN 3 to the port P 24 of the coupling device K 2 , a user TN 4 to the port P 34 of the coupling device K 3 and a user TN 5 to the port P 44 of the coupling device RM. These users can be, for example, automation devices, control and monitoring stations, servers, printers, other network segments, etc.
[0020] Logically, during error-free operation, the network is a local network with a linear topology, since the ring is interrupted at the coupling device RM, which is operated as the redundancy manager. This interruption is indicated by a switch S 4 . Corresponding switches S 1 , S 2 and S 3 in the coupling devices K 1 , K 2 and K 3 are closed. A closed switch S 1 of the coupling device K 1 , for example, means that the messages to be switched through by the coupling device K 1 in the line are transparently switched from the receive port, e.g., the port P 11 , to the send port, e.g., the port P 12 . The same is true in the opposite direction.
[0021] In the event of an error, i.e., if the depicted line is interrupted, the redundancy manager connects the two line ends together, i.e., it forwards the messages received at the port P 41 via the port P 42 and, vice versa, if they must be switched through and are not addressed to the user TN 5 . This corresponds to a switch S 4 in closed position. To monitor the line for possible interruptions, the redundancy manager RM sends initial test messages T 11 and T 12 into the ring at first predefined intervals via the two ports P 41 and P 42 with which it is connected to the ring. If these initial messages T 11 and T 12 are received at the other port P 42 or P 41 within a second predefined time interval, the line is not interrupted and the ring is opened to create or—depending on the previous status—maintain a linear topology, i.e., the switch S 4 is, or remains, opened.
[0022] If the initial test messages T 11 or T 12 are not received at the other port P 42 or P 41 within the second time interval, an error is present and the line is interrupted. The error is thus detected and the switch S 4 is closed, such that a functioning line is restored and communication continues to be ensured. When defining the first and second time intervals, the maximum circulation time of messages within the network and the maximum allowable reconfiguration time must be taken into account. If the time intervals are suitably selected this reconfiguration of the network is comparatively fast, which ensures that the connected users do not dismantle any logic communication connections, that communication continues without interruptions and that any automation solution realized by means of the network remains unaffected.
[0023] If the redundancy manager RM closed the switch S 4 due to an internal error without an interruption having occurred in the rest of the ring, then circulating messages could be created in the ring. This would be the case, for example, if the software of the redundancy manager RM incorrectly switched messages through because of a software or logic error even though there was no interruption in the rest of the ring. Such errors could affect the availability of the network. To prevent this, the coupling device K 3 , for example, is operated as a so-called redundancy manager observer. All the coupling devices in the embodiment shown, including the coupling devices K 1 and K 2 could be operated analogously. However, the description with reference to the coupling device K 3 is sufficient to explain the invention.
[0024] To monitor the redundancy manager RM, the coupling device K 3 also sends second test messages T 21 and T 22 at defined third intervals into the ring via the ports P 31 and P 32 . If the two test messages T 21 and T 22 do not reach the other port P 32 or P 31 of the coupling device K 3 within a fourth defined time interval, then there is an interruption in the remaining part of the ring. The switch S 3 remains closed. If the redundancy manager RM incorrectly closes the ring, the second test messages T 21 and T 22 reach the port P 32 or P 31 . As a result, a short circuit of the ring would be detected. In this case the coupling device K 3 opens the switch S 3 to again form a logically linear network topology overall. The third and fourth time interval can be determined analogously to the selection of the first and the second time interval. After a short reconfiguration time the network is again ready for operation.
[0025] As described above, the coupling devices K 1 and K 2 can analogously perform the above-described function of a redundancy manager. This has the advantage that any errors of the coupling device K 3 are also detected. The coupling device K 3 signals a detected error of the redundancy manager RM by a light emitting diode LED. In response, suitable error correction measures can be introduced. Another means to signal an error is, for example, to send an error message to a central network management station.
[0026] The described monitoring of the redundancy manager by a redundancy manager observer also makes it possible to detect errors where the software of the redundancy manager RM detects an error-free operation of the rest of the ring but the hardware of the redundancy manager RM is not behaving properly and incorrectly closes the switch S 4 . If there are no clear indicators for such errors in the redundancy manager RM itself, the redundancy manager cannot detect the error. Such an error is difficult to avoid completely because even a single bit-error in the complex hardware circuit of the redundancy manager RM, which the switch S 4 represents here in simplified form, could already lead to such an error. Such errors can be quickly detected using the following type of monitoring.
[0027] It is assumed here that the redundancy manager RM indicates the corresponding status in the test messages T 11 and T 12 , for example, “ring opened” or “connection closed.” The coupling device K 3 , which is configured as a redundancy manager observer, evaluates the messages received at its port P 32 , which connects it directly to the redundancy manager RM. A malfunction of the redundancy manager RM is present if the status “ring opened” is indicated in the test messages T 11 and other messages besides the test messages T 11 are received at the port P 32 . If those two conditions are met, the coupling device K 3 opens its switch S 3 and signals an error of the redundancy manager RM with its light emitting diode LED. When one of the two conditions is no longer met, the coupling device K 3 closes its switch S 3 again. This makes it possible to check the function of the redundancy manager RM without burdening the network with additional test messages of a redundancy manager observer. In addition, a rapid detection of such errors and a rapid network reconfiguration are achieved.
[0028] The redundancy manager observer (coupling device K 3 ) checks the decision of the redundancy manager RM to close the ring by sending two messages T 21 and T 22 . When the redundancy manager observer has received the information from the redundancy manager RM that the latter has closed the ring, but the redundancy manager observer itself receives the second test messages it has sent from its one ring port, e.g., the port P 31 , at its other ring port, here the port P 32 , then the redundancy manager observer assumes that the redundancy manager has incorrectly closed the switch S 4 . In response, the redundancy manager observer (coupling device K 3 ) opens the ring with its switch S 3 and signals the malfunction of the redundancy manager.
[0029] The above description of the exemplary embodiment has been given by way of example. From the disclosure given, those skilled in the art will not only understand the present invention and its attendant advantages, but will also find apparent various changes and modifications to the structures disclosed. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the invention, as defined by the appended claims, and equivalents thereof.
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A local network, particularly an Ethernet network having redundancy properties, in which coupling devices (K 1 , K 2 , K 3 ) and a redundancy manager (RM) are interconnected in a ring-shaped topology. The redundancy manager opens the ring to create a linear topology if test messages (T 11 , T 12 ) emitted by the redundancy manager (RM) are received at the other port (P 42 , P 41 ) within a given period of time, otherwise the redundancy manager (RM) closes the connection. As a so-called redundancy manager observer, at least one of the coupling devices (K 3 ) is configured such that it evaluates messages received at the port (P 32 ) thereof, the port (P 32 ) being connected to the redundancy manager, opens the ring to create a linear topology, and signals an error if more than initial test messages (T 11 ) have been received at this port (P 32 ) and if the status “ring opened” has been indicated by the redundancy manager (RM) in the last-received initial test message (T 11 ), whereby messages are prevented from circulating on the ring.
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FIELD OF INVENTION
[0001] The present invention relates to testing interconnectors. In particular, the present invention relates to a testing probe with an integrated spring member centrally held in a template in an individually replaceable fashion.
BACKGROUND OF INVENTION
[0002] With the advancement of micro fabrication techniques, probes for testing electronic circuitry may be increasingly mass fabricated at ever decreasing scale and increasing complexity. In an exemplary multilayer deposition process, a large number of microstructures are simultaneously grown on a substrate by the use of multiple masks and sacrificial fill structures to generate multistep structures substantially free of shape constraints. In the field of probe apparatus fabrication, this multilayer deposition process is used at the time of this invention, to fabricate the probes of a probe apparatus simultaneously on the substrate with a spacing that corresponds to the operational pitch of the finally assembled probes. Unfortunately, probe apparatus are highly individualized devices with many differing pitches of the assembled probes, which have to comply with the particularities of the tested circuitry and/or tested devices. To the contrary, the multilayer deposition process is very cost intensive due to the large number of deposition processes that need to be individually prepared and require also a large number of expensive masks. Therefore, there exists a need for probe designs and probe assembly techniques that utilize the free shaping capabilities of multilayer deposition processes without limitation of the affiliated fabrication spacing constraint. The present invention addresses this need.
SUMMARY
[0003] A probe for test connecting an apparatus contact of a probe apparatus with a test contact of a tested electronic device along a contacting axis has a top structure, a bottom structure a spring member and a guide. The guide may be an outer guide face of the spring member. The guide may also be part of the bottom or top structure in the form of a circumferential recess or a snap finger.
[0004] The snap finger may be arranged with respect to the contacting axis and extend substantially parallel to the contacting axis. The snap fingers may have snap hooks for snapping in at a rigid assembly hole of a rigid carrier structure for a releasable positioning together with other probes in a rigid carrier structure. The probe may be guided via its circumferential recess in a carrier structure in the configuration of a flexible membrane snapped on a rigid support frame. A flexible membrane and rigid carrier structure may be employed together.
[0005] The probes are assembled with their carrier structure(s) together with a space transformer that provides the apparatus contacts adjacent the top structure. The space transformer is in a plate spacing to the top of the top carrier structure that is larger than the top structure height such that the carrier structure may be assembled together with a number of probes and the space transformer substantially without deflection of the carrier structure and such that the top structures of the probes are brought into contact with the apparatus contacts during operational contact of the bottom structures with the test contacts.
[0006] The probes may be simultaneously fabricated in large numbers by micro fabrication techniques with a fixed fabrication pitch and assembled in a probe apparatus with a probe pitch independently of the fabrication pitch.
BRIEF DESCRIPTION OF THE FIGURES
[0007] FIG. 1 is a first perspective view of a partial probe apparatus according to a first embodiment of the invention.
[0008] FIG. 2 is a frontal cut view of the partial probe apparatus of FIG. 1 .
[0009] FIG. 3 is a first perspective view of a partial probe apparatus according to a second embodiment of the invention.
[0010] FIG. 4 is a frontal cut view of the partial probe apparatus of FIG. 3 .
[0011] FIG. 5 is a first perspective view of a probe assembly according to a third embodiment of the invention.
[0012] FIG. 6 is a frontal cut view of the probe assembly of FIG. 5 .
[0013] FIG. 7 is a detailed frontal cut view of a single assembled probe of the second embodiment.
[0014] FIGS. 8-10 are partial second perspective views of various exemplary configurations of the bottom structure of the probe of the three embodiments.
[0015] FIG. 11 is a second perspective view of the probe of the third embodiment.
[0016] FIG. 12 is a third perspective view of a probe according to a fourth embodiment.
[0017] FIG. 13 is the third perspective view of the probe of FIG. 12 assembled in a correspondingly shaped assembly hole of a rigid carrier structure.
DETAILED DESCRIPTION
[0018] As in FIGS. 1, 2 , a probe apparatus 1 according to a first embodiment may include a probe assembly having a number of probes 4 assembled with a probe pitch PPX and PPY in corresponding assembly holes 31 of a rigid carrier structure 3 preferably made of ceramic. The probe 4 has a top structure 43 for conductively operation contacting along a contacting axis CA a corresponding apparatus contact 22 of a circuit board 2 , a bottom structure 41 for conductively test contacting a well known test contact and a spring member 42 interposed in between the top structure 43 and the bottom structure 41 . The carrier structure 3 is substantially planar and extends preferably perpendicular with respect to the contacting axes CA. The contacting axes CA are preferably parallel to each other.
[0019] The spring member 42 conductively connects the structures 41 and 43 . The spring member 42 has an outer guide face 421 with which the probe 4 is guided within a corresponding guide hole 31 . The top structure 43 has a diameter 43 D that is larger than assembly hole diameter 31 D such that the top structure 43 is sandwiched between the carrier structure top 33 and the apparatus contacts 22 . Alignment features 21 of the circuit board 2 snugly fit in alignment holes 32 of the rigid carrier structure 3 for a precise positioning of the probe assembly within the probe apparatus 1 .
[0020] A top structure height 43 H is smaller than a plate spacing 1 H between the apparatus contacts 22 and the carrier structure top 33 such that the carrier structure 3 may be assembled together with a number of probes 4 and the circuit board 2 substantially without deflection of the carrier structure 3 and such that the top structures 43 are brought into contact with the apparatus contacts 22 during operational contact of the bottom structures 41 with the test contacts.
[0021] Operational contact is established when a test contact is forced against the bottom structure 41 forcing the probe 4 along its contacting axis CA towards a respective apparatus contact 22 until contact is established between top structure 43 and assembly contact 22 .
[0022] The spring member 22 may be a coil spring or any other spring structure fitting in close proximity around the contacting axis CA and providing an outer guiding face 421 suitable for slidably interacting with the rigid assembly hole 31 as may be well appreciated by anyone skilled in the art. Two or more coil springs may be interweaved around the contacting axis CA.
[0023] In the first embodiment, the probes 4 are prevented from falling out of the fully assembled probe apparatus 1 irrespective of the probe apparatus' 1 orientation. To provide additionally simplified handling of the probe assembly alone without risk of inadvertent falling out of individual probes 4 , second and third embodiments may be alternately utilized where probes 4 , 4 F are held in assembly position within the probe assembly alone. This may be advantageous for eventual maintenance work during which both the probes 4 , 4 F need to be accessed from top and bottom.
[0024] As in FIGS. 3, 4 , 7 , a probe apparatus 1 features probes 4 of a second embodiment that have a number of snap fingers 44 acting as guides between the probe 4 and the rigid assembly hole 31 and also provide guidance for the spring member 42 . The snap fingers 44 have snap hooks 441 at their free end for releasable snapping in the rigid carrier structure 3 . The snap fingers 44 may be concentrically arrayed with respect to the contacting axis CA having inner and outer guide faces 44 I, 44 O substantially concentric to their respective other. The outer guide faces 44 O and/or the inner guide faces 44 I may be cylindrical. An outer guide face diameter 44 OD may be slightly smaller than the assembly hole diameter 31 D and a finger length 44 H may be larger than the carrier structure thickness 3 H together with the difference of top structure height 43 H and plate spacing 1 H such that operational contacting may be established before contacting of the snap hooks 441 with the carrier structure bottom 34 . An inner guide face diameter 44 ID is sufficiently larger than a spring guide face diameter 42 OD such that the spring member 42 may freely deflect inside the snap fingers 44 .
[0025] The snap fingers 44 may be combined with the top structure 43 as shown in FIGS. 3, 4 , 7 or with the bottom structure 41 , in which case the finger length 41 is larger than the rigid carrier structure thickness 3 H together with the operational deflection range DR. Deflection range DR is the maximum deflection of the assembled probe 4 during operation of the probe apparatus 1 .
[0026] As in FIGS. 5, 6 , 11 , a probe assembly of a third embodiment includes alternately or combined flexible bottom membrane 51 and/or flexible top membrane 52 that guide with their respective bottom and top membrane assembly holes 511 , 521 the probes 4 F via respective first and second circumferential recesses 433 and 413 . In case both membranes 51 , 52 are employed together, full guidance of the probes 4 F along their contacting axes CA is provided by the flexibility of the membrane. The membranes 51 , 52 may be combined with a peripheral snap frame 53 and snapped on a rigid snap shoulder 35 of a rigid support frame 3 S. The membranes 51 , 52 may be made of well known Polyimide. The rigid support frame 3 S may be configured similar to the rigid carrier structure 3 . In case of both employed membranes 51 , 52 the rigid support frame 3 S may feature an assembly cavity 36 surrounding the probes 4 F.
[0027] In case of a single membrane 51 or 52 , the rigid support frame 3 S may also feature assembly holes 31 . Probes 4 F may be guided additionally within the probe assembly either by spring guide faces 421 or outer snap finger guide faces 44 O as described under first and second embodiments. Bottom membrane 52 is particularly advantageous for sealing the remainder of the probe apparatus 1 against eventual debris from the operational contacting of the bottom structures 41 with the test contacts.
[0028] As in FIGS. 8-10 , probes 4 , 4 F may feature numerous contacting features 411 such as a pointed tip 411 A, a wedge 411 B or a cross wedge 411 C. The contacting features 411 may be placed on the bottom structure 41 symmetrically with respect to the contacting axis CA. The pointed tip 411 A may be employed alone or in a number circumferentially arrayed with respect to the contacting axis CA.
[0029] As in FIGS. 12 and 13 , a probe 4 G of a fourth embodiment may be fabricated as a continuous profile with a profile height DH. In the first, second and third embodiment, the probes 4 , 4 F may be fabricated by layered fabrication processes in direction parallel to the contacting axis CA. In the fourth embodiment to the contrary, the probe 4 G may be fabricated by a layered fabrication process in a direction perpendicular to the contacting axis CA. In that fashion, only a single fabrication layer may be employed for fabricating a complete probe 4 G.
[0030] In the fourth embodiment, the spring member 42 B is configured as a buckling beam preferably with a buckling orientation substantially in plane with the two snap fingers 44 F. The buckling beam 42 B has a buckling beam height 42 BH preferably equal the profile height DH and slightly smaller than a hole width 31 H of a rectangular rigid assembly hole 31 R such that the buckling beam 42 B is supporting itself against the assembly hole 31 R in a direction perpendicular to the buckling orientation. In addition, the buckling beam 42 B may be configured for supporting itself in buckling orientation against at least one inner snap finger guide face 44 FI along at least one support interface 422 shaped for a snug contact with said snap finger guide face 44 FI during at least a portion of the probe's 4 G operational deflection range DR. The rectangular assembly hole 31 R has a hole length 31 W that corresponds to the distance 44 OW between the outer snap finger guide faces 44 FO. The bottom structure 41 is guided by the inner snap finger guide faces 44 FI.
[0031] The dimensions of all snap hooks 441 are selected in conjunction with other affiliated dimensions of assembly holes 31 , 31 R and probes 4 , 4 G for a maximum deflection of the snap fingers 44 , 44 F during insertion into the assembly hole 31 , 31 R unimpeded by adjacent probe structures or members as may be well appreciated by anyone skilled in the art. The probes 4 , 4 F may also be permanently combined with the apparatus contacts 22 by well known reflow techniques. The probes 4 , 4 F may be monolithically fabricated or may be made of materials suitable to accomplish their particular task. Nickel Cobalt plated with Gold is an example of suitable metal combination.
[0032] Accordingly, the scope of the invention described in the specification above is set forth by the following claims and their legal equivalent:
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A probe for test connecting an apparatus contact of a probe apparatus with a test contact of a tested electronic device along a contacting axis has a top structure, a bottom structure a spring member and a guide. The guide may be an outer guide face of the spring member or be part of the bottom or top structure in the form of a circumferential recess or a snap finger. The probe may be guided either slidably in a rigid carrier structure and/or via its circumferential recess in one or two flexible membranes snapped on a rigid support frame. The probes may be simultaneously fabricated in large numbers by micro fabrication techniques with a fixed fabrication pitch and assembled in a probe apparatus with a probe pitch independently of the fabrication pitch.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is directed to a method of cleaning semiconductor devices and, more particularly, to a method of cleaning damaged layers and polymer residue on semiconductor devices.
[0003] 2. Description of the Related Art
[0004] As the design rule of semiconductor device gets smaller, the contact region between layers decreases. Due to the small sizes involved, it is difficult to use conventional methods to form a contact region. Accordingly, a manufacturing process that self-aligns the contact pad with a semiconductor layer or an interconnect layer underlying the contact pad is employed for sub-quarter micron semiconductor devices. The resulting self-aligned contact (SAC) has the advantages of allowing increased margin for misalignment error during photolithography, and reducing contact resistance. In the case of forming the SAC, an etch technique having high selectivity is necessary.
[0005] However, it is difficult to remove the damage layer and polymer residue resulting from high-selectivity etch. Accordingly, a cleaning technique is required to remove the damage layer and polymer residue. A conventional cleaning solution contains APM (NH 4 OH/H 2 O 2 /H2O) or SPM (H 2 SO 4 /H 2 O 2 mixture).
[0006] Metal layers are often used in order to increase the speed of semiconductor devices. However, conventional cleaning solutions such, as the foregoing solution, damage metal layers. Therefore, cleaning solutions with EKC (NH 4 OH/C 6 H 4 (OH) 2 /Aminoethoxyethanol) or SMF ( NH 4 OH/CH 3 COOH/H 2 O/HF) are used. However, EKC and SMF solutions do not remove the damage layer and polymer residue resulting from etch processes;
[0007] therefore, contact resistance increases and failures of semiconductor devices occur. Accordingly, there is a need for a method for removing the damaged layer and polymer residue without damaging the metal layer of a semiconductor device.
SUMMARY OF THE INVENTION
[0008] In accordance with one aspect of the present invention, there is provided a method of cleaning a semiconductor device which includes the steps of: mixing HF and ozone water in a vessel to form a solution of HF and ozone water; and dipping a semiconductor device in the vessel containing the solution of HF and ozone water, wherein the solution contains about 0.034 to about 0.077 wt % HF.
[0009] In a more specific embodiment, the ozone water contains about 5 to about 150 ppm ozone. In another more specific embodiment, the semiconductor device is dipped for about 1 to about 30 minutes.
[0010] Preferably, damaged layers and polymer residue are removed from the semiconductor device by the inventive method.
[0011] In accordance with another aspect of the present invention, there is provided a method of cleaning a semiconductor device including the steps of: mixing HF and ozone water in a vessel to form a solution of HF and ozone water; dipping a semiconductor device in the vessel containing the solution of HF and ozone water, and thereafter introducing ozone water into the vessel to replace the solution of HF and ozone water in the vessel, wherein the solution includes about 0.034 to about 0.077 wt % HF.
[0012] In more specific embodiments, ozone water is flowed into the vessel thereby causing an overflow of the solution of HF and ozone water out of the vessel. According to specific embodiments, the ozone water is flowed into the vessel thereby causing the overflow of the solution of HF and ozone water out of the vessel for a period between about 1 and about 30 minutes.
[0013] In accordance with a further aspect of the present invention, there is provided a method of cleaning a semiconductor device including the steps of: introducing HF and ozone water into a vessel to form a solution of HF and ozone water; mixing the HF and ozone water in the vessel to form a uniform solution of HF and ozone water; and dipping a semiconductor device in the vessel containing the uniform solution of HF and ozone water.
[0014] In more particular embodiments, the HF and ozone water are mixed to form a uniform solution by circulation, more specifically by means of a pump.
[0015] In specific embodiments, the HF and ozone water are circulated by flowing the HF and ozone water from an inner bath to an outer bath and pumped back into the inner bath.
[0016] In accordance with still another aspect of the present invention, there is provided a method of cleaning a semiconductor device including the steps of: introducing HF and ozone water into a vessel to form a solution of HF and ozone water; mixing the HF and ozone water in the vessel to form a uniform solution of HF and ozone water; dipping a semiconductor device in the vessel containing the uniform solution of HF and ozone water; and introducing ozone water into the vessel to replace the solution of HF and ozone water in the vessel.
[0017] Other features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description. It is to be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not limitation. Many changes and modifications within the scope of the present invention may be made without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above features and advantages of the present invention will become more apparent by describing in detail specific embodiments thereof with reference to the attached drawings in which:
[0019] [0019]FIGS. 1A and 1B illustrate a cleaning method according to the present invention employing an exemplary apparatus as illustrated;
[0020] [0020]FIG. 2 is a graph showing the resistance of the contact region and breakdown voltage between the contact region and the conductive layer adjacent to the contact region as shown in FIGS. 5 and 6;
[0021] [0021]FIGS. 3 and 4 are X-ray photospectroscopy (XPS) analysis graphs comparing cleaning methods according to the invention with prior art methods; and
[0022] [0022]FIGS. 5 and 6 illustrate examples of semiconductor processes in which embodiments of cleaning methods according to the present invention are applied.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The priority Korean Patent Application No. 00-xxxxx, filed xxxxx, 2000, is hereby incorporated in its entirety by reference.
[0024] After forming a contact hole, polymer residue and damage layers resulting from etch process, which are a kind of abnormal oxide, remain. In order to remove the polymer residue and damage layers, the present invention use a cleaning solution with a mixture of ozone water and hydrofluoric acid (HF). Ozone water is effective in removing organic material such as polymers. Also, ozone water does not give rise to environment concerns. HF is effective in removing damage layers and polymer residue.
[0025] Ozone decomposes to generate active radicals, which work as strong oxidizers. The decomposition mechanism is as follows:
O 3 +OH − →O 2 − +HO 2 * (1)
O 3 +HO 2 *→2O 2 +OH* (2)
O 3 +OH*→O 2 +HO 2 * (3)
2H 2 O*→O 3 +H 2 O (4)
HO 2 *+OH*→O 2 +H 2 O (5)
[0026] The active radicals react with the organic material on the surface of the semiconductor substrate to break C—H, C—C, and C═O bonds. Thus, organic material is easily removed and the surface is oxidized.
[0027] The reaction mechanism of ozone (O 3 ) is as follows:
O 3 +organic material (e.g. polymer)→CO 2 +H 2 O (1)
O 3 +M(surface)→MOx+O 2 (2)
[0028] The present invention provides a cleaning process using the cleaning solution with ozone water and HF as follows (referring to FIGS. 1 A-B): first, inner bath 31 is supplied with ozone water and HF through supply lines 33 , 34 , respectively. Next, ozone water and HF are mixed by circulation. The circulation preferably is carried out by flowing the cleaning solution in the inner bath 31 into an outer bath 32 and then again flowing cleaning solution from outer bath 32 into the inner bath 31 through supply line 36 using a working pump connected to the outer bath 32 . Then, a semiconductor device is dipped into the bath.
[0029] It is desirable to overflow the ozone water after the last step (3) in FIG. 1B. Ozone water is overflowed by supplying it through the supply line 33 . Overflowing ozone water rinses the cleaning solution off and makes the surface of the semiconductor device hydrophilic to prevent contamination on the surface of the semiconductor.
[0030] In step 1 in FIG. 1B, it is effective that the concentration of the ozone water is between about 22 and about 27 ppm.
[0031] [0031]FIG. 2 shows the resistance of the contact region and the breakdown voltage between the contact region and conductive layer adjacent to the contact region as shown in FIGS. 5 and 6, according to the concentration of HF after cleaning by using HF and ozone water solution (the concentration of O 3 in ozone water being about 20 ppm). Line D shows that as the concentration of HF increases, the resistance of the contact region decreases. The resistance below line B (line B indicating 40 kohm ) doesn't lead to failure of the device. To meet this condition, the concentration of HF preferably should be more than about 0.034 wt %.
[0032] Line C shows that the breakdown voltage between the contact region and the conductive layer adjacent to the contact region decreases as the concentration of HF increases. The decrease in the breakdown voltage means an increase in the leakage current between the contact region and the conductive layer. The breakdown voltage above line A ( line A indicating 18V) doesn't lead to failure of the device. To meet this condition, the concentration of HF preferably should be less than about 0.077 wt %.
[0033] Accordingly, the effective concentration of HF preferably is about 0.034 to about 0.077 wt % in order to decrease the resistance of the contact region without decreasing the breakdown voltage between the contact region and conductive layer.
[0034] In step 2 in FIG. 1B, it is important to mix the ozone water and HF without dropping the concentration of O 3 . After supplying the ozone water and HF into the inner bath, the ozone water and HF from the inner bath to the outer bath is circulated before dipping wafers into the bath. Without the circulation, the uniformity of etch rate is about 0.3%. With circulation, the uniformity of the etch rate is about 0.1 to about 0.15%. Referring to table 1, it is desirable that the circulation proceed for about 30 to about 60 secs after supplying the ozone water and HF.
TABLE 1 Circulation 0 30 60 120 time(sec.) Drop of O 3 1.3 ppm 2.2 ppm 4.7 ppm concentration Etch About 0.3% 0.1˜0.15% 0.1˜0.15% 0.1˜0.15% uniformity
[0035] [0035]FIGS. 3 and 4 present X-ray Photospectroscopy (XPS) analysis graphs. The graph line 61 shows the result of no cleaning after forming a contact region. Graph line 62 shows the result of cleaning with EKC. Graph line 63 shows the result of cleaning with SMF. Graph line 64 shows the result of cleaning with ozone water and HF using a method of the present invention.
[0036] As seen in FIG. 3, when the present invention is applied to cleaning the contact region, the SiO x peak decreased. SiO x is considered a contaminant. As seen in FIG. 4, when the present invention is applied to cleaning the contact region, the Si—C peak decreases.
[0037] [0037]FIGS. 5 and 6 show examples of semiconductor processes in which methods according to the present invention is applied. FIG. 5 shows a Self Aligned Contact (SAC) structure, which is formed as follows. A gate insulator (not shown) is first formed on a semiconductor substrate 81 . Next, a gate electrode 82 is formed on the gate insulator. A first dielectric layer 83 is then formed on the gate electrode 82 and the surface of the semiconductor substrate 81 . A second dielectric layer 84 is formed on the first dielectric layer 83 , wherein the second dielectric layer 84 has a high etch selectivity compared to first dielectric layer 83 . Then, a contact hole 85 is formed by etching the second and first dielectric layers.
[0038] The second dielectric layer 84 preferably has a high etch selectivity compared to the first dielectric layer 83 so that the gate electrode is not exposed during the etch. For example, a nitride layer can be used as the first dielectric layer 83 , and an oxide layer can be used as the second dielectric layer 84 .
[0039] After forming the contact hole by using a cleaning method according to the present invention, the damage layer and the polymer residue resulting from the etch process are removed.
[0040] [0040]FIG. 6 shows a contact hole, wherein the contact hole connects a storage electrode to a contact pad. The contact hole is formed between bit lines. Thus, a dielectric layer 91 is provided in which a conductive layer 92 (i.e., a storage electrode) is formed. A bit line 93 is next formed, followed by formation of a first dielectric layer 94 and a second dielectric layer 95 . Contact hole 96 is then formed by etching the first and second dielectric layers 94 and 95 . After forming the contact hole 96 as shown FIG. 6, by using a cleaning method of the present invention, the damage layer and the polymer residue resulting from the etch process are removed.
[0041] While this invention has been particularly shown and described with reference to specific embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made to the described embodiments without departing from the spirit and scope of the invention as defined by the appended claims.
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A method of cleaning damaged layers and polymer residue on semiconductor devices includes mixing HF and ozone water in a vessel to form a solution of HF and ozone water, and dipping a semiconductor device in the vessel containing the solution of HF and ozone water. Preferably, ozone water is subsequently introduced into the vessel to replace the solution of HF and ozone water in the vessel.
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FIELD OF THE INVENTION
[0001] This invention relates to well servicing and more particularly to a method for the auxiliary use of ultrasonic energy in the case of differential sticking of pipe to reduce the contact area of a filtercake prior to applying freeing force.
BACKGROUND OF THE INVENTION
[0002] During the drilling of oil and gas wells, drilling fluid is circulated through the interior of the drill string and then back up to the surface through the annulus between the drill string and the wall of the borehole. The drilling fluid serves various purposes including lubricating the drill bit and pipe, carrying cuttings from the bottom of the well borehole to the rig surface, and imposing a hydrostatic head on the formation being drilled to prevent the escape of oil, gas, or water into the well borehole during drilling operations.
[0003] There are numerous possible causes for the drill string to become stuck during drilling. Differential sticking, one of the causes for stuck pipe incidents, usually occurs when drilling permeable formations where borehole pressures are greater than formation pressures. Under those conditions, when the drill pipe remains at rest against the wall of the borehole for enough time, mud filter cake builds up around the pipe. The pressure exerted by drilling fluid will then hold the pipe against the cake wall.
[0004] Some warning signs that put one on notice of the possibility of differential sticking are the presence of prognosed low pressure along with depleted sands; long, unstabilized bottom-hole assembly (hereafter BHA) sections in a deviated hole; loss of fluid loss control and increased sand content; and increasing overpull, slack off or torque to start string movement.
[0005] Indications of the actual presence of differential sticking include a period of no string movement; the string cannot be rotated or moved, but circulation is unrestricted.
[0006] Methods of freeing differentially stuck drill string include applying torque and jar down with maximum torque load; using a spot pipe releasing pill if jarring is unsuccessful; and lowering mud weight, which may have implications with respect to hole stability. The overpull required to release the pipe may exceed rig capacity, and even cause collapse of the rig. It would be very beneficial if a method were available to reduce the required freeing force so that the existing rig would be adequate for overpull without possibly causing collapse.
[0007] Application of wave energy in the oil industry is known, however the most common application of ultrasonic energy is cleaning of electronic microchips in the semiconductor industry and daily household cleaning of jewelry.
[0008] In addition to the use of acoustic and ultrasonic methods for core measurements in the laboratory, logging, and seismic applications in the field, acoustic energy has been shown by Tutuncu and Sharma to reduce the lift-off pressure of mud filter cakes by a factor of five. See Tutuncu A. N. and Sharma M. M., 1994, “Mechanisms of Colloidal Detachment in a Sonic Field”, 1st AIChE International Particle Technology Forum, Paper No 63e, 24-29.
[0009] Other uses of ultrasonic energy include supplying the energy through downhole tools into hydrocarbons to facilitate the extraction of the oil from the well by reducing the viscosity of the oil. See, for example, U.S. Pat. Nos. 5,109,922 and 5,344,532. U.S. Pat. No. 5,727,628 discloses the use of ultrasonic to clean water wells.
[0010] Freeing pipe using vibrational energy has also been tried in recent years. U.S. Pat. No. 4,913,234 discloses a system for providing vibrational energy to effect the freeing of a section of well pipe which comprises: a) an orbital oscillator including a housing; b) an elongated screw shaped stator mounted in said housing and an elongated screw shaped rotor mounted for precessionally rolling rotation freely in said stator; c) means for suspending said oscillator for rotation within said drill pipe about the longitudinal axis of the drill pipe in close proximity to the stuck portion thereof; and d) drive means for rotatably driving said rotor to effect orbital lateral sonic vibration of said housing such that said housing precesses laterally around the inner wall of said pipe, thereby generating lateral quadrature vibrational forces in said pipe to effect the freeing thereof from said well bore.
[0011] U.S. Pat. No. 5,234,056 discloses a method for freeing a drill string which comprises a) resiliently suspending a mechanical oscillator from a support structure on an elastomeric support having a linear constant spring rate; b) coupling said oscillator to the top end of the drill string, the elastomeric support creating a low impedance condition for vibratory energy at said drill string top end; c) driving said oscillator to generate high level sonic vibratory energy in a longitudinal vibration mode so as to effect high longitudinal vibratory displacement of the top end of the drill string; and d) the drill string acting as an acoustic lever which translates the high vibrational displacement at the top end of the drill string into a high vibrational force at the point where the drill string is stuck in the bore hole, thereby facilitating the freeing of the drill string.
[0012] Often when a drill pipe is differentially stuck the result is that it has to be cut and the target zone cannot be reached by the optimal route. It would be extremely desirable in the art if a method were available which provided a means of reducing the amount of force required for freeing a stuck drill pipe. Such a method could potentially save enormous amounts of time and money in drilling operations.
[0013] In the present invention, it has been discovered that the auxiliary use of ultrasonic energy can help reduce the pipe contact area, thus reducing the required freeing force and often permitting the existing rig to be sufficient for use in the overpull. The present invention will save rig time and prevent sidetracking of the well, a high cost operation especially in offshore deepwater environments.
SUMMARY
[0014] In accordance with the foregoing the present invention provides a method for reducing the amount of force necessary to free a stuck drill pipe which comprises an auxiliary method which provides a reduction in the amount of force required to free said pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a diagram of one possible position of a differentially stuck drill pipe.
[0016] [0016]FIG. 2 is a schematic diagram of the hollow cylinder filtration cell used in the experimental work.
[0017] [0017]FIG. 3 is a graph showing the reduction in pull out (freeing) force as a function of sonification time for an aloxite hollow cylinder sample damaged by drill-in fluid, where the filter cake was built at an elevated pressure and room temperature.
[0018] [0018]FIG. 4 is a graph showing the reduction in pull out (freeing) force as a function of sonification time for a Berea sandstone hollow cylinder sample.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The present invention describes a method of freeing stuck drill pipe, particularly in the case of differential sticking, by the auxiliary use of ultrasonic energy to reduce the amount of freeing force necessary.
[0020] [0020]FIG. 1 is a diagram representing one example of the position of a differentially stuck drill pipe. The drill string, 4 , becomes embedded in filter cake, 3 , opposite the permeable zone, 2 , at high differential mud pressure overbalance, leading to stuck pipe in the contact zone. Under dynamic circulating conditions, the filter cake is eroded both by hydraulic flow and by the mechanical action of the drill string. When the well is left static with no pipe rotation, a static filter cake may build up, which increases the overall cake thickness. The string may now become embedded in the thick filter cake, particularly when the wellbore, 1 , is at high deviation and/or the BHA is not properly stabilized. The static filter cake seals the wellbore pressure (at overbalance) from the backside of the pipe. An area of low pressure develops behind the backside of the string/BHA and starts to equilibrate to the lower formation pressure. A differential pressure starts to build up across the pipe/BHA. With time the area of pipe sealed in the filter cake increases. The overbalance pressure times the contact area provides a drag force that may prevent the pipe from being pulled free. The build-up of the drag force is very rapid from the start and will increase with time.
[0021] Typical actions used to free the string include applying torque and jarring down with maximum torque load. Circulation is usually not restricted in the case of differential sticking. Therefore, spotting fluids can be circulated across the zone causing the stuck pipe. Spotting fluids contain additives that can dehydrate and crack filter cakes and additives that can lubricate the drill string. Cracking the filter cake will help to transmit the mud pressure to the backside of the string and remove the differential pressure across the string, resulting in minimization of friction. The sticking force then is reduced by an equivalent amount as shown in Equation 1.
F s =μAΔP (1)
[0022] where μ is the friction coefficient, A is contact area and ΔP is overbalance. In order to free the pipe the freeing force needs to be equal to or greater than F s . However sometimes it is not possible to generate enough force due to drill string and/or rig limitations, in which case the drill string must be cut, thus causing great financial loss and making it impossible to reach the target zone by the preferred route. Lowering mud weight may be helpful in some cases, but may compromise hole stability.
[0023] Design of the drill string is a major consideration. The strength of drill pipe limits the maximum allowable weight and hence the ability to exert overpull. Even if the drill pipe is designed strong enough, the overpull required to release the pipe may exceed rig capacity. It is possible, particularly with small rigs in land operations, for rigs to collapse due to forces applied exceeding the maximum overpull. Downhole jars also allow high impact force to be exerted at the stuck point with relatively low overpull and setdown. However, sometimes the forces exerted are not enough to release the stuck pipe. Jar itself may become stuck as well. In the present invention decrease of contact area of the stuck pipe reduces the amount of overpull required for application. Since A is reduced, sticking force is also reduced (see Equation 1) Hence, the existing difficulties in the release of stuck pipe are minimized.
[0024] In the present invention an ultrasonic source is enclosed in a housing of a pipe that permits disposition in the drill string. The ultrasonic source is a high-power sweeping acoustic transducer that operates at either a fixed frequency of approximately 20 KHz, or the frequency can be varied between several Hz and 40 KHz. The tool is made up of a variable number of cylindrical ceramic transducers, which transmit the acoustic energy radially. The transmitter itself is a piece of solid steel to which a piezoelectric driver(s) are attached. The acoustic tool is connected via a normal logging cable to a high power amplifier. The power amplification is related to the ratio of the cross-sectional areas of the tool.
[0025] To demonstrate the invention, dynamic filtration experiments were conducted with fully brine-saturated Berea sandstone and aloxite hollow cylinder cores with known pore size distribution. FIG. 2 is a schematic drawing of the dynamic hollow cylinder filtration cell used in the experiments. Hollow core tests represent realistic borehole geometry. The cell is designed and built to handle core samples of 4-inch outside diameter (OD) with 8.3-inch length. Variable internal diameters (ID) for hollow cylinder cores can be used in the cell. For this invention, 0.9-inch ID samples were used.
[0026] A Digital Sonifier 450 Model by Branson Ultrasonics Corp. of Danbury, Conn. was used for ultrasonic cleaning purposes. The system consists of the power supply unit, the controls, the converter and a horn. A PC was used to interface with the system and to collect the data off the system.
[0027] The hollow cylinder Berea cores were first damaged using drilling and/or drill-in fluids of different formulations under various differential pressures. The drill-in fluid was used to conduct the static filtration. The filtration was performed in the cell at 600-psi pressure difference for about 12 hours. The cake thickness was varied between 2 to 3 mm. Drilling fluid was circulated into the hollow cylinder core and out from an annulus at 500-psi circulation pressure and 50 cc/min. Then the pump was stopped and static filtration was initiated at 500 psi long enough to stick a pipe and static filtrate was collected. Then the ultrasonic horn with 20 KHz central frequency was used to apply sonification from the interior of the pipe that stuck to the wall of the core. The permeability, differential pressure, sonification amplitude, power, and temperature were monitored as a function of sonification treatment time, and the energy requirement for near-complete permeability recovery and pullout force were investigated.
[0028] The following examples will serve to illustrate the invention disclosed herein. The examples are intended only as a means of illustration and should not be construed as limiting the scope of the invention in any way. Those skilled in the art will recognize many variations that may be made without departing from the spirit of the, disclosed invention.
[0029] Experimental Study
[0030] Experiments were designed to demonstrate the usefulness of ultrasonic in reducing pullout force for stuck pipe. A special dynamic hollow cylinder circulation device, described above and shown in FIG. 2 was designed for conducting experiments. The cell pressure, temperature, flow rate, applied horn power and the amplitudes were monitored continuously using data acquisition software. The distance between the damaged surface and the horn was varied to study the effect of distance away from the source.
[0031] Again referring to FIG. 2, the system comprises a stainless steel cell, two movable pistons, and an ultrasonic horn holder. It is capable of handling in excess of 5,000 psi pressure and also can be operated at elevated temperature under a specified differential pressure. Two syringe pumps (manufactured by and commercially available from ISCO, Inc. of Nebraska) were used to inject fluid and to control the differential pressure simultaneously with a precision of ±1 psi to measure the permeability of the sample. A data acquisition system was used to record and monitor the real-time pressure, flow rate, and volume of fluid injected. During sonification, the real-time amplitude, power, and time were also recorded and monitored.
[0032] Hollow cylinder Berea and aloxite core samples with 4″ OD, 0.9″ ID and 8.3″ length were placed in the dynamic hollow cylinder filtration device, and external filter cakes were built by circulating drilling or drill-in fluid under in situ stress conditions between a casing pipe and walls of the hollow cylinder as shown in FIG. 2. Continuous permeability measurements made it possible to observe when the fluid completely plugged the sample pore spaces. Then the ultrasonic horn was placed into the pipe simulating a stuck pipe scenario in the laboratory as shown in FIG. 2. No sonification was applied in the first test. The application of pulling force was initiated and applied to the stuck pipe in gradually increasing magnitude until the pipe was released. The load required to free the pipe was recorded in this case. Then other identical tests were run with the stuck pipe scenarios, but this time sonification was applied for 1, 3, 5, 10, 15, 20, 25, 30 and 35 minute intervals, respectively. After various-time sonifications, a small pulling force was applied and then the force was gradually increased until the pipe was released. The sonifications were repeated at three energy levels (30% amplitude, 50% amplitude, and 70% amplitude). A summary for the aloxite cylinder at various amplitude and sonification times is presented in FIG. 3. FIG. 3 is a graph showing the reduction in pull out (freeing) force as a function of sonification time for an aloxite hollow cylinder sample damaged by drill-in fluid, where the filter cake was built at an elevated pressure and room temperature. The pullout force ratio is the ratio of freeing force after sonification to freeing force before sonification.
[0033] The fastest reduction in the freeing force was observed when 70% (highest power) was applied; however, any amplitude level and timing of sonification helped reduce the freeing force compared to the case of no sonification. The results for Berea hollow cylinder cores are shown in FIG. 4. Different samples were used to test the effect of increasing sonification time. For all the tests except the 40-minute sonification test, a pulling force was applied to free the pipe. However, the longer the sonification time, the smaller was the magnitude of the required force. And, finally, for 40-minute sonification, no pulling force was needed; the release was instantaneous after the sonification. The test results were explained by reduction in the contact area. Because sonification reduced the thickness of the filter cake, it resulted in a reduction in the contact area. Therefore, from equation (1), F s =μAΔP, and ΔP are kept constant, A is smaller, hence F s is smaller. A summary of the pullout force ratios for aloxite and Berea hollow cylinder samples is shown in FIGS. 3 and 4.
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Disclosed is an auxiliary method for freeing a drill pipe stuck due to build up of filter cake, which provides a reduction in the amount of force required to free said pipe which comprises:
a) Lowering an ultrasonic horn type device down the drill pipe to the point of contact between said drill pipe and mud filter cake;
b) Producing ultrasonic energy at the point of contact until the contact area is sufficiently reduced such that substantially less force is required to free the pipe.
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BACKGROUND OF THE INVENTION
The present invention relates to an improved process for the allylation of carbon acids without the use of base. More particularly, the present invention comprises the reaction of carbon acids with allyl carbonates in the presence of molybdenum, tungsten, cobalt, nickel, ruthenium, rhodium, osmium, iridium or platinum catalysts.
It is already known to form allylic derivatives of carbon acids by contacting the same with allylic alcohols, amines or esters in the presence of homogeneous palladium catalysts. See, K. E. Atkins, Tetrahedron Letters, 43, 3821-3824 (1970). While the process has been found suitable for strongly acid compounds such as acetylacetone it has not been found suitable for allylation of less acidic compounds such as dialkyl malonates or phenylacetonitrile. Besides resulting in no or very little conversion of the acid compounds, the reactants reduce the homogeneous catalyst resulting in a metallic precipitate.
An improved process for the allylation of carbon acids which allows for the allylation of relatively weak carbon acids is desired. Further, a process that does not detrimentally affect the catalyst system is desired.
SUMMARY OF THE INVENTION
According to the present invention an improved process for the allylation of carbon acids is provided. The invented process comprising reacting the carbon acid with an allyl carbonate in the presence of a metal catalyst selected from the group consisting of molybdenum, tungsten, cobalt, ruthenium, rhodium, osmium, iridium or platinum catalyst. The process results in improved reaction times and lowered reaction temperatures compared to previously known processes. Also, the process for the first time allows the artisan to form allyl derivatives of carbon acids that have heretofore not been capable of allylation without the use of strong base.
The invented process provides a useful method for the preparation of substituted carbon acids from base sensitive reactants. Furthermore, the compounds prepared by the present process find use in various applications in industry as monomers capable of polymerization or copolymerization through the ethylenically-unsaturated allyl functionality to form resins useful in the manufacture of solid articles and as intermediates for preparing herbicides, insecticides and other useful chemicals.
DETAILED DESCRIPTION OF THE INVENTION
The allyl carbonates for use according to the invention are of the formula: ##STR1## where R 1 is ##STR2## wherein R 3 -R 7 are independently each occurrence hydrogen or a hydrocarbyl radical of up to 20 carbons selected from the group consisting of alkyl, aryl, alkaryl, aralkyl, alkenyl and inertly-substituted derivatives thereof; and
R 2 is R 1 or a hydrocarbyl radical of up to about 20 carbons selected from the group consisting of alkyl, aryl, alkaryl, aralkyl and inertly-substituted derivatives thereof.
By the term "inertly-substituted derivatives" is meant chemical derivatives of the named compounds containing substituents that are unreactive under the reaction conditions and non-interfering with the desired allylation reaction. Suitable inertly-substituted compounds are those compounds that do not contain ionizable carbon-hydrogen bonds. They may be easily identified by routine experimentation. It is already known, for example, that phenol-, carboxy- or amine-containing substituents are unsuitable but that alkoxy, aryloxy, halogen or halogenated alkyl or aryl substituents may be present.
The allyl carbonates for use according to the present invented process are known compounds or else they may be prepared by techniques well-known in the art. Preferred allyl carbonates are those wherein R 2 and C 1-4 alkyl and R 1 is allyl or methallyl. Particularly where R 2 is C 1-4 alkyl the byproduct alkanol formed is easily removed from the reaction mixture and in particular is separated from the desired allylated carbon acid.
The carbon acids for use according to the invention are those compounds having at least one acidic carbon-hydrogen bond. By the term "acidic" is meant an ionizable hydrogen giving the compound a pK equal to or less than 25. Representative carbon acids include those compounds listed in Table 9-1 of H. O. House, Modern Synthetic Reactions, 494, W. A. Benjaman, Inc., Menlo Park, Calif. (1972) which teaching is incorporated herein by reference. Generally, esters, ketones, alkyl cyanides and nitroalkanes having up to about 20 carbons with at least one α-hydrogen may be allylated. Also suitable are compounds of up to about 20 carbons which contain a terminal acetylene moiety.
The catalysts for use according to the invention include both homogeneous and heterogeneous catalysts. Included as representative are stable phosphine, phosphite, arsine or stibene complexes, and other homogeneous complexes of one of the previously identified metals or complexes of one of the above metals and a polymeric ligand, such as a functionalized styrene divinylbenzene copolymer wherein the functional groups are capable of forming complexes. Preferred ligands are the triorgano phosphines such as trialkyl phosphines of up to about 4 carbons in each alkyl group or triphenyl phosphine.
The metal may be present in the salts form, such as the corresponding metal halide, nitrate or carboxylate or as an organometallic compound. The metal may also be present in the heterogeneous form such as the elemental metal alone or more preferably the metal deposited onto an inert support such as carbon, diatomaceous earth, silica, alumina, zeolites, etc. A preferred support is carbon. Preferably, the amount of such complexing agent added will be from about 0.5 to 4 equivalents per equivalent of metal catalyst based on the stoichiometry of the complex formed.
In one embodiment of the invention, the ligand is added to the reaction mixture containing the metal salt, organometallic compound or heterogeneous metal. Alternatively, the chelated metal catalyst may be first prepared and added directly to the reaction mixture containing the carbonate reactant and carbon acid.
Preferred metals for use in the present invention are nickel and platinum, most preferably present as the elemental metal, especially a supported nickel or platinum metal.
According to the invention, the allyl carbonate, carbon acid and a catalytic amount of the metal catalyst are contacted under an inert atmosphere until the evolution of carbon dioxide ceases. The product may be then recovered by distillation.
The temperature of the reaction may be from about -20° C. to about 150° C. and preferably is from about 20° C. to about 100° C. Reduced or elevated pressures may be employed if desired but no advantage generally results thereby. Preferred is to employ atmospheric pressure and ordinary glass or glass-lined reactor vessels. Reaction times from 0.1 hour to 100 hours may be required depending on the reactants and the reaction conditions employed.
The presence of a solvent is not essential to the reaction but a solvent may be employed if desired to aid in temperature control and in the efficient mixing and contacting of reactants. Ethereal solvents, such as alkyl ethers, polyoxyalkylene ethers and tetrahydrofuran may be used. Other suitable solvents, depending on the nature of the reactants, including aromatic hydrocarbons, ketones, esters, alkyl carbonates, cyanoalkanes, alkanols and chlorinated hydrocarbons.
The amount of catalyst employed is generally from about 0.1 to about 10 percent by weight of metal, preferably from about b 0.1 to about 2 percent.
SPECIFIC EMBODIMENTS
Having described my invention, the following examples are provided as further illustrative and are not to be construed as limiting.
EXAMPLE 1
In a glass flask allyl methyl carbonate (4.0 g, 25 mmole), methyl cyanoacetate (0.99 g, 10 mmole) and tetrakis (triethylphosphite) nickel (0) (0.5 mmole) were combined with stirring and heated to about 23° C. for 15 minutes. In that time evolution of carbon dioxide subsided The reaction was discontinued and the contents of the flask were analyzed by standard techniques of gas-liquid chromatography using an internal standard. The primary reaction product was found to be methyl 2-allyl- -2-cyano-4-pentenoate. 97% yield based on methylcyanoacetate.
EXAMPLES 2-5
The reaction conditions of Example 1 were substantially repeated using allyl methyl carbonate and the carbon acids, catalysts, and reaction conditions further identified in Table I. The primary reaction product and percent yield based on carbon acid are contained in Table I. In Examples 2 and 3, 25 mmoles of allyl methyl carbonate were employed. In Examples 4 and 5, 20 mmoles of allyl methyl carbonate were employed.
TABLE I__________________________________________________________________________ Catalyst TTPNi.sup.1 Temp Time ProductExampleCarbon Acid (mmole) (mmole) Solvent (ml) (°C.) (hr) (% yield)__________________________________________________________________________2 methyl cyanoacetate (10) 0.3 -- 70 1 95.sup.23 cyano methyl benzene (10) 0.1 -- 80 1.75 90.sup.34 dimethyl malonate (20) 0.2 THF.sup.4 (5.0) 70 2.5 94.3.sup.55 dimethyl malonate (20) 0.2 THF.sup.4 (5.0) 75 3.5 85.sup.6__________________________________________________________________________ .sup.1 Tetrakis (triphenyl phosphite)nickel (0) .sup.2 The product was methyl 2allyl-2-cyano-4-pentenoate. .sup.3 The product was a mixture of 50 percent (1cyano-3-butenyl)benzene and 50 percent (1cyano-1-allyl-3-butenyl)benzene. .sup.4 Tetrahydrofuran. .sup.5 The product was a mixture of 94 percent dimethyl allyl malonate an 6 percent diethyl diallyl malonate. .sup.6 The product was a mixture of 81 percent dimethyl allyl malonate an 19 percent dimethyl diallyl malonate.
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Carbon acids are allylated by contacting with an allyl carbonate in the presence of an iron, cobalt, nickel, ruthenium, rhodium, osmium, iridium or platinum catalyst.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to a method and a system for heat recovery from hot gas, e.g. flue gas, produced in a thermal reactor, or—more precisely—for heating of water by means of the hot gases that are released by thermal conversion (gasification or combustion) of solid fuels e.g. biomass, waste or coal.
BACKGROUND OF THE INVENTION
[0002] Heating of water from hot gases that are released during thermal conversion of fuels is well known. The hot water can be used for heating purposes, e.g. in houses, apartment houses, offices, in industries etc. and for domestic water. Installations for such purposes are produced in very different sizes, approx. 1 kW-250 MW input effect.
[0003] Reference is made to “Varme ståbi”, Nyt teknisk Forlag, 4th ed., 2004, ordering No. 44031-1, ISBN 87-571-2546-5, Ullmann's Encyclopedia of Industrial Chemistry Release 2005, 7 th Edition, “User friendly it tool for biomass heating plants” in proceedings of “2 nd world conference and technological exhibition on biomass for energy, industry and climate protection” and DE 3544502 A1.
[0004] The water is usually heated in a closed circuit and led to a point of consumption, after which the water is returned to the heat production unit after release of the thermal energy. When the water leaves the production unit (supply), the water temperature usually is 60-90° C. The temperature of the water returning to the heat-production unit after cooling at the consumer (return) is about 30-50° C.
[0005] Concurrently with the technological development and the attention to energy savings, there has been a tendency to reduce the supply and return temperatures, as the heat loss from the distribution pipes is reduced in that way.
[0006] The hot water can be produced close to the required locations or be sent to the consumer via a district heating network.
[0007] The energy released by thermal conversion of a fuel can be transferred to hot water in stages, e.g.:
[0008] 1. By cooling of the area around the place where the thermal conversion takes place, e.g. a water-cooled feeder, a water-cooled grate, water-cooled areas in the reactor or other cooled surfaces where the thermal conversion takes place.
[0009] 2. Cooling of the (dry) hot gases
[0010] 3. Further cooling of the gases, by which vapours in the gas is condensed.
[0011] Re 2. Cooling of the (Dry) Hot Gases
[0012] The gas leaving the thermal unit is usually around 700-1000° C., depending on technology, fuel and operation conditions. It is well known, e.g. at CHP stations, that the temperature in the thermal unit can be adjusted or controlled by water injection in order to protect materials, e.g. the superheater, against a too high temperature. The amount of water injected in order to adjust the temperature in the boiler room is, however, very limited; the temperature of the gas remains high (above 600° C.), and the characteristics of the gas, e.g. the water dew point, are not changed substantially.
[0013] Usually, the energy from the hot gas is transferred to another medium, e.g. water, by using a heat exchanger where the hot gas is flowing at one side while another colder medium (e.g. water) is flowing at the other side. Thus, the water is heated whereas the gas is cooled. In some plants, more heat exchangers are used, e.g. air preheating and/or steam superheating and/or hot water production.
[0014] These heat exchangers are usually of the convection heat exchanger type, as the energy mainly is transferred from the gas via convection. Usually, steel pipes are used. When solid fuels are converted, the gas contains particles. These particles result in several problems in this heat exchanger: fouling, corrosion, low heat exchange rates etc. and often a device is mounted to keep the gas tubes clean, e.g. soot blowing or mechanical cleaning.
[0015] The heat exchanger used for transferring energy from the dry hot gas is made of materials matching the qualities of the gas, usually heat-proof steel.
[0016] Usually, the gas is cooled in the “convection part” to around 150° C., as the temperature of the gas then is above the acid dew point and the water dew point. If the gas is cooled to or below the acid or water dew points, severe corrosion may occur in the heat-proof material of the heat exchanger.
[0017] Ammonia, chlorine, sulphur, particles, salts etc. is often removed from the gas, for instance by a dry or semi-dry cleaning process. In this way, the materials causing problems for the environment or the materials blocking and/or corroding during the subsequent process stages can be removed.
[0018] Re 3. Further Cooling of the Gases by Which Vapour in the Gas is Condensed
[0019] In order to utilize more of the heat energy, the gas can be further cooled, by which vapours, including water vapour in the gas, are condensing. The composition of the gas depends on the fuel conversed and of the conditions in the thermal reactor. With high moisture content in the fuel and a low amount of excess air in the thermal unit, a high water dew point is obtained. Usually, the water dew point in the gas will be approx. 35-60° C., if the gas has atmospheric pressure. If the gas is cooled below the water dew point, water vapour will condense, and condensation energy is released which can be used for further heat production. Depending on the fuel and the conditions in the thermal process, the energy utilization can be increased by up to about 30%.
[0020] By condensing of water vapour, other materials are released from the gas too, e.g. ammonia, chlorine, sulphur, particles, salts etc. As some of these substances may spoil, e.g. corrode the materials used for cooling the dry gas (the convection part), the condensing part is usually made of other materials. In the condensing part, e.g. glass fibre, plastic material, glass, acid-proof stainless steel, titanium etc. are used.
[0021] As the gas which is led to the condensing unit is cooled to e.g. 150° C. and has a water dew point of around 35-60° C., the temperature of the water heated in the condensing unit becomes too low to be used for supply. Therefore, the water from the condensing unit must be further heated.
[0022] The energy in the gas after the condensing unit can be further utilized, for instance by transferring water vapour and heat to the combustion air that is added to the thermal process, or by means of a heat pump.
[0023] In some, especially chemical plants, chilling of hot gases by massive water injection into a “quench” is used. A “quench” is thus wet, as there is a surplus of water. In these plants, no considerable evaporations will take place of the injected water, as the water amount is very large in order to secure cooling of the gases. Similarly, no significant change of the gas characteristics (e.g. the dew point) will take place. The nozzles used in a quench are of the type generating large water drops and delivering a large amount of water. Thus, in a quench the heat capacity (approx. 4.16 J/g/° C.) of water is used to cool the gas.
[0024] In some, especially chemical plants, chilling of hot gases by water injection into an “evaporative cooler” is used. In an “evaporative cooler” the cooled gas can be dry and thus dry gas cleaning systems can be used for cleaning the gases, which is necessary due to environmental legislation. One example of such plants is cement production plants. The water vapour in the gas from “evaporative coolers” is not condensated and used for production of hot water.
[0025] In some plants, fuelled with gas or oil, the combustion chamber is very compact and followed by an injector which is used as a gas pump. The ejector can then be followed by a heat exchanger where water vapours condensate and energy hereby is be retrieved. However such systems can not be used for several reasons, for example:
[0026] A. Feeding systems and combustion chambers for solid fuels are very different from feeding systems and combustion chambers for gaseous fuels.
[0027] The following the condensing heat will corrode and/or block up with particles if solid fuels are used.
OBJECTS AND SUMMARY OF THE INVENTION
[0028] The invention provides a method and a plant allowing transfer of energy from hot gases to water or another fluid by means of considerably fewer heat transfer units, as the heat transfer from hot gases can be gathered in a single condensing unit. Moreover, a more simple water circuit is obtained as coupling and control of water circuit for a condensing unit as well as a convection part are avoided.
[0029] Thus, the invention provides a method for heat recovery from hot flue gas, produced in a thermal reactor. According to the method, water is injected at one or more injection zones in such an amount and in such a way that the flue gas temperature is reduced to below 400° C. and the gas dew point is at least 60° C. due to water evaporation. Subsequently, the gas is led through a condensing heat exchanger unit ( 8 ), where at least some of the water vapour is condensed, and the condensation heat is used for heating a liquid stream, mainly water.
[0030] In this way, the comprehensive evaporation heat of water (approx. 2.2 MJ/kg) is utilized twice:
[0031] 1. By injection of water and its evaporation, the amount of water vapour in the gas is increased, and thus the dew point of the gas is increased. As an example could be mentioned that injection of water into a flue gas from combustion of biomass in such an amount that the gas is cooled to 150° C. will increase the dew point for the flue gas to approx. 85° C. The dew point in flue gas is usually 35-60° C. without water injection.
[0032] 2. The cooled gas containing a large amount of water vapour can then produce the amount of energy in the condensing heat exchanger unit which was previously produced in at least two units, i.e. a dry and hot convection part and a condensing part. Besides, the dew point of the flue gas has increased considerably due to the water injection, which means that the condensing heat exchanger unit can heat water or another liquid to a temperature suitable for using the water directly as supply.
[0033] At least a part of the water injected into the hot gases will atomize in a nozzle, by which the water will evaporate more quickly.
[0034] Water injection into the hot gas may take place in several injection zones, which may comprise the fuel, the thermal reactor, a gas cleaning unit and/or the condensing heat exchanger unit. By water injection into fuel and/or the thermal reactor, a number of advantages are obtained:
[0035] If the plant is designed for wet fuels, the same plant can be used for dry fuels by water injection into the fuel and/or the thermal reactor. Thus, a fuel flexible plant is obtained.
[0036] NOx-formation can be controlled and reduced, as NOx formation is independent of temperature.
[0037] The thermal reactor and the gas pipes to the condensing heat exchanger unit may be separated or be built together in one unit, as the thermal conversion then takes place in one zone, whereas water injection may take place in that reactor zone and possible also somewhere else in a subsequent zone.
[0038] Before and/or after the condensing unit, the gas can be cleaned of undesirable materials such as e.g. ammonia, heavy metals, acids, chlorine, sulphur, particles, salts, etc. This may for instance be done in a bag filter, a cyclone, and electrofilter or in a scrubber, possibly combined with addition of absorbents such as active carbon, lime, bicarbonate etc. As long as the gas temperature is above the water dew point, dry gas cleaning technologies can be used, e.g. bag filter or electrofilter. If the gas is wet, scrubbers and/or wet electrofilters can be used.
[0039] A part of the water injected into the gas can advantageously be injected at great speed in the direction of the gas flow. By this, kinetic energy from the water can be transferred to the gas, and the water injection may then act as a gas pump (ejector).
[0040] If an especially high supply temperature is desired, the water heated in the condensing heat exchanger unit can be further heated, e.g. via a water-cooled feeder, a water-cooled grate water-cooled areas in the reactor and/or other cooled surfaces around the thermal conversion area or via another thermal production.
[0041] After the condensing heat exchanger unit, a certain energy amount will be left in the gas in the form of heat and water vapour. Some of that energy can be utilized by transfer to the combustion air via an enthalpy exchanger. In an enthalpy exchanger, water vapour and heat are transferred to the combustion air, implying an even higher water vapour amount in the gas and thus a higher efficiency of the condensing unit. Enthalpy exchangers can be designed in different ways, e.g. as rotating units, where combustion air flows on one side and hot gas on the other, or as a system where the gas after the condensing heat exchanger unit changes with cold water, whereby the water is heated. The heated water can then be used for heating and humidifying the combustion air.
[0042] By combustion of solid fuels, e.g. straw or waste sedimentation of particles will often occur on the convection part, as the hot particles are sticky due to a low ash melting point. By water injection and corresponding reduction of the gas temperature, this problem is eliminated.
[0043] The hot water can be produced close to the consumption place or be sent to the consumer via a district heating network. Plants designed according to the invention can be built in a very wide spectrum of sizes, approx. 1 kW-250 MW input effect.
[0044] The thermal unit may have other purposes than only heat production, e.g. production of gas and electricity among others. Among technologies relevant for the invention can be mentioned: Combustion plants for solid fuel (biomass, waste and coal) for mere heat production as well as CHP production, gas and oil fired boilers, motors, gas turbines, gasification plants etc.
[0045] If the thermal unit is of the fluid bed type, water injection into the bed can be used for adjusting the temperature in the bed, by which operational (e.g. slag formation) and environmental (e.g. reduction of NOx) advantages can be obtained. Water injection into the bed will further contribute to fluidization of the bed. This kind of temperature adjustment is considerably more robust than the traditional technique in the form of cooling coils which are quickly worn down of the bed material.
[0046] The condensed water can be cleaned of particles, salts, heavy metals etc. and be adjusted for pH, before it is used or led away.
[0047] The water injected into the fuel in the thermal unit, in the gases or in the condenser may be condensate, segregated in the condensing unit, or water added from outside.
[0048] In the thermal unit, the condensing unit and in the connecting gas duct there may be atmospheric pressure, or pressures above or below the atmosphere.
[0049] The invention further provides a system for decomposition of fuel and production of hot water, and comprising a thermal reactor, a flue gas duct, one or more water injection devices e.g. in the form of nozzles and a condensing heat exchanger unit connected to the flue gas duct. Here at least some of the water vapour of the gas is condensed, and the condensation heat is used for heating of a flow of fluid, preferably water, and means for control of the water injection into the flue gas in order that the flue gas temperature is reduced to below 400° C., and the gas dew point becomes at least 60° C. due to the evaporation of water.
[0050] Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] FIG. 1 schematically depicts a first design of a plant according to the invention;
[0052] FIG. 2 schematically depicts a second design of the plant according to the invention, where solid fuel is burned in a grate-fired boiler, and where particles are removed from the flue gas in a bag filter before condensing;
[0053] FIG. 3 schematically depicts a third design of the plant according to the invention, where solid fuel is burned in a grate-fired boiler, and where water is added by means of an ejector;
[0054] FIG. 4 schematically depicts a fifth design of the plant, where fuel is gasified and the heat energy in the gas is utilized;
[0055] FIG. 5 is a diagram of the flue gas output from cooling, with and without preceding water injection and evaporation; and
[0056] FIG. 6 are two tables with energy calculations, where wet and dry fuel, respectively, are converted. The calculations show results for today's standard technology and for the invention with and without moistening of combustion air.
[0057] In the following, corresponding parts in the different designs will have the same reference terms.
[0058] While the invention is susceptible of various modifications and alternative constructions, a certain illustrative embodiment thereof has been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific form disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0059] Referring now more particularly to FIG. 1 of the drawings, there is shown a unit or reactor 1 , to which fuel is added. The fuel is converted thermally by addition of air (and/or oxygen). Thus, a warm gas is produced in the thermal unit 1 . The fuel added to unit 1 is solid e.g. biomass, waste or coal. If the thermal unit 1 is designed for fuels with low calorific power, e.g. wet fuel, and if the added fuel has a higher calorific power, the temperature in the unit or in the generator 1 can be adjusted by adding water to the fuel at 2 and/or by adding water at 3 within the thermal unit 1 .
[0060] At 4 , water is injected into the hot gases leaving the thermal unit 1 . The water evaporates and cools the gases considerably, as the evaporation energy from water is very high. The unit in which injection 4 is placed can be built of heat-proof steel, bricks, castings and/or other materials. The amount of water dosed at 4 can be controlled on basis of the gas temperature and/or the dew point by means of adequate control means S, placed in a position after 4 , where the injected water has evaporated.
[0061] If the cooled gas contains impurities, e.g. particles, a gas cleaning unit 5 can remove these impurities from the dry gas. Via a gas blower or pump 6 , the gas can be pumped on to a condensing heat exchanger unit 8 , where the heat in the gases, including the condensation heat in the water vapour, can be transferred to the water to be heated. In the condensing unit, water can also be injected at 7 .
[0062] The gas sucker 6 can also be placed after the condensing unit 8 , where the gas flow is lower due to the cooling of the gas and the condensing of the water vapours.
[0063] In and/or after the condensing unit 8 , more impurities can be removed from the gas at 9 and/or from the produced condensate at 12 . After the condensing unit 8 , some of the energy left in the gas in the form of heat and moist can be transferred, at 10 , to the combustion air which is added to the thermal unit 1 . The humidified air can be further heated in a heat exchanger 11 , before the air is added to the thermal unit 1 , whereby the supply lines are kept dry.
[0064] This type of plant can be produced in many different sizes, from a few kW (villa boilers) to large plants above 100 MW.
[0065] FIG. 2 shows a combustion plant for production of district heating, and where the gas is cleaned before condensing and combustion air is moisturized. 1 is a burner for combustion of solid fuel. The plant is brick-lined so that it can burn fuels with a high water content (up to 60% water) or which otherwise have a low calorific value (below 10 MJ/kg). Fuels with a higher calorific value can also burn in such a plant, as water can be added to the fuel at 2 , or in the boiler room at 3 . Further, at 4 water is added to the hot gases leaving the burner 1 . The water evaporates and cools the gases to ca. 150-200° C. Subsequently, the gas is cleaned of particles in a bag filter 5 . If other substances are to be removed from the gas, absorbents can be added before the filter, e.g. lime, active carbon, bicarbonate etc.
[0066] The flue gas is sucked through the gas sucker or the pump 6 and is cooled in the condensing unit 8 , comprising two cooling towers placed above each other, designated respectively “Kol. 1 ” and “Kol. 2 ”, and a heat exchanger 13 , as the flue gas flows counter-flow with the cooled condensate 7 a . As the condensing unit 8 is built of glass fibre, it is important that the gas is cooled to below ca. 150° C., before the inlet. Addition of water in the nozzle in 7 b protects the condenser inlet 14 from becoming too warm. In the cooling tower “Kol. 1 ” cooling water is added at 7 a . Hereby, steam in the flue gas flow is condensed, and the condensate is gathered in a room 15 under the cooling towers and the inlet 14 . The hot condensate is heat exchanged in the heat exchanger 13 by water in a district heating system which is not shown, as the cold district heating water is added via a return pipe, whereas the hot water is led back to the system via a supply pipe. As the flue gas dew point is high, e.g. ca. 85° C., the temperature of the produced condensate can be about 85-90° C. Thus, the district heating water can be heated from the condensate at one single stage.
[0067] The combustion air added to the burner 1 can be heated in a humidifier 17 , where hot water is added at 18 , or by means of a heater device 11 , ensuring that the air ducts are kept dry. The water added at 2 - 4 , 7 a , 7 b and 18 , may—as shown—be the cooled condensate that leaves the heat exchanger 13 , and any surplus condensate can be led away at 19 . Condensate gathered at the bottom of the humidifier 17 can be used for addition to the cooling tower “Kol. 2 ”.
[0068] When the flue gas has been cooled by the condensate in the tower “Kol. 1 ”, it is led through another section, “Kol. 2 ”, where the gas is cooled by water having been cooled by the combustion air. The cooling of the flue gas and humidifying of the combustion air together form an enthalpy exchanger 10 , which increases the energy efficiency.
[0069] FIG. 3 shows a combustion plant for production of district heating. The gas is led through the plant by means of an ejector pump. 1 is a burner for combustion of solid fuel. At 4 , water is added to the hot gases leaving the burner 1 . The water evaporates and cools the gases. At 7 a water is injected at great speed in the direction of the gas flow through a pipe 20 , the cross section of which is increased in the flow direction. Thus, the water injection at 7 a through the pipe 20 acts as an ejector.
[0070] In a condensing heat exchanger 8 , heat energy is transferred from the flue gas to the district heating water. The heat exchanger in 8 may be made of glass, plastic or acid-proof stainless steel, but needs not be heat-proof. The exchanger can be cleaned of particles by means of water injected at 7 b , but this needs not be a continuous cleaning. The produced condensate can be cleaned of particles etc. at 12 , before it is used as injection water at 4 a , 4 b and 7 or drained off to a drain at 19 .
[0071] FIG. 4 shows a preferred design of a gasifier plant 1 , where the produced gas firstly is cooled by being used for preheating of combustion air in a heat exchanger 21 , and then is cooled by water injection at 4 . The drafted gasifier is of the type “staged fixed bed”, but can in principle be other gasifier types, e.g. a fluid bed gasifier.
[0072] After water injection at 4 , the gas is cleaned of particles (and possibly tars) e.g. in a bag filter and/or an active carbon filter 5 , after which the gas in a heat exchanger 8 is cooled during condensing of water. By means of a gas blower or pump 6 the gas is blown to a conversion unit, here illustrated by an engine, but there could also be other conversion units, e.g. a gas turbine, liquefaction equipment for conversion of the gas to fluid fuel etc.
[0073] The flue gas energy from the conversion unit can be utilized e.g. for heat production. Thus, the invention can be utilized twice.
[0074] In FIG. 5 is a diagram showing the calculation of the output from cooling of flue gas from respectively a traditional boiler and by water injection according to the invention, cf. FIGS. 2 and 3 . Common data for the two calculations are:
[0075] amount of fuel (waste/wood chip) of 3000 kg/hour
[0076] humidity content in the fuel is 45%
[0077] O 2 in the flue gas is 5% (dry)
[0078] the temperature of the flue gas out of boiler/after water injection=150° C.
[0079] It appears from FIG. 5 that about 1700 kW can be produced in the condensing unit by cooling of the flue gas to ca. 45° C. with standard technology, whereas 8500 kW can be produced by using the invention. The temperatures of the produced water are very different too. With standard technology water can be produced at about 65° C. However, by using the invention, water can be produced at 85-90° C. In most cases, a supply temperature of 85° C. will be satisfactory, but if this is not enough, a radiation section/grate cooling can be incorporated for boosting the temperature. If e.g. 95° C. supply temperature is desired, ca. 10-20% of the energy must be produced in the radiation section/grate cooling.
[0080] FIG. 6 shows two tables with key figures for selected calculations for district heating plants. It appears from the key figures that the efficiency by use of wet fuels will be the same for a standard design with condensing operation and with “water injection”.
[0081] The calculations concerning the invention are “conservative”, i.e. the fact that the invention allows for better control of the plant and thus for less surplus of air, giving a higher efficiency degree, has not been taken into account in the calculation.
[0082] As condensing operation on dry fuels is not standard, the new method gives a higher efficiency degree by use of dry fuels. It should be noted that in case of high return temperature (above 45° C.) and dry fuel, the process will be water consuming, unless moistening of combustion air is used.
[0083] Further, moistening will be able to increase the efficiency degree considerably, especially at higher return temperatures. Due to water injection, the amount of flue gas is increased during cooling of the flue gas. The condensing unit and belonging pipes must of course be dimensioned for this.
[0084] Summarization of the most important advantages of the invention:
[0085] Simpler and Cheaper Plant
[0086] The most important advantage of the concept is that the construction becomes considerably simpler and cheaper than for traditional condensing plants with both a convection part and a condensing unit. By use of the invention, a convection boiler and belonging boiler circuit with shunt and heat exchanger can be saved, and the water circuit and the control of the heat productions become much simpler and thus cheaper. However, there will be an extra cost of water dosing and a larger condensing plant, but that will be very small compared to the savings.
[0087] Compact Plant
[0088] The principles used for transferring heat from gas to water in the concept (evaporation of water in a hot gas and scrubber+plate exchanger/condensing pipe cooler) are very effective (compared to dry convection) and thus compact.
[0089] As the number of units is reduced, and as the principles for heat transfer are more effective, the total plant becomes more compact.
[0090] Lower Maintenance Costs
[0091] Maintenance costs of a water injection system become considerably lower than the present maintenance costs of “boiler operation”.
[0092] By use of fluid bed and by use of water injection to adjust the bed temperature, savings are also obtained for maintenance, as the traditional cooling pipes, which will be worn out of the bed material, are avoided.
[0093] Fuel Flexibility
[0094] Up to now, it has been necessary to construct plants for either wet or dry fuel. Wet fuel necessitates brick lining in the combustion chamber to obtain a good combustion. If dry fuel is used in brick-lined plants, the combustion temperature will be too high. With the water injection concept, the combustion chamber can be used for wet fuel, and in case of combustion of dry fuel, an adequate amount of water will be added in order to keep the temperature down.
[0095] Higher Efficiency by Better Control of Air
[0096] The efficiency is increased by lower air consumption, as the flue gas loss becomes smaller. With careful positioning and control of the water nozzles, the air consumption can be reduced compared to plants with “boiler operation”, which will give a better efficiency.
[0097] Higher Efficiency by Moistening of Combustion Air
[0098] The efficiency is further increased by 5-15% by moistening of combustion air.
[0099] Lower Emissions
[0100] Thermal NOx can be reduced by water injection in and around the combustion chamber, especially in case of gas and coal combustion.
[0101] Emissions of HCl, SO2, Dioxins etc, will be reduced when the water in the condensing unit is neutralized e.g. with NaOH.
[0102] Particle emissions will be reduced when filters are used e.g. bag filters.
[0103] It should be understood that numerous changes and modifications of the embodiments of the invention described above could be made within the scope of the appended claims. Furthermore, the use of solid fuel in the method and system defined by the claims could be replaced by or supplemented by the use of gaseous and/or liquid fuel.
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Heat can be recovered from hot gas produced in a thermal reactor ( 1 ), by injecting water into the gas at one or more injection zones ( 4 ) in such an amount and in such a way that the gas temperature due to water evaporation is reduced to below 400° C., preferably below 300° C., possibly below 150-200° C., and the gas dew point becomes at least 60° C., preferably at least 70° C., possibly 80 or 85° C. The gas can then be led through a condensing heat exchanger unit ( 8 ), where at least some of the gas contents of water vapour are condensed, and the condensing heat can be utilized for heating of a stream of fluid, mainly water. Hereby, a method for production of hot water is obtained, which is cheap and simple and has low maintenance costs, and which moreover has a high efficiency degree and good environmental qualities The method can be used for a broad spectrum of fuels and conversion technologies.
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CROSS REFERENCES
This patent application claims the benefit of U.S. Provisional Application Ser. No. 61/078,845 filed Jul. 8, 2008, the contents of which are incorporated by reference herein.
FIELD OF THE INVENTION
The present invention generally relates to circuits that provide improved electrostatic discharge (ESD) protection, and more particularly to method and apparatus for providing an improved voltage level based ESD protection circuit such that trigger voltage can be tuned to a desired value of a low trigger voltage and a low leakage current.
BACKGROUND OF THE INVENTION
ESD protection devices need to shunt current during ESD circumstances, but need to appear like an open during normal chip operation. This is achieved through the so-called trigger elements, a.k.a. ESD detectors. The trigger element needs to fulfill many requirements such as it must never trigger below the supply voltage (+margin) to prevent latch-up (if no transients); it must not trigger on transients caused by switching, noise, current injection or any other event during the normal operation of the chip; it must trigger before the failure voltage (−margin) of the devices it needs to protect and the leakage at the supply voltage needs to be within certain predefined limits. In many ESD applications a design window of an ESD protection circuit is so small that finding a trigger element which fits within this window fulfilling the above discussed requirements is very difficult.
One of the ESD protection circuits includes voltage level detection devices or circuits that need to be biased at a certain voltage level (trigger voltage) in order to conduct. These can be further divided into snapback devices (devices that go to a low-ohmic state with a voltage offset lower than the trigger voltage) and non-snapback devices that go to a low-ohmic state with a voltage offset equal to the trigger voltage. However, many of such voltage level detection devices trigger at a too high voltage and others have a too high leakage. An example of this is an ESD protection of an output driver . . . . The output NMOS transistor can be quickly turned. So, in the worst case the NMOS will trigger at its holding voltage. This means it is impossible to use a gate-grounded NMOS (ggNMOS) or any device that uses a ggNMOS as trigger element to protect such an output unless the failure voltage of the output driver is greater than the trigger voltage of the ggNMOS. In the case where the supply voltage is low enough, a diode chain (or any device that uses a diode chain as trigger element) could be used as ESD protection. However, this is limited by leakage considerations. The voltage drop over each diode should be sufficiently small so that hardly any leakage current flows through it. For higher supply voltages this can become a problem.
The solution to the above problem is generally solved by another type of ESD protection circuit that includes a transient detection circuit that only conducts when the voltage changes with time fast enough and can trigger at a low voltage level. An example of such a transient circuit is a form of RC controlled MOS device (or any device triggered by it). As long as a MOS operates in MOS-mode (if the current density stays below about 0.5 mA/um for an NMOS) the voltage over the MOS will be below its holding voltage. Therefore, it can be used to protect a device that can fails below the holding voltage of the ESD clamp (or at Vt2<Vt1). Despite the overall effectiveness of this approach there are some downsides and limitations. First, this approach consumes a lot of area. The RC chain is usually very large, and the MOS itself has to be large enough to be able to conduct enough current in MOS mode (either all ESD current or just the (possibly high) trigger current of another device). Another downside is that the time constant is influenced by parasitic capacitances along the chip. These may slow down the pulse and delay triggering, increasing the trigger voltage as well. Also noise or spikes on the powerline will induce an extra leakage path. Finally, when using RC controlled MOS devices as a trigger element of another device (e.g. an SCR), and when too many clamps are placed in parallel, it is possible that trigger current will become very high. This generally does not cause any problems for core protection, as the voltage over the parallel clamps will never exceed the maximum voltage over a single clamp, but it can create a problem for IO protection, where typically dual diodes are used as protection. All ESD current when stressing the IO has to go through one of these diodes. If the current demand of the parallel trigger elements is too high the total voltage over the sensitive node may become too high. This is the combined result of all current going through the diode's resistance and not enough of the current running through each individual clamp circuit preventing the clamps from triggering. Thus, several deficiencies with this transient detection circuit are that it has larger area and includes latch-up risk and further only one clamp can trigger at a low voltage because the transient dissipates after triggering.
Thus, there is a need in the art to provide a protection technique for ESD protection that overcomes the disadvantages of the above discussed prior art by providing a voltage level detection trigger device such that the trigger voltage can be easily altered to a desired value while maintaining a low leakage current.
SUMMARY OF THE INVENTION
In one embodiment of the present invention, there is provided an electrostatic discharge (ESD) protection device comprising an ESD circuit coupled between a first voltage potential and a second voltage potential. The device also comprises a trigger circuit having at least two triggering elements coupled between the first voltage potential and the second voltage potential. The trigger circuit is coupled to the ESD circuit. The device also comprises a voltage divider coupled between the first voltage potential and the second voltage potential. The voltage divider is coupled to at least one of the triggering element to control triggering voltage of the triggering circuit.
In another embodiment of the present invention, there is provided an electrostatic discharge (ESD) protection device comprising an ESD circuit coupled between a first voltage potential and a second voltage potential. The device also comprises a first ESD control device comprising a first trigger circuit having at least two triggering elements and a first voltage divider coupled to at least one of the triggering element of the first trigger circuit to control triggering voltage of the first triggering circuit. The device also comprises a second ESD control device comprising a second trigger circuit having at least two triggering elements and a second voltage divider coupled to at least one of the triggering elements of the second trigger circuit to control a triggering voltage of the second triggering circuit. The first and second ESD control device is coupled to each other and one of the first and second control devices is coupled to the ESD circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more readily understood from the detailed description of exemplary embodiments presented below considered in conjunction with the attached drawings, of which:
FIG. 1 illustrates an ESD protection device in accordance with an embodiment of the present invention.
FIG. 2 illustrates circuit elements of the block diagram of the ESD protection circuit of FIG. 1 in accordance with a preferred embodiment of the present invention.
FIG. 3 illustrates a graphical representation of trigger voltage in accordance with a embodiment of the present invention.
FIG. 4 illustrates an ESD protection device in accordance with an alternate embodiment of the present invention.
FIG. 5 illustrates an ESD protection device in accordance with a preferred embodiment of the present invention.
FIG. 6 illustrates ESD protection device in accordance with an alternate embodiment of the present invention.
FIG. 6A illustrates an ESD protection device of FIG. 6 in accordance with a preferred embodiment of the present invention.
FIG. 7 illustrates ESD protection device in accordance with another embodiment of the present invention.
It is to be understood that the attached drawings are for purposes of illustrating the concepts of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides an ESD protection device that is suitable for all voltage domains. More specifically, the invention disclosed herein provides a voltage level detection trigger device of which the trigger voltage can be flexibly altered between the minimum and maximum voltage, while the leakage is low. Also, the trigger device of the present invention is not influenced negatively by transient events and the area of the trigger element is low for its effectiveness.
Referring to FIG. 1 , there is illustrated a block diagram of an ESD control device 100 in accordance with one embodiment of the current invention. The device 100 comprises a voltage divider circuit 102 coupled to a trigger circuit 101 . The voltage divider circuit 102 functions to divide the voltage between the anode and the cathode and control the voltage at the trigger circuit 101 . The trigger circuit 101 functions to conduct current to trigger a ESD circuit 110 during an ESD event. The trigger circuit 101 and voltage divider 102 will be described in greater detail herein below.
As shown in FIG. 1 , one end of the trigger circuit 101 , voltage divider 102 and the ESD clamp circuit 110 is coupled to a first voltage potential 104 and the other end is coupled to a second voltage potential 105 . The voltage divider 102 preferably has three terminals such that the first terminal is coupled to the first voltage potential 104 , second terminal is coupled to the second voltage potential 105 and a third terminal is coupled to a trigger element of the trigger circuit 101 . It is known to one skilled in the art that the first voltage potential 104 can be a voltage supply (Vdd) or ground or an input/output pad, or connected to any internal circuitry such as an inter-power domain interface. Similarly, the second voltage potential 105 can preferably be ground, or an input/output pad, or connected to any internal circuitry. However, for the purpose of the invention as described, the first voltage potential 104 is preferably connected to the voltage supply and the second voltage potential 105 is preferably connected to the ground.
Referring to FIG. 2 , there are shown circuit elements of the block diagram of the ESD control device 100 and the ESD clamp circuit 110 of FIG. 1 in accordance with a preferred embodiment of the present invention. The ESD clamp circuit 110 preferably comprises an SCR, although other elements such as a bipolar transistor, Darlington transistor or a MOS can also be used. As a preferred embodiment of the trigger circuit 101 consists of an active element, for example, a trigger NMOS 103 and a passive element, for example pumping diodes 106 as shown in FIG. 2 . The voltage divider 102 consists of elements 112 and 114 . Element 108 is a node between the NMOS 103 and the diode chain 106 and element 107 is node to gate of the NMOS 103 . Even though in this embodiment, trigger element 103 is an NMOS, one of ordinary skill in the art would appreciate that the trigger element can also be a PMOS. Furthermore, if PMOS is the trigger element 103 , then the element 106 may also be preferably placed at the source of the PMOS. Furthermore, the number of diodes in diode chain 106 as shown in FIG. 2 is variable and depends on the desired properties of the trigger circuit. Although, FIG. 2 illustrates the trigger circuit 101 to be a combination of NMOS and diodes, one of ordinary skill in the art would appreciate that trigger circuit may preferably consists of other elements such as diodes, inverters, resistor, MOS, MOS diodes, and the like or any combination of these elements. For example element 106 may also include a resistor and/or a MOS. In case of a MOS as an example, the gate of the MOS may be coupled to various elements for example, source of the MOS, or node 107 or the divider circuit 102 . In another example, node of the diode chain 106 is coupled to the divider circuit 102 .
As shown in the embodiment of FIG. 2 , elements 112 and 114 are capacitor dividers of NMOS implementation between the two capacitors to divide the voltage between the anode and the cathode to a certain value. Also, only two elements, NMOS 112 and 114 are illustrated as voltage dividers, however, one of ordinary skill will appreciate that more than two elements in series could be used. It is noted that even though NMOS devices are used as voltage dividers, one of ordinary skill in the art would appreciate that circuit 112 and 114 may preferably consists of other elements such as resistors, PMOS devices, capacitors such as a varactor, an N-doped capacitor (NCAP), a metal oxide metal (MOM) capacitor, a metal insulator metal (MIM) capacitor, parallel connection of resistor and capacitor, reverse biased diodes, inverters and like or combination of these elements.
According to one embodiment of the present invention, parameters such as number of triggering elements such as diodes in the example of FIG. 2 and ratio of the voltage of the divider devices will influence on the trigger voltage of the circuit 102 as will be described in greater detail below.
Since in the example of FIG. 2 , the voltage dividers 112 and 114 are used capacitors, it is know in the art that the voltage across the capacitor devices is inversely proportion to the capacitance values. Alternatively, if the elements 112 and 114 were resistors, the voltage across the resistor devices would be directly proportion to the resistance values. So, depending on the relative sizes of the elements 112 and 114 , the voltage at the gate node 107 will be a fraction of the total voltage over the device at node 105 . If for example, the voltage on gate 107 of the NMOS 103 becomes higher than the sum of the voltage on the node 108 (i.e. source of NMOS 103 ) and the NMOS' threshold voltage (Vt), the NMOS 103 will start to conduct. Since current flowing through the NMOS 103 also flows through the diodes 106 , a voltage (Vt) will build up over the latter resulting in an increase in voltage at node 108 . Consequently, as long as the voltage on gate 107 is not high to compensate for the build-in voltage of the diodes 106 , there will be no current flow, and thus the NMOS 103 will not conduct. Thus, the objective of the present invention is to design the voltage/capacitor divider 112 and 114 and select the number of diodes preferably in the range of 1 through 10 diodes such that voltage at node 107 must be below the triggering voltage i.e. 1.7V during normal operation. This would prevent both the NMOS 103 and the diode chain 106 to conduct current during normal operation resulting in lower current leakage.
Referring back to FIG. 2 , in one example, there are two diodes 106 , NMOS 112 and 114 have the same size, thus the voltage divider 102 ratio is 1:1. The minimum voltage at the source 108 in order for current to flow is two times the build-in voltage of the diode, i.e. Vbi (.about. 0.7V), which is 1.4V. If the NMOS 103 has a Vt of 0.3V then 1.7V (triggering voltage) is needed at gate 107 to make the NMOS 103 conduct current. If 1.7V is at node 107 then that means 3.4V is required at Vdd supply node 104 for the SCR 110 to trigger (voltage divider with a ratio of 1:1). However, if higher trigger current is needed to trigger SCR 110 , then NMOS 103 and the diodes 106 will need to conduct even higher current, which could result in high overshoot voltage. In order to prevent the high overshoot and increase the turn-on speed of the diodes 106 , the NMOS 103 and the diodes 106 will preferably need to be laid out and shaped wider. The overshoot can be calculated with the resistance of the diodes and the amount of current needed to trigger the ESD clamp 110 . For a lower overshoot the resistance must be lowered by increasing the width of the trigger elements. Clearly, the trigger voltage will also preferably depend on the resistance of the NMOS 103 and the diode 106 of the trigger circuit 101 . Thus, the tailoring of the trigger circuit's parameters will allow for fine tuning the trigger characteristics of the SCR 110 .
As discussed above, one of the parameters that influences the trigger voltage is the number of diodes. During normal operation, voltage at source node 108 needs to be higher than the gate voltage at node 107 in order to prevent triggering of the NMOS 103 and the diode chain 106 . Yet during ESD event, the gate voltage at node 107 will be higher (due to increase of the voltage at node 104 ) which turns on the combination of the NMOS 103 and the diode chain 106 to conduct current to trigger the SCR 110 . By increasing the number of diodes 106 , the voltage required at the gate node 107 to trigger element NMOS 103 to conduct current also increases. So, number of diodes required in the diode chain 106 can preferably be selected (for example in the range of 1 to 10 diodes) both during normal operation and during ESD event.
Also, a parameter, the voltage ratio of the trigger voltage divider ( 112 , 114 ) is a factor that determines the multiplication of the minimum voltage over the diodes since it is effectively a trigger diode multiplier. So, for example, if the ratio of the voltage divider is 1 and you need 1.4V at the source node 108 to trigger the diodes 106 , then the total voltage needed to trigger the SCR is one times 1.4V plus the gate voltage at node 107 . If for example, the ratio is 2 then you need two times the 1.4V (2.8V) at the source node 108 to trigger the diodes 106 , then the total voltage needed to trigger the SCR will be 2.8V plus two times the gate voltage at node 107 .
One of other parameters that may also preferably influence the trigger voltage is the capacitance size of the voltage divider 102 . So, depending on the size of the capacitance of NMOS 103 , the capacitance size of the NMOS 112 and 114 of the voltage divider is preferably determined. In one implementation, the capacitance size (width) of the voltage divider 112 and 114 is same as that of the trigger NMOS 103 . In another implementation, capacitance size (width) of the voltage divider 112 and 114 can be based on the voltage required at gate node 107 for the NMOS 103 to conduct current. Another parameter is preferably a size of the trigger NMOS 103 . The wider the size of the NMOS 103 , the lower the trigger voltage/overshoot. The width of the NMOS may be in the range of 3-160 micrometer, preferably 20 to 80 micrometers. Note that this range is simply one example and the values of the width may be larger or smaller depending on the technology.
In general the following equation can be stated:
V 104 = ( V 108 + Vth ) · W 112 + W 114 W 112 ( 1 )
where V 104 is the voltage at node 104 , V 108 is the voltage at node 108 , W 112 is the width of divider element 112 , W 114 is the width of divider element 114 and Vth is the threshold voltage of MOS device 103 . This equation expresses the connection between the voltage at node 104 and the voltage at node 108 . The relation is governed by a factor corresponding to the divider ratio (W 112 /(W 112 +W 114 )) and a term corresponding to the threshold voltage of the MOS device (Vth).
There are three conditions related to the ESD operation. The first condition is that during operation of the chip under normal circumstances, leakage of the device should be minimal. This means that the voltage over the string of diodes 106 should be below a maximum value corresponding to a maximum allowed leakage. The second condition is that, during an ESD event, the voltage at the anode 104 of the ESD clamp 110 should never exceed the maximum allowed voltage (failure voltage). A third condition is that the ESD clamp 110 should not trigger below a minimum trigger voltage (Q·V sup ) which is larger than the supply voltage and determined by external factors such as maximum latchup test voltage or maximum overvoltage. The three conditions can be written as the following expressions (according to the equation 1):
V sup <( n·V max1 +Vth )·1/ F (2)
Q·V sup <( n·V bi +Vth )·1/ F (3)
V max >( n·V bi +Vth )·1/ F (4)
where Vsup is the supply voltage, Vth is the threshold voltage of the (N)MOS, Vbi is the built-in voltage of the diodes, n is the number of diodes, Vmax1 is the maximum allowed voltage over the diodes corresponding to maximum allowed leakage (this value is normally between 0.3V and 0.45V), Vmax is the maximum allowed voltage at the node under protection F is the divider ratio such as F=A/(A+B), where A is the width of a first (group of) element(s) of the voltage divider (W 112 ) and B is the width of a second (group of) element(s) of the voltage divider (W 114 ). A range of values can be determined so that the trigger voltage and leakage fulfill the three conditions stated above. Thus, the three expressions above determine the solution space for combinations of n and F which fulfill the three conditions.
Besides the parameters discussed above, another parameter that influences the trigger voltage is bulk connections of the NMOS 103 devices. Lower voltage potential of the bulk of the NMOS 103 will increase the threshold voltage of the NMOS, which will result in an increase in trigger voltage (combination of NMOS and diodes). Note that not only is the bulk connected to the source of the NMOS 103 as illustrated in FIG. 2 , but also may be connected to ground or between one of the diodes (or other elements) in element 106 . If the trigger MOS 103 is a PMOS, the bulk must not be connected to a lower potential but to a higher potential or even the positive potential 104 .
Although as shown in FIG. 2 , the voltage divider 102 is coupled directly to the first potential 104 and the second potential 105 , the voltage divider 102 may also be coupled to the first potential 104 through another circuit such as a base-emitter junction of the PNP of the SCR 110 or alternatively the voltage divider 102 may also be coupled to the second potential 105 through another circuit such as a base-emitter junction of the NPN of the SCR 110 .
Even though FIG. 2 represents an SCR with the trigger circuit 101 between the base of the PNP of the SCR 110 and the second potential 105 , it is noted that the trigger circuit 101 may alternatively be placed between the first potential 104 and the base of the NPN of the SCR 110 .
Although not shown, as an example the diode chain 106 may preferably include three trigger diodes with the NMOS 112 and 114 having the same size, so the voltage divider ratio is 1:1 and the Vt is about 0.23V. FIG. 3 illustrates a graphical representation of the trigger voltage with three diode chain. As shown in FIG. 3 , the NMOS overshoot is lowered. Simulations in FIG. 3 show that SCR is successfully triggered, and that the trigger voltage can be adjusted by applying the correct multiplication ratio and number of diodes. Although, not shown, number of fingers in the trigger NMOS 103 may preferably be increased to further reduce the overshoot voltage at the trigger element 101 .
Referring to FIG. 4 , there is illustrated a preferred embodiment of the present invention of FIG. 1 in which the voltage divider 102 includes a series connection of capacitors. One of the advantages of using the capacitors is that there is no junction divider and thus no leakage of the junction, which in turn results in an improved voltage divider ratio.
Referring to FIG. 5 , there is illustrated a preferred embodiment of the present invention of FIG. 1 in which the voltage divider 102 includes a series connection of NMOS devices 118 . Each of these NMOS devices 118 have another device 118 connected between its gate and drain, which is used as voltage shift. So, the voltage at the source of the chain of Ona NMOS device 118 is the supply voltage Vdd 104 minus 1 to 2 times the Vt of the NMOS. This source voltage of Ona NMOS 118 is applied to the gate of the next chain of Pna NMOS device 118 . The source voltage of this chain of Pna NMOS device 118 will again follow its gate voltage, which will be the supply voltage Vdd 104 minus 2 to 4 times the Vt of the NMOS. So the amount of voltage that is subtracted increases with every chain of NMOS device until you have reached back at the Ona NMOS 118 at which the source voltage of the Ona NMOS 118 will be Vdd 104 minus 1 to 2 times the Vt times the number of NMOS devices at the gate. So, by connecting these MOS devices in series, a voltage shift is introduced. So, the voltage at the node 107 connected to 101 will be determined by number of NMOS 118 devices that are between the Vdd 104 and the node 107 and the number of NMOS 118 devices that are between the Vss 105 and the node 107 . One of the advantages is less leakage current is more elements in series which can be made of very small size. Note that the bulk of the different MOS is connected to ground in this example of FIG. 5 , but it may also be connected to the source of the MOS or other intermediate voltage level. Also, NMOS may preferably be replaced by a PMOS device or even a combination of a NMOS and a PMOS. Also, FIG. 5 shows four MOS in series with at each MOS and two MOS are connected to the gate. The number of MOS connected in series and connected to the gate may be more or less depending on the desired voltage divider.
Referring now to FIG. 6 , there is illustrated an alternate embodiment of the present invention of FIG. 1 by adding a switch regulating buffer circuit 103 coupled directly between the voltage divider 102 and the trigger circuit 101 . The switch regulating buffer circuit may include elements such as inverters, passgate(s), resistor(s), diode(s) or combinations of these elements.
As an example, the switch regulating buffer circuit 103 is an inverter as shown in FIG. 6A . By adding the inverter, the input will be the detector which will change to high or low output depending on the state of the voltage divider circuit 102 . The advantage of using an inverter is to change the voltage level at the input of trigger circuit 101 . This threshold voltage is the minimum input voltage that is needed to switch the inverter 103 from a low output state to a high output state or vice versa. A low voltage input at the inverter 103 will set the output voltage high. When the output voltage of the inverter 103 is high, the trigger circuit 101 will be charged up to conduct current which in turn will trigger the ESD clamp 110 . Then, at a certain voltage, (i.e. the threshold voltage of the inverter 103 ) the inverter 103 will switch the output voltage from a high value to a low value. So, by adding the inverter, the voltage over the voltage divider 102 can be altered to be tuned at the gate of inverter 103 to be able to easily turn on the trigger element 101 .
FIG. 7 illustrates another embodiment of the present invention in which at least two of the ESD control devices 100 are coupled to each other as shown. So, there would be two of the voltage divider circuits 102 and two of the trigger circuits 101 functioning together to trigger the ESD clamp 110 . One of the advantages of this technique is that elements in the circuits may preferably be of different voltage domains. So, elements from lower voltage domain can be used in the higher voltage domain. By stacking the circuits as shown in FIG. 7 , the voltage over each element will be limited to lower voltage, i.e. below the failure voltage. With the elements from a lower domain, a more specific trigger voltage can be chosen or a smaller area can be used (smaller elements). Note that even though only two ESD protection devices 100 are shown in FIG. 7 , there may preferably include more than two devices 100 coupled to each other.
Although various embodiments that incorporate the teachings of the present invention have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings without departing from the spirit and the scope of the invention.
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An improved ESD protection circuit having an ESD device and a triggering device to provide a continuously adjustable trigger voltage. This can be accomplished by various techniques such as placing a selected number of triggering elements in series, modifying the gate control circuitry and varying the size of the triggering elements.
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FIELD OF THE INVENTION
[0001] The present invention relates to an earphone, more particularly to an improved portable earphone with a structure having color illuminating members in an independent unit and providing configurations for setting up the mode and type of the illumination according to the using conditions, such that the illuminating members show a blinking effect according to the frequency of the sound source or the independent constant speed, as well as providing a safety warning function.
BACKGROUND OF THE INVENTION
[0002] In general, the basic models of earphones or noise-resisting earpieces sold in the market have the functions of transmitting sound or preventing noises. The design of the present invention is to build an electronic circuit on an earphone, and make use of the frequency of the sound source and the sound volume to produce variations of color or monochrome light sources, allowing people around to see the portable earphone with an obvious illuminating warning effect, and the illuminating section includes an earplug or an earpiece, an earphone cable, and an ear hanger or ear frame. Thus, the invention provides an illumination for joggers at night and a warning effect for the drivers to notice the position of the joggers. The invention can be used by airport ground service staff, tunnel construction workers, or nighttime road construction workers. If a large color illuminating warning noise-proof earpiece is worn, then it can achieve a significant warning effect to enhance visibility of the position of the operator who wears the large color illuminating warning noise-proof earpiece.
[0003] There are many types of color illuminating earphones, such as those illuminating according to the frequency of sound, volume of sound, or blinking with a constant frequency, which is set by users freely. The position of the illumination can be set according to the user's purchase option, such as setting the illuminating position at the earplug or earpiece of an earphone, an earphone cable, an ear hanger, an ear frame, or a support frame at the top of a large noise-proof earphone. The color of the illumination can be set according to the types of the products, such as monochrome, multiple colors, or color, and the light source could be a lamp or an LED component.
SUMMARY OF THE INVENTION
[0004] The primary objective of the invention is to provide an earphone which is a popular and safe creation having a color illuminating member for an independent unit, setting the earphone to various modes and types for the illumination according to the using conditions to show monochrome or colored beams in different occasions, setting up the frequency of sound source or providing the independent blinking at a constant speed, and also providing a safety warning function for special environments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view of the color illuminating earphone according to a preferred embodiment of the present invention.
[0006] FIG. 2 is an exploded view of a control board of the color illuminating earphone according to a preferred embodiment of the present invention.
[0007] FIG. 3 is a perspective view of a control board of the color illuminating earphone according to a preferred embodiment of the present invention.
[0008] FIG. 4 is an exploded view of the earphone section of the color illuminating earphone according to a preferred embodiment of the present invention.
[0009] FIG. 5 is a perspective view of ear-hanging type color illuminating earphone according to a preferred embodiment of the present invention.
[0010] FIG. 6 is a perspective view of the back-hanging type earphone according to a preferred embodiment of the present invention.
[0011] FIG. 7 is a perspective view of the large color warning noise-proof earphone according to a preferred embodiment of the present invention.
[0012] FIG. 8 is a block diagram of the control circuit according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] The detailed description and technical characteristics of the present invention are described together with the drawings as follows.
[0014] Please refer to FIGS. 1 and 2 , the color illuminating earphone 1 according to the present invention comprises an electronic control board 11 , a connector 12 , an earphone illuminating wire 13 , and an illuminating earplug or earpiece 14 , wherein the earphone wire material 13 is disposed outside a core of the earphone illuminating wire 131 and wrapped with an earphone transparent material 132 having a light guiding effect.
[0015] The color illuminating earphone 1 according to the present invention comprises an electronic control board 11 thereon, a chip 111 , and a plurality of illuminating components 112 , 113 , 114 , 115 , which can produce a blinking light source according to the frequency of the sound source or the volume of sound, and produce an illumination through the earphone wire 13 , the upper transparent casing 116 of the control board 11 and the lower transparent casing 117 of the control board 11 .
[0016] In FIG. 3 , the illuminating components 112 , 113 , 114 , 115 of the electronic control board 11 may vary the blinking illumination or warning according to the frequency of the inputted sound or the volume of sound, or has the constant blinking cycle to produce a monochrome or multiple-color light for the blinking function. Metal particles are added into the transparent earphone wrapping material for its wire formation, such that the light source produced by the illuminating components 112 , 113 , 114 , 115 is projected onto the transparent material 132 of the earphone illuminating wire 13 through light guiding to produce a refraction of the light source to enhance the diffusion feature of light to the surroundings. Please refer to the control circuit block diagram as shown in FIG. 8 for the principle of controlling the illumination of the light source according to the invention.
[0017] In FIG. 8 , the control circuit block diagram shows an electronic circuit chip 111 and a plurality of illuminating components 112 , 113 , 114 , 115 on the electronic control board 11 . After the audio signal provided by the earphone illuminating wire 13 is inputted to the electronic circuit chip 111 and the control circuit distinguishes different frequencies and sound volume of the signal source to control the blinking brightness and time of the control illuminating components 112 , 113 , 114 , 115 , and then the control illuminating components 112 , 113 , 114 , 115 produce a light source and a projection effect through the light guiding material of the transparent material 132 wrapped around the earphone wire 13 , or directly use the transparent upper casing 116 of the control board 11 and the lower casing 117 of the control board 11 , which are transparent material having the light guiding property, to produce the radiation of the color light. The electronic control board 11 can be designed to carry a battery 118 or an electric power supply to supply power to the sound source.
[0018] In FIG. 4 , the illuminating earplug or earpiece 14 of various types of earphones according to the invention comprises a circuit board 141 having an illuminating component 142 , a transparent casing 143 , and a loudspeaker 144 , such that the earpiece section also has an illuminating function. A sponge member 145 may be added to the earphone as needed.
[0019] Please refer to FIGS. 5 and 6 for the actual object according to a preferred embodiment of the invention, which can be designed as an ear-hanging type earphone 2 and a back hanging type earphone 3 that includes an illuminating wire 13 and an illuminating earpiece 23 .
[0020] Please refer to FIG. 7 for the actual object according to the preferred embodiment of the invention. A large color illuminating noise-proof earphone 4 is made according to the structure and principle of the invention, so that sportsmen jogging at night, airport ground service staff, tunnel construction workers, road construction workers at night or people working in a dark environment can wear the large color illuminating noise-proof earpiece 4 according to the invention. By means of the functional design of the earpiece, a support frame 41 of the color illuminating noise-proof earpiece 4 has a warning light 42 , 43 to produce a constant blinking light for the illuminating earpiece 44 and the earphone illuminating wire 13 in order to achieve the safety warning effect, and prevent any dangerous collision.
[0021] In FIG. 1 , metal particles 133 or other illuminating materials such as thin metal films and gold thread materials are added into the earphone illuminating wire 13 of the invention to improve the light diffusion effect of the earphone illuminating wire 13 .
[0022] The illuminating components 112 , 113 , 114 , 115 can be made of different colored LEDs, such that the color illumination effect with different color combinations can be generated.
[0023] In summation of the description above, the color illuminating earphone 1 and the principle of using the ear-hanging type earphone 2 or the back-hanging type earphone 3 use the electronic control board 11 of the color illuminating earphone 1 and the control board 11 of an illuminating earplug or earpiece 14 or the circuit control of the circuit board 141 to project the light produced by the illuminating components 112 , 113 , 114 , 115 according to the frequency of the sound source, volume of sound, and a constant blinking function onto the earphone illuminating wire 13 , the upper casing 116 of the control board 11 , the lower casing 117 of the control board 11 , the transparent member 143 , and the warning light 41 , 42 , and then produce radiated lights, so that users may wear the color illuminating earphone having popular and safety warning functions at a concert, with an audio device, or in a dark place.
[0024] While the invention has been described by way of example and in terms of a preferred embodiment, it is to be understood that the invention is not limited thereto. To the contrary, it is intended to cover various modifications and similar arrangements and procedures, and the scope of the appended claims therefore should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements and procedures.
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An improved portable earphone with a structure having color illuminating members in an independent unit and providing configurations for setting up the mode and type of the illumination according to the using conditions. The illuminating members show a blinking effect according to the frequency of the sound source or the independent constant speed, as well as providing a safety warning function.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of provisional patent application Ser. 61/214,726 filed 2009 Apr. 28 by the present inventor.
This application claims the benefit of provisional patent application Ser. 61/217,828 filed 2009 Jun. 5 by the present inventor.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not applicable
BACKGROUND OF INVENTION
1. Field of Invention
This invention relates to floor mats in general, but most specifically those used in cars, trucks, and other human operated equipment where vehicle appearance and protection, personal appearance and protection, and air quality within the vehicle are all of concern.
2. Description of Related Art
Upon entering a vehicle, depending on location and weather conditions, it is normal to track into the vehicle, the following undesired elements (undesirables); water, snow, ice, earth, grass, pollen, gravel, sand, animal excrement, and anything else one has had the misfortune to step on or into. To protect the vehicle's original floor mat covering from these undesirables, a variety of accessory floor mats are currently on the market. These floor mats are typically made of a carpet material, similar to the material used in the vehicle's original floor mating, or a waterproof elastomeric material, more suited for inclement weather conditions. Such waterproof elastomeric mats are commonly known as All Weather mats, and typically have numerous indentations and wells for collecting dirt and water. While these standard floor mat mats are effective at protecting the original floor mat covering of the vehicle, there are adverse effects, caused by the introduction of the undesired elements, for which the standard floor mats do not protect against.
One such adverse effect, common among carpeted floor mats, is the diminished appearance of the floor mat once these undesirables are introduced. The simple presence of the undesirables is unsightly, requiring the floor mat to be vacuumed on a regular basis. Even when vacuumed, the undesirables often leave stains, requiring the floor mat to be washed. Even when washed, the abrasive nature of some of the undesirables causes wear on the floor mat and eventually the floor mat must be replaced. In most cases the first area to wear out is the heel pad area, generally as a result of the accumulated debris being ground into the mat by the back of the driver's shoe as he operates the accelerator and brake pedals.
Another adverse effect is salt damage and this commonly occurs during protracted inclement weather such as snow. Salt, used to keep roads from freezing, along with excess snow and ice, are tracked onto the floor mat and quickly result in a salt water solution. This solution not only has the potential to spill onto the car floor mat, later causing rust, it is also often absorbed by the heel of the occupant's shoe and lower pant leg, causing salt stains and damage upon drying.
There are a number of prior art patents which have proposed solutions to this problem and which show various means for collecting and/or draining off the water and snow melt, none of which proposed solutions are considered completely satisfactory. Examples of the patented devices are shown in: U.S. Pat. Nos. 2,650,855 to Peirce; 3,149,875 to Stata; 3,284,836 to Ioppolo; 4,211,447 to DiVincenzo; 4,280,729 to Morawski and 4,420,180 to Dupont.
Yet another adverse effect not covered by the prior art, is the pollution of cabin air caused by the introduction of the undesirables. Once tracked into the vehicle, the undesirables are then deposited on the floor mat and further ground down by the action of one's feet on the mat. This grinding down phenomenon creates a fine dust and particle mixture of the undesired material. The heater, air conditioner, or ventilation fan blows down upon the surface of the mat, which introduces the undesired and potentially unhealthy, dust and debris mixture into the vehicle's cabin air. Compounding this problem is the fact that each year, as cars get smaller and lower, the interior space of the cabin gets smaller. This has two consequences that cause the degree of air pollution to increase exponentially. The first consequence is that the volume of cabin air decreases, yet the amount of introduced undesirables remain the same. The second consequence of the smaller and lower cars, is that the distance from the fan to floor mat, along with the distance from the floor mat to the occupants, are both significantly reduced.
BRIEF SUMMARY OF THE INVENTION
Vehicle Mat Embodiment
In accordance with one embodiment, a floor mat system utilizing floor mat with a top surface created by a multitude of projections or blades, a predetermined hole pattern in the bottom surface, and a multi planar surface on the mat bottom surface that directs substantially all the debris that has fallen down through the blades into the holes and down into a tray with raised edges. The tray (waterproof sealed base with raised edges), into which the mat is inserted has depressions that match the hole pattern of the mat. This allows for a greater amount of debris to accumulate as well as for better protection for the accumulated debris. Provision is made for the mat to move the precise distance, relative to the tray to seal all the depressions and further protect the accumulated debris. In one embodiment that describes the mat system for use in a vehicle, provision is also made for a replaceable heel pad as well as a carpeted mat with the same shape and locking features of the floor mat so as to be interchangeable with the floor mat when an all carpet appearance is preferred.
Entrance Mat Embodiment
The aforementioned problems also exist with entrance mats, more specifically, large entrance mats typically found in large commercial buildings. The basic floor mat as described herein provides the best scraping mat available and has been very successfully marketed as such for many years by the manufacturers of a similar product (Solutia). However, due to its very nature, it is very difficult to vacuum since the hose can never be brought close to the bottom. In ordinary household mats, this is overcome by merely turning the mat upside down. In large entrance mats, especially like those in office building entrances, this is not the case.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Several embodiments of the present invention will be provided, by way of examples only, with reference to the appended drawings, wherein:
FIG. 1A shows the completed assembly in accordance with one embodiment of the vehicle floor mat, herein called the First Embodiment.
FIG. 1B shows the exploded view of the First Embodiment assembly; an Floor mat, a waterproof lining welded to the underside of said Floor mat, a plastic rubber border either welded or sewn to said Floor mat, and a carpet heel pad.
FIG. 1C shows a close up view of the Floor mat crimped projections and the holes in the bottom surface of the Floor mat in accordance with the First Embodiment.
FIG. 1D shows a cross section of heel pad 112 set within floor mat pad 106 with the top surface of heel pad 112 A flush with top surface of floor mat pad 106 A.
FIG. 2A shows the completed assembly in accordance with another embodiment of the vehicle floor mat, herein called the Second Embodiment.
FIG. 2B shows the exploded view of the Second Embodiment assembly; a replaceable heel pad, a heel pad plate, an Enhanced Floor mat with a multi-planar bottom surface and hole pattern herein called Enhanced Floor mat, a waterproof tray, a rotatable cam, a cover plate and sponges.
FIGS. 3A and 3B show various views of the Enhanced Floor mat with multi-planar bottom surface, hole pattern, crimped blade like projections, and cam follower, in accordance with the Second Embodiment.
FIG. 4 shows the water proof tray, with a plurality of ribs matching the hole pattern of the Enhanced Floor mat, water drainage slots, a water collection area, and a heel pad section
FIG. 5A shows the Enhanced Floor mat inside the waterproof tray without the cam, in accordance with the Second Embodiment.
FIG. 5B shows a close up of the cam and the cam follower attached to the Enhanced Floor mat, in accordance with the Second Embodiment.
FIG. 5C shows the top and bottom view of the rotatable cam used for shifting the position of the Enhanced Floor mat.
FIG. 5A shows the Enhanced Floor mat inside the waterproof tray with the cam set in the open position, in accordance with the Second Embodiment
FIG. 6B shows the Enhanced Floor mat inside the waterproof tray with the cam set in the closed position, in accordance with the Second Embodiment.
FIG. 7A shows an exploded view of the cover plate, sponge, and cam assembly, in accordance with the Second Embodiment.
FIG. 7B shows a close up view of the cover plate, sponge, and cam assembly, in accordance with the Second Embodiment.
FIG. 8A shows the replaceable heel pad and heel pad plate with a locking lever, in accordance with the Second Embodiment.
FIG. 8B shows a close up view of the heel pad and heel pad plate locking into the waterproof tray, in accordance with the Second Embodiment.
FIG. 9 shows a waterproof tray with vertical ribs, in accordance with another embodiment
FIG. 10A shows an Enhanced Floor mat with ribs molded to the underside surface, in accordance with another embodiment
FIG. 10B shows a section view, in accordance with another embodiment of the vehicle floor mat, a water proof tray, the Enhanced Floor mat with a hole pattern and ribs on the underside, a replaceable heel pad, and a moveable plastic sheet.
FIG. 11A shows another embodiment herein called the OEM embodiment utilizing a waterproof tray designed to fit into a recess, an Enhanced Floor mat with carpeted heel pad. This embodiment allows for a standard sized unit that can be installed in either the OEM carpet, the OEM aftermarket floor mat, or any one of the custom aftermarket floor mat mats available, whether made of plastic or carpeted material.
FIG. 11B shows the OEM embodiment sitting inside the recess cut out of an aftermarket carpet floor mat
FIG. 12 shows an entrance mat made from Enhanced Floor mat placed inside a waterproof tray in accordance with another embodiment
DRAWINGS
Reference Numerals
100 —First Embodiment
102 —Floor mat
104 —Hole pattern in Floor mat
106 —Floor mat projections (blades)
106 A top surface of projections
108 —Waterproof Lining (welded to Floor mat)
108 A underside of Floor mat
110 —Raised plastic rubber border
110 A—Floor mat perimeter
112 —Heel pad
112 A top surface of heel pad
112 B underside of heel pad
114 —Cut out section for Heel Pad in Floor mat
200 —Second Embodiment
202 —Waterproof tray
202 A—Bottom surface of waterproof tray
202 B—Inside perimeter of tray
204 —Ribs for collecting and sealing undesirables
204 A—Top surface of ribs
206 —Water Drainage Slots
208 —Water collection area
208 A—Water collection area ribs
208 B—Water drainage slots in ribs
210 —Cam
210 A—Open position of cam
210 B—Closed position of cam
212 —Cam Compartment
214 —Cover plate
214 A—Screw holes in cover plate
214 B—Screw posts for cover plate in tray
216 —Sponge
218 —Enhanced Floor mat
220 —Multi-planar bottom surface
222 —Cam follower
224 —Heel pad plate
224 A—Locking lever
224 B—Locking channel in waterproof tray
226 —Section in tray for heel pad/heel plate assembly
302 —Waterproof tray with vertical ribs
304 —Vertical ribs
306 —Side mounted cam
308 —Water collection area
400 —Third Embodiment
402 —Waterproof tray (no ribs)
404 —Moveable plastic sheeting
406 —Enhanced Floor mat with ribs molded to the underside
408 —Ribs on the underside of the Floor mat
410 —Water collection area
500 —OEM Embodiment
502 —OEM waterproof tray
504 —Vertical Edges
506 —Lip on top surface
508 —Recess cut out from carpet floor mat
510 —OEM Vehicle Type Carpet Floor Mat
602 —Waterproof tray—Commercial Entrance Mat Embodiment
604 —Ribs on the top surface of the tray
DETAILED DESCRIPTION OF THE INVENTION
First Embodiment
It should be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical, mechanical or electrical connections or couplings. Furthermore, and as described in subsequent paragraphs, the specific mechanical and/or electrical, other configurations illustrated in the drawings are intended to exemplify embodiments of the invention. However, other alternative mechanical and/or electrical or other configurations are possible which are considered to be within the teachings of the instant disclosure.
One embodiment of the vehicle floor mat, herein called the First Embodiment 100 is illustrated in FIG. 1A and FIG. 1B (exploded view). This embodiment utilizes a plastic mat with a multitude of crimped projections 106 ,a predetermined hole pattern 104 herein called Floor mat 102 ( FIG. 1C ). A waterproof lining 108 is attached to the underside of the Floor mat 108 A and a plastic rubber border 110 is attached to the entire Floor mat perimeter 110 A ( FIG. 1B ). The attachment of the waterproof lining 108 and the plastic rubber border 110 would ideally be accomplished through thermal welding however other embodiments may employ other means of attachment such as gluing, chemical welding, sewing or the like. A heel pad 112 , in this embodiment made of carpet, is placed into a cutout section of the Floor mat 114 (shown in FIG. 1B ) such that the top of the heel pad 112 A sits flush with the top of the Floor mat projections 106 A as seen in FIG. 1D . Other embodiments may utilize another soft, non abrasive, non skid material for the heel pad such as a foamed flexible plastic that could be easily replaceable. It should be noted, that the overall effect of adding a waterproof sealed bottom with a raised edge border could easily be replaced by using a tray with molded raised edges into which the Floor mat is placed.
Operation
First Embodiment FIGS. 1 A, 18 , 1 C and 1 D
The crimped projections 106 of the Floor mat 102 are ideal for scraping any undesired material off the sole of a shoe and for concealing said undesired material below the visible top surface of the projections 106 A. The flush nature of the top surface of the heel pad 112 A with the top of the Floor mat projections 106 A, enable the occupant of the vehicle to simply push any undesired material off the surface of the heel pad 112 A with a simple swipe of his shoe sole edge into the crimped Floor mat projections 106 where it will then drop down to the bottom surface and be concealed as well. The crimped projections 106 also serve as an air flow deflection, reducing the amount of undesirables mixing with the cabin air when the air conditioner, heater, or ventilation fan is turned on. The combination of a waterproof lining 108 , welded to the bottom of the Floor mat 108 A, and the plastic rubber border 110 welded to the perimeter of the Floor mat 110 A, create a waterproof enclosure capable of containing any water caused by snow melt. The crimped projections 106 also serve as a barrier, preventing the heels of the operator's shoe, and the bottom of the operator's pant leg from coming into contact with any water. After months of use in off road and winter conditions, the mat still looks clean and the undesirables are contained and protected without the need to clean.
Second Embodiment
Another embodiment of the vehicle floor mat, herein called the Second Embodiment 200 is illustrated in FIGS. 2A through 88 . This embodiment utilizes the following components ( FIG. 2A and exploded view FIG. 2B ): a heel pad 112 , which could be replaceable, a heel pad plate 224 with locking lever 224 A, a water proof tray with raised edges 202 , a cover plate 214 , a sponge 216 , and enhanced Floor mat 218 with a multi-planar bottom surface 220 , crimped projections 106 , and a predetermined hole pattern 104 , herein called Enhanced Floor mat 218 . FIGS. 3A and 3B show various views of the Enhanced Floor mat 218 , with the multi-planar bottom surface 220 , the predetermined hole pattern 104 , the crimped blade like projections 106 , and a cam follower 222 . As shown in FIG. 4 , the waterproof tray 202 contains a plurality of ribs 204 , water drainages slots 206 , a cam compartment 212 , and a water collection area 208 . The water collection area 208 is contained by the inside perimeter 202 B of the tray 202 and a rib 208 A. The Enhanced Floor mat 218 is placed inside a waterproof tray 202 as shown in FIG. 5A . A cam 210 is placed inside the waterproof tray cam compartment 212 where it is connected to said cam follower 222 as shown in FIG. 58 . FIG. 5C shows the top and bottom views of the Cam 210 . Illustrated in FIG. 6A , the waterproof tray 202 has a plurality of ribs 204 that match the predetermined hole pattern of the Enhanced Floor mat 218 . The Enhanced Floor mat 218 rests on the top surface 204 A of the plurality of ribs 204 . As shown in FIG. 6A , when the cam 210 is in the open position 210 A, the Enhanced Floor mat 218 is shifted into a position such that the predetermined hole pattern 104 rests in between the plurality of ribs 204 of the waterproof tray 202 . As shown in FIG. 5B , when the cam 210 is in the dosed position 210 B, the Enhanced Floor mat 218 is shifted into a position such that the predetermined hole pattern 104 rests on top of the plurality of ribs 204 of the waterproof tray 202 . Illustrated in FIG. 7A (exploded view) and 78 , is the assembly of the cover plate 214 , the sponge 216 , and the cam 210 . The sponge 216 is placed in the water collection area 208 , and the cam 210 is placed in the cam compartment 212 . The cover plate 214 is then placed on top of the cam 210 and the sponge 216 and with screws is attached using the provided screw holes 214 A on the cover plate 214 and the screw posts 2148 inside the waterproof tray 202 . In other embodiments of the vehicle floor mat, the sponge 216 may be attached to the cover plate 214 or may not be used altogether. In other embodiments of the vehicle floor mat the cover plate 214 may be attached to the tray using other attachment methods aside from screws such as rivets, snap fittings, glue or chemical or thermal welding. FIG. 8A shows the replaceable heel pad 112 and heel pad plate 224 with locking lever 224 A. In this embodiment the replaceable heel pad 112 and heel pad plate 224 will be attached using glue. Other embodiments may use another means of attachment such as sewing or staples or the like. Other embodiments might not utilize a heel pad plate 224 at all and would simply use a replaceable heel pad 112 . The replaceable heel pad 112 and heel pad plate 224 are contained in the heel pad section 226 of the waterproof tray 202 . FIG. 5B shows a section view illustrating the heel pad 112 and heel pad plate 224 with locking lever 224 A, locking into the heel pad section 226 of the waterproof tray 202 . As in the first embodiment, the top surface 112 A of the heel pad 112 sits flush with the top surface 106 A of the Enhanced Floor mat 218 .
Operation
Second Embodiment FIGS. 2 A Through 7 B
The Second Embodiment 200 of the vehicle floor mat incorporates the majority of operations and benefits described in the First Embodiment 100 . The differences and additional benefits are explained as follows. The undesirable material is scraped off the soles of the operator's shoes, by the crimped blade like projections 106 of the Enhanced Floor mat 218 . The material then falls to the bottom multi-planar surface 220 and then through the predetermined hole pattern 104 of the Enhanced Floor mat 218 and then into the waterproof tray 202 . The multi-planar bottom surface 220 is designed such that each plane of the surface slopes towards the predetermined hole pattern 104 , and there are no horizontal surfaces for the undesired material to collect. When exposed to the vibrations of use, the undesirable material is then directed to the predetermined hole pattern 104 where it will then fall through and into said waterproof tray 202 . It should be noted, the blade like projections 106 of the Enhanced Floor mat 218 , as best shown in FIG. 1C , are formed from circular tufts of blades that have holes 104 in the center of the tufts. The undesirables that fail through this area fall straight through, as the blades 106 also have no horizontal areas. Either attached to, or molded as part of the Enhanced Floor mat 218 is a cam follower 222 . The cam 210 is attached to the cam follower 222 and held in place by the cover plate 214 . When rotated, the cam 210 , shifts the Enhanced Floor mat 218 position inside the waterproof tray 202 . When the cam 210 is rotated to the open position 210 A, the predetermined hole pattern 104 , of the Enhanced Floor mat 218 , rests in between the plurality of ribs 204 of the waterproof tray 202 ( FIG. 6A ). The undesirable material that falls through the predetermined hole pattern 104 , of the Enhanced Floor mat 218 , then falls in between the plurality of ribs 204 , and onto the bottom surface 202 A of the waterproof tray 202 . When the cam 210 is rotated to the sealed position 2108 , the predetermined hole pattern 104 , of the Enhanced Floor mat 218 , rests on the top surface 204 A of the plurality of ribs 204 ( FIG. 6B ). This traps any undesirable material that has previously fallen to the bottom surface 202 A of the waterproof tray 202 , and prevents said undesirable material from mixing with the cabin air, and provides more space and better concealment for the undesirables. This feature is especially important for those who suffer allergies due to dust, pollen, spores, and other similar matter. The waterproof tray 202 contains water drainage slots 206 which direct any water that has accumulated in said tray 202 , to a water collection area 208 . A sponge 216 is located in the water collection area 208 that will absorb any water and facilitate water removal when required. ( FIG. 7A ). The cover plate 214 covers the water collection area 208 and provides a means to secure the cam. The replaceable heel pad 112 and heel pad plate 224 with locking lever 224 A has the ability to lock into the heel pad section 226 of the waterproof tray 202 , through the locking channel 2245 as shown in FIG. 88 . This prevents the possibility of the heel pad accidently shifting out of position during operation, causing a potentially dangerous situation, while at the same time holding down the top section of Enhanced Floor mat 218 .
Other Embodiments
Other embodiments of the vehicle floor mat, having similar features and benefits are possible as well. For example, one such embodiment may utilize a waterproof tray 302 having vertical ribs 304 instead of horizontal ribs and the Enhanced Floor mat 218 would be shifted horizontally instead of vertically using a cam 306 mounted on the side of the tray ( FIG. 9 ). This would allow all the dirt and debris to easily flow straight to the water collection area 308 .
Another embodiment 400 might utilize a waterproof tray without any ribs at all 402 . Instead ribs 408 might be molded onto the underside of the Enhanced Floor mat 406 ( FIG. 10A ), which would sit on top of a moveable plastic sheet 404 , located inside the waterproof tray 402 ( FIG. 10B ). In this embodiment, dirt and debris (undesirables) would fall through the predetermined hole pattern of the further Enhanced Floor mat 406 with ribs molded to the underside 408 , and land on the moveable plastic sheet 404 . The sheet 404 can then be rolled, or pulled, carrying the fallen dirt and debris and depositing it into the water collection area 410 .
Another embodiment herein called the OEM Embodiment 500 , would utilize all or some of the above features. An OEM waterproof tray 502 , with similar features to the Second Embodiment tray 202 , but shaped with substantially vertical edges 504 and preferably with a lip 506 on the top surface, along with the Enhanced Floor Mat 218 and heat pad 112 , would be inserted into a recess cut 508 out of the original OEM car mat 510 . The carpeting that is cut out could be then be cut into the shape of the Floor mat 218 and the heel pad insert 112 . The heel pad carpet would be lined with a plastic backing similar to the heel pad backing 224 and the Floor mat shaped cut out would be lined with a similar plastic backing but in the shape of the Floor mat 218 together with cam follower 222 . FIG. 11A shows the cutout 508 cut out of an aftermarket floor mat shape, but the same cutout could be made in the original carpet as installed in a new car. In the former case, the aftermarket custom shape mat could be plastic or carpeting, and if it is plastic, the carpet needed for the carpeted insert would preferably be the same as that chosen for the heel pad. This embodiment would provide a flush installation in the car with the possibility of using either the Floor mat insert when conditions demanded it, or the carpeted mat insert when a more formal appearance is desired. It should be noted that the use of well secured custom shapes is of particular commercial importance now as a result of massive re calls by some car manufacturers and the resultant media attention, all as a result of several floor mat mats jamming under the accelerator pedal. Customized floor mat mats have the car shape of that particular model and the securement provisions designed to fit that model. This embodiment allows for a standard Floor mat unit, with its resultant cost savings to be applied in a market where customizing the mat is of the most importance. It further provides an all season, all weather floor mat system that one can change over as required, from Floor mat insert to fully carpeted.
It should be noted that the same combinations of mat and tray can be set into any floor mating material to provide the advantages of such a combination in a flush with floor mating embodiment.
Entrance Mat Embodiment FIG. 12
The use of the improved floor mat in combination with a tray provides a means to hold, conceal, and seal large quantities of debris. The use is not limited to vehicle mats. In large entrance mats, especially those used in office building entrances, this feature would have significant benefits. The basic floor mat 102 as described herein provides the best scraping mat available and has been very successfully marketed as such for many years by the manufacturers of the product (Solutia). Due to its very nature, it is very difficult to vacuum since the vacuum hose can never be brought dose to the bottom. In ordinary household mats, this is overcome by merely turning the mat upside down. For large entrance mats in commercial applications, this is not easily done, as the size and weight of the mat prohibit easy lifting. The improved floor mat 218 when used in combination with a waterproof tray 602 , having ribs 604 similar to those mentioned in the vehicle floor mat embodiment 200 , seals in debris making regular cleaning unnecessary. When cleaning is finally required, the light weight floor mat 218 could be easily removed and the waterproof tray 502 , which would normally be made of a heavy rubber composite with wide sloping edges and a depression to accommodate the mat could easily be vacuumed.
Those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof of parts noted herein. While a device or an accompanying method have been described for what are presently considered the exemplary embodiments, the invention is not so limited. To the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
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An improved apparent surface (Astroturf like) material surrounded by a water tight enclosure with raised borders that better control and conceal any debris and dirt that is scraped off the shoes or otherwise fall onto the mat. Means are provided to direct the debris to an area where it is better concealed from view and more protected from any blowing air. The debris is less likely to be blown about by any stream of air, such as a heater fan. In one configuration the debris is substantially completely sealed.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method for monitoring a voltage supply of a control unit in a motor vehicle.
BACKGROUND INFORMATION
[0002] In other systems, a voltage supply of a control unit faults may be recognized in the voltages used for supplying the components of the control unit, and then the function of the components of the control unit may be interrupted via a RESET line from a supply module, resulting in a shutdown. The voltages are monitored for faults using bands around a specified quantity.
[0003] German Published Patent Application No. 44 36 372 discusses a circuit arrangement for an electronic regulating system for motor vehicles, where monitoring of the power supply is provided. If a fault is detected, the regulation is switched over or switched off. An interrupt signal to a monitoring processor is taken into account in the analysis of the monitoring signals. Signal lines are provided, which conduct monitoring signals and test signals to a logic. German Published Patent Application No. 39 28 537 discusses a CAN bus, which connects control units to one another. The resettability of a bus module is monitored. The reset procedure is performed repeatedly in a loop. A time-out counter defines the reset time. Within this time, a check determines whether the reset status has been set. German Patent No. 198 18 315 discusses the provision of independent reference voltages. A supply module generates the required voltages and is resettable.
SUMMARY OF THE INVENTION
[0004] The method for monitoring a voltage supply of a control unit in a motor vehicle according to the present invention may provide that a test of the RESET line is performed, this may allow for a safe simulation of a fault. This provides the information that the monitoring circuit is active and results in increased dependability of the control unit function. This method is applicable in particular in those cases where more than one supply voltage is to be provided by the supply module, such as 5 V, 3.3 V, and 1.8 V, for example.
[0005] In testing the RESET line, the limits of the bands used to monitor the supply voltages are alternately shifted over and below the specified value, so that a RESET is forced. This makes the effect clear for the processor, and the processor counts the time of the duration of a RESET pulse, this may allow for checking of the operation of the RESET line. Both limits are tested and this may increase the dependability of the method according to the present invention.
[0006] In addition, the method according to the present invention is executed when starting up a control unit, so that operability is always monitored when starting operation.
[0007] The components of the control unit which are stopped in the event of a fault do not become active again until the supply module signals no faults for all of its monitoring functions; this accomplishes the result that the control unit only operates when no fault is present. This is useful in safety-relevant systems such as restraint systems for preventing malfunctions.
[0008] At least two independent voltages are provided, the first being used for regulation and the second for monitoring. This rules out a fault which affects only one of the voltages having an effect on the other voltage thus causing the fault to propagate. In order to generate two independent voltages, either two voltage sources isolated from one another or one voltage source including two impedance transformers connected are required.
[0009] On failing the RESET line test, a warning or blocking of the control unit function is performed. This prevents a defective control unit from causing dangerous situations, which is of interest in particular in the case of control units for restraint systems.
[0010] A control unit including the arrangement for executing the method according to the present invention is provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 shows a block diagram of the control unit according to the present invention.
[0012] [0012]FIG. 2 shows a flow diagram of the method according to the present invention.
[0013] [0013]FIG. 3 shows a voltage/time diagram illustrating the variation of a voltage with the limits of a monitoring band and a specified value.
[0014] [0014]FIG. 4 shows a test sequence of RESET pulses in a voltage/time diagram.
[0015] [0015]FIG. 5 shows a block diagram of a supply module according to the present invention.
[0016] [0016]FIG. 6 shows two voltage sources for supplying the regulating voltage and the test voltage.
[0017] [0017]FIG. 7 shows a voltage source including two impedance transformers for supplying the regulating voltage and the test voltage.
[0018] [0018]FIG. 8 shows a band gap voltage reference.
DETAILED DESCRIPTION
[0019] In safety-relevant systems in motor vehicles including integrated control units, the supply voltages to be supplied must be monitored in order to guarantee proper operation of the control unit components only at supply voltages which are within predefined parameters.
[0020] According to the present invention, a method of monitoring a voltage supply to a control unit in a motor vehicle is described, in which a fault may be safely simulated during a test. The test is performed with each startup of the control unit, a test of the RESET line being executed by manner of which the function of control unit components may be interrupted. The test is initiated by a supply module of the control unit, so that the RESET line interrupts the components and the control unit processor for a predefined time period using periodic pulses. The processor counts the time between the interrupts in order to monitor the operation of the RESET line.
[0021] [0021]FIG. 1 shows the control unit according to the present invention in the form of a block diagram. A supply module 1 is supplied with the required electric power by a battery voltage VBATT to provide the predefined voltages for the individual components of the control unit. Supply module 1 is connected to an acceleration sensor 5 , a rotational speed sensor 6 , a controller 4 , an ignition circuit trigger 3 , a PAS (peripheral acceleration sensor) interface 50 , and a CAN (controller area network) bus interface 51 via a first electrical power supply line 9 . PAS sensors are acceleration sensors distributed in the vehicle, for example, for side impact sensing.
[0022] Power supply line 9 has a voltage of 5 V. In addition, supply module 1 is connected to all components of the control unit via a RESET line 7 . Supply module 1 is connected to ignition circuit trigger 3 , controller 4 , PAS interface 50 , CAN bus interface 51 , a processor 2 , and a memory 52 via a second power supply line 8 . Power supply line 8 has a supply voltage of 3.3 V. Supply module 1 is connected to processor 2 via a third power supply line 10 , which has a voltage of 1.8 V. The processor core and the memory core of processor 2 are supplied with voltage here in particular. Individual power supply lines 8 , 9 , and 10 may also be connected to further components such as interfaces, sensors, and memories. More or less than three supply voltages may also be provided by supply module 1 , and different components may be simultaneously connected to different voltage supply lines.
[0023] Supply module 1 converts battery voltage VBATT into the supply voltages that are required for the control unit components. This means that 5 V, 3.3 V, and 1.8 V are generated from the battery voltage. Data connections that concern the functions of the individual components are not shown. Control lines are also not shown. After power-on, a test is automatically initiated in supply module 1 . Here this test concerns RESET line 7 in particular, to which the individual components of the control unit are connected. This ensures that, in the event of a fault in the voltage supply, the components are stopped, so that the control unit will not issue erroneous signals which might result in dangerous situations in the motor vehicle.
[0024] After all three voltages 5 V, 3.3 V, and 1.8 V are within their monitoring windows for the first time or again, a fixed sequence controller in supply module 1 starts the test of supply module 1 . This allows for monitoring of the test step-by-step via RESET line 7 . Since the system, i.e., all components of the control unit, are simultaneously stopped via this line 7 , it is also possible to monitor, and ultimately to confirm, the proper effect of the reset signals on the system.
[0025] Supply module 1 generates a RESET pulse, which is transmitted to all components via RESET line 7 . This RESET pulse stops the functions of the components for the duration of the pulse. However, a plurality of RESET pulses are used in the test, so that processor 2 is capable of counting the time between the RESET pulses and their frequency in order to establish whether the RESET test is successful. If the RESET test is unsuccessful, a warning is issued, for example, via display devices, and/or the functions of the control unit are blocked. If the test is successful, the control unit is enabled. The RESET pulse sequence may be implemented using a sequence control which includes a shift register.
[0026] The RESET pulses are triggered by the fact that the supply voltages, which are monitored via bands having upper and lower limit values, display a fault due to a shift in these limits and thus cause a RESET. Since both the upper and lower limits for each supply voltage are shifted to produce a fault, twice as many tests, i.e., six tests, and thus also six pulses, are required to test all limits of the three supply voltages in this case.
[0027] [0027]FIG. 2 shows a flow diagram of the method according to the present invention. In method step 11 the control unit is powered on. Battery voltage VBATT is then applied. Supply module 1 converts battery voltage VBATT into the required voltages for the components in the control unit. Then, in method step 12 , processor 2 executes self-start programs and a pre-initialization for itself and the ICs and/or components in the control unit. At the same time, the test of supply module 1 occurs independently in method step 60 in that a test-specific RESET is generated via RESET line 7 . In the event of a major fault, the entire system is blocked, including processors 2 , 4 , by RESET line 7 (reset-low). In the event of a minor fault, the test of supply module 1 is analyzed in method step 13 . Then, if it is determined in method step 14 that the test was successful, the function of the control unit is enabled in method step 15 . However, if it was determined in method step 14 that the test was unsuccessful, then in method step 16 the individual components of the control unit are brought to a defined safe state via control lines, for example SPI (serial peripheral interface), and in method step 17 a warning is output and, if appropriate, the functions of the control unit are blocked.
[0028] [0028]FIG. 3 shows the variation of supply voltage 23 on power-on in the form of a voltage/time diagram. Specified value 18 of an upper limit 20 and a lower limit 19 is given for supply voltage 23 , i.e., 5 V, 3.3 V, or 1.8 V. If these limits are exceeded by voltage 23 , a fault of the supply voltage exists. After the voltage enters the monitoring window, the test for limits 19 and 20 being exceeded is started after a defined filter time. However, a defined waiting period may be allowed for the supply voltage to reach steady state before the test for limits 19 and 20 being exceeded is started. Reference value Vref, which is equal to specified value 18 but independent of it, is used for the test. For this purpose, in the feedback of the output voltage to the voltage regulator, in addition to the actual voltage, voltage 20 , which is greater than the regulating reference (Vregul) and corresponds to the upper band limit, and voltage 19 , which is less than the regulating reference and corresponds to the lower band limit, are tapped and compared to independent value Vref 23 . If Vref 23 is shifted below the lower band limit, a fault occurs and a RESET pulse is transmitted over RESET line 7 . If Vref is shifted above the upper band limit, another fault occurs and another RESET pulse is generated.
[0029] [0029]FIG. 4 shows the signals on RESET line 7 in the form of a voltage/time diagram. During the test, RESET pulses which stop the functions of the components are generated. If voltage V1 is applied to RESET line 7 , the components of the control unit are enabled. However, if voltage V2 is applied, the functions of the components are stopped. FIG. 4 shows three RESET pulses as an example of this event. The RESET pulses have a duration of t2-t1, t4-t3, and t6-t5. These time differences are always the same. The processor counts the times between t2 and t3 and t4 and t5. If these times are as specified, then the RESET test is successful. The duration of the pulses and the intervals between pulses may be set via hardware in supply module 1 by using delay elements or shift registers.
[0030] [0030]FIG. 5 shows a block diagram of supply module 1 according to the present invention. Battery voltage VBATT is applied to a potentiometer 24 , whose second input is connected to a regulator 25 , which influences potentiometer 24 as a function of the output signals so that it outputs a predefined output voltage. The output voltage of potentiometer 24 is supplied to a voltage divider, which includes resistors 26 , 27 , 28 , and 29 . Resistor 26 and output 50 are connected to the output of potentiometer 24 . Resistor 27 and a positive input of a comparator 31 are connected to the other side of resistor 26 . The other side of resistor 27 is connected to a first input of regulator 25 and to resistor 28 . The other side of resistor 28 is connected to a negative input of a comparator 30 and to resistor 29 . The other side of resistor 29 is connected to ground.
[0031] The voltages from resistors 26 and 28 to the comparator inputs are compared to a reference voltage Vref. Outputs 32 and 33 of the comparators then issue a low signal when the supply voltage generated here exceeds or drops below the band limits. The supply voltage may be tapped at output 50 . Regulating reference voltage Vregul is furthermore connected to the second input of regulator 25 , so that the output voltage of potentiometer 24 is compared here with reference voltage Vregul.
[0032] A resistor network as illustrated here, which is used in integrated circuits both for delivering the supply voltage and for the upper and lower band limits, is manufactured in a particularly precise manner with regard to the divider ratios as well as regulator and monitoring accuracies. This configuration, as shown in FIG. 5, may be implemented for each supply voltage. In the case of three supply voltages, three such circuits are used as shown in FIG. 5.
[0033] [0033]FIG. 6 is a block diagram of a circuit for supplying voltages Vregul and Vref. It has two voltage sources 36 and 35 , which are connected in parallel between a pre-stabilized voltage 34 and ground, and are connected to positive inputs of operational amplifiers 37 and 38 , respectively, the outputs of operational amplifiers 37 and 38 being looped back to the negative inputs. This results in an impedance converter, and voltages vregul and Vref, applied to the particular outputs, are independent of one another. As FIG. 7 shows, this may also be implemented using one voltage source 39 , whose output voltage is then connected to the positive inputs of operational amplifiers 37 and 38 .
[0034] [0034]FIG. 8 shows how such a voltage source 39 , 35 , or 36 may be implemented. In this case it is a band gap reference. A voltage, which is a function of the band gap, is applied to output 40 . This voltage is generated here using a current balancing circuit including a downstream transistor in an emitter configuration. The emitter of a transistor 46 is connected to ground and its collector is connected to a resistor 41 and to its base terminal. The base terminal of transistor 46 is also connected to the base of transistor 45 , whose emitter is connected to ground via a resistor 44 . The collector of transistor 45 is connected to the base of a transistor 43 and also to a resistor 42 . The emitter of transistor 43 is connected to ground, while the collector is connected to voltage output 40 . The other sides of resistors 42 and 41 are connected to output 40 .
[0035] In the case of the band gap reference, the voltage between emitter and base is used as a reference, with a current balancing circuit including transistors 46 and 45 being the basic element. The two transistors 46 and 45 have different current densities, typically with a ratio of 10 to 1 . Using resistor 42 , the current of the current balancing circuit is converted into a voltage, to which the base-emitter voltage of transistor 43 is added. Using a suitable selection of resistor 42 , temperature independence may be achieved if the total voltage corresponds to the band gap of silicon, or approximately 1.22 V. The output current via resistor 41 is used as the constant current required for the current balancing circuit.
[0036] Supply module 1 is configured here as an IC. It may, however, also be made of a plurality of electronic components.
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In a method of monitoring a voltage supply of a control unit in a motor vehicle, a supply module which provides the voltages is connected to the components of the control unit via a RESET line and the RESET line is tested every time the control unit is started or all monitoring limits of the supply module show no fault again after the faults of the monitored voltages have been filtered. This test occurs by forced periodic pulses which are generated on the basis of a shift in the limits of the monitoring bands of the supply voltages. The reference voltages VREGUL and VREF are kept independent of each other here in order to prevent system perturbations.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the priority under 35 U.S.C. §119 of European patent application no. 11182503.0, filed on Sep. 23, 2011, the contents of which are incorporated by reference herein.
FIELD OF THE INVENTION
The invention relates to a system for commissioning devices. The invention also relates to a method for commissioning devices.
BACKGROUND OF THE INVENTION
Radio frequency identification technology (RFID) and, more specifically, near field communication technology (NFC), have proven to be of particular value for setting up Wi-Fi networks and for pairing Bluetooth devices. Furthermore, these technologies can be of high value in the field of smart buildings. For example, they can be used to simplify the commissioning of wireless devices in a smart building.
In this context, the term “commissioning” is used to refer to operations that relate to the configuration of devices, such as establishing a network connection between devices, establishing a control relationship between devices and localizing devices in an environment.
In a typical commissioning procedure two wireless devices are brought in close proximity of each other or in direct contact with each other. Subsequently, these devices establish a secure network connection and/or a control relationship between each other. Network parameters, including encryption keys, are exchanged over a very short distance which makes eavesdropping difficult. NFC technology, which typically requires distances of a few centimeters, provides a particular advantage in this respect. Another advantage of NFC technology is the so-called ease-of-install; NFC technology makes commissioning procedures easy and intuitive to perform and it reduces the error-proneness of these procedures.
As a result, the Wi-Fi Alliance (http://www.wi-fi.org/) has standardized NFC as optional means for Wi-Fi Simple Configuration (WSC), formerly known as Wi-Fi Protected Setup (WPS). This has been described in the document “Wi-Fi Simple Configuration, Technical Specification”, version 2.0.0, December 2010 by the Wi-Fi Alliance.
In accordance with this known commissioning procedure an RFID tag is physically attached to the housing of a first wireless device. The RFID tag contains contact data of the first wireless device, such as its Media Access Control (MAC) address. In order to integrate the first wireless device into a Wi-Fi network, a second wireless device is equipped with an RFID reader unit. The second wireless device is brought into close proximity of the first wireless device in order to enable the RFID reader unit to read out the contact data of the first wireless device from the RFID tag. Then, the second wireless device may use the contact data in so-called in-band communication over the Wi-Fi network in order to integrate the first wireless device in a secure manner into the network.
In a similar way Bluetooth Easy Pairing enables establishing a secure Bluetooth connection between two devices, for example a phone and a headset. In this case not only a network connection is set up, but also a control relationship is established. For example, the audio stream from the phone may be routed to the headset and the headset may transmit commands back to the phone.
Both the Wi-Fi and the Bluetooth examples are based on RFID technology, in particular NFC technology. Specific details of the NFC communication involved have been described in the document “Connection Handover, Technical Specification” by the NFC Forum, version 1.2, July 2010 (http://www.nfc-forum.org/).
Another example of the use of RFID/NFC technology to establish a control relationship between devices is described in patent application WO 2010/032227 A1, filed by NXP Semiconductors and published on 25 Mar. 2010.
WO 2010/032227 A1 discloses a method for controlling controllable devices, such as lamp units that are installed in a building, with a plurality of control interface units, such as light switches. Each control interface unit has a receptor, such as a light switch, for receiving user actuations. Addresses to be used for selective transmission of messages to controllable devices are established by enabling the control interface unit that should control a controllable device to read a tag on or in the controllable device. The control interface units each have their own tag reader capable of reading the tag when the tag is in proximity of the control interface unit. The controllable devices are brought into the proximity of a selected one of the control interface units before installation of the controllable device, in order to indicate that the controllable device has to be controlled by actuation of a receptor of the selected one of the control interface units. The tag of the controllable device is read from the selected one of the control interface units. Information from the tag is automatically used to establish destinations to be used for messages from the selected one of the control interface units in response to future detection of user actuation of the receptor of the selected one of the control interface units. Subsequently, the controllable device may be installed in the building at a location outside said proximity.
Although these examples clearly show that RFID/NFC technology provides important advantages when it is used to commission wireless devices of the kind set forth, there are still a number of shortcomings which hinder large-scale deployment thereof. For example, a typical prior art procedure for connecting a Bluetooth headset with a Bluetooth-enabled mobile phone involves switching on the headset by pushing its power button and bringing it in close proximity of the phone. The procedure requires two end-user actions: (1) switching on the headset and (2) bringing the phone and the headset in close proximity of each other. It is essential that the headset is switched on before or while the phone is in close proximity of the headset; otherwise the procedure will fail. This procedure is not user-friendly and prone to errors. For instance, forgetting to switch on the headset before touching the phone is a mistake which is easily made. Therefore, a bad overall end-user experience may be the result. Furthermore, the headset needs to be equipped with a power button which increases its costs and limits the freedom to design it. It will be appreciated that the headset cannot stay powered all the time in view of the limited capacity of its battery, so it must be brought in a low-power or sleep mode when it is not in use.
A similar problem occurs when securely setting up a Wireless Sensor Network (WSN) comprising of wireless sensor nodes. Wireless sensor nodes are energy-frugal devices (having an average power consumption of less than 100 μW) that may extract the energy required for their operation from their environment. The extremely low average power consumption is achieved through duty cycling, i.e. the device wakes up, for example, every few minutes to perform some measurements and transmit a few tens of bytes and subsequently goes back to sleep. The total duration of the active period may be no more than a few milliseconds.
Wireless sensor nodes are able to configure themselves automatically in a WSN, but this procedure is not secure. For example, in home automation systems it is not possible to distinguish between sensor nodes belonging to one's own house and the neighbor's house. One would like to configure a network comprising the sensor nodes in one's own house, but not those in the neighboring houses. Furthermore, privacy and security present a problem. For example, one doesn't want one's presence to be inferred from wireless sensor messages, and one doesn't want someone to hack one's home automation system. Finally, although (unsecure) network joining may take place automatically, automation is less trivial for other aspects of commissioning such as establishing control relationships between devices and localization of devices.
Also in this case NFC-based “touching” enables easy and secure commissioning of a wireless sensor node. For example, an NFC-enabled installation device may be used to “touch” a sensor node which has an RFID tag attached to it in order to make it join the WSN in a secure manner, to establish a control relationship and/or to localize it. However, since the sensor node may only be in an active state once every few minutes it is necessary to explicitly force it to become active, for instance by pressing a button. Again, the button complicates the commissioning procedure and increases the cost of the sensor node. Furthermore, adding a button may be impractical in view of the small form factor of the sensor node. Also, the time span between a user pushing the button and subsequently bringing the installation device and the wireless sensor node in close proximity of each other (typically in the order of seconds) may already be too long considering the very limited energy resources of the wireless sensor node.
Therefore, there exists a need to simplify the procedures for commissioning devices of the kind set forth.
SUMMARY OF THE INVENTION
It is an object of the invention to simplify the procedures for commissioning devices of the kind set forth. This is achieved by a system as defined in claim 1 and by a method as defined in claim 9 .
According to an aspect of the invention a system for commissioning devices is provided, which system comprises: a first device and a second device; an RFID tag comprised in the first device; a host processor comprised in the first device; wherein the second device is arranged to generate an electromagnetic field; wherein the RFID tag is arranged to detect the electromagnetic field and to wake up the host processor upon detecting said electromagnetic field in order for the second device to communicate with the host processor.
Since the RFID tag comprised in the first device is arranged to wake up the host processor, an end-user does not have to switch on the first device manually. Therefore, the user interaction is simplified. Furthermore, there is no need for a separate power button on the first device. The latter reduces cost and simplifies the design of the first device.
According to another aspect of the invention, the second device is arranged to read out configuration data comprised in the RFID tag and to use said configuration data to commission the first device.
According to a further aspect of the invention, the configuration data comprise contact data and the second device is arranged to use said contact data for establishing a network connection with the first device.
According to a further aspect of the invention, the host processor comprises an interface unit and the second device is arranged to establish the network connection with the first device via the interface unit.
According to a further aspect of the invention, the RFID tag comprises a tag controller which is arranged to send a wake-up signal to the host processor in order to wake up the host processor.
According to a further aspect of the invention, the tag controller is further arranged to send the wake-up signal only if data are read from and/or written to the tag memory or if data are read from and/or written to predetermined areas of the tag memory.
According to a further aspect of the invention, the first device is a Bluetooth headset and the second device is a Bluetooth-enabled mobile phone. An advantage of using the invention in combination with a known method of pairing Bluetooth devices, such as Bluetooth Easy Pairing, is that it is backward compatible. This means that a new headset can be manufactured without a power button and it still works seamlessly with any Bluetooth Easy Pairing enabled phone.
According to a further aspect of the invention, the network is a wireless sensor network, the first device is a wireless sensor node and the second device is arranged to commission the wireless sensor node.
According to an aspect of the invention, a method for commissioning a first device and a second device is provided, which method comprises that an RFID tag comprised in the first device wakes up a host processor comprised in the first device upon detecting an electromagnetic field generated by the second device, in order for the second device to communicate with the host processor.
According to another aspect of the invention, the second device reads out configuration data comprised in the RFID tag and uses said configuration data to commission the first device.
According to a further aspect of the invention, the configuration data comprise contact data and the second device uses said contact data for establishing a network connection with the first device.
According to a further aspect of the invention, the contact data comprise a Media Access Control (MAC) address and a public key.
According to a further aspect of the invention, the second device encrypts network parameters with the public key and subsequently sends the encrypted network parameters to the host processor utilizing the Media Access Control address, and the host processor receives the encrypted network parameters and subsequently decrypts the encrypted network parameters with a private key corresponding to the public key.
According to a further aspect of the invention, the host processor uses the decrypted network parameters for establishing the network connection.
According to a further aspect of the invention, subsequent to establishing the network connection, the first device sends a message to the second device for initiating a control relationship between the first device and the second device.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in more detail with reference to the appended drawings, in which:
FIG. 1 shows a system diagram of an embodiment of the invention;
FIG. 2 shows a system diagram of another embodiment of the invention;
FIG. 3 shows a system diagram of a further embodiment of the invention;
FIG. 4 shows a system diagram of a further embodiment of the invention;
FIG. 5 shows a system diagram of a further embodiment of the invention;
FIG. 6 shows a system diagram of a further embodiment of the invention;
FIG. 7 shows a system diagram of a further embodiment of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a system diagram of an embodiment of the invention. The system comprises a first device 100 and a second device 104 . The first device 100 comprises an RFID tag 102 and a host processor 116 . The second device 104 comprises an RFID reader unit (not shown) which is arranged to read out data from the RFID tag 102 provided that the first device 100 is within the range of an electromagnetic field generated by the reader unit of the second device 104 . The RFID tag 102 comprises a tag memory 106 , an RFID interface 108 and a tag controller 110 . The host processor 116 comprises a host memory 118 , a host controller 120 and an interface unit 122 .
In operation, the second device 104 interacts, via its RFID reader unit, with the RFID tag 102 of the first device 100 . The second device 104 may for example read out data (such as a MAC address of the first device 100 ) from the tag memory 106 . Alternatively the second device 104 may write data into the tag memory 106 . When such an interaction takes place the RFID tag 102 activates and sends a wake-up signal 112 to wake up the host processor 116 . The RFID tag 102 may be a passive tag, which means that it has no built-in power source. In that case, the RFID reader unit of the second device 104 wirelessly supplies operating power to the RFID tag through magnetic induction. Optionally, the tag controller 110 may have a data connection 114 with the host controller 120 .
In an exemplary embodiment of the invention the first device 100 is a Bluetooth headset. The Bluetooth headset comprises headset speakers (not shown) and the interface unit 122 of the host processor 116 is a Bluetooth radio. In this exemplary embodiment the second device 104 is a mobile phone which is also equipped with a Bluetooth radio (not shown). In operation, the mobile phone reads out data from the RFID tag of the headset in order to establish a connection with the headset. After this network connection between the headset and the mobile phone has been established, a control relationship may also be established between them.
In another exemplary embodiment the first device 100 is a wireless sensor node and the interface unit 122 of the host processor 116 is an Ultra Low Power radio, for example an IEEE 802.15.4 radio. In this exemplary embodiment the second device is an NFC-enabled installation device which, again, may be a mobile phone, a personal digital assistant (PDA) or a portable computer. In operation, the installation device commissions the wireless sensor node by integrating it into a wireless sensor network.
The wake-up signal 112 is used to cause the host processor 116 of the first device 100 to move from an inactive state to an active state when the second device 104 interacts with the RFID tag 102 of the first device 100 . The inactive state may be a low-power mode, a sleep mode or any other mode in which the power usage is significantly lower than in the active state.
FIG. 2 shows a system diagram of another embodiment of the invention. In particular, it shows an example of a wake-up signal 112 which is used to wake up the host processor 116 . In this example, the power supply of the host processor 116 is disabled in the inactive state and the wake-up signal 112 pulls a switch, for example a galvanic switch or a MOSFET switch, to connect a power source 200 to the host processor 116 such that the host processor 116 receives power and enters into the active state. In this way the power consumption in the inactive state is zero, but no data other than data in non-volatile memory of the host processor 116 can be retained and some start-up or boot time is required before the host processor 116 is fully operational.
FIG. 3 shows a system diagram of a further embodiment of the invention. In this alternative embodiment, the host processor 116 is capable of one or more low-power modes. As an example, NXP Semiconductors' product family LPC11xxL has a so-called Deep-Sleep and a Deep-Power-Down mode in which a current of 2 μA and 220 nA, respectively, is drawn from the power supply. The typical operating current in an active state is at least three orders of magnitude higher than that at a few mA. In this alternative embodiment the wake-up signal 112 is provided as a trigger signal on one of the pins, for example a PIO-pin or wake-up pin, of the host processor 116 . When the host processor 116 receives the trigger signal on one of these pins it will move from a low-power mode to the active state. The selected power mode determines which internal blocks of the host processor 116 are switched off and which remain operational. Furthermore, the selected power mode determines the extent to which data can be retained in the host memory 118 .
The embodiment of FIG. 3 is a refinement of the embodiment of FIG. 2 in the sense that it enables that different internal blocks of the host processor 116 can be switched off independently or switched to a mode with less functionality and less power consumption, whereas the embodiment of FIG. 2 merely enables to switch off the host processor 116 completely. In the embodiment of FIG. 3 additional logic (not shown) is available to wake up the internal blocks in the correct order when the wake-up signal 112 is received.
FIG. 4 shows a system diagram of a further embodiment of the invention. In particular, it shows how a wake-up signal can be generated for waking up the host processor 116 .
In a typical RFID system an RFID reader unit provides power to a passive RFID tag through inductive coupling. Data communication between the RFID reader unit and the RFID tag is established through load modulation. Typically, a protocol for address resolution is provided for selecting a particular RFID tag for further interaction in case multiple RFID tags are present in the electromagnetic field generated by the RFID reader unit. Furthermore, a typical interaction involves reading and/or writing data from/to a memory unit comprised in the RFID tag. The RFID tag usually comprises a tag controller, for example a microcontroller, which is arranged to control these operations.
According to an exemplary embodiment of the invention the tag controller 110 sends a wake-up signal 112 to the host processor 116 upon detecting an electromagnetic field generated by the second device 104 . The tag controller 110 is able to detect the presence of an electromagnetic field via the RFID interface 108 . Furthermore, the tag controller 110 also knows whether or not this presence is intentional, i.e. whether the RFID reader unit that generates the field has indeed selected the particular RFID tag for the communication. If the presence of a field is detected and the presence is intentional in the aforementioned meaning, then the tag controller 110 will send the wake-up signal 112 to the host processor 116 .
Optionally, the tag controller 110 may be arranged to send the wake-up signal 112 only if data are read from and/or written to the tag memory 106 , or, more specifically, only if data are read from and/or written to predetermined areas of the tag memory 106 .
Furthermore, the conditions that determine whether or not a wake-up signal 112 is generated may be reconfigurable. Re-configurability can be achieved as follows. The second device 104 may write configuration parameters into a dedicated area of the tag memory 106 . Alternatively, or additionally, re-configurability can be achieved by the host processor 116 writing configuration parameters into said dedicated area by means of the optional host connection 114 . The tag controller 110 will interpret the configuration parameters to decide whether or not to trigger the wake-up signal 112 .
Typically, a prior-art RFID tag is implemented as a single Integrated Circuit (IC) with no leads being connected to it other than the RFID antenna coil. In order to have the tag controller 110 provide a wake-up signal 112 a new IC needs to be designed and fabricated.
However, instead of designing and fabricating an RFID tag IC capable of generating and sending a wake-up signal, a prior-art RFID tag IC can be used which is extended with a dedicated wake-up circuit. This is illustrated in FIG. 5 , which shows a system diagram of yet a further embodiment of the invention. In this case, a dedicated wake-up circuit or field detector 500 must be added next to the prior art IC. In its most simple form this wake-up circuit 500 has its own antenna coil. Clearly, this antenna coil must be mounted in very close proximity to the RFID tag's antenna. Only then both antennas will be powered simultaneously when the second device 104 is in close proximity to them.
The skilled person will recognize that the wake-up signal 112 in this embodiment is only indicative of the presence of a field. It does not indicate whether a second device 104 actually interacts with the RFID tag 102 , i.e. it does not indicate whether this particular RFID tag 102 is selected for communication by the second device 104 . This means that the host processor 116 preferably will check whether an actual interaction has taken place with the RFID tag 102 , e.g. by verifying whether a particular memory location has been written to, before e.g. proceeding with a certain commissioning operation such as establishing a network connection and/or establishing a control relationship.
FIG. 6 shows a system diagram of a further embodiment of the invention. In particular, it shows a refinement of the embodiment described with reference to FIG. 5 . This embodiment also has a separate wake-up circuit 500 , but in this case the wake-up circuit 500 shares an antenna coil with the RFID tag 102 . This embodiment reduces cost and it makes sure that the RFID tag 102 and the wake-up circuit 500 both detect the same field.
FIG. 7 shows a system diagram of a further embodiment of the invention. In particular, it shows a further refinement of the embodiment described with reference to FIG. 6 , and it involves further circuitry, i.e. a tag selection detector 700 , capable of detecting whether the RFID tag 102 continues interacting for a longer period of time after an initial field is detected in its antenna coil. When an RFID reader creates a field multiple tags may respond. In a so-called anti-collision loop the reader will only select a single tag for further interactions. This selected tag will continue to (load) modulate the field, whereas the other tags will stop doing so. The tag selection detector 700 is arranged to detect whether such continued (load) modulation takes place in the antenna coil of the RFID tag 102 and only if this is the case it will send the wake-up signal 112 to the host processor 116 .
The advantage of this further embodiment is that the host processor 116 will only be woken up if its RFID tag 102 is actually selected by the RFID reader unit and not just by the fact that a field is present in its coil. This avoids unnecessary wake-ups of the host processor 116 and therefore unnecessary power consumption by the host processor 116 . Furthermore, the host processor 116 does not have to check whether an actual interaction has taken place with the RFID tag (as in the embodiment described with reference to FIG. 5 ). This means, for example, that it is not necessary for the RFID reader unit to write data to the RFID tag 102 only in order for the host processor 116 to know whether or not an actual interaction has taken place. Such additional writing of data is a drawback because it may break backward compatibility of a prior art commissioning procedure.
An important aspect of commissioning devices is establishing a network connection. The RFID tag 102 may be used to exchange configuration data such as contact data which enable the second device 104 to integrate the first device 100 into an existing network, for example, or to establish a network connection between the first device 100 and itself. Furthermore, commissioning may, for example, involve establishing a control relationship between the first device 100 and the second device 104 . To this end, the RFID tag 102 may be used to exchange further configuration data. After waking up, the host processor 116 of the first device 100 will engage in out-of-band (i.e. RFID) communication and/or in-band (i.e. longer range like RF) communication with the second device 104 .
An exemplary method of commissioning a first device 100 in accordance with the invention comprises the following steps. First, an end-user brings a second device 104 in close proximity of the (RFID tag 102 of the) first device 100 with the intent to integrate the first device 100 into a network administered by (or via) the second device 104 . Note that in accordance with the invention the first device 100 does not have to be powered for this.
Second, the RFID reader unit of the second device 104 interacts with the first device 100 which results in two simultaneous actions: (1) the RFID tag 102 of the first device 100 raises the wake-up signal 112 according to the invention in order to wake up the host processor 116 of the first device 100 , and subsequently the host processor 116 powers up its interface unit 122 and starts listening for a message; (2) the RFID reader unit of the second device 104 reads out certain contact data from the RFID tag 102 of the first device 100 , for example a Media Access Control (MAC) address and a public key belonging to the first device 100 . Subsequently, the second device 104 obtains network parameters belonging to the network to be joined, e.g. as stored in its internal memory. For example, a network ID (e.g. SSID for Wi-Fi network) and a network key (e.g. WPA2-key for a Wi-Fi network). Then, the second device 104 encrypts those network parameters with the public key belonging to the first device 100 and subsequently sends a message with this encrypted data over a radio interface unit addressed to the interface unit 122 of the first device 100 by utilizing the MAC-address of the first device 100 .
Third, the first device 100 receives the message sent by the second device 104 and decrypts it with the private key corresponding to the public key, i.e. the private key of the public/private key pair. Then, the first device 100 utilizes the network parameters (network ID and network key) to connect to the network. This may involve further interactions over the (in-band) network and as a result the first device 100 may obtain a (dynamically assigned) network address.
Optionally, the first device 100 sends a message to the second device 104 in order to establish a control relationship with the second device 104 . The dynamically assigned network address of the first device 100 may be part of this message. For example, if the first device 100 is a Bluetooth headset and the second device 104 is a mobile phone, the control relationship may involve streaming audio data. Alternatively, if the first device 100 is a wireless sensor node which measures a light level and the second device 104 is an installation device, the second device 104 may use the dynamic network address of the first device 100 in a subsequent step to associate it with a third device, for example a smart lamp that will control its light level based upon the light level measured by the wireless sensor node.
It must be emphasized that the implementation details are merely examples. The skilled person will appreciate that other network establishment protocols, other sets of network parameters, other mechanisms for secure in-band exchange of network keys, other networking technologies, and other types of devices may be used in a method according to the invention.
The above-mentioned preferred embodiments illustrate rather than limit the invention, and the skilled person will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference sign placed between parentheses shall not be construed as limiting the claim. The word “comprise(s)” or “comprising” does not exclude the presence of elements or steps other than those listed in a claim. The word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. The invention may be implemented by means of hardware comprising several distinct elements and/or by means of a suitably programmed processor. In a device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
LIST OF REFERENCE SIGNS
100 first device
102 RFID tag
104 second device
106 tag memory
108 RFID interface
110 tag controller
112 wake-up signal
114 optional host connection
116 host processor
118 host memory
120 host controller
122 interface unit
200 power source
500 wake-up circuit
700 tag selection detector
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According to an aspect of the invention a system for commissioning devices is provided, which system comprises: a first device and a second device; an RFID tag comprised in the first device; a host processor comprised in the first device; wherein the second device is arranged to generate an electromagnetic field; wherein the RFID tag is arranged to detect the electromagnetic field and to wake up the host processor upon detecting said electromagnetic field in order for the second device to communicate with the host processor. Furthermore, a corresponding method for commissioning devices is provided. Since the RFID tag comprised in the first device is arranged to wake up the host processor, an end-user does not have to switch on the first device manually. Therefore, the user interaction is simplified. Furthermore, there is no need for a separate power button on the first device. The latter reduces cost and simplifies the design of the first device.
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BACKGROUND
[0001] The present invention relates to so-called “frac tanks” which are used in connection with production in oil and gas wells. The tanks contain thousands of gallons of water or proppant, which is pumped under high pressure down the well bore to push open, i.e., fracture, the earth formation or to keep the formation open.
[0002] It is known to provide cylindrical frac tanks supported on an L-skids, which brace the tanks externally and enable the tanks to be transported to the field and repositioned upright on a well pad for production. The tanks generally have a capacity of about 400 barrels, requiring a diameter of 12 feet. This width of tank has caused difficulties during transport on truck bodies over public roads, requiring special permitting, administration, and thus additional cost.
SUMMARY
[0003] The purpose of the present invention is to provide a cylinder-type frac tank that does not require extensive internal reinforcement, avoids the difficulties and costs associated with the transport of conventional over-width cylindrical frac tanks, and is at least as space efficient as cylindrical frac tanks when arrayed on a well pad or the like.
[0004] The frac tank of the present invention can be considered as having the shape of two intersecting parallel cylinders.
[0005] With this shape, tanks having a maximum width of only eight feet and a capacity of about 300 barrels can easily be transported on a conventional flatbed truck, without special permitting and administrative delays and costs. As an example of development, an array of twelve such tanks closely spaced on a well pad of given size, provides greater capacity than a closely spaced array of eight 400 barrel cylindrical tanks on the same size pad.
[0006] According to one aspect, the invention is disclosed as a frac tank adapted for vehicular transport and field storage of a liquid, comprising two elongated hollow sections, each section having an arcuate wall defining a cross-section of greater than 180°, a major diameter, and a minor diameter at the ends of the arcuate wall, wherein the ends of the arcuate wall of each section are sealingly joined. The joined ends of the arcuate walls form inwardly directed cusps along the length of the tank with the major diameters spaced apart on either side of the cusps.
[0007] In a more detailed aspect, the disclosure includes an optional L-frame skid having one leg joined to an exterior surface of the wall of one section and another leg joined to the bottom of the tank. The one leg of the frame is attached to a truck body for horizontally orientated transport of the tank to the field, and the tank with skid are removable from the truck body for upright positioning of the tank in the field while resting on the other leg of the frame.
[0008] The invention can take the form of a stand-alone tank, a tank unit in which the tank is in combination with a skid or similar support, or a plurality of tanks arrayed in the field.
[0009] Another aspect of the invention is a method of fabricating a frac tank having the shape of two hollow, intersecting parallel cylinder sections. The method comprises: fabricating a plurality of metal rings, each ring composed of two opposed segments, with one segment forming a portion of one cylinder section and the other segment forming a portion of the other cylinder section, each segment having an arcuate wall defining a cross section of greater than 180 deg.; sealingly joining the ends of the arcuate wall of each segment to produce a plurality of metal rings; joining the rings to form an elongated tank wall having open ends; and capping the open ends of the tank wall.
BRIEF DESCRIPTION OF THE FIGURES
[0010] FIG. 1 is an oblique view taken from above a frac tank unit including tank and skid or frame;
[0011] FIG. 2 shows one segment of the tank, which is mateable with an identical segment, to form one ring of a plurality of rings that are joined together to form the tank;
[0012] FIG. 3 is an end view of a representative mid-region of the tank, showing how two segments are joined together to form a ring which resembles the intersection of two parallel cylinders;
[0013] FIG. 4 is an oblique view of a representative skid or frame;
[0014] FIG. 5 is an oblique view of the tank before the end caps have been secured;
[0015] FIG. 6 is an oblique view of one of two bottom caps for the tank;
[0016] FIG. 7 is an oblique view of the top cap of the tank;
[0017] FIG. 8 is a schematic, longitudinal view of the tank unit, showing the preferred shape and orientation of the end caps; and
[0018] FIG. 9 shows the footprints of twelve intersecting cylinder tanks, each having eight foot major diameters, superimposed on the footprints of eight conventional cylindrical tanks having twelve foot diameters.
DETAILED DESCRIPTION
[0019] FIG. 1 shows a horizontally oriented tank unit 10 formed by the combination of tank or container 12 and skid or frame 14 . The tank has a first or upper section 16 (resembling a portion of one hollow cylinder), and a second or lower section 18 (resembling a portion of another hollow cylinder). The tank 12 is formed by a plurality of connected rings 20 . In the orientation of FIG. 1 , the tank unit 10 can be loaded onto a transport vehicle such as a flatbed truck and delivered to a drilling or production site.
[0020] FIG. 2 shows the basic building block for each ring 20 . Each ring is composed of two segments 22 , each having a rolled portion 24 defining an arcuate wall which spans an arc of more than 180°. At one end of the arcuate wall, a relatively longer flange 26 extends substantially horizontally, and at the other end of the arcuate wall, a relatively shorter flange 28 also extends horizontally, leaving a gap between the two flanges. An opening 30 in the longer flange is provided to assure that the fluid in the tank can pass freely within the volume to maintain balanced weight distribution.
[0021] FIG. 3 shows how two of the segments 22 a , 22 b are joined together to form one ring among the plurality of rings that define the overall cross-section of the tank, which resembles the intersection of two parallel cylinders. Preferably, the upper and lower segments 22 a , 22 b are identically fabricated. They are joined such that the second segment 22 b is reoriented by two, 180° rotations relative to the first segment 22 a.
[0022] Thus, the longer flange 26 a confronts the shorter flange 28 b and the longer flange 26 b confronts the shorter flange 28 a . The confronting flanges are welded together along the full length of the cusp 34 (of the ring) formed at the intersection of the segments. The longer flanges 26 a , 26 b overlap at the center of the ring at 32 and are also welded together.
[0023] Upon viewing FIG. 3 , it can be appreciated that the maximum width of the tank is at the major diameter D a and (with identical segments) at the identical major diameter D b . One can consider that the minor diameters d a and d b are defined at the ends of the arcuate wall of each segment, and that is where the flanges form a support plate that connects the opposed cusps 34 .
[0024] FIG. 4 shows the preferred form of the frame 14 , comprising a horizontal, preferably longer leg 36 and a vertical, preferably shorter leg 38 . Leg 36 has a plurality of straight support posts 40 and transverse, curved braces 42 that are supported by horizontal rails 44 . The other leg 38 is likewise formed from a plurality of rails 46 which carry respective support bars 48 .
[0025] FIG. 5 shows the tank during fabrication, wherein the cusps 34 can be seen more clearly as extending longitudinally at the intersection of the upper 16 and lower 18 sections of the tank. In the illustrated embodiment, four individually pre-assembled rings 20 are welded together, with each ring formed by the joining of segments 22 a and 22 b as described with respect to FIG. 3 . The joining of the flanges within a ring and the optional joining of adjacent flanges from adjacent rings forms an overall unitary central support plate 50 extending between the cusps 34 of the tank, or a plurality of side by side supports plates associated with respective rings.
[0026] The plates 50 provide support against unbalanced force components that might arise at the inward (i.e., concave) cusps 34 , in a direction parallel to the minor diameter. However, the convex arcuate shape of most of the ring surface 24 retains the strength of a cylindrical tank and needs no support or reinforcement against force components in a direction perpendicular to the minor diameter.
[0027] It should be understood that in the illustrated embodiment the upper and lower segments 16 , 18 have the same size and shape, and thus the major diameters D a and D b , and minor diameters d a and d b are the same, with the minor diameters being congruent and coextensive, and the major diameters spaced apart on either side of the minor diameters and cusps, but this is not absolutely necessary. Each segment 22 a , 22 b and thus each section 16 , 18 is a portion of a cylinder in which the ends of the arcuate wall preferably span an included angle of at least about 200 deg., most preferably in the range of 220-250 deg.
[0028] The internal support for the tank can take a variety of forms, with at least one reinforcing member extending between spaced apart points on the wall of each section, preferably extending between the cusps.
[0029] FIGS. 6 , 7 and 8 show the preferred manner in which the ends of the tank 12 are closed, with FIG. 8 also depicting the tank unit 10 as would be deployed upright in the field for short term use. The bottom of the tank is closed at an angle by one or two connected bottom caps 52 and the closure 56 at the top of the tank has two angled portions 56 , 58 . The angle at the bottom assures that all liquid in the tank flows toward the valve 60 , whereas the angle at the top helps shed rain or snow, etc.
[0030] FIG. 9 shows the perimeter of one possible frac tank well pad 62 , which for convenience is selected as a 26 ft.×52 ft. rectangle, on which a plurality of frac tanks are situated without skids or frame, for long-term use. The pad accommodates eight conventional cylindrical tanks 64 , each having a twelve foot diameter and a 400 barrel capacity, for a total volume of 3,200 barrels. The footprints of the eight conventional tanks are superimposed with the footprints of twelve tanks 66 according to FIG. 8 (without the skid), each having the same height but with a major diameter (maximum width of one section) of eight feet and a capacity of almost 300 barrels, for a total volume of 3,526 barrels. In this comparison, the maximum transverse dimension T m of the inventive tank 66 is about twelve feet, the same as the diameters of the cylindrical tanks 64 . In this preference but not limitation, the maximum transverse dimension T m is 50% greater than the major diameters D a and D b .
[0031] It can thus be appreciated that the present invention provides a frac tank of smaller width that is more convenient to transport by truck relative to a conventional twelve foot diameter frac tank. When arrayed on a well pad of given area, similar or greater fluid capacity can also be achieved. Although to achieve this capacity advantage more tanks must be fabricated, the net cost is no greater. The total required surface areas of metal are similar, but the metal blanks can be thinner and more easily shaped and welded for the inventive tanks. Even if the inventive tanks did not provide any initial manufacturing cost advantage for the same total fluid volume required on a particular well pad or site, the combined advantages of routine tank transport without sacrificing fluid volume capacity on a given well pad, represent a significant improvement over conventional practice.
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A frac tank adapted for vehicular transport and field storage of a liquid, comprising two parallel, elongated, hollow, intersecting cylinder sections that are capped at the longitudinal ends. Each section has an arcuate wall defining a cross-section of greater than 180°, a major diameter, and a minor diameter at the ends of the arcuate wall, wherein the ends of the arcuate wall of each section are sealingly joined to form the tank wall. The joined ends of the arcuate walls form inwardly directed cusps along the length of the tank with the major diameters spaced apart on either side of the cusps.
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[0001] This Nonprovisional application claims priority under 35 U.S.C. § 119(a) on Patent Application No. 10-2004-0080640 filed in Korea on Oct. 8, 2004, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a plasma display panel, and more particularly, to a plasma display panel comprising scanning bus electrodes and sustaining bus electrodes formed on R, G and B cells.
[0004] 2. Background of the Related Art
[0005] In a conventional plasma display panel, a barrier rib formed between front and rear substrates made of soda-lime glass constitutes one unit cells, Each cell is filled with an inert gas such as helium-xenon(He—Xe), helium-neon(He—Ne), etc., If the inert gas is discharged with a high frequency voltage, vacuum ultraviolet rays are generated. Phosphor formed between the barrier ribs emits light corresponding to images.
[0006] FIG. 1 is a perspective view schematically showing the structure of a conventional plasma display panel. As shown in FIG. 1 , the plasma display panel comprises a front glass substrate 10 and a rear glass substrate 20 . The front glass substrate 10 and the rear glass substrate 20 are coupled in parallel to each other with a predetermined distance therebetween.
[0007] A sustaining electrode pair 11 and 12 for sustaining the light emission of a discharge cell is formed on the front glass substrate 10 . The sustaining electrode pair 11 and 12 consists of a scan electrode 11 and sustain electrode 12 . The scan electrode 11 is supplied with a scan pulse for scanning and a sustain pulse for sustaining discharging. The sustain electrode 12 is applied with a sustain pulse alternated with a sustain pulse applied to the scan electrode 11 . The scan electrode 11 and the sustain electrode 12 are composed of transparent electrodes 11 a and 12 a made of transparent ITO material and bus electrodes 11 b and 12 b made of metal, respectively. The sustaining electrode pair 11 and 12 are covered with a dielectric layer 13 a . A protective layer 14 made of MgO is formed on the upper surface of the dielectric layer 13 a so as to facilitate discharging more easily.
[0008] A plurality of address electrodes 22 are arranged on the rear glass substrate 20 alternatively with the sustaining electrode pair 11 and 12 . A dielectric layer 13 b is formed on the address electrodes 22 . Barrier ribs 21 for forming discharge cells are formed on the dielectric layer 13 b . A phosphor 23 for emitting visible light is coated between the barrier ribs 21 .
[0009] FIG. 2 shows an electrode structure of the conventional plasma display panel. As shown in FIG. 2 , the bus electrodes 11 a and 11 b are formed at upper and lower parts of a discharge cell 30 coated with R(red) phosphor, a discharge cell 40 coated with G(green) phosphor and a discharge cell 50 coated with B(blue) phosphor. The transparent electrodes 12 a and 12 b are formed in such a manner to be projected from the bus electrodes 11 a and 11 b toward the center of the discharge cell 30 coated with R(red) phosphor, of the discharge cell 40 coated with G(green) phosphor, and of the discharge cell 50 coated with B(blue) phosphor.
[0010] The bus electrodes 11 a and 11 b and transparent electrodes 12 a and 12 b formed on the regions of each discharge cell have the same area. As a result, when discharging occurs in each of the discharge cells, the amount of discharge is the same. Since the amount of discharge is the same in each discharge cell, the discharge efficiency in each discharge cell is significantly depending on the phosphor type. The emission efficiency of B phosphor is less than the emission efficiency of R phosphor or G phosphor. That is, the amount of light emitted from the B phosphor according to a specific amount of discharge is less than the amount of light emitted from the R phosphor or G phosphor. Therefore, if the area of the electrodes formed on each discharge cell is the same, the color temperature of an image displayed by the conventional plasma display panel is not being set to an appropriate level.
SUMMARY OF THE INVENTION
[0011] Accordingly, an object of the present invention is to solve at least the problems and disadvantages of the background art.
[0012] The present invention provides a plasma display panel comprising electrodes with an enhanced structure for improvement of color temperature.
[0013] The plasma display panel of the present invention comprises: a first discharge cell provided with a first phosphor among a plurality of phosphors; a second discharge cell provided with a second phosphor among the plurality of phosphors; a first sustaining electrode pair formed on the first discharge cell and having a first area; and a second sustaining electrode pair formed on the second discharge cell and having a second area smaller than the first area.
[0014] The plasma display panel of the present invention comprises: a first discharge cell partitioned by barrier ribs and provided with a first phosphor among a plurality of phosphors; a second discharge cell partitioned by barrier ribs and provided with a second phosphor among the plurality of phosphors; a first transparent electrode portion projected on the first discharge cell toward the center of the first discharge cell and having a first partial area; and a second transparent electrode portion projected on the second discharge cell toward the center of the second discharge cell and having a second partial area smaller than the first partial area.
[0015] In the present invention, the color temperature of an image displayed by a plasma display panel is set to the appropriate level by enlarging the area of electrodes in the regions of a discharge cell provided with a specific phosphor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention will be described in detail with reference to the following drawings in which like numerals refer to like elements:
[0017] FIG. 1 is a perspective view schematically showing a structure of a conventional plasma display panel;
[0018] FIG. 2 shows an electrode structure of the conventional plasma display panel;
[0019] FIG. 3 is a plane view of a plasma display panel according to a first embodiment of the present invention; and
[0020] FIG. 4 is a plane view of a plasma display panel according to a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Preferred embodiments of the present invention will be described in a more detailed manner with reference to the drawings.
[0022] The plasma display panel of the present invention comprises: a first discharge cell provided with a first phosphor among a plurality of phosphors; a second discharge cell provided with a second phosphor among the plurality of phosphors; a first sustaining electrode pair formed on the first discharge cell and having a first area; and a second sustaining electrode pair formed on the second discharge cell and having a second area smaller than the first area.
[0023] The first phosphor is a blue phosphor.
[0024] The first sustaining electrode pair comprises a first scanning bus electrode, the second sustaining electrode pair comprises a second scanning bus electrode, and the first scanning bus electrode is wider than the second scanning bus electrode.
[0025] The first sustaining electrode pair comprises a first scanning bus electrode, the second sustaining electrode pair comprises a second scanning bus electrode, and the first scanning bus electrode is wider than the second scanning bus electrode.
[0026] The plasma display panel of the present invention comprises: a first discharge cell partitioned by barrier ribs and provided with a first phosphor among a plurality of phosphors; a second discharge cell partitioned by barrier ribs and provided with a second phosphor among the plurality of phosphors; a first transparent electrode portion projected on the first discharge cell toward the center of the first discharge cell and having a first partial area; and a second transparent electrode portion projected on the second discharge cell toward the center of the second discharge cell and having a second partial area smaller than the first partial area.
[0027] The first phosphor is a blue phosphor.
[0028] The first transparent electrode portion comprises a first scanning vertical connecting portion formed toward the center of the first discharge cell, the second transparent electrode portion comprises a second scanning vertical connecting portion formed toward the center of the second discharge cell, and the first scan vertical connecting portion is wider than the second scanning vertical connecting portion.
[0029] The first scanning vertical connecting portion is wider than the second scanning vertical connecting portion, and the width of the first scanning vertical connecting portion increases in the direction of the barrier ribs partitioning the first discharge cell.
[0030] The first transparent electrode portion further comprises a first scanning horizontal connecting portion connecting to the first scanning vertical connecting portion, the second transparent electrode portion further comprises a second scanning horizontal connecting portion connecting to the second scanning vertical connecting portion, and the first scanning horizontal connecting portion is wider than the second scanning horizontal connecting portion.
[0031] The first scanning horizontal connecting portion is wider than the second scanning horizontal connecting portion, and the width of the first scanning horizontal connecting portion increases in the direction of the barrier ribs partitioning the first discharge cell.
[0032] The first transparent electrode portion comprises a first sustaining vertical connecting portion formed toward the center of the first discharge cell, the second transparent electrode portion comprises a second sustaining vertical connecting portion formed toward the center of the second discharge cell, and the first sustaining vertical connecting portion is wider than the second sustaining vertical connecting portion.
[0033] The first sustaining vertical connecting portion is wider than the second sustaining vertical connecting portion, and the width of the first sustaining vertical connecting portion increases in the direction of the barrier ribs partitioning the first discharge cell.
[0034] The first transparent electrode portion further comprises a first sustaining horizontal connecting portion connecting to the first sustaining vertical connecting portion, the second transparent electrode portion further comprises a second sustaining horizontal connecting portion connecting to the second sustaining vertical connecting portion, and the first sustaining horizontal connecting portion is wider than the second sustaining horizontal connecting portion.
[0035] The first sustaining horizontal connecting portion is wider than the second sustaining horizontal connecting portion, and the width of the first sustaining horizontal connecting portion increases in the direction of the barrier ribs partitioning the first discharge cell.
[0036] Hereinafter, specific embodiments of the present invention will be described with reference to the accompanying drawings.
Embodiment 1
[0037] FIG. 3 is a plane view of a plasma display panel according to a first embodiment of the present invention. As shown in FIG. 3 , the plasma display panel comprises a first discharge cell 300 , a second discharge cell 310 , a first sustaining electrode pair 320 and a second sustaining electrode pair 330 .
[0038] The first discharge cell 300 is partitioned by barrier ribs and provided with a first phosphor among a plurality of phosphors. It is preferable that the plurality of phosphor comprises a R(red) phosphor, a G(green) phosphor and a B(blue) phosphor. Preferably, the first phosphor is a B phosphor.
[0039] The second discharge cell 310 is partitioned by barrier ribs and provided with a second phosphor among a plurality of phosphors. Preferably, the first phosphor is a R(red) phosphor or a G(green) phosphor.
[0040] The first sustaining electrode pair 320 is formed on a front glass substrate (not shown) on the first discharge cell 300 and has a first area. Such first sustaining electrode pair 320 comprise a first scanning bust electrode 3201 , a first sustaining bus electrode 3203 , a first scanning transparent electrode 3205 and a first sustaining transparent electrode 3207 . The position of the first scanning bus electrode 3201 and the first scanning transparent electrode 3205 , and the position of the first sustaining bus electrode 3203 and the first sustaining transparent electrode 3207 can alternate with each other. That is, the first scanning bus electrode 3201 and the first scanning transparent electrode 3205 can be positioned at a lower part of the first discharge cell 300 , and the first sustaining bus electrode 3203 and the first sustaining transparent electrode 3207 can be positioned at an upper part of the first discharge cell 300 .
[0041] The second sustaining electrode pair 330 is formed on a front glass substrate (not shown) on the second discharge cell 310 and has a second area smaller than the first area. Such second sustaining electrode pair 330 comprises a second scanning bust electrode 3301 , a second sustaining bus electrode 3303 , a second scanning transparent electrode 3305 and a second sustaining transparent electrode 3307 . The position of the second scanning bus electrode 3301 and the second scanning transparent electrode 3305 , and the position of the second sustaining bus electrode 3303 and of the second sustaining transparent electrode 3307 can alternate with each other. That is, the second scanning bus electrode 3301 and the second scanning transparent electrode 3305 can be positioned at a lower part of the second discharge cell 310 , and the second sustaining bus electrode 3303 and the second sustaining transparent electrode 3307 can be positioned at an upper part of the second discharge cell 310 .
[0042] As shown in FIG. 3 , the first scanning bus electrode 3201 and first sustaining bus electrode 3203 of the first sustaining electrode pair 320 is wider than the second scanning bus electrode 3301 and second sustaining bus electrode 3303 of the second sustaining electrode pair 330 . As a result, as the first scanning bus electrode 3201 and the first sustaining bus electrode 3203 are formed on the first discharge cell 300 where the B phosphor is formed, and the second scanning bus electrode 3301 and the second sustaining bus electrode 3303 are formed on the second discharge cell 310 where the R phosphor or G phosphor is formed, the amount of discharge of the first discharge cell 300 becomes greater than the amount of discharge of the second discharge cell 310 . Therefore, because the first discharge cell in which the B phosphor having a smaller light emission efficiency is formed, emits a greater amount of light than an amount of light emitted by the second discharge cell, the color temperature of an image displayed by the plasma display panel can be set to the appropriate level.
Embodiment 2
[0043] FIG. 4 is a plane view of a plasma display panel according to a first embodiment of the present invention. As shown in FIG. 4 , the plasma display panel comprises a first discharge cell 400 , a second discharge cell 410 , a first sustaining electrode pair 420 and a second sustaining electrode pair 430 .
[0044] The first discharge cell 400 is partitioned by barrier ribs and provided with a first phosphor among a plurality of phosphors. It is preferable that the plurality of phosphor comprises a R(red) phosphor, a G(green) phosphor and a B(blue) phosphor. Preferably, the first phosphor is a B phosphor.
[0045] The second discharge cell 410 is partitioned by barrier ribs and provided with a second phosphor among a plurality of phosphors. Preferably, the first phosphor is a R(red) phosphor or G(green) phosphor.
[0046] The first sustaining electrode pair 420 is formed on a front glass substrate (not shown) on the first discharge cell 400 and has a first area. Such first sustaining electrode pair 420 comprise a first scanning bust electrode 4201 , a first sustaining bus electrode 4203 , a first scanning transparent electrode 4205 and a first sustaining transparent electrode 4207 . The position of the first scanning bus electrode 4201 and the first scanning transparent electrode 4205 , and the position of the first sustaining bus electrode 4203 and of the first sustaining transparent electrode 4207 can alternate with each other. That is, the first scanning bus electrode 4201 and the first scanning transparent electrode 4205 can be positioned at a lower part of the first discharge cell 400 , and the first sustaining bus electrode 4203 and the first sustaining transparent electrode 4207 can be positioned at an upper part of the first discharge cell 400 . The first scanning transparent electrode 4205 and the first sustaining transparent electrode 4207 are projected from the first scanning bus electrode 4201 and the first sustaining bus electrode 4203 , respectively, toward the center of the first discharge cell 400 . The first scanning transparent electrode 4205 and the first sustaining transparent electrode 4207 have a first partial area. That is, the first partial area is the sum of the areas of the first scanning transparent electrode 4205 and first sustaining transparent electrode 4207 . The first scanning transparent electrode 4205 comprises a first scanning vertical connecting portion 4205 - 1 vertically connecting to the first scanning bus electrode 4201 and a first scanning horizontal connecting portion 4205 - 2 vertically connecting to the first scanning vertical connecting portion 4205 - 1 . The first sustaining transparent electrode 4207 comprises a first sustaining vertical connecting portion 4207 - 1 vertically connecting to the first sustaining bus electrode 4203 and a first sustaining horizontal connecting portion 4207 - 2 vertically connecting to the first sustaining vertical connecting portion 4207 - 1 .
[0047] The second sustaining electrode pair 430 is formed on a front glass substrate (not shown) on the second discharge cell 410 and has a second area smaller than the first area. Such second sustaining electrode pair 430 comprises a second scanning bust electrode 4301 , a second sustaining bus electrode 4303 , a second scanning transparent electrode 4305 and a second sustaining transparent electrode 4307 . The position of the second scanning bus electrode 4301 and the second scanning transparent electrode 4305 , and the position of the second sustaining bus electrode 4303 and of the second sustaining transparent electrode 4307 can be alternate with each other. That is, the second scanning bus electrode 4301 and the second scanning transparent electrode 4305 can be positioned at a lower part of the second discharge cell 410 , and the second sustaining bus electrode 3303 and the second sustaining transparent electrode 4307 can be positioned at an upper part of the second discharge cell 410 . The second scanning transparent electrode 4305 and the second sustaining transparent electrode 4307 are projected from the second scanning bus electrode 4201 and the second sustaining bus electrode 4303 , respectively, toward the center of the second discharge cell 410 . The second scanning transparent electrode 4305 and the second sustaining transparent electrode 4307 have a second partial area. That is, the second partial area is the sum of the areas of the second scanning transparent electrode 4305 and second sustaining transparent electrode 4307 . The second scanning transparent electrode 4305 comprises a second scanning vertical connecting portion 4305 - 1 vertically connecting to the second scanning bus electrode 4301 and a second scanning horizontal connecting portion 4305 - 2 vertically connecting to the second scanning vertical connecting portion 4205 - 1 . The second sustaining transparent electrode 4307 comprises a second sustaining vertical connecting portion 4307 - 1 vertically connecting to the second sustaining bus electrode 4303 and a second sustaining horizontal connecting portion 4307 - 2 vertically connecting to the second sustaining vertical connecting portion 4307 - 1 .
[0048] As shown in FIG. 4 , the first partial area of the first scanning transparent electrode 4205 and the first sustaining transparent electrode 4207 is larger than the second area of the second scanning transparent electrode 4305 and second sustaining transparent electrode 4307 . As a result, as the first scanning transparent electrode 4205 and the first sustaining transparent electrode 4207 are formed on the first discharge cell 400 where the B phosphor is formed, and the second scanning transparent electrode 4305 and the second sustaining transparent electrode 4307 are formed on the second discharge cell 410 where the R phosphor or G phosphor is formed, the amount of discharge of the first discharge cell 400 becomes greater than the amount of discharge of the second discharge cell 410 . Therefore, because the B phosphor having a lower light emission efficiency emits a greater amount of light, the color temperature of an image displayed by the plasma display panel can be set to the appropriate level. The width w 1 of the first scanning vertical connecting portion 4205 - 1 of the first scanning transparent electrode 4205 can be wider than the width w 2 of the second scanning vertical connecting portion 4305 - 1 of the second scanning transparent electrode 4305 . The width w 3 of the first scanning horizontal connecting portion 4305 - 2 of the second scanning transparent electrode 4305 can be wider than the width w 4 of the second scanning horizontal connecting portion 4305 - 2 of the second scanning transparent electrode 4305 . Likewise, the width w 6 of the first sustaining vertical connecting portion 4207 - 1 of the first sustaining transparent electrode 4207 can be wider than the width w 5 of the second sustaining vertical connecting portion 4307 - 1 of the second sustaining transparent electrode 4307 . The width w 7 of the first sustaining horizontal connecting portion 4207 - 1 of the first sustaining transparent 4207 can be wider than the width w 8 of the second sustaining horizontal connecting portion 4307 - 2 of the second sustaining transparent electrode 4307 .
[0049] If the width of the first scanning horizontal connecting portion 4205 - 2 and first sustaining horizontal connecting portion 4207 - 2 increases toward the center of the first discharge cell 400 , a discharge gap is reduced and thus a discharge firing voltage increases. As a result, it is preferable that the first scanning horizontal connecting portion 4205 - 2 and the first sustaining horizontal connecting portion 4207 - 2 have a width that increases toward the barrier ribs, respectively.
[0050] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art area intended to be comprised within the scope of the following claims.
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Disclosed is a plasma display panel, more particularly, a plasma display panel comprising scanning bus electrodes and sustaining bus electrodes formed on top of RGB cells. The plasma display panel comprises a first discharge cell provided with a first phosphor among a plurality of phosphors, a second discharge cell provided with a second phosphor among the plurality of phosphors, a first sustaining electrode pair formed on the first discharge cell and having a first area, and a second sustaining electrode pair formed on the second discharge cell and having a second area smaller than the first area. The color temperature of an image displayed by a plasma display panel can be set to appropriate level by enlarging the area of electrodes in the regions of a discharge cell provided with a specific phosphor.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application relates to commonly owned U.S. patent application Ser. No. 09/631,629, entitled “System for Providing Golfers with Golf Related Information Via a Global Network”, filed Aug. 4, 2000, which is currently pending, and, to the extent relevant, incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a golfer's aid. More particularly, the invention relates to a method and system allowing golfers to download particular golf course information to a personal digital assistant containing a global positioning satellite chip.
[0004] 2. Description of the Prior Art
[0005] More people around the world than now play golf at any time since the game was invented. A wide variety of mechanical advances have been recently applied to improve an individual's ability to play and enjoy a round of golf. These advances include new training equipment, clubs fabricated from advanced materials, reshaped club heads, aerodynamically designed golf balls improving upon a golfer's ability to hit a ball toward a desired target, and a host of other advances focused upon improving the game of both novices and experts.
[0006] However, those associated with the game of golf have yet to fully take advantage of information technology, including, but not limited to, convenient information transfer via portable digital assistants, the power offered by the Internet and other global communication networks, and global positioning satellites (GPS), to improve upon golfers' ability to play and enjoy a round of golf. With this in mind, the present invention offers a readily usable information transfer device designed to improve upon one's enjoyment of a round of golf.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a system for providing golfers with golf related information. The system includes a personal digital assistant having a GPS function, a memory, a processor and an input/output. The system also includes a cradle shaped and dimensioned for receiving the personal digital assistant and transferring information thereto. The cradle includes a memory storing information relating to coordinates on a golf course and an input/output transmitting information to the personal digital assistant. The personal digital assistant includes software for calculating and displaying distance between a golfer's location and a designated coordinate on the golf course.
[0008] It is also an object of the present invention to provide a similar method for providing golf related distance information.
[0009] Other objects and advantages of the present invention will become apparent from the following detailed description when viewed in conjunction with the accompanying drawings, which set forth certain embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a schematic of the present system.
[0011] [0011]FIG. 2 is a schematic of the central processor in accordance with the present invention.
[0012] [0012]FIG. 3 is a view of a personal digital assistant used in accordance with the present invention.
[0013] [0013]FIG. 4 is flow chart for the uploading of golf course information to the golf course module.
[0014] [0014]FIGS. 5 and 6 show various displays in accordance with the present invention.
[0015] [0015]FIG. 7 is schematic of personal digital assistant in accordance with an alternate embodiment of the present invention.
[0016] [0016]FIG. 8 is a schematic of a representative golf hole.
[0017] [0017]FIG. 9 is a schematic of a cradle and a PDA used in accordance with an alternate embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The detailed embodiments of the present invention are disclosed herein. It should be understood, however, that the disclosed embodiments are merely exemplary of the invention, which maybe embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limited, but merely as the basis for the claims and as a basis for teaching one skilled in the art how to make and/or use the invention.
[0019] With reference to FIGS. 1, 2 and 3 , a system 10 for providing golfers with golf related information via a global communication network 12 , for example, the Internet, is disclosed. In accordance with a preferred embodiment of the present invention, the system 10 utilizes the Internet 12 to facilitate the transfer of information between a user station 14 and a central processor 16 of the present system 10 . The transfer of information between the user station 14 and the central processor 16 is facilitated through the use of TCP/IP, although other communication protocols may be utilized without departing from the spirit of the present invention.
[0020] As will be discussed below in greater detail, the user station 14 may take a variety of forms depending upon the needs of the individual accessing the central processor 16 of the present system 10 . In accordance with a preferred embodiment of the present invention, the user stations are personal digital assistants 14 . This allows golfers to readily download relevant information as discussed below and bring the information onto the course with them. However, it is contemplated that the central processor 16 may also be accessed via desktop computers, laptop computers, and cellular communication devices, although those skilled in the art will readily understand that many other communication devices may be utilized without departing from the spirit of the present invention.
[0021] The cornerstone of the present system is a central processor 16 accessed by the user via the Internet 12 . The central processor 16 includes a golf course module 18 , a score entry module 20 , a statistic storage module 22 , an analysis module 24 and a playing tip module 26 .
[0022] The golf course module 18 contains golf course information from a plurality of golf courses. The information maintained in the golf course module 18 includes, for example, hole layouts, distances, pin and tee placements, hazard locations, and topographical data. The previous list of golf course information which maybe stored in the golf course module 18 is considered to be merely exemplary of information which might be useful to golfers accessing the central processor 16 in accordance with the present invention, and the list of available golf course information may be readily varied to suit the needs of golfers as available information changes and the needs of those golfers accessing the central processor 16 changes.
[0023] The golf course module 18 is readily accessed by those using the central processor 16 . As such, golf course information stored therein may be readily downloaded. Similarly, golf course information maybe readily uploaded to the golf course module 18 . The proprietors of golf courses 28 participating with the present system 10 are thereby permitted to continually keep their course information up-to-date so that golfers at these courses will have the most up to date information available as they access the central processor 16 . The process for uploading information is generally outlined in FIG. 4. Briefly, the golf course module first acquires ortho-rectified images of a golf course. The images are then spatially enabled, including, recording waypoints of the course and course information, such as, par. Finally, the golf course module stores the information.
[0024] The score entry module 20 is designed to allow a golfer to input each shot from a round of golf in relation to the golf course information maintained in the golf course module 18 . With this in mind, the score entry module 20 provides the golfer with a graphical user interface when golfers download golf course information from the central processor 16 . As such, the interface 30 maybe used by a golfer to enter each shot by marking ball positions on a rendering of a hole layout 32 .
[0025] For example, the interface 30 provides the golfer with the layout of hole 1 at the golfer's local golf course. The golfer is then prompted to enter the location of his or her first shot, second shot etc. The shot information is stored and placed within the statistic storage module 22 .
[0026] The statistic storage module 22 includes a database 34 in which data input via the score entry module 20 is maintained for subsequent processing to provide golfers with desired information. The analysis module 24 and playing tip module 26 are linked to the statistic module 22 . Specifically, the analysis module 24 is associated with the statistic storage module 22 and the golf course module 18 for adding-value to the information contained therein. Value-added information is considered to be information developed from multiple sources such that the resulting information provides a benefit not provided by information generated from a single source.
[0027] For example, the analysis module 24 might determine that a golfer hits his tee shot in the rough on the second hole 80 percent of the time by comparing the stored shot information and the course information. This information would then be passed onto the golfer.
[0028] Similarly, the playing tip module 26 offers golfers information concerning their golf game based upon information maintained by the statistic storage module 22 . With this in mind, the playing tip module 26 is linked with the analysis module 24 and statistic storage module 22 to provide customized tips based upon value-added information generated by the analysis module 24 .
[0029] As mentioned above, a golfer may access the central processor 16 of the present system 10 through the use of a personal digital assistant 14 . Enhanced use of the personal digital assistant 14 is provided by the inclusion of a global positioning chip 36 , or system, within the personal digital assistant 14 .
[0030] When a global positioning chip 36 is used in conjunction with a downloaded golf course, a software program within the personal digital assistant permits the global positioning chip 36 to take a reading of the golfer's location, calculate the golfer's position on the golf course and display all desired distances on any given hole (see FIGS. 5 and 6). For example, it is contemplated that a golfer may simply point upon the personal digital assistant 14 to identify the distance between two points on the golf course. The personal digital assistant 14 is carried by the golfer as he or she plays a round of golf and is able to continually determine the golfer's position on the course. This position information is used by the personal digital assistant 14 to provide the golfer with a wealth of real-time information.
[0031] In accordance with one embodiment of the present system, the golf course module contains ortho-rectified pictures of the golf holes of a plurality of golf courses. The ortho-rectified pictures are downloadable to the personal digital assistant 14 using conventional downloading techniques currently available. Specifically, and with reference to FIGS. 4 and 5, the system 10 utilizes a global communication network 12 to transfer ortho-rectified pictures 38 of golf holes of golf courses to the personal digital assistant 14 containing a global positioning satellite chip 36 . The transfer of the ortho-rectified pictures 38 to the personal digital assistant 14 is facilitated through the use of TCP/IP, although other communication protocols may be utilized without departing from the spirit of the present invention. It is also contemplated that the golf course information may be accessed via a desktop PC or cellular communication device, although those skilled in the art will readily understand the many other communication devices that may be utilized without departing from the spirit of the present invention. The cornerstone of this feature of the system 10 is to allow the golfer to bring the ortho-rectified pictures 38 of golf holes of a golf course to the golf course on a personal digital assistant 14 containing a global position satellite chip 36 for the purpose of retrieving and storing golf related information.
[0032] When the global positioning satellite chip 36 of the personal digital assistant 14 is used in conjunction with the downloaded ortho-rectified pictures 38 of golf holes of a golf course, a software program within the personal digital assistant 14 permits the global positioning satellite chip 36 to take a reading of the golfer's location and to calculate and display the golfer's position on the personal digital assistant. Then, using the software and the ortho-rectified pictures 38 , the personal digital assistant 14 is able to calculate and display relevant distances to desired geographical and topographical locations on the golf hole. This may be done time and again throughout a round of golf.
[0033] For example, a golfer is going to play course A tomorrow. The golfer can access course A from the courses stored on the golf course module 18 and download the ortho-rectified pictures 38 and software of course A to a personal digital assistant 14 which the golfer takes to the course. When the golfer commences the round, the golfer is on the back tee box of hole 1 , a long par four. The golfer presses the global positioning satellite button 40 on the personal digital assistant 14 which then displays to the golfer that the location is the back tee, the distance to clear the lake is 160 yards, the distance to a preferred spot in the middle of the fairway is 260 yards and the length necessary to clear the large tree necessary to cut the corner of the slight dog leg is 300 yards in the air (see FIG. 5). After hitting the drive in the preferred spot in the middle of the fairway, the golfer then stands next to the ball and again presses the global positioning satellite chip button 40 to take a reading. The golfer learns that the drive was 265 yards, that the remaining distance to the front of the green is 180 yards, the remaining distance to the middle of the green is 195 yards, the distance to the out of bounds marker behind the green is 230 yards and the distance to clear the creek running in front of the green is 165 yards (see FIG. 6).
[0034] In summary, by integrating the global positioning satellite chip 36 contained in the personal digital assistant 14 with the ortho-rectified pictures 38 of the golf holes downloaded to the personal digital assistant 14 position information is made readily available to the golfer. Specifically, once a global positioning system reading of the golfer's location on a given golf hole is taken, the personal digital assistant 14 uses that reading in conjunction with the ortho-rectified pictures 38 to calculate and display distances to desired locations on the golf hole.
[0035] In addition to providing position information, the golfer may input each of his or her shots for later uploading to the score entry module 20 of the central processor 16 . Specifically, the golfer will input the exact location of each shot, thereby creating a map of the shot taken as the golfer makes his or her way through a round of golf. This creates not only a record of the golfer's score, but a record of the position of each shot taken by the golfer during his or her round.
[0036] The information retrieved by the golfer while on the golf course is stored in the personal digital assistant 14 and is by uploaded by the golfer to the golfer's personal account on the central processor 16 accessed via the global communication network 12 . Uploading of the information is performed using conventional technology currently available.
[0037] In accordance with alternate embodiments of the present invention, the personal digital assistant may be continually linked with the central processor during a round of golf, thereby, eliminating the need to upload information at the end of a round of golf. Specifically, the personal digital assistant would be linked to the score entry module of the central processor and each stroke is thereby directly uploaded to the central processor immediately after it is recorded on the personal digital assistant by the golfer. That is, the golfer will simply input a shot immediately after completion, at which time the personal digital assistant will transmit the shot and position information to the score entry module for recordation.
[0038] In practice, the present system provides golfers with golf related information by providing a central processor via a global communication network The central processor includes a golf course module containing golf course information from a plurality of golf courses, a score entry module including means allowing a golfer to input each shot from a round of golf in relation to the golf course information maintained in the golf course module and a statistic storage module including a database in which data input via the score entry module is maintained for subsequent processing to provide golfers with desired information. The system then gathers scoring information from individuals accessing the central processor and processes the scoring information to add value thereto.
[0039] A simplified version of the present system is also contemplated in accordance with the present invention. With reference to FIGS. 7 to 9 , and in accordance with this embodiment, a personal digital assistant 102 including a GPS function 104 is provided. In addition to the GPS function 104 , the PDA 102 need only be provided with a memory 106 , processor 108 and input/output 110 .
[0040] In practice, an operator of the present system will obtain two location readings for each hole of each golf course participating in the present system; a first location reading 111 relating to the front of the green and a second location reading 112 relating to the middle of the green. As such, only 36 readings are required for each course participating in the present system.
[0041] It is contemplated that an operator will simply walk the course while carrying a PDA loaded with software designed to record location readings. The location readings are recorded and stored within the PDA, and subsequently uploaded to a central processor. The central processor then crunches the location readings into first and second coordinates to be used by golfers in a manner described below in greater detail.
[0042] In order to obviate the need for Internet connections as discussed above in accordance with the prior embodiment, the present embodiment utilizes the generated first and second coordinates 111 , 112 respectively relating to the front of the green and the middle of the green by storing the coordinates within the memory 114 of a PDA cradle 116 maintained at the respective golf course facility. With this in mind, a golfer need only show up to play golf carrying his PDA 102 loaded with software for operating in accordance with the present invention.
[0043] Specifically, the golfer will place his or her PDA 102 upon the cradle 116 , pay a required charge and upload the coordinates for the course he or she is about to play. The required coordinates are uploaded via the input/output 118 and memory of the cradle 116 . The PDA 102 is then loaded with the required respective first and second coordinates 111 , 112 for identifying the front of a green and the middle of a green. When the golfer arrives at the first hole, the golfer will input a location on the first hole and the PDA 102 will calculate his or her location relative to the front and middle of the first green. The calculation is simply based upon the first and second coordinates 111 , 112 relating to the first green as stored by operators of the present system as loaded onto the PDA 102 via the cradle 116 maintained at the golf course pro shop (or other location convenient to golfers). For example, when a golfer arrive at the first tee and designates the PDA 102 as such, the PDA display will indicate the following, for example:
[0044] 1st Hole—Green Grass Golf Club
[0045] 405 yds.—Front
[0046] 420 yds—Middle
[0047] Once the golfer has hit his or her first shot and found the struck golf ball, the PDA will be refreshed and the display will indicate the following, for example:
[0048] 1st Hole—Green Grass Golf Club
[0049] 155 yds.—Front
[0050] 170 yds.—Middle
[0051] Upon completing the first hole, the golfer will simply designate the second hole and repeat the process.
[0052] The alternate embodiment described above simplifies the underlying concept of the present invention by requiring the mapping of only 36 coordinates. In fact, it is contemplated that the 36 coordinates could be stored by an individual walking the course, uploaded to the central processor for data crunching, downloaded to the PDA of the individual taking the coordinates and stored within a cradle memory in a few hours (if not less).
[0053] While the preferred embodiments have been shown and described, it will be understood that there is no intent to limit the invention by such disclosure, but rather, is intended to cover all modifications and alternate constructions falling within the spirit and scope of the invention as defined in the appended claims.
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A system for providing golfers with golf related information includes a personal digital assistant having a GPS function, a memory, a processor and an input/output. The system also includes a cradle shaped and dimensioned for receiving the personal digital assistant and transferring information thereto. The cradle includes a memory storing information relating to coordinates on a golf course and an input/output transmitting information to the personal digital assistant. The personal digital assistant includes software for calculating and displaying distance between a golfer's location and a designated coordinate on the golf course.
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BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates generally to refrigeration compressors and more specifically to such compressors incorporating shields for reducing the lubricating oil level in the area surrounding the rotating rotor.
Typical refrigeration compressors incorporate a lubricant sump in the lower or bottom portion of the housing into which the drive shaft extends so as to pump lubricant therefrom to the various portions requiring lubrication. In addition, the lubricant also often acts to aid in removal of heat from the various components. In order to insure sufficient lubricating oil is contained within the sump to assure adequate lubrication and/or cooling of the moving parts while also minimizing the overall height of the housing, it is sometimes necessary that the oil level extend above the rotating lower end of the rotor. However, the higher viscosity of the oil as compared to refrigerant gas creates an increased drag on rotation of the rotor resulting in increased power consumption. This problem is further aggravated in scroll type compressors which typically employ a counterweight secured to the lower end of the rotor.
The present invention, however, provides a shield which projects above the oil level in the sump and is positioned in surrounding relationship to the lower end of the rotor via a close fit with the drive shaft whereby the oil level in the area within the shield is reduced by the initial rotation of the rotor upon startup and return oil flow into this area is greatly restricted. Thus, the oil induced drag on the rotor and resulting increased power consumption of the motor is greatly reduced. In one embodiment, a rotation inhibiting projection is provided on the shield while in another embodiment the shield is allowed to rotate with the drive shaft although the speed of rotation thereof will be substantially less than that of the drive shaft due to the drag exerted thereon by the lubricant. In both embodiments, however, the power consumption of the motor is greatly reduced thus resulting in significant improvement in the operating efficiency of the compressor.
Additional advantages and features of the present invention will become apparent from the subsequent description and the appended claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section view of a refrigeration compressor of the scroll type incorporating a shield surrounding the lower end of the motor rotor in accordance with the present invention, the section being taken along a radial plane extending along the axis of rotation of the drive shaft;
FIG. 2 is a section view of the compressor of FIG. 1, the section being taken along line 2--2 thereof;
FIG. 3 is a perspective view of the shield shown in FIGS. 1 and 2; and
FIG. 4 is a fragmentary section view similar to FIG. 1 but showing only a portion of the oil sump and an alternative embodiment of the shield, all in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and more specifically to FIG. 1, there is shown a hermetic refrigeration compressor 10 incorporating a shield 12 all in accordance with the present invention.
Compressor 10 comprises an outer shell or housing 14 within the lower portion of which is disposed an electric motor 16 including a stator 20 and a rotor 22. Motor 16 is operative to drive a compressor assembly 24 disposed in the upper portion of shell 14 via a drive shaft 26 extending therebetween and to which rotor 22 is secured adjacent the lower end. As shown, compressor assembly 24 is of the scroll type and incorporates an upper fixed scroll member 28 and a lower scroll member 30 which is driven by drive shaft 26 in orbiting motion relative to the fixed scroll member 28. Drive shaft 26 is rotatably supported within shell 14 by means of upper and lower bearing assemblies 32 and 34 respectively each of which are fixedly secured to shell 14. Compressor 10 is described in greater detail in presently pending application Ser. No. 899,003 filed Aug. 22, 1986 entitled "Scroll Type Machine With Axially Compliant Mounting" assigned to the same assignee as the present application, the disclosure of which is hereby incorporated by reference.
The lower portion of shell 14 defines a lubricant sump 36 containing a supply of oil for lubrication of the various components of compressor 10 as well as augmenting cooling thereof. In order to both minimize the overall height of compressor 10 as well as to assure an adequate supply of lubricant is contained within the sump, oil level 38 extends above the lower ends of the end turns 40 of stator 20 and both a counterweight 42 and the lower end portion 44 of rotor 22 to which counterweight 42 is secured.
Shield 12 is preferably formed as a one piece structure from a suitable polymeric composition such as a nylon material for example. It should be noted that other materials may be utilized so long as they are able to resist degradation from both the oil and refrigerant utilized in the system as well as the heat generated during operation of compressor 10. It should also be noted that the use of a dielectric non-magnetic material is believed preferable due to the proximity of the shield to the motor rotor and stator and the desire to avoid any interference with the operation thereof.
As best seen with reference to FIGS. 1 and 3, shield 12 incorporates a first generally cylindrically shaped portion 46 open at the upper end thereof and positioned in surrounding relationship to lower end portion 44 of rotor 22 and associated counterweight 42. Cylindrical portion 46 extends axially upwardly between rotor 22 and the end turns 40 of stator 20 to a height just slightly above maximum normal oil level 38. A lower hollow generally cylindrically shaped portion 48 extends axially downwardly therefrom in relatively closely spaced relationship to shaft 26 and includes an annular radially inwardly extending flange portion 50 which is received within a reduced diameter portion 51 of shaft 26. A radially extending annular flange portion 52 extends between and interconnects cylindrical portions 46 and 48. In order to restrict rotation of shield 12, a generally flat flange portion 54 is integrally formed on shield 12 extending axially downwardly from the lower surface of flange portion 52 and generally radially outwardly from cylindrical portion 48. Leg 56 extends axially downwardly from flange portion 54 and is received between a pair of support legs 58, 60 forming a part of lower bearing assembly 34 and cooperates therewith to restrict rotational movement of shield 12.
In operation, the rotational movement of the lower end portion 44 of rotor 22 and the associated counterweight 42 will operate to throw oil which has accumulated within the hollow shield 12 radially outwardly and over the top edge of shield 12 through the open spaces in the stator end turns as well as between shield 12 and these end turns and into sump 36 thereby lowering the oil level in the area surrounding the rotating rotor. Because the lower cylindrical portion 48 of shield 12 is closely fitted to the shaft 26, only a very small amount of oil will flow upwardly therebetween. Further, once a substantial amount of the oil within shield 12 has been expelled, shield 12 will become buoyant and float upwardly in the oil sump. As this occurs, flange portion 50 will move into engagement with the annular shoulder 62 on crankshaft 26 thus limiting further axial movement so as to thereby prevent shield 12 from moving upwardly into engagement with the spinning rotor 22. This engagement will also operate to establish a further restriction or seal against oil flow into the interior of shield 12. Thus, shield 12 will operate to effectively reduce the drag on rotor rotation due to its partial immersion into the oil in the lubricant sump and thereby eliminate the resulting power consumption. In this regard, it should be noted that the clearance between cylindrical portion 48 and shaft 26 is sufficient to avoid any excessive wear or drag on shield 12 but yet small enough to enable shaft 26 to effectively maintain shield 12 and particularly upper cylindrical portion 46 thereof the desired substantially coaxial position with respect to rotor 22 so as to avoid the possibility of contact therebetween. When compressor 10 is de-energized, shield 12 will slowly settle axially downwardly as lubricating oil gradually flows back into the interior thereof until such time as it comes to rest on lower bearing assembly 34 as shown in FIG. 1.
Referring now to FIG. 4, a modified embodiment of a shield 64 in accordance with the present invention is shown in operative relationship to a motor assembly 66 and associated drive shaft 68 of a refrigeration compressor 70. Shield 64 is virtually identical to shield 12 with the exception that flange portion 54 and associated leg 56 have been deleted therefrom. Accordingly, corresponding portions of shield 64 have been indicated by like numbers primed. Because shield 64 does not incorporate any means to prevent relative rotation thereof, the viscous drag resulting from the oil disposed between cylindrical portion 48' and shaft 66 will result in rotational movement thereof. However, this rotation will be substantially slower than the speed of rotation of drive shaft 66 because of the viscous drag exerted on shield 64 by the oil within sump 36'. Hence, it is believed only a slight stirring of the oil within sump 36' will occur as shield 64 is allowed to rotate which stirring may be beneficial to aid in cooling of the lower end turns of stator 20'.
Thus, as may now be appreciated, substantial improvements in operating efficiency are achieved by incorporation of either shield 12 or 64 due to the reduced motor power consumption. These longlasting benefits are achieved at a relatively low cost as shields 12 and 64 may be easily and inexpensively formed in any suitable manner such as injection molding or the like and further enable the overall height of the motor compressor to be kept to a minimum.
While it will be apparent that the preferred embodiments of the invention disclosed are well calculated to provide the advantages and features above stated, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims.
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A refrigeration motor compressor assembly has a housing including a lubricant sump in the bottom thereof into which the lower end of the drive shaft and associated rotor extend. A shield is provided which is positioned by the drive shaft and extends above the oil level in the sump in surrounding spaced relationship to the lower end of the rotor. As the rotor rotates within the shield, lubricant contained therein is thrown out of the surrounding shield and a close fit between the shield and the shaft restricts return flow of lubricant into the area occupied by the rotating rotor.
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TECHNICAL FIELD
This invention relates to a specialized trailer designed to facilitate the transport and lifting of railway cars after removal of their supporting wheel trucks.
BACKGROUND OF THE INVENTION
The present invention is designed for moving used railway cars, such as box cars and refrigerator cars, from one site to another. Surplus railway cars are recyclable for use as storage sheds or utility buildings. They are particularly desirable for rural and manufacturing storage. Refrigerated cars, being insulated and provided with a self-contained refrigeration system, are utilized by farmers as refrigerated storage buildings for produce, meat, dairy products and other applications where refrigeration is desirable.
The conventional manner by which railway cars are moved from one site to another involves use of a crane or a tractor forklift and a supporting flatbed trailer. However, the use of such equipment requires at least two operators and generally involves substantial expense for rental of machinery. More importantly, the transporting of moving box cars while supported on a typical flatbed trailer requires special height permits for highway travel. Height restrictions on highways can make such transport efforts prohibitively expensive.
Railway box cars are relatively uniform in height. In the United States, most box cars, after removal of their supporting wheel trucks, have a height of thirteen feet, six inches, from ground to roof surface. Since the normal height limits for loads carried on interstate highways in the United States is fourteen feet, the unsupported box car has only six inches of clearance available, much too little for effective use of an underlying flatbed trailer.
The specialized trailer described herein has been designed to lift a box car at its opposite ends, transport the box car while supported with an acceptable ground clearance and maximum height suitable for highway transport purposes, and subsequently position and lower the box car onto an awaiting foundation for stationary storage purposes. It is adaptable to railway cars of any length, since it utilizes two opposed support structures interconnected only by the structure of the railway car itself. The machinery for transporting, unloading and loading a railway car can be readily operated and moved by a single person.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiment of the invention is illustrated in the accompanying drawings, in which:
FIG. 1 is a side assembly view showing a loaded trailer;
FIG. 2 is a top view;
FIG. 3 is a side assembly view showing an unloaded trailer;
FIG. 4 is a side view of the front trailer unit;
FIG. 5 is a top view;
FIG. 6 is a rear view;
FIG. 7 is a perspective view of the partially assembled frame and forklift elements; and
FIG. 8 is a fragmentary longitudinal sectional view taken alongside a loaded forklift arm.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following disclosure of the invention is submitted in compliance with the constitutional purpose of the Patent Laws "to promote the progress of science and useful arts" (Article 1, Section 8).
The superstructure of a typical railway car 10 is shown in FIGS. 1, 2 and 8. When decommissioned after normal railway use, the wheel trucks (not shown) that support the railway car on a track are removed from beneath front and back transverse frames 12 that extend under its floor 19. Floor 19 is also structurally supported by a central longitudinal beam 11 that extends between the opposed transverse outer ends 13 of the railway car. The transverse frames 12 are located longitudinally inward adjacent to the outer ends 13 of the railway car 10.
The present trailer includes front and rear units illustrated at the left and right hand ends, respectively, of FIGS. 1 through 3. The principal elements of both units are identical to one another, and will be described by use of identical reference numerals applied to corresponding elements of each unit. The structural and operational differences that exist between the two units will be detailed below.
Each unit includes a rigid wheel-supported frame 14, shown as being fabricated from conventional metal beams. The front unit carries the frame 14 and an underlying floor member 19 on a conventional fifth-wheel assembly 38 attached to a highway tractor 37. The rear unit includes a dual-axle bogey 40 preferably connected to frame 14 for relative movement with respect to a transverse axis and a central vertical axis. The connection about the vertical axis permits the rear bogey 40 to be independently steered through a connection to an extendible hitch 41 that can be attached to a tractor or other vehicle (not shown) to assist in placing the railway car precisely over a receiving foundation (not shown).
One end of each frame 14 is provided with perpendicular hollow tubular guides 15 that slidably support a vertically movable forklift assembly 16. Each forklift assembly includes a pair of transversely spaced vertical posts 17. Their upper ends are rigidly connected by a horizontal cross-member 18. Outwardly protruding arms 20 extend from their respective lower ends. Covering abutments 22 overlap and are fixed to the posts 17. The outer surfaces of abutments 22 provide upright members adapted to abut an outer end of a railway car. The arms 20 serve as perpendicular protruding members adapted to be engaged beneath the outer end 13 of the railway car 10 for carrying the weight of the railway car at the abutted end for lifting purposes. Actual lifting forces on the railway car 10 are exerted through a solid pad 21 fixed along a portion of the upper surface of each arm 20.
The forklift assemblies 16 are elevationally adjustable relative to the wheel-supported frames 14 by power means operably connected between them. This power means is shown in the form of an upright hydraulic cylinder 23 anchored at its lower end to frame 14 and having an extensible piston rod connected to the center of cross member 18.
The trailer assembly shown in FIGS. 1 and 2 is completed by releasable securing means on the frames 14 that prevent longitudinal movement of the railway car 10 relative to the lifting forklift assemblies 16. In the present form of the invention, the preferred securing means is a length of chain 27 having a hook 28 at one end. The operational section of chain 27 is extended through the hollow arm 20 that supports it. This permits hook 28 to be engaged about a transverse edge of frame 12 under the railway car 10. Chain 27 can then be pulled manually toward the frame 14, where its remaining end is selectively attached to the inner end of its supporting arm 20 by a releasable locking pin assembly shown at 30 (FIG. 8).
As a safety feature, the front and rear units of the trailer are also secured to one another by tension applied to a continuous length of cable 31. One end of the cable 31 is anchored to the frame 14 of the front unit, as shown at 36 (FIGS. 2, 5). The opposite end of cable 31 is wound about a powered winch 35 on the front unit. The intermediate portions of cable 31 are guided by sheaves 32 at the inner end of each forklift arm 20, as well as by transfer sheaves 33 on the frames 14. Tension applied to cable 31 is used to pull the two wheeled units toward one another and into secure abutment with the intervening railway car 10.
It is to be understood that other arrangements can be readily utilized to secure the forklift assemblies 16 to the railway car 10 supported upon them. As examples, the forklift arms 20 might be pinned or bolted to the transverse frames 12 beneath the railway car 10, or to other structural elements adjacent to them. The hollow nature of arms 20 also facilitates the use of extendible hooks located within them (not shown), which might be operated by suitable mechanical or hydraulic mechanisms.
In addition to the hydraulic cylinders 23, the elevated forklift assemblies 16 are preferably supported by a mechanical interlock to prevent the supported weight of the railway car 10 from dropping in the event of failure of the hydraulic system. This interlock is shown as individual ratchet arms 24 pivotally supported on each frame 14 immediately behind the vertical post 17 of the forklift assembly 16. The ratchet arms 24 can be slidably received between spaced brackets 25 fixed at the upper end of each post 17. The brackets 25 include an outer guide pin 29 and an inner releasable pin 26. Pin 26 can be selectively placed between the inclined teeth formed along one edge of each ratchet arm 24, thereby providing vertical support between the forklift assembly 16 and frame 14. When not needed, the ratchet arms 24 can be released from within brackets 25 by elevating the forklift assembly 16, which permits the upper ends of ratchet arms 24 to swing clear of the brackets 25.
The described trailer can be readily configured between an unloaded transport position (FIG. 3) and a fully loaded configuration (FIGS. 1 and 2), where the independent front and rear units are interconnected by the interposed railway car 10. It requires no use of wheels or other ground supports under the superstructure of the railway car 10, thereby minimizing the overall height of the assembly for highway height limitation purposes. The railway car 10 is effectively lifted at its opposed outer transverse ends, by engaging downwardly facing horizontal support surfaces recessed upwardly within the longitudinal and transverse frame elements that support the floor 19.
When connected for transport purposes in an unloaded condition, the abutting front and rear units of the trailer can be connected to one another by tightening the cable 31 that is entrained about the sheaves 32 and 33 on the respective forklift assembly 16 and supporting frames 14. An interior connecting member can be inserted within the hollow ends of arms 20 to maintain them in alignment, if desired. The forklift assemblies 16 can be transported at a desired elevation above the ground surface by operation of the hydraulic cylinders 23, which are preferably operated in unison with one another through a common valve and hydraulic pressure system, which can be located on frame 14 of the rear unit. Suitable interconnecting hydraulic hoses 39 can be extended between the two units as required by the hydraulic systems contained on them.
To attach the trailer to a railway car 10, the operator of the trailer must locate the forklift assemblies 16 against its opposed outer ends 13. The front unit can be readily positioned by operation of the tractor 37. The rear unit can similarly be positioned by attachment of hitch 41 to a tractor or vehicle that can roughly push it into place.
The transversely spaced forklift arms 20 are positioned on frames 14 to straddle the central longitudinal beam 11 provided along the underside of a railway car 10. After arms 20 are located beneath the floor 19, with the abutments 22 in engagement with the opposed outer ends 13 of the railway car 10, the assembly can be tightened by operation of winch 35 and the interconnecting cable 31 strung between the two units. The tension applied to cable 31 will pull the wheel-supported frames 14 snugly against the opposed ends 13 of the railway car 10.
Once the forklift assemblies 16 are fitted beneath the floor 19 of the railway car 10, the hydraulic cylinders 23 can be actuated to raise and lower it as required for movement relate to underlying foundations and for roadway transport purposes. The railway car 10 can be elevated with minimum clearance from the roadway to permit its transport within highway height limitations.
The front and rear units can be used to move the railway car 10 into proper position above a new foundation. They are operated in unison to raise or lower it as required. After placement of the railway car, the two units can be disengaged and moved independently apart by means of the tractor 37 and the releasable towing connection provided at hitch 41.
In compliance with the statute, the invention has been described in language more or less specific as to structural features. It is to be understood, however, that the invention is not limited to the specific features shown, since the means and construction herein disclosed comprise a preferred form of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims, appropriately interpreted in accordance with the doctrine of equivalents.
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A trailer for lifting and transporting a railway car minus its usual wheeled trucks utilizes a pair of independently positioned wheeled frames in the form of front and rear units that can be located at opposite ends of the railway car. Each wheeled frame supports a forklift assembly having transversely spaced protruding arms capable of fitting under the floor of the railway car while straddling the central longitudinal beam extending from its one end to the other. The forklift assemblies are selectively secured to the railway car to form an integral trailer capable of transporting it on a highway within normal height limitations. The front and rear units can be used to maneuver the railway car into place above a foundation, and can raise or lower the railway car as necessary to remove or place it as desired.
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TECHNICAL FIELD
[0001] This invention relates to bonding electrical components to substrates.
BACKGROUND
[0002] In a typical membrane switch, for example, a polyester substrate bears a silver-filled conductive ink in a pattern of conductors that forms an electrical circuit. Several conductor layers may be used, for example two conductor layers separated by a dielectric layer. Electrical components are bonded to the circuit using a conductive adhesive, e.g., a silver-filled epoxy adhesive, to provide a conductive interface between the components and the circuit.
[0003] A typical LED or diode bears a pair of spaced conductive pads, usually gold plated, on its back surface. These component pads are bonded to two corresponding pads on the substrate using dots or “beads” of conductive adhesive that are printed or dispensed onto the substrate pads. The electrical component is then placed onto the adhesive, and the adhesive is cured to bond the component in place. The bond between a component pad and a substrate pad defines an electrical contact point.
[0004] A typical process for bonding an LED to a substrate is shown in FIGS. 1 - 1 B. As shown in FIG. 1, looking from the underside, a conductive ink is printed on a flexible substrate 10 to form printed conductive traces 1 , 11 and to define a pair of pads 2 , 12 to which an LED 4 is attached. (Substrate 10 is generally much larger than the area indicated by the dotted lines in FIGS. 1 - 3 ; the dotted lines indicate a portion of the substrate.) The substrate 10 may be, e.g., a sheet of transparent flexible polyester film. As shown in FIG. 1A, beads 3 , 13 of conductive adhesive are then dispensed onto the pads 2 , 12 . FIG. 1B shows the LED 4 positioned over the pads 2 , 12 . The conductive adhesive has been displaced (squished) by the LED 4 , and has migrated to regions 5 that are between the beads 3 , 13 .
[0005] Because the adhesive is heavily filled with silver particles to make it conductive, the shear strength of the adhesive is relatively low, and thus the strength of the bond between the component and the substrate is also relatively low. The component bond line failure that may occur as a result of this low bond strength may cause the membrane switch to fail.
[0006] In addition, because the conductive pads on the component are close together, the squished conductive adhesive may form a bridge 15 between the pads, electrically shorting the component.
SUMMARY
[0007] The invention enables an electrical component to be bonded to a substrate with a relatively high bond strength and without shorting. These advantages can be provided without significantly increasing the cost of the membrane switch.
[0008] In one aspect, the invention features a method comprising (a) bonding separate conductive areas of an electrical component to a substrate using a conductive adhesive; and (b) bonding an area of the electrical component lying between the conductive areas to the substrate using a non-conductive adhesive.
[0009] Implementations of this aspect of the invention may include one or more of the following features. The method further includes forming, on the substrate, a pair of spaced conductive attachment areas to which the spaced conductive areas are bonded. The substrate includes a flexible sheet, e.g., a polyester film. The electrical component is an LED or diode. The conductive adhesive is a silver-filled epoxy adhesive. The non-conductive adhesive is an epoxy adhesive. The method further includes forming a membrane switch that includes the electrical component and the substrate. The method further includes hardening the conductive and non-conductive adhesives to secure the electrical component to the substrate.
[0010] In another aspect, the invention features an article comprising (a) a substrate; (b) an electrical component comprising separate electrical contacts; (c) a conductive adhesive bond between each of the separate electrical contacts and the substrate; and (d) a non-conductive bond between the substrate and a portion of the component that lies between the electrical contacts.
[0011] Implementations of this aspect of the invention may include one or more of the following features. The article includes a membrane switch. The substrate includes a flexible sheet, e.g., a polyester film. The electrical component is an LED or diode. The conductive adhesive is a silver-filled epoxy adhesive. The non-conductive adhesive is an epoxy adhesive. The non-conductive adhesive defines a barrier stripe between the adhesive bonds. The conductive bonds are squished.
[0012] In a further aspect, the invention features a membrane switch including (a) a flexible sheet substrate; (b) an electrical component comprising separate electrical contacts; (c) a conductive adhesive bond between each of the separate electrical contacts and the substrate; and (d) a non-conductive bond between the substrate and a portion of the component that lies between the electrical contacts; (e) the non-conductive bond comprising a barrier stripe between the adhesive bonds.
[0013] A “conductive adhesive” is a hardenable material that is sufficiently conductive so that, when properly applied and hardened, it provides an electrical contact point between an electrical component and a substrate to which the component is bonded. Preferred conductive adhesives exhibit as volume resistivity of less than about 5×10 −3 Ohms/mil/cm, more preferably less than about 5×10 −4 Ohms/mil/cm, when tested according to ASTM D2739-97.
[0014] A “non-conductive adhesive” is a hardenable material that is essentially non-shorting when placed between and in contact with two electrical contact points bonding an electrical component to a substrate. Preferred non-conductive adhesives exhibit a dielectric strength of greater than 2400 volts AC @ 1 mil (25 microns) when tested according to ASTM D149-81.
[0015] Other features and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0016] [0016]FIGS. 1, 1A and 1 B are schematic backside views, looking through the substrate, of a portion of a membrane switch during various stages of a prior art production process. These views are taken from the backside of the substrate, looking through the substrate.
[0017] [0017]FIGS. 2 and 2A are schematic backside views of a membrane switch according to one embodiment of the invention, during various stages of production.
[0018] [0018]FIG. 3 is a front view of a membrane switch assembled by the process shown in FIGS. 2 and 2A.
[0019] [0019]FIG. 4 is a side view of the membrane switch shown in FIG. 1A.
[0020] [0020]FIG. 5 is a side view of the membrane switch shown in FIG. 2A.
DETAILED DESCRIPTION
[0021] As shown in FIG. 2, to manufacture a membrane switch a conductive ink is first printed on a transparent flexible substrate 10 to form printed conductive traces 1 , 11 and to define a pair of pads 2 , 12 , as explained above. Each bead of conductive adhesive typically measures about 0.025 inch by 0.050 inch by 0.006 inch.
[0022] Next, a bead of non-conductive adhesive 6 is placed between the pads 2 , 12 . After the non-conductive adhesive 6 is in place, and before it hardens, beads 3 , 13 of conductive adhesive, e.g., silver-filled epoxy adhesive, are deposited on the substrate 10 (FIG. 2A). The non-conductive adhesive can be printed or dispensed as a line, a dot, or a number of dots. The non-conductive adhesive typically measures about 0.025 inch by 0.050 inch by 0.007 inch.
[0023] An LED 4 is then positioned on the beads 3 , 13 as shown in FIG. 3. The non-conductive adhesive 6 squeezes out into a broader area 16 in the vicinity of the center of the LED 4 , preventing the displaced regions 5 of conductive adhesive from bridging under the LED.
[0024] Finally, the non-conductive adhesive 6 and the conductive adhesive 3 , 13 are hardened, e.g., by curing, to secure the LED 4 in place.
[0025] Suitable non-conductive adhesives include heat curable epoxy adhesives, cyanoacrylates, silicones and hot melts.
[0026] The bond strength of the LED to the substrate 10 in the configuration shown in FIG. 3 is generally higher than the bond strength in the prior art configuration shown in FIG. 1B for two reasons. First, the non-conductive adhesive 6 is stronger than most silver filled adhesives. Second, the total amount of surface area bonded by adhesive is greater. Depending on the adhesive deposition method (dispensed or printed), the increase in bond strength can be 2 to 4 fold. In some implementations, the bond strength is at least 10 pounds when measured by modified version of ASTM F1995-00.
[0027] Providing the non-conductive adhesive 6 generally prevents shorting of the electrical component, by providing a non-conductive barrier between the beads 3 , 13 of conductive adhesive.
[0028] Other embodiments are within the scope of the following claims. For example, while LEDs and diodes have been discussed above, other electrical components may be bonded using the methods of the invention. Also, the methods of the invention may be used to bond electrical components to substrates other than flexible films, for example to printed circuit boards. The number and configuration of the pads could be different. The number and configuration of the adhesive dots and areas could be different.
EXAMPLE
[0029] A number of LEDs (size 0603) were bonded to a 7 mil treated Mylar substrate having conductive pads as described above, using the following procedure. First, a non-conductive epoxy adhesive was printed in the center, between the two pads. Then, dots of conductive epoxy adhesive were dispensed on each of the pads. The LEDs were placed on the pads, and the substrate/LED assembly was heated for 3-5 minutes at 135° C. to cure the epoxy adhesives. The bond strengths were tested, using a push tester, with results ranging from 4 pounds to 9 pounds. No shorting was observed during electrical testing.
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Methods are provided including (a) bonding separate conductive areas of an electrical component to a substrate using a conductive adhesive; and (b) bonding an area of the electrical component lying between the conductive areas to the substrate using a non-conductive adhesive.
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PRIORITY CLAIM
[0001] The present application is a continuation of U.S. patent application Ser. No. 11/043,670 (Atty. Docket No. END920040158US1), filed on Jan. 25, 2005, and entitled, “Configurable Business Controls Task Notification,” which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates in general to data processing and in particular to improving efficiency of data access, distribution and modification within distributed databases containing diverse event notifications. Still more particularly, the present invention relates to a system, method and computer program product for generating, accessing, distributing and/or modifying events in multiple business control databases that contain event reminders.
[0004] 2. Description of the Related Art
[0005] The profusion of business control schedules, representing processes wherein distributed employees and organizations must complete activities that define the operational compliance of a business with defined standards, has created an entangled and incomprehensible web of activities that must be performed by employees and organizations. Application of these processes runs from governmental compliance such as environmental, health, safety, and accounting regulation to business certifications such as ISO9000 and internal procedures such as information technology and security. In many industrial organizations, employees find themselves bombarded with multiple sets of business controls compliance tasks, coming from multiple sources, with no integrated system for delivery or prioritization.
[0006] Conventionally, distributed database systems define and store records, such as user IDs, user groups and other information in a variety of different locations and storage systems related to specific functions. The existing standards-based information storage and retrieval methods (e.g. Distributed Computing Environment (DCE), Lightweight Directory Access Protocol (LDAP), Network Information System (NIS+) and others) were designed to serve disparate purposes.
[0007] As can be foreseen from the description of each of the task types listed above, the emphasis on compliance with individual processes has encourage conflicting demands on employees. Further, because of the different purposes driving the designs of the business control procedures listed above, each procedure set has tended to reside within its own administrative tools, requiring employees to learn those tools.
[0008] There is presently no adequate mechanism for managing events in multiple business control databases. The increasing need for employees to comply with multiple such business control systems has created an unfulfilled and increasing need for unified management of business control tasks, particularly in large organizations. What is needed is a way to enable integrated interaction with business control schedule events, which are distributed across several storage locations and tied to different tasks, for consolidated management of business control tasks.
SUMMARY OF THE INVENTION
[0009] A method for performing business control task notification is proposed. The method comprises processing a combination of one or more databases and one or more user profiles to generate a schedule template and receive a request for a schedule. A computer program product compares attributes of the request for the schedule to a user profile and a schedule template to identify one or more events of the schedule template to be accessed from one or more of a plurality of distributed databases and forms a query to be sent to the one or more distributed databases. The query is sent to a particular database among the plurality of distributed databases. The computer program product receives a positive response to the query, indicating that the particular database contains a first event for the schedule, and the event. In response to receiving the event, the schedule is created. The schedule is stored. One or more current events in the schedule requiring a notification are identified, and the notification is sent to a destination.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
[0011] FIG. 1 illustrates a distributed database in a network environment, in which preferred embodiments of the method, system and computer program product for performing business control task notification is implemented;
[0012] FIG. 2 is a high-level logical flowchart of a process for checking a schedule and sending notices in performing business control task notification in accordance with a preferred embodiment of the present invention;
[0013] FIG. 3 is a high-level logical flowchart of a process for preparing a schedule in performing business control task notification in accordance with a preferred embodiment of the present invention;
[0014] FIG. 4 is a high-level logical flowchart of a process for querying schedule databases in performing business control task notification in accordance with a preferred embodiment of the present invention; and
[0015] FIG. 5 is a high-level logical flowchart of a process for preparing template data in performing business control task notification in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] With reference now to the figures and in particular with reference to FIG. 1 , there is depicted an exemplary network environment with which the present invention may be advantageously utilized. The illustrated network environment includes a local or wide area network 100 , such as the Internet or another packetized digital network. An integrated control manager data processing system 102 , an information technology schedule database 104 , an ISO schedule database 106 , a health and environment schedule database 108 , a first client 128 and a second client 130 are attached to network 100 , and communication is enabled through contact and routing information contained in database configuration 110 .
[0017] Each of information technology schedule database 104 , ISO schedule database 106 , and health and environment schedule database 108 contains business control schedule events stored in electronic records, representing processes wherein distributed employees and organizations must complete activities. Any employee or organization may be involved in the completion of activities reflected in business control schedules on one or more of information technology schedule database 104 , ISO schedule database 106 , and health and environment schedule database 108 . Employees interact with the schedules created by integrated control manager data processing system 102 through first client 128 and second client 130 . Integrated control manager data processing system 102 performs functions related to access and distribution and of events stored in electronic records, located on information technology schedule database 104 , ISO schedule database 106 , and health and environment schedule database 108 . Integrated control manager data processing system 102 uses data stored in database configuration 110 to communicate with information technology schedule database 104 , ISO schedule database 106 , and health and environment schedule database 108 over network 100 .
[0018] For the purpose of simplifying discussion of the invention itself, many details of integrated control manager data processing system 102 , which details are well within that which is known to one of skill in the relevant data processing arts, have been omitted from the discussion of the present invention. The operations of integrated control manager data processing system 102 with respect to information technology schedule database 104 , ISO schedule database 106 , and health and environment schedule database 108 may be implemented with conventional or later-developed hardware or software.
[0019] The functions of integrated control manager data processing system 102 include, but are not limited to access to and distribution of electronic records containing schedule events. In the example shown with respect to integrated control manager data processing system 102 , integrated control manager data processing system 102 operates under instructions to assemble, based on the content of a template database 132 a user schedule 152 for a given user profile among user profiles 142 (e.g. first user profile 140 , second user profile 144 , third user profile 146 and fourth user profile 148 ) containing a group of schedule events, such as a first event 112 , a second event 114 , a third event 116 , and a fourth event 118 . For some of first event 112 , second event 114 , third event 116 , and fourth event 118 , integrated control manager data processing system 102 will have access to stored information, hereafter called assignments, sometimes internally stored in template database 132 and sometimes stored on database configuration 110 , relating to the location from which some events can be retrieved, but may have no such assignment information relative to the locations from which other events may be retrieved.
[0020] User schedule 142 is contained in master schedule database 176 along with fulfillment URLs 150 . Fulfillment URLS 150 contains LURLs that can be used to help users perform actions associated with specific events. Many of these events can be performed or confirmed by transmission of messages to one of information technology schedule database 104 , ISO schedule database 106 , and health and environment schedule database 108 , such as client-to-database message 178 to ISO schedule database 106 and database-to-client message 180 from ISO schedule database 106 . Events from user schedule 152 are sent to first client 128 and second client 130 by notification engine 126 . Notification engine 126 is capable of receiving a schedule request 154 from a client, such as first client 128 and sending notification messages, such as notification message 156 to first client 128 and notification message 158 to second client 130 . When notification engine 126 receives a schedule request 154 from first client 128 , notification engine 126 sends a query request 188 to query engine 190 . Query engine 190 sends a template request 192 to template database 132 and receives a template reply 194 in response. Query engine 190 also sends a profile request 196 to user profiles 142 and receives a profile reply 198 in response. Notification engine 126 can also send a notification message 158 in response to receiving a schedule alert 186 from master schedule database 176 .
[0021] Template engine 138 can send a database request, such as database request 172 to health and environment database 108 and receive a database result transmission 174 . Template engine 138 also sends a user profile request 182 to template user profiles 142 and receives a profile result transmission 184 . Template engine 138 delivers current templates 136 as a template report 199 .
[0022] Template database 132 contains data for determining what events to assemble for a user schedule 152 based on the content of a user profile (e.g., first user profile 140 ) and is generated by template engine 138 . Template database 132 contains current templates 136 and past template archive 134 . Past template archive 134 contains a record of past templates and schedules. First event 112 , second event 114 , third event 116 , and fourth event 118 are retrieved into user schedule 152 in master schedule database 176 by integrated control manager data processing system 102 through the sending of queries, which queries are based on current templates 136 , to information technology schedule database 104 , ISO schedule database 106 , and health and environment schedule database 108 . For purposes of explanation, the example illustrated with respect to FIG. 1 operates on the assumption that integrated control manager data processing system 102 will have access to information, stored in current templates 136 relating to the location among information technology schedule database 104 , ISO schedule database 106 , and health and environment schedule database 108 at which first event 112 and third event 116 can be accessed. With respect to second event 114 and fourth event 118 , the example illustrated with respect to FIG. 1 assumes that no location data is available to integrated control manager data processing system 102 that would be helpful in ascertaining the location of the events among information technology schedule database 104 , ISO schedule database 106 , and health and environment schedule database 108 of second event 114 and fourth event 118 .
[0023] A client, such as first client 128 , can communicate directly with a database, such as ISO schedule database 106 , through messages, such as client-to-database message 178 and database-to-client message 180 .
[0024] The process for managing database records with events located in multiple registries in accordance with a preferred embodiment of the present invention, described in detail below with respect to FIG. 4 , will result in the sending and receiving of several messages. As examples of these messages, first query message 160 contains first query 120 , directed to information technology schedule database 104 , and includes a request for first event 112 , second event 114 and fourth event 118 . No request for third event 116 is included in first query 120 , because location data is available to integrated control manager data processing system 102 that indicates the presence of third event 116 on health and environment schedule database 108 . The response to first query 120 arrives at integrated control manager data processing system 102 in the form of first event message 162 , which contains first event 112 and data acknowledging the absence from information technology schedule database 104 of second event 114 and fourth event 118 .
[0025] Similarly, second query message 164 contains second query 122 , directed to ISO schedule database 106 , and includes a request for second event 114 and fourth event 118 . No request for third event 116 is included in second query 122 , because location data is available to integrated control manager data processing system 102 that indicates the presence of third event 116 on health and environment schedule database 108 . Likewise, no request for first event 112 is included in second query 122 , because integrated control manager data processing system 102 received first event 112 in first event message 162 . The response to second query 122 arrives at integrated control manager data processing system 102 in the form of second event message 166 , which contains second event 114 and data acknowledging the absence from ISO schedule database 106 of fourth event 118 .
[0026] As a final example, third query message 168 contains third query 124 , directed to health and environment schedule database 108 , and includes a request for third event 116 and fourth event 118 . No request for first event 112 or second event 114 is included in third query 124 , because integrated control manager data processing system 102 received first event 112 in first event message 162 and received second event 114 in second event message 166 . The response to third query 124 arrives at integrated control manager data processing system 102 in the form of third event message 170 , which contains third event 116 and data acknowledging the absence from health and environment schedule database 108 of fourth event 118 .
[0027] Turning now to FIG. 2 , a high-level logical flowchart of a process for checking a schedule and sending notices and performing business control task notification in accordance with the preferred embodiment of the present invention is depicted. The process starts at step 200 , which will typically correspond to activation of master schedule database 176 on integrated business control manager 102 . The process next moves to step 202 . At step 202 , master schedule database 176 verifies whether any schedules exist, which have not been checked recently for near-term event dates. If no such unchecked schedules exist, then the process ends at step 204 . If unchecked schedules exist, then the process next moves to step 206 , which depicts master schedule database 176 loading user schedule 152 . The process then proceeds to step 208 .
[0028] At step 208 , master schedule database 176 on integrated business control manager 102 examines user schedule 152 for events with near-term dates. This examination for near term dates is accomplished by reviewing the required performance dates in first event 112 , second event 114 , third event 116 and fourth event 118 . If events with near term dates do not exist, then the process ends at step 204 . If events with near term dates do exist, then the process next moves to step 210 .
[0029] At step 210 , master schedule database 176 sends a schedule alert 186 , containing any events with near-term required performance dates to notification engine 126 . The process next moves to step 212 , which depicts notification engine 126 processing schedule alert 186 by sending a notification 158 to second client 130 . The process then returns to step 202 , which is described above.
[0030] With reference now to FIG. 3 , a high-level logical flowchart of a process for preparing a schedule and performing business control task notification in accordance with a preferred embodiment of the present invention is illustrated. The process starts at step 300 , which corresponds to activation of notification engine 126 . The process then moves to step 302 . At step 302 , notification engine 126 receives a schedule request 154 from first client 128 . The process then proceeds to step 304 , which depicts integrated business control manager 102 comparing a user profile, such as fourth user profile 148 to data from current templates 136 in compliance with schedule request 154 . This is accomplished as notification engine 126 sends a query request 188 to query engine 190 . Query engine 190 then sends a profile request 196 to user profiles 142 and receives a user profile such as fourth user profile 148 in a profile reply 198 . Query engine 190 then sends a template request 192 to template database 132 and the template database replies by sending an appropriate subset of current templates 136 in a template reply 194 to query engine 190 .
[0031] The process next moves to step 306 . At step 306 , query engine 190 queries databases for attributes called for in the template from among current templates 136 received in template reply 194 , as is detailed below with respect to FIG. 4 . Upon receipt of responses to database queries as a part of the process of step 306 , the process then moves to step 308 . At step 308 , master schedule database 176 prepares, delivers, and stores a user schedule 152 . Delivery of a schedule can be accomplished by sending a schedule alert 186 to notification engine 156 . The process then ends at step 310 .
[0032] With reference now to FIG. 4 , there is depicted a high-level logical flowchart of a process for managing database records with events located in multiple registries in accordance with a preferred embodiment of the present invention. While the process of FIG. 4 has been illustrated in a simplified embodiment as a logical flowchart, wherein single operations are explained sequentially for the purpose of explanatory clarity, one skilled in the art will quickly recognize that the process depicted in FIG. 4 can be separated into a group of interacting processes, operating as modules or program objects in parallel processes and interacting with one another.
[0033] Among these subprocesses, which can be described as modules and whose parts will be explained in greater detail below, assignment module 454 comprises steps 404 - 412 . Assignment module 454 performs steps related to identifying whether, for each requested event, a known schedule database location exists, such as information technology schedule database 104 as a location for first event 112 . As will be detailed below, with respect to the example portrayed in FIG. 1 , the steps of assignment module 454 include analysis by integrated control manager data processing system 102 of current templates 136 in template database 132 as to which schedule database can appropriately provide a given event, and the assignment of the event to a list, which is then used by integrated control manager data processing system 102 in query preparation module 456 .
[0034] Query preparation module 456 comprises steps 414 - 430 and step 450 . Query preparation module 456 prepares queries for integrated control manager data processing system 102 to send to databases across network 100 . The third module, query communication module 458 , includes steps 432 - 440 and sends queries to databases across network 100 .
[0035] The process of FIG. 4 begins at step 400 , which depicts integrated control manager data processing system 102 beginning the process of creating a schedule by accessing, distributing and modifying events in databases that are distributed across multiple data processing systems connected to a network. Step 400 typically involves activation of a query process on integrated control manager data processing system 102 , and activation may come from a user or an automated query. The process then proceeds to step 402 , which illustrates integrated control manager data processing system 102 receiving schedule request 154 . Schedule request 154 is received at notification engine 126 . As depicted with respect to the example in FIG. 1 , integrated control manager data processing system 102 processes a query for four events of one or more records. The requested events are first event 112 , second event 114 , third event 116 , and fourth event 118 .
[0036] The process of FIG. 4 next moves to step 404 , which is part of an assignment subprocess, previously identified as assignment module 454 . Step 404 depicts integrated control manager data processing system 102 determining whether any requested events (e.g., first event 112 , second event 114 , third event 116 , and fourth event 118 ) remain in an ‘unassigned’ condition. For purposes of the discussion with respect to FIG. 4 in light of the example described with respect to FIG. 1 , an unassigned condition exists whenever, with respect to one of first event 112 , second event 114 , third event 116 , and fourth event 118 , integrated control manager data processing system 102 does not possess information as to the location among information technology schedule database 104 , ISO schedule database 106 and health and environment schedule database 108 on which the needed event is stored. If the location of all desired events is known, then the process of FIG. 4 moves to step 414 in query formation module 456 , which is described in detail below.
[0037] If, however, as in the example portrayed in FIG. 1 , there exist events in an unassigned condition, for which location data is not available on integrated control manager data processing system 102 , then the process of FIG. 4 next proceeds to step 406 , which illustrates integrated control manager data processing system 102 queuing a next event for identification of its location. The process then moves to step 408 , which illustrates integrated control manager data processing system 102 determining whether a database from among those to which integrated control manager data processing system 102 can send queries (e.g., information technology schedule database 104 , ISO schedule database 106 and health and environment schedule database 108 ) is assigned to provide the event in question. The determination as to whether a database among those to which integrated control manager data processing system 102 can send queries is assigned to provide the event in question can be made from data received in a request to access events in step 402 , from data stored on integrated control manager data processing system 102 or from data stored by other sources.
[0038] If a database is specified for the event in question, the process then moves to step 410 which depicts integrated control manager data processing system 102 assigning the event in question to a location list for the specified database. With respect to the example portrayed in FIG. 1 , because the location of first event 112 on information technology schedule database 104 is known, integrated control manager data processing system 102 assigns first event 112 to the list of events to be queried from information technology schedule database 104 . Similarly, because the location of third event 116 on health and environment schedule database 108 is known, integrated control manager data processing system 102 assigns third event 116 to the list of events to be queried from health and environment schedule database 108 .
[0039] In step 408 , if no location data is available for first event 112 , then the process proceeds to step 412 , which depicts integrated control manager data processing system 102 assigning an event to the list of events for which no database is known. In the example depicted in FIG. 1 , database locations are assigned and known for first event 112 and third event 116 , which would be assigned to query lists for their respective information technology schedule database 104 and health and environment schedule database 108 . However, no location data is available for second event 114 and fourth event 118 . Second event 114 and fourth event 118 would be assigned to the query list for those events for which no database location data is known. After the completion of step 410 or the completion of step 412 , the process returns to step 404 .
[0040] If, in step 404 , no events remain which have not been assigned to the lists for a particular database or to the list for which no database location is known, the process then enters query preparation module 456 as the process moves to step 414 . Step 414 illustrates integrated control manager data processing system 102 adding any known unused database location data to the list of databases which will be queried with respect to events for which no location database is known. This data will typically be available from database configuration 110 .
[0041] The process of FIG. 4 then proceeds to step 416 , which depicts integrated control manager data processing system 102 determining whether any unreceived events remain. If no unreceived events remain, then the process leaves query preparation module 456 and enters return module 460 as the process moves to step 442 , which will be described in detail below.
[0042] If any unreceived events remain, then the process of FIG. 4 proceeds to step 418 , which illustrates integrated control manager data processing system 102 determining whether it has exhausted all of the possible databases that are available to receive queries for any unreceived events. The databases, which are available to receive queries for unreceived events, will include those databases referenced in information stored on integrated control manager data processing system 102 , those databases referenced in information received from database configuration 110 , and those databases referenced in any information received in response to queries to previously queried databases. An individual database is exhausted after a query has been sent to it.
[0043] If the available databases have not been exhausted, then the process moves to step 420 , which depicts integrated control manager data processing system 102 queuing the next event for possible addition to the query, which is being prepared for transmission to the current database selected in step 420 . The process then proceeds to step 422 , which depicts integrated control manager data processing system 102 determining whether any of the desired events remain untried for the current database selected in step 420 . This step involves determining whether each of the unreceived events has been tried for the current database selected in step 440 .
[0044] If, in step 422 , untried events remain, then the process of the preferred embodiment will move to step 424 , which illustrates the integrated control manager data processing system 102 designating the next event for possible addition to the query being sent the current database selected in step 420 . The process then proceeds to step 426 , which depicts integrated control manager data processing system 102 determining whether the database specified in step 424 to receive the query currently being formed is the desired database that is assigned as containing the event under consideration. To determine if the database specified in step 424 to receive the query currently being formed in query formation module 456 is the desired database that is assigned as containing the event under consideration, integrated control manager data processing system 102 refers to the list prepared in assignment module 454 for the current database selected in step 420 , and ascertains whether the current event contained is identified on the list generated in assignment module 454 . If the specified database being tried is the desired database, which is known to contain the required event, then the process moves to step 428 , which depicts integrated control manager data processing system adding the current event to the query for the current database.
[0045] If in step 426 , the specified database is not the desired database, the process proceeds to step 430 , which illustrates integrated control manager data processing system determining whether any database is specified with respect to the event under consideration. Integrated control manager data processing system 102 determines that no database is specified for an event by searching for the current event in the list prepared by assignment module 454 , containing those events for which no database was specified. If no database is specified for the event under consideration, the process moves to step 428 , in which integrated control manager data processing system 102 adds the event under consideration, for which no location data is available, to the query being prepared for the current database selected in step 420 .
[0046] If a specified database is available but the current database is not the specified database, then the process returns to step 422 , which is discussed above. Returning to step 422 , if no events remain untried for the current database, then the process moves to step 432 , which depicts sending a query to the current database.
[0047] In the example illustrated with respect to FIG. 1 , three queries are presented. First query 120 is a query for first event 112 , fourth event 118 , and second event 114 . Second query 122 is a query requesting second event 114 and fourth event 118 . Third query 124 requests third event 116 and fourth event 118 .
[0048] Returning to FIG. 4 , the process of FIG. 4 next passes to step 434 , which illustrates client data processing 102 receiving events. As noted above, sending query 120 as a first query message 160 would result in the return of event 112 in first event message 162 . Similarly, sending second query 122 as second query message 164 would result in receipt of second event 114 as second event message 166 , and sending third query 124 as third query message 168 would result in receipt of third event 116 as third event message 170 . The process then proceeds to step 436 , wherein integrated control manager data processing system 102 stores location data for the events that it has received in step 434 . The process next moves to step 438 , which depicts integrated control manager data processing system performing operations on or with the received events. Operations performed on the received events will vary from embodiment to embodiment, and can include any operation that would be performed in the conventional. The process of FIG. 4 next proceeds to step 440 , which depicts the recording on un-received events, and is then followed by a return to step 416 , which is discussed above.
[0049] Returning to step 416 , if integrated control manager data processing system determines that no un-received events remain, the process next moves to step 442 , which depicts integrated control manager data processing system 102 determining whether a return of any events is required. If the return of events is required, the process of FIG. 4 then proceeds to step 444 , which depicts modification of events which require modification. The process then moves to step 446 , which depicts replacing the modified events in their original databases by reference to the stored location information. The process then ends at step 448 . If, in step 442 , integrated control manager data processing system 102 determines that no events require modification, then the process of FIG. 4 next moves to step 448 , where it ends.
[0050] Returning to step 418 , if, in step 418 integrated control manager data processing system 102 determines that all of its available databases have been queried and there are events that have not been found in any database, then the process moves to step 450 , which illustrates integrated control manager data processing system reporting failures and ends at step 448 .
[0051] Turning now to FIG. 5 , a high-level logical flowchart of a process for preparing template data and performing business control task notification in accordance with the preferred embodiment of the present invention as depicted. The process starts at step 500 , which corresponds to activation of template engine 138 . The process next proceeds to step 502 . Step 502 depicts template engine 138 requesting a database and a user profile. Template engine 138 requests a user profile by sending profile request 182 to user profiles 142 . Template engine 138 requests a database by sending database request 172 to a database such as health and environmental schedule database 108 . The process then moves to step 504 which depicts template engine receiving a database and a user profile. As depicted in the example illustrated in FIG. 1 , template engine 138 receives a profile result transmission 184 containing first user profile 140 , second user profile 144 , third user profile 146 and fourth user profile 148 . Template engine 138 also receives health and environment schedule database as part of database result transmission 174 . The process then moves to step 506 . Step 506 depicts template engine 138 determining whether it has exhausted available common events from first user profile 140 , second user profile 144 , third user profile 146 and fourth user profile 148 . If common events from first user profile 140 , second user profile 144 , third user profile 146 and fourth user profile 148 have been exhausted, then the process proceeds to step 507 , which depicts template engine generating a report. A template report 199 is sent to template database 132 , and the process then ends at step 508 .
[0052] If at step 506 , common events from first user profile 140 , second user profile 144 , third user profile 146 and fourth user profile 148 have not been exhausted, then the process proceeds to step 510 , which depicts template engine 138 identifying and processing a next common event from among two or more of first user profile 140 , second user profile 144 , third user profile 146 and fourth user profile 148 . The process then moves to step 512 , which depicts template engine 138 determining whether the common event processed in step 510 correlates to a common trait. If the common event correlates to no discernable common trait, then the process proceeds to step 514 , which depicts template engine 138 flagging the common event for later processing. If the common event correlates to a common trait in step 512 , then the process next moves to step 516 . Step 516 depicts template engine 138 adding the common event and common trait to template report 199 .
[0053] As has been described, the present invention provides a system, method and computer program product for accessing and distributing events in business control database that are distributed across multiple data processing systems connected to a network. The present invention provides facilities for sending a queries from a local integrated control manager data processing system to a remote database, wherein that query is composed of requests for events known to be stored on the database and events whose location is unknown. Once an event is received from a remote database, the present invention provides facilities for creating schedules and for notifying clients. The present invention improves interaction between clients and business control databases by providing an orderly and methodical system for dealing with events distributed across multiple databases.
[0054] While the invention has been particularly shown as described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. It is also important to note that although the present invention has been described in the context of a fully functional computer system, those skilled in the art will appreciate that the mechanisms of the present invention are capable of being distributed as a program product in a variety of forms, and that the present invention applies equally regardless of the particular type of signal bearing media utilized to actually carry out the distribution. Examples of signal bearing media include, without limitation, recordable type media such as floppy disks or CD ROMs and transmission type media such as analog or digital communications links.
[0055] The present invention has been described in relation to particular embodiments that are intended in all respects to be illustrative rather than restrictive. Although specific terms are used, the description thus given uses terminology in a generic and descriptive sense only and not for purposes of limitation.
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A method for performing business control task notification is proposed. The method comprises processing a combination of one or more databases and one or more user profiles to generate a schedule template and receive a request for a schedule. A computer program product compares attributes of the request for the schedule to a user profile and a schedule template to identify one or more events of the schedule template to be accessed from one or more of a plurality of distributed databases and forms a query to be sent to the one or more distributed databases. The query is sent to a particular database among the plurality of distributed databases. The computer program product receives a positive response to the query, indicating that the particular database contains a first event for the schedule, and the event. In response to receiving the event, the schedule is created. The schedule is stored. One or more current events in the schedule requiring a notification are identified, and the notification is sent to a destination.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an oscillator device utilizing a crystal oscillator, more specifically, to a crystal oscillator device, which can simultaneously generate a plurality of signals with different oscillation modes of the crystal oscillator.
2. Description of the Related Art
The crystal oscillator used in oscillator devices generates not only main oscillation but also sub-oscillation. Generally, only the main oscillation of oscillator devices is utilized, and therefore it is required that the sub-oscillation does not cause deterioration of the main oscillation, this is achieved by controlling the sub-oscillation. However, extraction and utilization of the signal of such a sub-oscillation for the purpose of temperature compensation and so forth have been proposed.
It is widely known that the crystal oscillators such as SC-cut and IT-cut crystal oscillators, for example, generate sub-oscillation (B-mode) with a frequency of 9% in higher frequency of resonance frequency of the oscillation mode (C-mode) of the main oscillation. It is proposed in Patent Document 1 (U.S. Pat. No. 4,079,280) that as the frequency of the B-mode signal as a function of temperature is linear, the oscillation frequency of the C-mode can be stabilized by temperature-compensation based on the nature of the functional relationship between the frequency of the B-mode signal and the temperature.
FIG. 1 is a circuit block diagram of the crystal oscillator described in Patent Document 1, etc.
In the oscillator device described in FIG. 1 , a feedback signal is provided to an SC-cut crystal oscillator 121 after amplification by amplifier 123 . The output from the crystal oscillator 121 is filtered utilizing two filters 122 a and 122 b , and is output as B-mode and C-mode signals respectively.
The oscillator device in Patent Document 1 can perform more accurate temperature compensation, compared with a method, which estimate the temperature using a temperature sensor equipped by the crystal oscillator, because it can detect the actual temperature of a resonator of crystal consisting the crystal oscillator from the frequency of the B-mode signal with high accuracy.
The oscillator devices, utilizing an AT-cut crystal, in Patent Document 2 (U.S. Pat. No. 4,525,647) and Patent Document 3 (U.S. Pat. No. 4,872,765) simultaneously generate two signals, output from the crystal oscillator device, by two different oscillation modes of an AT-cut crystal, namely thickness shear and face contour oscillation modes.
The method of simultaneously generating a plurality of signals with different oscillation modes of an oscillator is described in the above Patent Documents 2 and 3. However, none of the Patent Documents 1 to 3 describe the detailed configuration of a circuit to realize the simultaneous generation of two modes. For example, in the configuration in Patent Document 1, the signals of the B mode and the C-mode are output separately, as shown in FIG. 1 . However, because they are common outputs, the output and the B-mode and C-mode feedback signals of FIG. 1 are in practice the same signal, that is a signal with B-mode and C-mode combined. In order to obtain individual mode signal outputs, the signals should be separated by performing processing on the shared output. In Patent Document 1, however, does not describe any method for so doing.
In Patent Document 2, the configuration of the crystal oscillator comprises, independent terminals for thickness shear oscillations and for contour oscillations, and four input and output terminals. However, in reality such a crystal oscillator does not exist.
When the simultaneous generation of signals with two different oscillation modes from a crystal oscillator is attempted, a see-saw phenomenon in which either one or the other of the signals is generated because of fluctuations in supply voltage and surrounding temperature. The range of supply voltage and surrounding temperature within which the signals of two modes are simultaneously generated is very narrow, and if the temperature or the voltage fluctuate beyond this range, either one of the signals or neither of the signals is generated. Especially, in order to unfailingly generate upon power supply, very difficult fine control is required However, none of the Patent Documents above has any description of a means for addressing the see-saw phenomenon. Therefore with the descriptions of the above Patent Documents, it is difficult to guarantee the stable generation of the signals of two oscillation modes without failure and to maintain the condition as stable as possible.
The temperature compensation of the crystal oscillator, for stabilizing the oscillation frequency of the crystal oscillator, comprises a heater in the proximity of the crystal oscillator, thermally connecting the heater with the crystal oscillator and an oscillation circuit, and maintains a certain high temperature of the heater.
The types of heater used are the rim type, where the heater surrounds the crystal oscillator, and the heat tube type, where the oscillator circuit is sealed inside a metal package and a heater wire is coiled around the package. However, such heaters have a large thermal resistance in the part between the heater and a piece of crystal inside the crystal oscillator package, which is kept at high vacuum, thus thermal efficiency is low and lack long-term stability. Further the complicated assembly increases cost.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a crystal oscillator device, which enables stable and simultaneous generation of the oscillation signals of two kinds of oscillation modes produced by a crystal unit.
It is another object of the present invention to provide a crystal oscillator device, realizing temperature compensation with good thermal efficiency and highly accurate control.
The present invention is based on the assumption that oscillation signals with a plurality of oscillation modes of a crystal unit are generated simultaneously, and in order to solve the problems mentioned above, the present invention comprises a primary resonator unit, a secondary resonator unit, a primary phase synthesis unit, a tertiary resonator unit, a quaternary resonator unit and a secondary phase synthesis unit.
A primary resonator unit performs filtering of the oscillator signal of a primary oscillation mode, which is one of the oscillator modes, from the output of the crystal unit.
A secondary resonator unit, bearing a different resonant frequency from that of the primary resonator unit, performs filtering of the oscillator signal of a primary oscillation mode from the output of the crystal unit.
A primary phase synthesis unit synthesizes the phases of the output signal of the primary resonator unit and the output signal of the secondary resonator unit.
A tertiary resonator unit performs filtering of the oscillator signal of a secondary oscillation mode, which is one of the oscillation modes, from the output of the crystal unit.
A quaternary resonator unit, bearing a different resonant frequency from that of the tertiary resonator unit, performs filtering of the oscillator signal of a tertiary oscillation mode from the output of the crystal unit.
A secondary phase synthesis unit synthesizes the phases of the output signal of the tertiary resonator unit and the output signal of the quaternary resonator unit.
Such a configuration allows stable oscillation of both oscillation signals of the primary oscillation mode and of the secondary oscillation mode because the signals and their phases, synthesized by the primary phase synthesis unit and the secondary phase synthesis unit, have stable gain and phase to the frequency oscillation.
The primary phase synthesis unit and the secondary phase synthesis unit are realized by a differential amplifier, for example. In such a way, instability caused by temperature fluctuation can be avoided and long-term stability can be achieved.
The primary resonator, the secondary resonator, the tertiary resonator and the quaternary resonator can be directly connected to the crystal oscillator device.
By this configuration for each oscillation mode, the interference between one oscillation mode and another caused by active circuits can be reduced.
The crystal unit is either an SC-cut or an IT-cut crystal unit, and the primary oscillation mode is the C-mode and the secondary oscillation mode is the B-mode
This configuration realizes temperature compensation control using the B-mode oscillation signal.
In addition, this configuration does not require an additional mixer but instead, in order to obtain the beat signal, a beat signal extraction unit is comprised, which extracts the B-mode oscillation signal and the C-mode oscillation signal for the purpose of ascertaining the temperature of the crystal unit.
The crystal oscillator device further comprises a temperature compensation control unit, which calculates the value representing the oscillation frequency of the beat signal from the C-mode oscillation signal and the B-mode oscillation signal with reference to the oscillation frequency of the C-mode oscillation signal, executes the temperature compensation control based on the oscillation frequency value of the beat signal when fluctuation of the oscillation frequency value of the beat signal is small, and executes the temperature compensation control based on the oscillation frequency value of the beat signal and a primary specified value when fluctuation of the oscillation frequency value of the beat signal is large.
Such a configuration as briefly described above realizes highly accurate temperature compensation control.
The temperature compensation unit executes temperature compensation control based on a secondary specified value when the oscillation frequency value of the beat signal indicates lower than a temperature 1 , and executes the temperature compensation control based on the tertiary specified value when the oscillation frequency value of the beat signal indicates higher than a temperature 2 , which is even higher than a temperature 1 .
A primary temperature detector unit, which detects whether the temperature in the proximity of the crystal unit is lower than the temperature 1 or not, and a secondary temperature detector unit, which detects whether the temperature in the proximity of the crystal unit is higher than the temperature 2 , higher than the temperature 1 , or not, can be further comprised. The temperature compensation control unit executes the temperature compensation control based on the secondary specified value when the primary temperature detector unit detects that the temperature in proximity of the crystal unit is lower than the temperature 1 , and carries out the temperature compensation control based on the tertiary specified value when the secondary temperature detector unit detects that the temperature in proximity of the crystal unit is higher than the temperature 2 .
The above configuration allows temperature compensation control with a high resolution.
The configuration may also comprise a heater unit, installed so as to be in contact with a terminal of the crystal unit and heating the crystal unit through the terminal.
This configuration enables heating of the crystal unit in a thermally efficient manner.
The oscillation method using the crystal unit device and the heater used in the crystal unit are included in the present invention.
According to the present invention, the oscillator signals of two different oscillation modes can be generated simultaneously and stably despite fluctuations of supply voltage and changes in surrounding temperature.
Temperature compensation, which is thermally efficient and enables highly accurate control, can be also realized.
Thus the present invention enables the output of a highly precise frequency signal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit block diagram of the crystal oscillator described in Patent Document 1;
FIG. 2 is a simplified block diagram of the crystal oscillator of the illustrated embodiment;
FIG. 3 is a schematic of an example of configuration of the oscillator circuit;
FIGS. 4A and 4B show the signal characteristics of a phase-synthesized signal element filtered by two filters;
FIGS. 5A and 5B show the characteristics of the amplifier circuit of the oscillator circuit of the illustrated embodiment;
FIG. 6 is a block diagram illustrating a control circuit of the temperature compensation unit;
FIG. 7 shows temperature control by the temperature control unit;
FIG. 8 describes a configuration of the temperature compensation unit of the second embodiment;
FIG. 9 shows a configuration of the temperature compensation unit of the second embodiment;
FIG. 10 is a drawing of the configuration of the heater used in the crystal unit of the illustrated embodiment;
FIG. 11 illustrates a configuration, in which the power transistor driving the heater is in thermal contact with the crystal unit; and
FIG. 12 is a cross-section drawing showing the inside of the crystal oscillator device package of the illustrated embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following description, details of one embodiment of the oscillator of the present invention are set forth with reference to drawings. The following description is based on an example configuration of an SC-cut or an IT-cut crystal oscillator, which simultaneously generates C-mode and B-mode signals, executes temperature compensation using the B-mode output signal, and outputs the C-mode signal with high frequency precision. However, the crystal oscillator of the present invention is not limited to SC-cut or IT-cut crystal oscillators but can be adopted for use with any oscillators which generate a signal with a plurality of oscillation modes in general, for example, crystal oscillators with different plate cut geometries, such as the signals of the fundamental frequency mode and the third harmonic frequency mode of an AT-cut crystal oscillator.
FIG. 2 is a simplified block diagram of the crystal oscillator of the illustrated embodiment.
The crystal oscillator of the illustrated embodiment comprises a oscillator circuit 1 and a temperature compensation unit 2 , and the temperature compensation unit 2 controls the temperature of each elemental device comprising the oscillation circuit 1 and its crystal oscillator by controlling a heater unit 3 based on a C-mode output signal (hereinafter referred to as the C-mode signal), and the beat signal of a B-mode output signal (hereinafter referred to as the B-mode is signal) and C-mode signal(hereinafter referred to as the C/B mode beat signal), are all generated by the oscillator circuit 1 (when the oscillator circuit 1 comprises a temperature switch, as described later, the output from the temperature switch is also taken into account).
FIG. 3 is an example of configuration of the oscillation circuit 1 .
The crystal oscillator of the illustrated embodiment is directly connected to the crystal oscillator, and inputs the signal element passing through the SC-cut or the IT-cut crystal oscillator Xtal without involving any active device such as an amplifier. Such a configuration reduces the intervention, caused by active circuits, between the circuit for the B-mode signal and the circuit for the C-mode signal. If the input terminal of a feedback loop in the oscillator circuit has the configuration with active devices, as one oscillation mode signal input increase, the output level of the other mode signal decreases, failing to maintain stable oscillation of both modes. On the contrary, even though one mode signal input increases, the oscillation circuit 1 of FIG. 3 , enables the maintenance of a constant output level of the other mode signal by directly connecting the output of the crystal oscillator Xtal and the crystal oscillator.
Two crystal resonators are comprised in each of the B-mode and the C-mode. A constant phase and gain are obtained even during frequency fluctuation, by synthesizing the phases of the output signals from these two crystal resonators. As a result, two constant signals are output from start up without producing the see-saw phenomenon even if the temperature or the supply voltage fluctuate.
FIG. 3 illustrates a configuration including a C-mode oscillator circuit on top and a B-mode oscillator circuit below. The C-mode signal generated by the circuit on top is output as an oscillation signal. At the same time, the C-mode signal and the B-mode signal generated by the circuit below are loosely coupled by resistor R 1 and amplified by an amplifier A 1 . Then the high-frequency signals such as the B-mode and C-mode signals remaining in the coupled signal are removed, and the product, the C/B mode beat signal, is output to the temperature compensation unit 2 .
In the configuration of the C-mode oscillator circuit shown in FIG. 3 , the output of the crystal oscillator Xtal is connected to parallel crystal resonators F 11 and F 12 . The outputs of crystal resonators F 11 and F 12 are connected to the bases of transistors Tr 11 and Tr 12 after passing through input resistors R 101 and R 102 and capacitors C 102 and C 103 , respectively. The emitters of the transistors Tr 11 and Tr 12 are connected to each other, and together connected to ground through a resistor R 108 . The collector of the transistor Tr 11 is connected to a voltage source +DC through resistor R 107 . The collector of the transistor Tr 12 is connected to the input of an inverting amplifier A 11 through a capacitor C 105 . The output of the inverting amplifier A 11 is applied to a non-inverting amplifier A 12 and a capacitor C 106 . The C-mode signal is output from the other side of the capacitor C 106 . The output of the noninverting amplifier A 12 is connected to a resistor R 1 through a capacitor C 107 and a resistor R 112 , and is connected to the crystal oscillator Xtal through a capacitor C 1 .
Resistors R 103 , R 104 and R 107 are bias resistors used to bias the transistor Tr 11 , resistors R 105 , R 106 and R 109 to bias transistor Tr 12 , and resistor R 108 to bias both transistors Tr 11 and Tr 12 . A resistor R 101 is the input resistor of the transistor Tr 11 , and a resistor R 102 is the input resistor of the transistor Tr 12 . Capacitors C 102 , C 103 , C 105 , C 106 and C 107 are coupling capacitors for blocking DC and permitting the input of AC. Capacitors C 101 , C 104 and C 108 are bypass capacitors for the power source.
In such a configuration, the signal from the crystal oscillator Xtal is filtered by passing through the crystal resonators F 11 and F 12 . The output is phase-synthesized by a differential amplifier comprised of two transistors Tr 11 and Tr 12 . The signal, which meets one of the generation requirements, that is the feedback signal has the same phase as the original signal, is amplified with a phase shift of 180 degrees by an inverting amplifier A 11 . The output of the inverting amplifier A 11 with any DC component removed by the capacitor C 106 is provided as the C-mode signal output of the oscillation circuit 1 . The output of the inverting amplifier A 11 , split from the C-mode signal by the noninverting amplifier A 12 , is applied to a resistor R 1 through the capacitor C 107 and a resistor R 112 , and loosely coupled to the B-mode signal from the circuit comprising the lower half of FIG. 3 and resulting in generation of the C/B mode beat signal.
The lower half configuration of the B-mode oscillator circuit is much the same as that of the C-mode oscillator circuit. The crystal resonators F 21 and F 22 are equivalent to the crystal resonators F 11 and F 12 of the C-mode oscillator circuit, and transistors Tr 11 and Tr 12 are equivalent to the transistors Tr 21 and Tr 22 of the C-mode oscillator circuit. The amplifiers A 21 and A 22 are equivalent to the amplifiers A 11 and A 12 . The bias resistors R 203 ˜R 209 are equivalent to the bias resistors R 103 ˜R 109 . The resistors R 210 ˜R 212 are equivalent to the resistors R 10 ˜R 112 . The coupling capacitors C 202 , C 203 , C 205 , and C 206 are equivalent to the coupling capacitors C 102 , C 103 , C 105 and C 107 , and the source bypass capacitors C 201 , C 204 and C 207 are equivalent to the capacitors C 101 , C 104 and C 108 .
The B-mode output signal from the amplifier A 22 , after being passed through the capacitor C 206 and the resistor R 212 , is loosely coupled to the C-mode output signal from the amplifier A 12 , similarly passed through the capacitor C 107 and the resistor R 112 , by the resistor R 1 . After being amplified by the amplifier A 1 and having the high-frequency signals such as B-mode and C-mode signals remaining in the beat signal removed by a lowpass filter LPF 1 , the signal is output by the oscillator circuit 1 as the C/B mode beat signal output.
In order to perform temperature compensation, a mixer circuit is required to generate the C/B mode beat signal, which is the difference generated by mixing the C-mode signal and the B-mode signal, to measure frequency fluctuations of the B-mode signal based on the C-mode signal, which has a highly stable frequency, as a time base. However, in the illustrated embodiment, the C/B mode beat signal can be obtained from the oscillation circuit 1 , therefore it is not necessary to comprise any mixer circuit external to the oscillator circuit 1 .
The circuit in FIG. 3 stabilizes and outputs the two signals by inputting the output of the crystal oscillator to two crystal resonators F 11 (F 21 ) and F 12 (F 22 ) in each of the C-mode oscillation circuit and the B-mode oscillation circuit, and phase-synthesizing the output passed through the crystal resonator.
FIGS. 4A and 4B show the signal characteristics of a phase-synthesized signal element filtered through the two crystal resonators F 1 and F 2 .
The oscillation circuit 1 in FIG. 3 , using two crystal resonators for each of the B-mode and the C-mode circuits in order to consist filters, synthesizes the phases of the outputs from each circuit.
FIG. 4B shows the phase curve 31 and gain curve 32 of the output signal OUT when the filtered outputs of the crystal resonators F 1 and F 2 are phase-synthesized using coils L 1 and L 2 as described in FIG. 4A . The frequency of the input signal IN is on the horizontal axis, and the level of the phase and the gain of the output signal OUT is on the vertical axis.
The center frequency of the resonator F 1 in FIG. 4A is f 1 and the center frequency of the resonator F 2 in FIG. 4A is f 2 . The range over which the phase 31 and the gain 32 are stable can be configured over a wide frequency range between the frequencies f 1 and f 2 as in FIG. 4B . Consequently, even if the frequency of the input signal IN changes because of fluctuations in supply voltage and temperature, stable signal generation can be obtained, and the see-saw phenomenon can be prevented as long as the frequency of the input signal IN lies between the frequencies f 1 and f 2 . For that reason, the resonant frequencies f 1 and f 2 should be selected so that the frequencies of the B-mode and the C-mode signals lie around the center f of the frequency range f 1 through f 2 , and that the both modes can be kept within the range in which the phase and the gain are constant even if the frequencies of the B and C-mode signals are changed by perturbations in the temperature or supply voltage (i.e. between frequencies f 1 and f 2 ).
In the circuit of FIG. 3 , the crystal resonators F 11 and F 12 are selected so that the frequency of the C-mode signal lies between the center frequency f 11 of the crystal resonator F 11 and the center frequency f 12 of the crystal resonator F 12 , even if the frequency of the C-mode signal varies due to fluctuations in the temperature or supply voltage. In a similar way, the crystal resonators F 21 and F 22 are selected so that the frequency of the B-mode signal lies between the center frequency f 21 of the crystal resonator F 21 and the center frequency f 22 of the crystal resonator F 22 , even if the frequency of the B-mode signal varies. By this configuration, the generation requirements, which are for stabilizing the phase and the gain of the feedback signal, are satisfied; therefore the oscillator circuit 1 enables the stable generation of signals with two kinds of oscillation modes.
In the circuit of FIG. 3 , the phase synthesis does not employ inductors but a differential amplification circuit of the transistors. Such a configuration avoids the instability caused by temperature perturbations when inductors are used, provides long-term stability and thus allows the circuit to realize and to maintain stable simultaneous generation on and after start-up.
The B-mode signal requires phase synthesis of signals from two oscillators because of the possibility of large frequency fluctuations. However, as the C-mode signal has small frequency fluctuations phase synthesis as described above is not required, and a configuration in which the output of the crystal oscillator Xtal is filtered using a filter whose center frequency is the frequency of the C-mode signal can be used.
Also, the circuit in FIG. 3 utilizes crystal resonators for oscillators F 11 , F 12 , F 21 and F 22 , however a material, with appropriate temperature characteristics and which, provides a high enough Q, such as a monolithic crystal filter, can be used as a substitute.
FIGS. 5A and 5B show the characteristics of the amplifier circuit of the oscillator circuit 1 of the illustrated embodiment.
FIG. 5A shows the characteristics of the amplifier circuit of the C-mode oscillator circuit, and FIG. 5B shows the characteristics of the amplifier circuit of the B-mode oscillator circuit.
FIG. 5A indicates the change in the C-mode output when the input level of the B-mode signal is changed. The graph of FIG. 5A has the level of the B-mode input signal on the horizontal axis and the levels of the B-mode and the C-mode output signals on the vertical axis. The curve 42 represents the level of the B-mode input signal, and the curve 41 represents the level of the C-mode output signal.
In the oscillator circuit 1 of FIG. 5A , the output level 41 of the C-mode signal is constant, and is unaffected by the increase in the input level 42 of the B-mode signal.
FIG. 5B indicates the change in the B-mode output when the input level of the C-mode signal is changed. The graph of FIG. 5B has the level of the C-mode input signal on the horizontal axis and the levels of the B-mode output and the C-mode output signals on the vertical axis. The curve 43 represents the level of the B-mode output signal, and the curve 44 represents the level of the C-mode input signal.
From FIG. 5A and FIG. 5B , it is shown that the level 43 of the B-mode output signal is constant even if the level of the C-mode input signal is changed, and thus that variation in the level of the C-mode input signal does not affect the level 43 of the B-mode output signal.
In the crystal resonator of the illustrated embodiment, as explained above, the resonator F 21 and F 22 of the B-mode signal and the resonator F 11 and F 12 of the C-mode signal have different impedances. Because one has a higher impedance than the other, the resonator F 11 and F 12 perform filtering separately. Therefore, change in the input level of one signal does not affect the output level of the other signal.
In the following description, temperature control by the temperature compensation unit 2 is explained.
The temperature compensation unit 2 controls the temperature of a piece of crystal consisting the crystal unit Xtal in the oscillator circuit 1 by using the C-mode signal and the C/B mode beat signal from the oscillator circuit 1 .
FIG. 6 is a block diagram illustrating the control circuit of the temperature compensation unit 2 .
In the illustrated embodiment, the C/B mode beat signal is counted with reference to the C-mode signal as the clock signal, and the count during a certain time period is accumulated by an integrator. According to the accumulated count, the transistor driving the heater unit 3 is under PWM control.
Generally, the temperature is low on start-up. The cumulative sum of the count resulting from the low temperature on start-up would cause a bias in the cumulative sum and consequently, accurate control would not be achieved.
The control circuit in FIG. 6 addresses this problem by waiting until the temperature reaches a predetermined target temperature before the integrator calculates the cumulative sum. The cumulative sum calculated after the temperature exceeds the target temperature is not subject to the above bias and thus accurate temperature control is realized.
The following explanation assumes that the C-mode signal is 5 MHz, and 16-bit processing is performed in the temperature compensation unit 2 of FIG. 6 .
In the temperature compensation unit 2 of FIG. 6 , the C-mode signal from the oscillator circuit 1 is divided into 1/n (=2 15 =32768) by a frequency divider 501 , and a time interval signal for counter S 501 is generated. An S-CLK is obtained by using a PLL multiplier 518 to multiply the frequency of the C/B mode beat signal of the oscillator circuit 1 by 100. By counting the S-CLK with a counter 505 , the temperature is calculated and a heater 523 in heater unit 3 can be controlled.
The S-CLK signal and the output of the divider 501 (S 501 ) are asynchronous. In order to synchronize these two signals, flip-flops 502 ˜ 504 , connected in series, are used. S 501 is input to the flip-flop 502 , the S-CLK is input from each clock input, then the signal S 503 is obtained from the output of the flip-flop 503 . The output of the flip-flop 503 (S 503 ) is delayed for one signal period of the S-CLK by applying it to the flip-flop 504 , which operates with the S-CLK as a clock signal. The output signal S 504 of the above operation is inverted by a NOT gate 520 , and is ANDed with S 503 by AND gate 519 . The obtained signal S 1 serves as the clear signal of a counter 505 and the load signal of a register 506 .
The counter 505 clears the count of S-CLK every time the clear signal S 1 is input. The clear signal S 1 is the load signal of the register 506 , therefore the S-CLK is counted for one signal period of the signal S 1 , and the count is provided to an adder 507 by the register 506 as a multiplied clock counter output holding signal S 506 .
The adder 507 subtracts the preset target value from the count S 506 held in the register 506 , and outputs the result S 507 in two's complement. This value is provided to a register 508 , which stores the latest data, a comparator 509 and a bit scaler 514 .
The comparator 509 compares the latest data output from the register 508 and the preset data output from the adder 507 . When the high side 8 bits of 16-bit operation match, the comparator 509 outputs logic H, and when they do not match, it outputs logic L.
When logic H is output by the comparator 509 , a switch 501 turns ON, the output S 507 of the computing unit 507 is provided to an adder 512 . When logic L is output by the comparator 509 , a switch 511 turns ON, the center value of the two's complement 0000H is input to a computing unit 512 . Consequently, 0000H is input to the adder 515 , when the change in the output S 507 of the adder 507 is large, and a difference in the high side 8 bits of the latest data set in the register 508 is caused. The output S 507 is input to the adder 515 , when the change in the output S 507 of the adder 507 is small keeping the same high side 8 bits of the latest data set in the register 508 .
An adder 512 and a register 513 comprise an integrator, which sums the latest data output from the register 513 and the output from the switch 510 or the switch 511 . The result is provided to the adder 515 as well as set in the register 513 for integration operation. At a time, when the result of the comparison by the comparator 509 is that the high side 8 bits do not match as explained above, the center value 0000H of the two's complement is input to the computing unit 512 and integrating processing is performed. The update period of the data in the register 513 is calculated from the C/B mode beat signal and a thermal response time constant.
The scaler 514 performs scaling by shifting and multiplying the 16-bit value, which is in the difference data output on start-up from the computing unit 507 , within the range that does not cause overflow errors. The output of the scaler 514 and the output of the register 513 are added, and the result is provided to a pulse width modulator 516 . Based on the input, the pulse width modulator 516 modulates the pulse width, that is, to increase and decrease the number of pulses at random within a certain time period. The modulated signal is converted into the analog signal by the lowpass filter 517 , and the modulator drives the heater by inputting the modulated signal to the power transistor of the heater unit 3 .
In the above example, the analog signal controlling heater input of the heater unit 3 is generated using the pulse width modulator 516 and the lowpass filter 517 . However, a D/A converter can be used to convert the output of the computing unit 515 into analog data.
In this way, the temperature compensation unit 2 of the illustrated embodiment performs integration operation, accounting for the fact that the temperature on start-up is far from the target temperature. Therefore, it quickly reaches the target frequency, and achieves highly accurate temperature control. And it is not necessary a fine adjustment to the low pass filter 517 and an analog portion of the heater unit.
The following description is an explanation of the second embodiment of the temperature compensation unit 2 .
FIG. 7 shows temperature control by the temperature control unit 2 .
In FIG. 7 , the target temperature is set at 85° C., and the temperature compensation unit 2 controls the heater based on the C/B mode beat signal of the oscillator circuit 1 . When the temperature is controlled from start-up the temperature is low and the resolution of control is low because it takes some time for the temperature to reach the target temperature and the range to be controlled is wide.
The temperature compensation unit 2 of the second embodiment addresses this problem. The heater is driven at full power from start up until the temperature reaches the predetermined target temperature (85° C. in FIG. 7 ). When the temperature reaches the predetermined temperature 1 (75° C. in FIG. 7 ), accurate control of the temperature based on the C/B mode beat signal is performed. As soon as the temperature surpasses the predetermined temperature 2 (95° C. in FIG. 7 ), the heater is turned off so that the temperature drops below the predetermined temperature 2 (95° C.).
FIG. 8 describes a configuration of the temperature compensation unit 2 of the second embodiment.
In the second embodiment, a temperature switch for 95° C. and a temperature switch for 75° C. are arranged near the crystal oscillator Xtal of the oscillator circuit 1 . The temperature compensation unit 2 executes temperature control by further using the outputs from these switches.
In addition to the configuration shown in the first embodiment in FIG. 6 , the temperature compensation unit 2 of the second embodiment further comprises configuration elements shown in FIG. 8 between the adder 515 and the pulse width modulator 516 .
The 95° C. temperature switch and the 75° C. temperature switch output the logic H when the temperature exceeds 75° C. (95° C.), and otherwise output the logic L. When the temperature is below 75° C., L is output from both the 75° C. temperature switch and the 95° C. temperature switch. The maximum value is output from AND gate 74 to OR gate 75 and 0 is output from AND gates 72 and 73 to OR gate 75 . Then the maximum value is input to the pulse width modulator 516 , and the heater is fully driven.
When the temperature is higher than 95° C., H is output from both the 75° C. and the 95° C. switches, therefore the OR gate 75 receives the minimum value from the AND gate 72 and 0 from the AND gates 73 and 74 . Then the minimum value is input to the pulse width modulator 516 , and heating by the heater is minimized.
When the temperature is between 75° C. and 95° C., H is the output of 75° C. temperature switch and L is the output of 95° C. temperature switch. The output of the adder 515 is input from the AND gate 73 to the OR gate 75 , 0 is input from the AND gates 72 and 74 , and the output of the adder 515 is input to the pulse width modulator 516 . Under these conditions the temperature compensation unit 2 performs control similar to the control shown as in the first embodiment described above, and based on the C/B mode beat signal, and accurate temperature control is achieved.
FIG. 9 shows a configuration of the temperature compensation unit 2 of the second embodiment.
In the third embodiment, control similar to the second embodiment is realized without comprising any temperature switch in the oscillator circuit 1 .
The temperature compensation unit 2 of the third embodiment, in addition to the configuration shown in FIG. 6 , further comprises configuration elements described in FIG. 9 between the adder 515 and the pulse width modulator 516 .
In the third embodiment, the output of the switch 82 is controlled by a comparator 81 based on the output of the adder 507 . The comparator 81 causes the switch 82 to output the maximum value when the temperature, which the C/B mode beat signal in the output S 507 of the adder 507 indicates, is lower than 75° C., the output of the adder 515 when it is between 75° C. and 95° C. and the minimum value when it is higher than 95° C. The pulse width modulator 516 drives the heater according to the output of the switch 82 .
Such configuration allows the third embodiment to perform accurate control, in the same way as the second embodiment without the temperature switches in the oscillation circuit 1 , by the C/B mode beat signal within the range of 75˜95° C. At the temperature lower than 75° C. or higher than 95° C., heater is driven by a specified value so that the desired temperature can be obtained quickly, and the narrow temperature range can be controlled with high resolution and high accuracy.
The following description provides an explanation of the heater unit 3 of the crystal oscillator of the illustrated embodiment.
FIG. 10 is a drawing of the configuration of the heater used in the crystal oscillator of the illustrated embodiment.
In the crystal oscillator of the illustrated embodiment, for the purpose of improvement of the thermal efficiency in the heater 3 , a disk heater 92 is fixed to a part comprising terminals, such as the base of the crystal unit 91 , which is the part in closest thermal contact to a piece of crystal or the part with the lowest thermal resistance. A disk heater 92 is adjusted to have the same shape as the aforementioned part and is fixed to it using an adhesive sheet with high thermal conductivity such as aluminum nitride. By so doing, the heat from the disk heater 92 is directly conducted from the terminal 93 of the crystal oscillator 91 , which has high thermal conductivity to a piece of crystal, thus the piece of crystal is heated with high thermal efficiency.
The disk heater 92 is formed, by sputtering a nickel chrome alloy onto a ceramic disk. The terminals applying voltage to the disk heater 92 are placed in the center and around the circumference of the disk heater 92 , so that the thermal distribution of the disk heater 92 will be uniform. This configuration enables the heater to make the thermal resistance of the heating element highly precise and, consequently, to secure long-term stability.
In order to strengthen the thermal binding, an aluminum nitride epoxy adhesive is used for the adhesion between the disk heater 92 and the crystal unit 91 so that the heat of the heater 92 can be efficiently conducted to a piece of the crystal. As a result, excellent thermal response can be secured.
As depicted in FIG. 11 , a power transistor 101 , which drives the heater 92 , is brought into thermal contact with the crystal oscillator 102 so that the heating by the power transistor 101 for driving the heater 92 can be utilized to heat the crystal oscillator 102 . As a result, further improved thermal response can be secured.
In FIG. 11 , the power transistor 101 is adhered to a metal plate 102 for thermal conduction with silver filler adhesive, fixed and thermally adhered to the crystal unit 103 . Such a configuration allows a uniform conduction of heat to the crystal unit 103 through the metal plate 102 when the power transistor 101 generates heat.
FIG. 12 is a cross-section drawing showing the inside of the crystal oscillator device package of the illustrated embodiment.
The crystal oscillator device of the illustrated embodiment has a basal plate 111 , comprising each constituent element 112 of the oscillator circuit 1 , a temperature switch not shown in the drawings, a crystal unit 113 and a power transistor 118 , placed and vacuum-sealed in a metal package 114 so that each element on the basal plate 111 can be isolated from the external temperature. The basal plate 111 is electrically connected to the outside of the metal package 114 by hermetically sealed terminals 119 .
At that time, the basal plate 111 sits in the package 114 with its four corners on bases 115 , which are set inside the package 114 . The areas where the base 115 contacts the basal plate 111 , are covered by a layer of glass 116 . The basal plate 111 rests on the glass 116 so that it does not have direct thermal contact with the base 115 , and it is fixed with epoxy adhesive 117 with a poor thermal conductivity.
Because the glass 116 and the adhesive 117 are highly insulating, the thermal conduction between the basal plate 111 and the package 114 at the four points of contact can be reduced. As a result, the thermal efficiency of the heater 113 is improved, reducing power consumption.
The glass 116 and the epoxy adhesive 117 can be replaced by other materials, as long as the material is highly insulating.
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The crystal oscillator device for simultaneously generating oscillator signals with a plurality of oscillation modes of a crystal unit, comprising: a primary resonator unit filtering the oscillator signal with a primary oscillation mode, which is one of the oscillation modes, from the output of the crystal unit, a secondary resonator unit filtering the oscillation signal, bearing a different resonance frequency from that of the primary resonator unit, with the primary oscillation mode from the output of the crystal unit, a primary phase synthesis unit, synthesizing the phases of the output signal of the primary resonator unit and the output signal of the secondary resonator unit, a tertiary resonator unit, a quaternary resonator unit, and a secondary phase synthesis unit.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to yarn support apparatus and will particularly pertain to the new and improved dual spindle yarn support and delivery apparatus wherein the same rotatively mounted the plurality of cylindrical spindles to permit dual delivery of yarn filaments during a plural filament weaving procedure.
2. Description of the Prior Art
The use of yarn support apparatus is well known in the prior art. The prior art has heretofore been of a cumbersome and expansive configuration as opposed to the invention which permits a knock-down organization receivable within a carrying case to enable portage thereof from one forum to another. An example of the prior art include U.S. Pat. No. 4,548,055 to MACDONALD where the patent utilizes a series of aligned parallelepiped containers where the containers include central bores to direct yarn therethrough. The present invention defines an improvement over the patent where the cylindrical containers of the invention permit a tangle free interweaving of yarn utilizing a dual filament weaving procedure as opposed to that of the MACDONALD patent setting forth a stationary series of containers.
U.S. Pat. No. 3,054,277 to BROSCHARD provides plural reels of yarn including elongate guide to direct the yarn therethrough. These reels are of a stationary configuration as is typical of the prior art.
U.S. Pat. No. 2,493,208 to SEDGEWICK provides an organization wherein a bracket member secures a series of bobbins to enable directing individual filament from the various bobbins through a weaving station.
U.S. Pat. No. 4,635,834 to LINDQUIST provides a teaching to disclose a series of compartments securing yarn rolls therewithin to enable directing of yarn from the rolls through associated apertures.
U.S. Pat. No. 4,724,687 to GARIBOLDI ET AL, wherein stacked reels of yarn are mounted through underlying guides to direct the yarn through a weaving organization positioned thereunder.
As such, it may be appreciated there appears to be a need for a new and improved dual spindle yarn support and delivery apparatus where the same permits the tangle free delivery and directing of spaced yarn filaments in a dual filament weaving procedure.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of yarn support apparatus now present in the prior art, the present invention provides an improved dual spindle yarn support and delivery apparatus wherein the same permits a tangle free delivery of yarn in a dual yarn knitting procedure. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved dual spindle yarn support and delivery apparatus which has all the advantages of the prior art yarn support apparatus and none of the disadvantages.
To attain this, the dual spindle yarn support apparatus of the invention includes apparatus comprising a horizontal rectangular frame and a vertical rectangular frame receivable within the horizontal frame. The framework of the horizontal frame includes plural link members mounted vertically of a forward end of the horizontal rectangular frame and to an upper end of the vertical rectangular frame to pivotally receive the vertical rectangular frame within the horizontal rectangular frame. A propeller support brace is pivotally mounted to the vertical rectangular frame and includes a plurality of threaded bosses to threadedly mount a spaced plurality of yarn containers thereto wherein each yarn container is of a cylindrical configuration formed with a coaxial bore therethrough including an upper lid thereof to direct yarn therethrough.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefor, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved dual spindle yarn support and delivery apparatus which has all the advantages of the prior art yarn support and delivery apparatus and none of the disadvantages.
It is another object of the present invention to provide a new and improved dual support and delivery apparatus which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved dual spindle yarn support and delivery apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved dual spindle yarn support and delivery apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such dual spindle yarn support and delivery apparatuses economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved dual spindle yarn support and delivery apparatus which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new and improved dual spindle yarn support and delivery apparatus which may be compactly stored during periods of non-use.
Yet another object of the present invention is to provide a new and improved dual spindle yarn support and delivery apparatus where the same permits a directing, in a tangle free manner, a plurality of filaments from a like plurality of horizontally mounted yarn support containers.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an isometric illustration of a prior art yarn support delivery apparatus.
FIG. 2 is an isometric exploded view of a prior art yarn support container.
FIG. 3 is an orthographic side view taken elevation of the instant invention.
FIG. 4 is an orthographic rear view taken elevation of the instant invention.
FIG. 5 is an orthographic view taken along lines 5--5 of FIG. 4 in the direction indicated by the arrows.
FIG. 6 is an orthographic view taken along the lines 6--6 of FIG. 4 in the direction indicated by the arrows.
FIG. 7 is an isometric illustration of a carrying case utilized by the instant invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 7 thereof, a new and improved dual spindle yarn support and delivery apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
FIG. 1 is illustrative of a prior art yarn delivery organization 1 wherein an elongate base 2 mounts a series of yarn containers 3 to deliver various yarn filaments 4 therefrom to a knitting procedure. FIG. 2 illustrates the container 3 formed with a base 5 receiving a cap 6 thereon where the cap is forming with a central aperture 7 therethrough to deliver the yarn filaments 4 therethrough. The generally rectangular configuration of the containers 3 discourages a rotatable delivery system as utilized by the instant invention.
More specifically, the dual spindle yarn support and delivery apparatus of the invention essentially comprises, a horizontal framework receiving a vertical framework pivotally therewithin as illustrated in FIG. 5 for example. The horizontal framework includes a first horizontal support leg 11 spaced from and parallel to a second horizontal support leg 29. The first and second horizontal support legs include respective forward portions 11a and 29a extending beyond respective forward pivots defined by a second pivot point 14 and an associated further second pivot point 14a. Similarly a first pivot 13 joins a forward terminal end of the first support leg 11 to a first vertical support leg 12 of the vertical framework wherein the second horizontal support leg 29 is joined by a like further first pivot (not shown) to the second vertical support leg 28. The first and second vertical support legs 12 and 28 are spaced parallel to one another and mounted interiorly of the parallel first and second horizontal support legs 11 and 29 respectively. A forward frame leg 31 is orthogonally mounted between forward terminal ends of the first and second forward portions 11a and 29a to complete the horizontal framework wherein a clamping plate 30, as illustrated in FIG. 5 for example, may be optionally employed to overly the forward portions to enhance securement to a supports surfaces as illustrated in FIG. 3 by the associated clamp member 19 defined as a C shaped clamp.
The first and second vertical support legs 12 and 28 include articulated support linkage to an enable pivotment of the vertical framework interiorally of the horizontal framework per the directional arrow 45 is illustrated in FIG. 5. An upper right link 15 and a lower right link 16 are pivotally mounted relative to one another by a first intermediate pivot connection 17 with an upper right pivot connection 18 pivotally mounting the upper right leg 15 to an upper terminal end of the first vertical support leg 12. The second pivot 14 pivotally mounts the lower terminal end of the first lower right leg 16 to the first horizontal support leg 11 adjacent the further portion of the first horizontal support leg 11a. Similarly a lower left link 32 and an upper left link 33 are joined together by a second intermediate pivot connection 34 with the further second pivot 14a joining the lower terminal end of the lower left leg 32 in alignment with the second pivot 14. Similarly a further upper right pivot connection 18 pivotally joins the upper terminal end of the upper left link 33 to an upper terminal end of the second vertical support leg 28. A top horizontal frame member 27 is orthogonally mounted to upper terminal ends of the first vertical support leg 12 and the second vertical support leg 28 with the parallel second vertical support leg 28 joining lower terminal ends of the same vertical support leg. An intermediately positioned cross shaft 21 is integrally mounted to intermediate portions of the first vertical support leg 12 and the second vertical support leg 28. A bushing bore 24 rotatably receives the rotatable shaft 20 therewithin which in turn includes a cross propeller support brace 25 fixedly mounted to a forward terminal end of the rotatable shaft 20. The shaft 20 includes a first circumferential shaft groove 22a and a second circumferential shaft groove 23a spaced apart a predetermined distance equal to a predetermined width of the cross shaft 21 to rotatably secure the shaft 20 within the bushing bore 24 utilizing spaced first and second u-shaped spring clip member 22 and 23 secured in the respective shaft grooves 22a and 23a capturing member 22 and 23 forward and rear surfaces of the associated cross shaft 21 therebetween. A first threaded boss 35 and a second threaded boss 36 are orthogonally and outwardly and fixedly mounted adjacent opposed terminal ends of the support brace 25. Threadedly mounted to back of the respective threaded bosses 35 and 36 are yarn containers 37.
Each yarn container 37 is defined as a cylindrical container including an upper threaded end receiving a threadedly mounted cap 38 thereto which includes an internally threaded downwardly directed annular skirt 38a to threadedly secure the cap 38 to the cylindrical body 40 of the yarn container 37. A yarn cavity 40a is thereby defined within the yarn container 37 wherein the associated yarn is directed outwardly thereof through a central bore 39 coaxially aligned with the cap 38.
The base 41 of the yarn container 37 is defined by a predetermined axial height that includes a coaxially aligned threaded bore 42 directed interiorly of the base 41 from an exterior surface interiorially thereof and is defined by a length less than the axial height of the base 41 to fixedly receive an associated boss 35 or 36 therewithin.
In use, the yarn containers 37 are free to rotate about the cross shaft 21 and are used to form a tangle free delivery of associated filaments 4 directed from within the yarn container as illustrated in FIG. 3 for example.
FIG. 7 illustrates a carrying case 43 formed with a handle 44 to receive the apparatus 10 when in closed configuration. The apparatus is collapsed by directing the first intermediate pivot connection 17 and the second intermediate pivot connection 34 downwardly towards the first and second horizontal support legs 11 and 29 to enable collapsing of the vertical framework downwardly relatively towards the horizontal framework. The shaft 20 and associated structure is removed from the bushing bore 24 and also positioned within the case 43 for subsequent transport thereof.
As to the manner of use the operation of the instant invention, the same should be apparent when the above disclosure and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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Apparatus including a horizontal rectangular frame and a vertical rectangular frame receivable within the horizontal frame. The framework of the horizontal frame includes plural link members mounted vertically of a forward end of the horizontal rectangular frame and to an upper end of the vertical rectangular frame to pivotally receive the vertical rectangular frame within the horizontal rectangular frame. A propeller support brace is rotatably mounted to the vertical rectangular frame and includes a plurality of threaded bosses to threadedly mount a spaced plurality of yarn containers thereto where each yarn container is of a cylindrical configuration formed with a coaxial bore therethrough including an upper lid thereof to direct yarn therethrough.
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This invention relates to conveyor systems and particularly to power and free conveyor systems.
BACKGROUND OF THE INVENTION
In power and free conveyor systems wherein carriers are moved along predetermined paths by engagement with conveyors, it is often necessary to transfer the carriers from one predetermined path to another. In one type of system, this transfer is achieved by providing a transfer conveyor that engages the carrier and transfers it between the predetermined paths. In another type of system, the carrier is moved from one path toward the other and then pushed through the transfer area to the second path.
The invention is also applicable to the transfer of a carrier from one powered conveyor to another, either from a faster to a slower conveyor or from a slower conveyor to a faster conveyor or between conveyors moving at the same speed.
In U.S. Pat. Nos. 3,640,226, and 3,662,873, there is shown a power and free conveyor system wherein each of the carriers has a second dog that is normally urged to operative carrier position but is held by the track out of operative position. At a transfer point, a portion of the track is cut away to permit the second dog to move to operative carrier transferring position. Such a system effectively provides for transfer of the carrier without any change in elevation of the power and free tracks. However, where the pushers on the conveyor chain are spaced apart greater distances or where the system includes transfer across short and long distances, a loss of efficiency in transfer may occur either because of the time delay in awaiting a pusher on the conveyor chain or minimum length between the first and second dogs.
It has also been heretofore suggested to provide a third dog on the carrier which has the same configuration as the second dog and is normally held out of operative position by the track but can be brought to operative position to transfer the carrier across a greater distance.
Among the objects of the present invention are to provide a power and free conveyor system wherein a carrier is transferred from one predetermined path to another by pushing across a transfer zone in a minimum period of time and wherein such system is achieved with minimum cost and maintenance; and wherein selective transfer of the carrier can be achieved over short and long distances as desired.
SUMMARY OF THE INVENTION
In accordance with the invention, a third dog is provided in longitudinally spaced relation to the first and second dogs and is normally urged to an operative carrier pushing position but is held by the track out of operative position. The second and third dogs include cam projections thereon that engage portions of the track which hold the second and third dogs out of operative position. The cam projection on the second dog extends oppositely to the cam projection on the third dog. As the carrier moves to a transfer zone one or the other of the second and third dogs is successively moved to operative position. By providing selectively operable second and third dogs, it is possible to transfer across short or long distances thereby accommodating various systems wherein the transfer varies between short and long distances.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary side elevational view of a conveyor system embodying the invention.
FIG. 2 is a fragmentary elevational view on an enlarged scale of a portion of the system shown in FIG. 1.
FIG. 3 is a fragmentary sectional view taken along the line 3--3 in FIG. 2.
FIG. 4 is a fragmentary side elevational view similar to FIG. 2 showing the parts in a different operative position.
FIG. 5 is a fragmentary view similar to FIGS. 2 and 4 showing the parts in different operative position.
FIG. 6 is a fragmentary sectional view taken along the line 6--6 in FIG. 2.
FIG. 7 is a fragmentary plan view of the system.
FIG. 8 is a fragmentary plan view of a modified form of conveyor system.
FIG. 9 is a fragmentary plan view of a further modified form of conveyor system.
FIG. 10 is a fragmentary plan view of another modified form of conveyor system.
FIG. 11 is a fragmentary plan view of a further modified form of conveyor system.
FIG. 12 is a fragmentary plan view of a further modified form of conveyor system.
DESCRIPTION
Referring to FIG. 1, the invention relates to a conveyor system wherein a power chain is adapted to selectively engage trolleys and move them in predetermined paths. The trolley motion is from right to left. Specifically, conveyor chain 10 is supported by chain trolleys 11 for movement along a track 12. The chain 10 includes longitudinally spaced pushers 13 that are adapted to engage carriers, as presently described, to move them. As shown, a carrier 15 may comprise longitudinally spaced trolleys 16,17,18 pivotally interconnected by tie bars 19,20. The trolleys include wheels 22 that engage the lower flanges of spaced inwardly facing C-shaped channels of track 21 (FIGS. 3 and 6). The foremost trolley 16 includes an actuating lever 23 that is operatively connected to a pusher dog 24 so that when lever 23 engages an obstacle or a projection 25 on the rear trolley 18 of a preceding carrier, the lever 23 is swung clockwise as viewed in FIG. 1 to lower the pusher dog 24 out of the path of a pusher 13. Such an arrangement is known as an accumulating conveyor system. The foremost trolley 16 further includes a pivoted holdback dog 26 in accordance with conventional practice.
As further shown in FIG. 7, the conveyor system is shown in connection with an exit switch which includes a second track 27 that extends at an angle from the track 21 and a switch tongue 28 that is operated to selectively guide the carrier 15 into the second track 27. The switch tongue 28 is controlled by signal devices such as are well known in the art, for example, as shown in the U.S. Pat. No. 2,868,139. A second power chain 29 is provided in overlying relation to a portion of the track 27 and is adapted to pick up the carrier and move it along the track 27.
Referring more specifically to FIG. 1, succeeding trolleys 17, 18 of the carrier 15 are each provided with a pivoted pusher dog 30,31 respectively, each of which is pivoted intermediate to its ends to its respective trolley and counterweighted so that the pusher dog end 30,31 thereof is urged normally to operative pushing position. However, the width of each pusher dog 30,31 is such that the top edges of projections 30a,31b respectively, normally engage the underside of the upper horizontal flanges 21a,21b of the track so that the pusher dogs 30,31 are normally in the position shown in FIG. 4, namely, out of the path of pushers 13. Projection 31b extends beneath the flange 21b while projection 30a extends in the opposite direction beneath the flange 21a. As shown in FIG. 7, in the case of a transfer of the carrier from the track 21 to the track 27 by positioning of the switch tongue 28, a portion of the flange 21a is cut away as at 34a, to permit the pusher dog to swing counterclockwise under the action of the counterweight to the position shown in FIGS. 2 and 5 and thereby be in position for engagement with a pusher 13 which will push the carrier 15 through the switching or transfer area into position for engagement of the leading power dog 24 with the pusher of a secondary chain 29 along second track 27.
When the switch tongue 28 is actuated to divert the carrier, the pusher 13 which is in engagement with the pusher dog 24 will disengage from the pusher dog 24 as the foremost trolley 16 of carrier 15 is diverted to the track 27. The carrier 15 will then be momentarily stopped. However, by this time, the pusher dog 30 will have been moved upwardly through track opening 34a so that the succeeding pusher 13 of the power chain 10 will engage and cause the carrier 15 to be moved further along the track 27 sufficiently to permit dog 24 to be picked up by a pusher of the second power chain 29. As the carrier is moved along track 27, the upper flange 21a of track 27 is provided with a cam down opening 35a which will engage projection 30a of the pusher dog 30 to pivot it down out of the path of the pusher of chain 29. In order to cause downward movement of the pusher dog 30a, a portion 35a of the flange 21a is bent upwardly. Through this transfer, dog 31 is held down by flange 21b out of operative position.
Referring to FIG. 8, there is shown an exit system where the transfer is across a greater gap than in FIG. 7. In FIG. 8 when the switch tongue 28 is actuated to divert the carrier, the pusher 13 which is in engagement with pusher dog 24 will disengage from the pusher dog 24 as the foremost trolley 16 of the carrier 15 is diverted to the track 27'. The carrier 15 will then be momentarily stopped. However, by this time, the pusher dog 31 will have been moved upwardly through track opening 34b so that a succeeding pusher 13 of the power chain 10' will engage pusher dog 31 and cause the carrier 15 to be moved further along the track 27' sufficiently to permit dog 24 to be picked up by a pusher of the second power chain 29'. As the carrier is moved along track 27', the upper flange 21b of track 27' is provided with a cam down opening 35b which will engage projection 31a of the pusher dog 31 to pivot it down out of the path of the pusher of chain 29'. In order to cause downward movement of the pusher dog 31, a portion 35b of the flange 21b is bent upwardly. Through this transfer dog 30 is held down by flange 21a in inoperative position.
More specifically, as shown in FIGS. 7 and 8, the dog 30 can be used for a short distance of transfer (FIG. 7) while dog 31 can be used for a long distance of transfer as when the chain 29' is a greater distance from chain 10' (FIG. 8).
Cam down openings 35a, 35b may normally be both provided, as shown. Although not used to effect transfer to: (1) simplify design and construction; and (2) return dog 30,31 to inoperative position which may have not been used to effect transfer but was moved to the operative position while passing through the switch area.
It can thus be seen that in accordance with the invention, a third dog is provided in longitudinally spaced relation to the first and second dogs and is normally urged to an operative carrier pushing position but is held by the track out of operative position. As the carrier moves to a transfer zone, one or the other of the second and third dogs is successively moved to operative position. As a result, it is possible to transfer selectively across a greater or shorter distance thereby accommodating various systems wherein the transfer varies between short and long distances.
In both forms of FIGS. 7 and 8, a carrier which is not switched off is pushed all the way through the switching area by engagement of its front dog 24 with a dog 13 of the power chain so that the trailing dogs 30,31 move through this area without being in contact with a dog 13. As a result, dogs 30,31 are free to swing upward to their operating position at the start of the track flange cut-outs 34a,34b and are forced down again at 35a,35b.
In a track configuration as in FIGS. 7 and 8, but with the carriers and chains moving in the opposite direction as shown in FIGS. 9 and 10, a carrier would move either from left to right on the straight tracks 21 or would enter this track from track 27. No cut-outs 34a,34b are needed in tracks 21 in this case, but only in track 27 to move dog 30,31 to operative position to enable a pusher dog 13 on power chain 29 to advance the carrier far enough to place the front dog 24 into the path of the chain 10 and pusher dogs 13. Cam down openings 35a, 35b will normally be located on track 21 to return dog 30,31 to inoperative position after transfer.
More specifically, referring to FIG. 9, wherein the carrier is to be moved across the shorter gap from track 27, the dog 30 is permitted to move upwardly through opening 34a' into the path of a succeeding pusher of chain 29 which will, in turn, push the carrier to bring dog 24 into the path of a pusher on chain 13 moving along track 21. Further movement of the carrier along track 21 will bring the projection on pusher dog 30 into engagement with cam down portion 35a' to pivot dog 30 downwardly.
Similarly, where the gap to be traversed is greater as in FIG. 10, the cut out portion 34b' permits dog 31 to pivot upwardly so that a succeeding pusher on chain 29 will push the carrier to bring its dog 24 into the path of a pusher 13' on the chain moving along track 21'. As the carrier is moved along track 21', cam down portion 35b' will pivot dog 31 downwardly.
Throughout the portion of the system wherein the transfer is achieved, the relative positions vertically of the power track 12 and carrier tracks 21,27 remain constant and are not changed.
In another type of system, the carrier is moved from one path toward the other and then is pushed through the transfer area to the second. Specifically, as shown in FIG. 11, the carrier is moved along a track 40 in a portion between spaced power conveyors 41,42, each of which has pushers 43,44. As the conveyor 41 moves over its sprocket 45, the pusher 43 thereon which is in engagement with the pusher dog 24 of the carrier will disengage from the pusher dog 24 and will be momentarily stopped. At this point, cut-away portion 46a, along the track 40 will have permitted the second pusher dog 30 of the carrier to pivot upwardly into the path of a succeeding pusher 43 which then pushes the carrier across the gap between the conveyors 41,42 bringing the leading pusher dog 24 into a position of engagement with a pusher dog 44 of the succeeding conveyor 42. As the carrier is pulled across the space by pusher 44 between the conveyors 41,42, the cam projection 30a on the second pusher dog 30 engages the cam down portion 47a which pivots dog 30 downwardly returning it to an inoperative position.
A greater gap to be traversed than FIG. 11, is shown in FIG. 12. This arrangement is such that the third dog 31 is permitted to pivot upwardly. Specifically, the carrier is adapted to move along a track 40' in a portion between spaced power conveyors 41',42', each of which has pushers 43', 44'. As the conveyor 41' moves over its sprocket 45', the pusher 43' thereon which is in engagement with the pusher dog 24 of the carrier will disengage from the pusher dog 24 and will be momentarily stopped. At this point, cut-away portion 46b along the track 40' will have permitted third pusher dog 31 of the carrier to pivot upwardly into the path of a succeeding pusher 43' which then pushes the carrier across the gap between the conveyors 41', 42' bringing the leading pusher dog 24 into a position of engagement with a pusher 44' of the succeeding conveyor 42'. As the carrier is pulled across the space by pusher 44' between the conveyors 41',42', the cam projection 31b on the third pusher dog 31 engages the cam down portion 47b which pivots dog 31 downwardly returning it to an inoperative position.
Thus, the dog 30 can be used to transfer across a short distance (FIG. 11) and the dog 31 can be used to transfer across a long distance (FIG. 12).
In addition to selectively permitting either dogs 30 or 31 to move upwardly for transfer, the system can be operated also by moving the dogs upwardly simultaneously or sequentially as may be required.
For example, where it is desired to minimize the number of pushers on the conveyor, it might be desirable to cut away both flanges of the track at appropriate points to permit both dogs 30,31 to be simultaneously moved upwardly. In this manner, the pusher 13 which is nearest to one of the dogs 30,31 will move the carrier forwardly. Thus, the number of pushers on the conveyor chain can be minimized thereby reducing costs and still retaining a minimum lapse of time in transfer.
The dogs might also be operatively positioned sequentially such as in a situation wherein a long transfer is desired. The first dog 30 is permitted to move upwardly to permit a succeeding pusher 13 to move the carrier partway and then a second dog 31 is permitted to move upwardly to permit a succeeding pusher 13 to move the carrier a further distance. Such an arrangement might also be advantageous where it is desired to depress the first-mentioned dog 30 for clearance or other purposes.
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A conveyor system including a first load supporting track and a second load supporting track with an intermediate transfer portion. A powered conveyor is provided in association with each of the first and second tracks. A plurality of carriers are provided. Each of the carriers has a first dog that is in position for normal engagement with the pusher member of the conveyor and longitudinally spaced second and third dogs that are normally urged to an operative carrier pushing position but are held by the track out of operative position. The second and third dogs include cam projections thereon that engage portions of the track which hold the second and third dogs out of operative position. The cam projection on the second dog extends oppositely to the cam projection on the third dog. At a transfer point, an appropriate portion of the track is cut away to permit either the second or third dogs to move to operative carrier transferring position.
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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
This invention was made with Government support under grant R44CA096409 awarded by the US National Cancer Institute, National Institutes of Health. The Government has certain rights in the invention.
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
BACKGROUND
Field of Invention
This invention relates to a process for treating primary or metastatic lung tumors by inhalation of the anticancer drug paclitaxel in an aerosol formulation comprising paclitaxel along with α-tocopheryl succinate, sorbitan trioleate, and ethanol as solubility enhancers, and carbon dioxide as solvent.
Lung cancer is the leading cause of cancer deaths in the U.S. and other developed countries, and there remains a great need for improvements in its prevention, detection, and treatment. Tobacco use is the predominant risk factor for lung cancer, with about 87% of lung cancer cases linked to cigarette smoking (3), making smoking cessation an essential part of reducing the personal and societal impacts lung cancer (5). However, even if dramatic reductions in smoking were achieved, there would still remain a crucial need for improved forms of lung cancer treatment. Surgery remains a primary focus of therapy, but a prominent role for chemotherapy has grown over the past decade, with demonstrated survival benefits demonstrated for a variety of chemotherapeutic approaches (2, 17). It is expected that continued advances in early detection technologies will further increase the importance of chemotherapy in lung cancers (9). Furthermore, about half of lung cancer patients develop lung tumor recurrence or develop secondary tumors after surgical resection of early-stage lung cancer tumors (23), making concurrent chemotherapy a critical component of treatment. Unfortunately, the therapeutic results of chemotherapy in treating lung cancer have been hindered by the inability to achieve therapeutic drug concentrations at the site of the tumor, raising interest in targeted forms of administration (18). The good news is that lung cancer may in fact be the easiest form of cancer to treat with a targeted delivery approach, given that pharmaceutical aerosols can directly reach the affected sites with some forms of lung cancer.
In the US, aerosol drug delivery is a mainstay for treatment of lung illnesses such as asthma and is making inroads into the treatment of other diseases such as cystic fibrosis. Aerosol delivery of anticancer drugs to the lungs is an intriguing prospect, but its potential is severely limited by the nebulizer systems that are currently available. Many chemotherapeutic agents such as as paclitaxel, taxotere, etoposide, topotecan, and camptothecin have very low solubility in aqueous solutions. Current nebulizers and spray systems require water-soluble formulations. Aerophase has developed an aerosol drug-delivery method that should overcome these limitations based on the use of supercritical CO 2 as the solvent and propellant for aerosol generation. The use of CO 2 solves the problem that aqueous nebulizers have with aerosolizing lipophilic drugs.
Carbon dioxide propellant aerosol systems may be advantageous for lung cancer aerosol therapy because CO 2 stimulates deep breathing. Increased respiratory tract deposition of inhaled aerosol particles of anticancer drugs has previously been demonstrated for 5% CO 2 -enriched air (48). As taught by Waldrep, et al., in U.S. Pat. No. 6,440,393, carbon dioxide gas can be mixed with air and then an aqueous drug solution or suspension can be aerosolized in said CO 2 -air mixture. The present invention is clearly distinct from U.S. Pat. No. 6,440,393, and has the advantage that CO 2 is already present in the drug solution and drug aerosol product, and does not need to be added separately, only diluted to an appropriate inhalation level with air or oxygen.
In addition to lipophilic drug capability, a significant advantage of the CO 2 propellant aerosol systems for lung cancer therapy is aerosol size and range. The high pressure and high energy released in the CO 2 expansion ensure the formation of small aerosols. The optimal aerosol size for effective lung deposition is around 1 μm. The CO 2 aerosol generation system described in the present invention has significant flexibility in adjusting aerosol size around 1 μm with pressure, composition, and mechanical configuration.
Due to the high reactivity and toxicity of chemotherapeutic agents, and interest in targeted delivery, many scientists and clinicians have noted that aerosol delivery of anticancer drugs by inhalation directly to the lung epithelium appears to be highly desirable (18, 21). In fact, aerosol administration has been gaining in interest for oncologic use and has been examined as a way to get interferon-γ, interleukin-2, tocopherol succinate, granulocyte-macrophage colony-stimulating factor (GM-CSF), 13-cis-retinoic acid, paclitaxel, and 9-nitrocamptothecin into the lungs (1, 4, 10-13, 18, 19, 21, 22, 24). In a review article published in 2003, it was noted for paclitaxel (PTX):
“The potential of inhaled PTX therapy is just beginning to be grasped. It is likely that the inhalation studies of PTX and other anticancer agents will increase dramatically both because of the ease of drug delivery and its ability to permit lung targeting. To accomplish this, several challenges need to be overcome, including optimization of delivery formulations . . . (8)”
Aerosol delivery of pharmaceuticals is a fast-growing field, but no approved aerosol therapies are available for the treatment of lung cancer. Many of the agents that can act as cancer cell growth inhibitors are highly lipophilic and cannot readily be delivered to the lungs with traditional aerosol methods—most of which rely on the water solubility of the drugs. The goals of this project are to develop marketable instrumentation and aerosol methodology to safely and practically administer chemotherapeutic agents directly to the pulmonary epithelium using supercritical CO 2 . The instrumentation will be designed to be simple to use for aerosol delivery of anticancer agents such as paclitaxel, taxotere, etoposide, topotecan, and camptothecin, which are currently FDA-approved for injection delivery. The aerosol delivery of lipophilic antineoplastics will create a local high concentration of the chemotherapeutic agent for targeted delivery to the lungs with less systemic stress (18). An improved method for aerosol delivery of anticancer agents to the lungs may significantly reduce mortality from lung cancer. The reasons for using intrapulmonary aerosol deposition as the drug delivery method include 1) increased efficacy of drug, 2) decreased systemic absorption and concomitant side effects, and 3) increased local concentration of drug at the site of the tumor cells. Our primary motive for pursuing supercritical fluid aerosol delivery of chemotherapeutic pharmaceuticals is for more efficient and selective deposition of the agent. This method will almost certainly allow deposition of lipophilic anticancer drugs in the more distal parts of the lungs than is possible with other aerosol delivery systems.
The present invention pertains to aerosol paclitaxel delivery for treatment and/or prevention of primary or metastatic cancer in the lungs using a formulation of paclitaxel, tocopheryl succinate, sorbitan trioleate, ethanol, and carbon dioxide. This combination demonstrated beneficial results in a mouse model of lung cancer.
α-Tocopheryl succinate (αTS) is a vitamin E analogue that helps to solubilize paclitaxel in supercritical carbon dioxide and that has gained extensive interest in recent years for its possible use in combination with other chemotherapeutic agents (25). In the present invention, αTS is included in the aerosol paclitaxel formulation to improve solubility and effectiveness for lung cancer treatment. Sorbitan trioleate (SPAN 85) is a lipid-soluble nonionic surfactant used in the present invention to increase the solubility of paclitaxel in supercritical carbon dioxide. Ethanol is used in the present invention as a cosolvent to increase the solubility of paclitaxel in supercritical carbon dioxide. Supercritical carbon dioxide is used in the present invention as a solvent and propellant to dissolve the paclitaxel and surfactant/cosolvent mixture and form a spray to generate respirable aerosols of paclitaxel.
In one embodiment, the pressure of the formulation is maintained between 900 and 5000 psi prior to spraying the formulation through a valve into a region of ambient atmospheric pressure for inhalation administration.
The present invention also includes the capability of adding additional active agents to the inhaled formulation:
Some lung tumors exhibit resistance to drugs including paclitaxel. A variety of mechanisms may be involved, including tubulin-related mutations and multidrug resistance gene upregulation. In the case of drug resistance, agents can be added to interfere with the expression and activity of P-glycoprotein transport of paclitaxel out of the targeted cells. In other words, in addition to the paclitaxel, the formulation can include active agents to decrease drug resistance to paclitaxel. For example, the formulation can include cyclosporin, Other lung cancer drugs can be utilized in the supercritical fluid formulation in addition to or in the place of paclitaxel. This would include, but not be limited to, other taxanes such as docetaxel, topoisomerase inhibitors such as etoposide, camptothecin, or doxorubicin, DNA crosslinking agents such as cisplatin, and other agents active against lung tumors.
Sievers, Hybertson, and Hansen initially studied supercritical fluid carbon dioxide as a solvent to generate small aerosols of pharmaceuticals to be directly inhaled because the particle size was easy to control. Coincidentally, carbon dioxide is also a practical respiratory stimulant along with its role as an aerosol generating propellant in the present pulmonary aerosol delivery device.
Aerosol drug inhalation is an ancient practice that extends back to as long as people have intentionally inhaled smoke, but more recently it has been suggested as a particularly attractive route for the prevention or treatment of lung cancer (4-6, 16, 18, 20). It has been considered to be one of the research priorities for the future lung cancer chemoprevention. Other potential anti-neoplastic agents, such as liposomal interleukin-2, liposomal interferon-γ, vitamin A, paclitaxel, 9-nitrocamptothecin, 5-fluorouracil, and doxorubicin (91) have been studied for possible aerosol inhalation delivery to patients with lung cancer (7, 10, 12-15, 21, 22). The advantages of this approach include reducing or preventing systemic toxicities due to directly targeting pulmonary tissue.
The most common types of aerosol generators used in aerosol medicine are dry powder inhalers, nebulizers, and pressurized metered dose inhalers. The dry powder inhaler (DPI) is breath activated using the inhaled air to move a dry powder into the lungs. Formulation of drugs for this type of inhaler is particularly difficult because most pharmaceuticals stick together and form large particles that can't be inhaled. Nebulizers work on the Bernoulli effect using compressed air to draw the liquid solution up a tube and the shearing energy of the air to break the liquid into small droplets. The metered dose inhaler (MDI) uses drugs dissolved or suspended in freons. Aerosols are generated by both the gas expansion energy and solvent evaporation. In the present invention, the aerosol generation occurs by expansion of a supercritical carbon dioxide solution formulation, which has higher aerosolization energy than the other aerosol methods, which allows very fine aerosol formation which can reach the upper airways and the distal parts of the lungs.
Advantages
Accordingly one or more embodiments of the present invention may have one or more of the following advantages:
It is an advantage of the invention to provide a method for treating lung cancer that with paclitaxel that allows much lower amounts of paclitaxel to be used, due to its targeted delivery to the lungs.
BRIEF DESCRIPTION OF THE DRAWINGS
The Detailed Description and Examples should be viewed together with the Drawings in which:
FIG. 1 shows particle size distribution after collection of an aerosol as described in Example 1;
FIG. 2 shows mean body weight of mice as described in Example 1; and
FIG. 3 shows mean tumor volume as described in Example 1.
DETAILED DESCRIPTION OF THE INVENTION
One of ordinary skill in the art will be able to envision and practice the invention as described or in related, alternative embodiments.
In one embodiment, the invented formulation comprises 60 mg paclitaxel, 0.3 g α-tocopheryl succinate (αTS), 0.66 g sorbitan trioleate (SPAN85), 5.8 g ethanol (EtOH), and 230 g of CO 2 enclosed in a 48 ci pressure vessel, then pressurized to 1600 psig with helium gas.
Broadly, the invented lung cancer therapeutic formulation includes paclitaxel, solubility enhancing agents αTS, SPAN85, and EtOH, and carbon dioxide as the solvent and propellant.
The ratios of paclitaxel to the solubility enhancing agents and pressurized solvent is not firmly fixed, but can be varied. By mass, the formulation can be described as
TABLE 1
Relative mass
Formulation component
1
paclitaxel
5
α-tocopheryl succinate (αTS)
11
sorbitan trioleate (SPAN85)
97
ethanol (EtOH)
3833
CO 2
As noted, these relative ratios are not fixed, but can be adjusted to meet the paclitaxel delivery needs. For example, for a given amount of paclitaxel the relative amounts of the solubility enhancing agents αTS, SPAN85, and ethanol can be adjusted, as well as the amount of carbon dioxide solvent needed to dissolve the resultant mixture. In such a case, one of many permutations would be that the use of additional SPAN85 could decrease the amount of αTS needed in the formulation. Depending on the desired amount of paclitaxel delivered, the formulation can include, minimally, paclitaxel and carbon dioxide alone. Therefore, the invention description can be described as ranges of concentrations used to create a suitable paclitaxel formulation for aerosol delivery, as low as zero for individual solubility enhancing agents depending on the amounts used of the others, and a range of carbon dioxide solvent for dissolving the resultant paclitaxel-containing mixture:
TABLE 2
Formulation component
Relative mass range
paclitaxel
1
α-tocopheryl succinate (αTS)
0 to 100
sorbitan trioleate (SPAN85)
0 to 200
ethanol (EtOH)
0 to 2000
CO 2
100 to 10000
In other embodiments, other agents are added to improve the formulation effectiveness against lung tumors that exhibit resistance to paclitaxel. A variety of mechanisms may be involved. In the case of multidrug resistance gene upregulation, agents can be added to interfere with the expression and activity of P-glycoprotein transport of paclitaxel out of the targeted cells. In other words, in addition to the paclitaxel, the formulation can include active agents to decrease drug resistance to paclitaxel. For example, the formulation can include cyclosporin, quinidine, biricodar, or other agents to decrease paclitaxel efflux from tumor cells.
Other lung cancer drugs can be utilized in the supercritical fluid formulation in addition to paclitaxel. This would include, but not be limited to, other taxanes such as docetaxel, topoisomerase inhibitors such as etoposide, camptothecin, or doxorubicin, DNA crosslinking agents such as cisplatin, and other agents active against lung tumors.
DETAILED DESCRIPTION
Examples
Example 1
We demonstrated the use of an aerosol formulation of 60 mg paclitaxel, 0.3 g αTS, 0.66 g SPAN85, 5.8 g EtOH, and 230 g of CO 2 , pressurized to 1600 psi with helium gas headspace and released through a high pressure nozzle to form respirable, airborne paclitaxel aerosol particles, deposit relevant doses in mouse lungs, and inhibit lung tumor growth in a mouse model of nonsmall cell lung cancer.
FIG. 1 shows the particle size distribution after collection of said paclitaxel aerosol on Anderson cascade impactor and quantitative analysis of paclitaxel on the stages by HPLC-MS/MS. The mass median aerodynamic diameter is 1.2 μm which is ideal for particle inhalation:
Aerosol delivery of the paclitaxel formulation to mice gave a per-mouse, lung-specific dose of 30±5 ng paclitaxel, an amount calculated to be appropriate for further study in a lung tumor model.
A mouse model of lung cancer was used for further testing of the paclitaxel aerosol formulation. Briefly, athymic nude mice were injected with human nonsmall cell lung cancer A549 cell line cell stably transfected with the firefly luciferase gene (A549-luc cells). On day 12, mice verified to have lung tumor formation in vivo by luciferin-dependent chemiluminescence were divided into two groups, one untreated control tumor group and one aerosol-treated tumor group, receiving 30 ng of paclitaxel by inhalation of the aforementioned aerosol formulation 3× per week, with monitoring of body weights. At day 33, the experiment was ended, body weights assessed and excised lung tumor volumes measured.
It was determined that tumor-bearing mice treated by inhalation of the paclitaxel aerosol formulation gained weight, but untreated tumor-bearing mice lost weight, an indication that the overall health of the treated mice was better than that of the untreated mice. The mean body weight was higher in the paclitaxel aerosol-treated mice than the untreated mice at day 31 after A549 lung tumor cell injection (p<0.05) as shown in FIG. 2 .
Notably, there was also a decrease in lung tumor volume in the mice treated with inhaled paclitaxel aerosol formulation compared to the untreated mice. The total number of lung tumors per mouse was not different between the two groups, but the lung tumor volume was significantly lower in the mice that were treated with the inhaled paclitaxel aerosol formulation (p<0.05), as shown in FIG. 3 .
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15. Kohlhaufl M, Haussinger K, Stanzel F, Markus A, Tritschler J, Muhlhofer A, Morresi-Hauf A, Golly I, Scheuch G, Jany B H, and Biesalski H K. Inhalation of aerosolized vitamin a: reversibility of metaplasia and dysplasia of human respiratory epithelia—a prospective pilot study. Eur J Med Res 7: 72-78., 2002.
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The present invention provides a method of inhibiting cancer growth in the lungs of a mammal through the inhalation administration of aerosol particles of an anti-cancer drug formulation. Further, the present invention provides a formulation for aerosol delivery that comprises a combination of paclitaxel, α-tocopheryl succinate; sorbitan trioleate, ethanol, and carbon dioxide. Prior studies have indicated that aerosol administration of cancer drugs holds great potential as a treatment modality, both for lung cancer and for lung metastases of other cancers. Practice of the invention has been demonstrated using a mouse model of lung cancer, in which intrapulmonary deposition of paclitaxel by aerosol inhalation reduced lung tumor size and increased body weight in tumor-bearing mice.
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BACKGROUND
1. Field of Invention
The present disclosure relates to sampling methods and apparatus, and more particularly to sequencing and averaging multiple sampling methods and systems.
2. Prior Art
Continuous online analysis of components in liquid and gas streams is a common practice in industry today. For example, routine sampling and analysis is conducted in power plant smokestacks, liquid waste streams, industrial process streams, the head space in storage vessels and many other sources. Because analytical monitors and instrumentation are quite expensive, it is often desirable to share an analyzer bank with multiple sample streams. This is usually accomplished by one of two methods—sequencing or averaging.
In sequencing, the analyzer tests each sample in sequence, on a time share basis. A controller or multiplexer system may utilize a programmable logic controller (PLC), distributed control system (DCS) or a computer to sequence through multiple sample chambers, each obtaining samples via valve-controlled orifices. An example of a sequencing sampling system in shown in U.S. Pat. No. 4,325,910 (Jordan). Averaging systems involve feeding multiple input samples into a central manifold or header and mixing the samples prior to analyzing the mixture. A control device, such as a needle valve, is used to precisely control the flow of each sample into the manifold. The combined mixture is then analyzed to provide an average reading for all of the samples.
Either of the above two methods works fairly well in the absence of an upset condition. However, when a problem arises with one of the sampled streams, both prior art systems have difficulty in quickly locating the stream that is out of specification. In the case of sequencing, the upset condition will not be detected during the time that the analyzer is testing other samples. If the streams being analyzed are potent, toxic, flammable, radioactive or otherwise dangerous, the delay in detecting an upset condition could have serious consequences. An averaging system could also involve a substantial delay in finding an upset condition, because the samples are all mixed before being analyzed. Moreover, it may be difficult to even detect the presence of a problem sample because each sample is substantially diluted with other samples before being analyzed. Accordingly, new methods and apparatus are needed to quickly and accurately locate an upset condition in a stream flow using a multiple stream analyzer.
SUMMARY
In a first embodiment of the present disclosure, apparatus is provided for testing and analyzing a plurality of stream sources to monitor for an upset condition in one of the stream sources. A manifold is provided having a plurality of manifold inlets and a manifold outlet. A plurality of sampling devices for sampling the plurality of stream sources are coupled to the manifold inlets to provide stream samples to the manifold. A controller is in electronic communication with each of the plurality of sampling devices for providing test samples to the manifold. The controller alternately operates the sampling devices in (1) a sequencing mode in which each test sample is a stream sample from one of the plurality of sampling devices or (2) an averaging mode in which each test sample is representative of an average of the stream samples from the plurality of sampling devices. An analyzer is coupled to the manifold outlet to receive the test samples from the manifold and analyze each test sample for the presence of the upset condition.
In another embodiment of the present disclosure, a method is provided for testing and analyzing a plurality of stream sources having various flow rates or velocities to monitor for an upset condition in one of the stream sources. A plurality of samples are provided from the plurality of stream sources using a plurality of sampling devices coupled to a manifold. A controller electronically communicates with the plurality of sampling devices to provide test samples to the manifold, alternately operating in (1) a sequencing mode in which each test sample is a stream sample from one of the plurality of sampling devices or (2) an averaging mode in which each test sample is representative of an average of the stream samples from the plurality of sampling devices. The test samples are analyzed using an analyzer coupled to the manifold to determine the presence of the upset condition.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned features and other features and advantages of this disclosure will become more apparent and the disclosure will be better understood by reference to the following description of an exemplary implementation taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic diagram showing the fluid flow arrangement of the sequencing and averaging apparatus according to an embodiment of the present invention;
FIG. 2 is a schematic diagram showing the electrical control arrangement of the sequencing and averaging apparatus according to the embodiment shown in FIG. 1 ;
FIGS. 3 and 4 are plan drawings showing the sequencing and averaging apparatus according to the embodiment shown in FIG. 1 ; and
FIG. 5 is a perspective view of manifold and valve apparatus according to the embodiment shown in FIG. 1 ;
FIGS. 6 , 7 , 8 and 9 are flow diagrams showing methods of the sequencing and averaging apparatus according to the embodiment shown in FIG. 1 .
Throughout the drawings, identical reference numbers may designate similar, but not necessarily identical, elements. The examples herein illustrate selected implementations of the disclosure in certain forms, and such exemplification is not to be construed as limiting the scope of the disclosure in any manner.
DETAILED DESCRIPTION
The embodiments described herein provide unique apparatus and methods for analyzing samples of various industrial sources, using a combination of sequencing and averaging methods to determine the presence of an upset condition in one or more of the sources. As used herein, the term “upset condition” refers to the sensing of one or more parameters in a source being monitored to determine the presence, absence, excessive amount or deficient amount in a quantity that deviates from a pre-selected standard by an unacceptable amount. Examples could be excessive amounts of contaminants, the presence of unacceptable toxic elements, or the absence of beneficial elements.
The apparatus and methods disclosed herein utilize the same hardware to carry out both the sequencing and the averaging methods, relying on software or programmed firmware to vary the sequencing and/or averaging processes, as needed. By utilizing both sequencing and averaging, the delay time in finding an upset condition is minimized, thereby lessening the possibility of damage to the related equipment, exceeding regulated standards or causing health-threatening conditions. Moreover, the use of the same apparatus for both sequencing and averaging methods substantially reduces monitoring costs, space requirements and maintenance.
The sequencing and averaging multiple sample system of the present invention is useful in monitoring a wide variety of industrial sources and processes. For example, the present system may be used to monitor exhaust gas flow from turbines or boilers, measuring oxygen or carbon monoxide output to control the fuel and air mixture in the burners. Combustion output may also be monitored to insure that products of combustion, such as sulfur oxides, nitrogen oxides, mercury, carbon monoxide, hydrochloric acid and hydrofluoric acid, are within prescribed limits. Liquid flow may also be monitored in a series of process streams to measure pH or to determine the level of toxic waste. In solid processes, coal conveyer belts may be monitored to sense the presence of carbon monoxide, indicating a fire that must be extinguished. Storage vessels and the head space in storage vessels, as well as many other sources may also be monitored and analyzed with the present system.
Referring now to FIG. 1 , a schematic diagram discloses a simplified fluid flow arrangement according to an embodiment of the present invention. A manifold 20 , disposed within an enclosure (not shown), is adjacent to four fluid sample input connections 21 – 24 . Four three-way valves 31 – 34 each connect to one of ports 21 – 24 . Valves 31 – 34 each have output ports 35 – 38 that feed into the enclosure of manifold 20 . An output line 40 provides a sample in manifold 20 to sample outlet connection 42 .
Each of valves 31 – 34 also have constant flow ports 44 – 47 that are coupled to a common bypass line 48 which is connected to a bypass outlet connection 50 . Bypass line 52 is powered by a fluid pump 54 and checked by a flow meter 56 before being shunted to an output vent 58 . Likewise, a sample line 60 is coupled to sample outlet 42 and runs to a fluid pump 62 , a filter 64 and a flow meter 66 in series. The fluid sample in line 60 flows from flow meter 66 to an analyzer 70 , used for monitoring various parameters, as discussed above. An output line 72 also flows to output vent 58 .
Thus, as shown in FIG. 1 , fluid flow samples are provided on input ports 21 – 24 from external sources (not shown). The three way valves 31 – 34 provide the samples into the manifold, where they are mixed (if in the averaging mode), the result test sample is sensed and is provided to the analyzer for the appropriate monitoring. The valves 31 – 34 may be mounted on the manifold 20 or disposed to stand alone.
FIG. 2 is a related schematic diagram showing the electrical control connections of the embodiment shown in FIG. 1 . Valves 31 – 34 are each connected to and controlled by a programmable logic controller 80 , which also drives fluid pumps 54 and 62 . Pumps 54 and 62 may be a common pump device with two heads driving the bypass line 52 and the sample line 60 . Programmable logic controller 80 is connected to analyzer 70 to interrelate functions between controller 80 and analyzer 70 , as needed.
FIGS. 3 and 4 show side and front views, respectively, of an enclosure 90 that houses the sequencing and averaging system of the present embodiment. In FIG. 3 , enclosure 90 includes sample inlet connections 21 – 24 . Sample output connection 42 is disposed near the bottom of enclosure 90 , adjacent to bypass outlet connection 50 and an atmospheric bleed connection 51 . A louvered fan vent 92 is also provided at the side of enclosure 90 .
FIG. 4 shows the front of enclosure 90 with a front door (not shown) removed. Sample inlet connections 21 – 24 are shown connecting to valves 31 – 34 . Fluid pumps 54 and 62 and filter 64 are mounted in the enclosure 90 . Flow meters 56 and 66 are mounted on an inner door 94 having a touch panel view window 96 . The programmable logic controller 80 (not shown) is mounted within enclosure 90 behind inner door 94 .
The analyzer 70 (not shown) may be also be located within enclosure 90 or at some location remote from enclosure 90 and in communication with manifold 20 and programmable logic controller 80 . Analyzer 70 may be a convention analyzer such as model number Ultramat 23 made by Siemens. Programmable logic controller 80 may by a conventional controller such as model number 06 made by Automation Direct.
FIG. 5 shows a perspective view of manifold 20 having openings 101 – 106 to accommodate six solenoid valves. The four three-way valves 31 – 34 are shown. The valves may be high-speed three-way solenoid valves, such as Type 6608 analytical solenoid valves made by Burkert Controlmatic USA in Irvine, Calif. Any number of valves may be mounted on a convention manifold or header, as needed. Outlet sample connection 42 and bypass connection 50 are also shown. Manifold 20 may be a convention manifold having chamber volume ranging from 5 ml to 100 ml, with 10 ml being a typical volume.
Referring now to FIGS. 6 , 7 and 8 , flow diagrams are provided showing methods carried out by the sequencing and averaging apparatus of the embodiments disclosed herein. The flow diagrams represent algorithms that may be programmed in software or firmware in the programmable logic controller 80 . As shown in FIG. 6 , a system 120 is shown with multiple sources to be sampled. The programmable logic controller 80 is initially calibrated, at step 122 , for each valve 31 – 34 by pumping a calibration fluid through each sampling source and each valve to establish a flow rate and other parameters for each valve. In situations involving gas testing, a typical calibration gas might be sulfur dioxide or nitrogen oxide having nitrogen gas doped with the impurity to be tested. During calibration, the flow rate is determined for of each source being monitored, for a purpose to be discussed below.
Next, at step 124 , the system is operated in an averaging mode in the programmable logic controller 80 actuates each of the valves 31 – 34 to provide samples to the manifold 20 from each of the sources to be monitored. The samples are mixed to form an average test sample, which is sent to the analyzer 70 to be tested for the presence of a predetermined parameter. The averaging mode can be carried out in at least two different ways. The valves may be rapidly sequenced to provide samples from each source that are mixed in the manifold to form an average test sample. Alternately, the valves may be turned on simultaneously during a sampling period to provide samples that are mixed in the manifold to form an average test sample.
In either averaging sampling process, the valves may be actuated for different time periods, depending on the flow rate of each source being sampled. For example, if the flow rate of the sample obtained from valve 31 is twice the flow rate of the sample obtained from valve 32 , the sample time for valve 31 may be half of the sample time of valve 32 . In this manner, the same amount of each monitored sample is mixed in the manifold to obtain a true average test sample.
For example, in the sequential averaging process, a sample time of one second might be used. During that one-second sample time each valve is sequenced for a different fraction of one second corresponding to the ratio of the flow rate of the respective monitored source relative to a standard flow rate. Similarly, in the simultaneous averaging process, each valve may be actuated at the beginning of the one-second sample period. Then, each valve shuts off at the end of a predetermined fraction of the sample period, depending on the flow rate of the respective source being sampled. Sampling periods during the averaging mode may fall within a range of ⅕ seconds to 5 seconds. It is important to maintain the averaging mode sampling times relative short, in order to provide a true average test sample in a relatively small manifold chamber volume and to quickly detect an upset condition.
Next, at step 126 , analyzer 70 tests the average sample for an upset condition. If no upset condition is detected, the averaging mode of sampling is continued. If an upset condition is detected, the programmable logic controller 80 switches over to a sequencing mode, as shown at step 128 , to detect the problem valve, at step 130 , that is sampling a problem source. In this mode, the programmable logic controller 80 sequentially actuates each valve 31 – 34 for a period long enough to provide a test sample in the manifold 20 that can be sent to the analyzer 70 for testing. A typical sample time during the sequencing mode is 15 seconds. The sample time may vary over a wide range of as much as 10 seconds to 5 minutes, depending on the flow rates and the length of sample line of the sources being sampled.
Looking now at FIG. 7 , an alternate method is shown for operating the sequencing and averaging system of the present embodiments. The method shown in FIG. 7 is helpful, in situations, such as system 140 , where there are a large number of valves sampling a large number of sources. At step 142 , the programmable logic controller 80 is calibrated for each of the valves 31 – 34 , as previously discussed. At step 144 , the system is operated initially in the averaging mode and continues in that mode until an upset condition is detected, at step 146 .
At the time of upset condition detection, the programmable logic controller 80 divides the sampling valves into two equal groups. At step 148 , an averaging mode operation may then be carried out for the first group in which samples from each source in the group are mixed in the manifold 20 to form a first group test sample. This sample is then tested by the analyzer 70 , at step 150 , to determine whether the upset condition is in the first group. If so, the valves of the first group are sequentially sampled, at step 152 , to detect the problem sample source, as shown at step 154 . If the first group does not show an upset condition, then the problem is in the second group. Accordingly, as shown at step 156 , the second group is sequentially sampled to detect the problem sample source. It should be understood that the sampling valves may be divided in any number of groups to carry out the dividing process shown in FIG. 7 . If more than two groups are selected, then additional averaging mode testing must be carried out to find the problem.
FIG. 8 shows one example of a system 160 having multiple groups involving a large number of valves and sources. In this situation, it might not be practical to average samples from all of the sources, as was done with systems 120 and 140 in FIGS. 6 and 7 . Rather, after the calibration step 162 , the system might be separated into multiple groups, such as first, second and third groups shown. Then the system may be sequenced through each of the average samples of the groups to determine whether an upset condition had occurred. If so, then sequencing may be used to locate the problem.
Thus, at step 164 , the first group is averaged and the output sampled. If an upset condition is detected, at step 166 , the first group is selected for sequencing, at step 168 , to detect a problem, at step 170 . If an upset condition is not detected at step 166 , the second group is averaged and the output sampled, at step 172 . If an upset condition is detected, at step 174 , the second group is selected for sequencing, at step 168 . If an upset condition is not detected, at step 174 , the third group is averaged and the output sampled, at step 176 . If an upset condition is detected, at step 178 , the third group is selected for sequencing, at step 168 . If an upset condition is not detected at step 178 , the system sampling returns to the first group at step 164 .
In other situations, a system might be initially sequenced in a calibration mode to calibrate each valve. In the event that a valve is found to be out of calibration, an adjustment is made. The system may continue to sequence in the calibration mode until no calibration problems are detected or for a safe period of time, after which the system may go into a normal sampling process, such as those shown in FIGS. 6 , 7 and 8 .
For example, in a large boiler, several dampers may control the fuel-air mixture in various parts of the boiler. In the event that too little air is found to be going to a burner, the respective damper may signal an out-of-calibration condition, at which time the damper position may be changed to allow more air to the burner. After the dampers are all in calibration, or after a safe period of time, such as twenty minutes, the system may go into an averaging mode, pending the detection of an upset condition.
FIG. 9 shows an example of such a system 180 . At step 182 , the system conducts a calibration sequencing through each valve or damper to determine whether a valve is out of calibration. If a calibration problem is detected, at step 184 , the appropriate valve is adjusted to correct the problem, at step 186 . The system 180 then continues at step 182 with its initial calibration sequencing. After calibration has been completed, the system 180 moves on to an averaging step 188 , until an upset condition is detected, at step 190 . Then, at step 192 . the system sequences through each valve until a problem is detected at step 194 .
While this disclosure has been described as having preferred embodiments, the present disclosure 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 disclosure 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 disclosure pertains and which fall within the limits of the appended claims.
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Apparatus and methods are provided for testing and analyzing a plurality of stream sources to monitor for an upset condition in one of the stream sources. A manifold is provided having a plurality of manifold inlets and a manifold outlet. A plurality of sampling devices for sampling the plurality of stream sources are coupled to the manifold inlets to provide stream samples to the manifold. A controller is in electronic communication with each of the plurality of sampling devices for providing test samples in the manifold. The controller alternately operates the sampling devices in (1) a sequencing mode in which each test sample is a stream sample from one of the plurality of sampling devices or (2) an averaging mode in which each test sample is representative of an average of the stream samples from the plurality of sampling devices. An analyzer is coupled to the manifold outlet to receive the test samples from the manifold and analyze each test sample for the presence of the upset condition.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 12/628,141 filed Nov. 30, 2009, now issued as U.S. Pat. No. 8,457,671, which is a continuation of U.S. Application Ser. No. 11/232,642 filed Sep. 22, 2005 now issued as U.S. Pat. No. 7,626,952 which is a continuation of U.S. application Ser. No. 10/914,710 filed Aug. 6, 2004, now issued as U.S. Pat. No. 6,985,450, which is a continuation of U.S. application Ser. No. 10/175,482 filed Jun. 18, 2002, now issued as U.S. Pat. No. 6,795,404, with all applications incorporated herein by reference in their entireties.
TECHNICAL FIELD
The present invention relates to electronic device interactions. More specifically, the present invention relates to an aggregator of device interaction for an environment.
BACKGROUND
Electronic devices such as household appliances, audio-video equipment, computers, and telephones operate within a given environment such as the home of a user. However, these devices function independently of one another. The user must initiate actions on the devices to cause the devices to change to a particular state of operation to thereby perform a function desired by the user.
Often, the state of one or more of the electronic devices is related to the state of one or more other electronic devices within the same environment. For example, a user may be watching television (TV) when the telephone rings. The user wishes to answer the call, but to effectively communicate with the caller, the user must mute the television so that sound from the TV does not interfere with the telephone conversation. Every time a telephone call is to be answered while the user watches TV, the user must again repeat the muting process. For each call, once the user hangs up the phone, the TV must be manually unmuted so that the user can once again listen to the TV program being watched.
The TV-telephone scenario discussed above is only one example. There is an undeterminable number of scenarios and devices involved within a given environment. In each scenario, the devices do not communicate with one another and do not coordinate activities, and as a result the user is overly burdened. The number of electronic devices for a household is continually increasing, and the resulting burden on the user to manually coordinate states of the devices for given scenarios is increasing as well.
To address this problem, devices can be configured with communication abilities so that they can communicate with one another when one or more devices experience a user driven state change. However, when several devices are involved in the interaction, various complexities are introduced. As devices and associated interactions are added to the environment, communication paths begin to multiply non-linearly necessitating wider bandwidths to accommodate the increase. Interaction rules become ambiguous because devices down a chain of interaction cannot determine a proper state change due to several degrees of removal from the user driven event.
Additionally, many different transports are available for communication between devices. Absent a standard specifying a transport for an environment, any transport may be chosen as the transport for a particular device. If two devices are not equipped with the same transports, then communication between the devices becomes impossible. These devices will not satisfactorily coexist and interact in an environment.
Therefore, there is a need for aggregating communication paths, interactions, and/or message transports within a device environment to address these problems.
SUMMARY
Embodiments of the present invention address the problems discussed above through application of an aggregator to the device environment. An aggregator embodiment may be employed to act as a single point of communication between many devices thereby limiting the communication paths to the number of devices in the environment. An aggregator embodiment may also be employed to accept communications from multiple transport types to act as a translator between devices of different transports. An aggregator embodiment may also be employed to control device interaction by employing interaction rules.
An aggregator device embodiment includes at least one transmitter and at least one receiver. The embodiment also includes a memory that stores interaction rules for the plurality of devices of the environment. A processor in communication with the transmitter, receiver, and memory is also included. The processor is configured to receive a message from a first device through the at least one receiver, reference the interaction rules in relation to the message from the first device to direct communications through the at least one transmitter to one or more devices of the plurality.
The logical operations of the processor that involve implementing the interaction rules are embodied in methods. The methods specify how a particular device or group of devices communicate. One embodiment of a method involves transmitting a message to the aggregator from a first device and receiving the message at the aggregator. The aggregator references interaction rules in relation to the message from the first device to direct communications from the aggregator to one or more devices of the plurality.
Another embodiment of a method involves detecting a change of state at a first device and in response to detecting the change of state, transmitting a change of state message to the aggregator. The aggregator receives the change of state message and references interaction rules in relation to the change of state of the first device to determine a change of state instruction for a second device of the plurality. The aggregator then transmits the change of state instruction to the second device.
The various aspects of the present invention may be more clearly understood and appreciated from a review of the following detailed description of the disclosed embodiments and by reference to the drawings and claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a device environment.
FIG. 2 is a diagram showing the major components of an embodiment of an interactive device.
FIG. 3 is an exemplary operational flow of an interactive device communicating with other devices of the environment.
FIG. 4 is an exemplary operational flow of communication between interactive devices involving a message broadcast to all devices of the environment.
FIG. 5 is an exemplary operational flow of communication between interactive devices involving a message directed to a specific device of the environment.
FIG. 6 is an exemplary operational flow of communication between interactive devices involving a request and a response to the request.
FIG. 7 is an exemplary operational flow of rule acquisition of an interactive device.
FIG. 8 is an exemplary operational flow of rule acquisition of an interactive device involving learning by a device receiving a state change after a state change of another device.
FIG. 9 is an exemplary operational flow of rule acquisition of an interactive device involving learning by a device receiving a state change before a state change of another device.
FIG. 10 is an exemplary operational flow of rule acquisition of an interactive device involving a request for rules to a device and a subsequent response.
FIG. 11 is an exemplary operational flow of content control among interactive devices.
FIG. 12 is an exemplary operational flow of media rights sharing among interactive devices.
FIG. 13 is a diagram of a device environment that illustrates the complexity that occurs in relation to interactivity among an increasing number of devices.
FIG. 14 is a diagram of a device environment including an embodiment of an aggregator that also illustrates the major components of the aggregator.
FIG. 15 is a diagram of an embodiment of an aggregator illustrating the components for translating among multiple communication transports.
FIG. 16 is an exemplary operational flow of device interaction involving an aggregator.
FIG. 17 is an exemplary operational flow of device interaction involving an aggregator that learns interaction rules and translates among multiple communication transports.
FIG. 18 is a diagram of a device environment interacting with notification devices interfaced with a user.
FIG. 19 is an exemplary operational flow of interaction from a device environment to a remote notification device through a remote communication transport.
FIG. 20 is an exemplary operational flow of interaction from a remote notification device to a device environment through a remote communication transport.
FIG. 21 is a diagram of an embodiment of a device for providing a display of information about a device environment.
FIG. 22 is an exemplary screenshot of the device of FIG. 21 that illustrates a device menu and a learn mode menu.
FIG. 23 is an exemplary screenshot of the device of FIG. 21 that illustrates a learn mode allowing the user to select function representations on the screen to associate functions of devices.
FIG. 24 is an exemplary screenshot of the device of FIG. 21 that illustrates a learn mode allowing the user to select functions on devices that are to be associated.
FIG. 25 is an exemplary screenshot of the device of FIG. 21 that illustrates a rule display mode for visually conveying the stored rules to a user.
FIG. 26 is an exemplary operational flow of a learn mode where the user selects functions on the devices that are to be associated.
FIG. 27 is an exemplary operational flow of a device information display mode.
FIG. 28 is an exemplary operational flow of a learn mode where the user selects function representations on a display screen to associate functions of devices.
DETAILED DESCRIPTION
Interaction among devices of an environment permit the devices to perform automatic changes of state without requiring the user to individually control each device. Through recognition of patterns of user behavior, interactive devices can associate the various user driven events from one device to the next to effectively create interaction rules. Application of these interaction rules allow the devices to implement the state changes automatically through communication of events between the devices.
A device environment is shown in FIG. 1 and is representative of a small area such as within a single household. However, a device environment may expand beyond a single area through networking of devices among various areas. This simplified device environment 100 shows three devices for exemplary purposes, but any number of devices may be present within a given environment 100 . The devices of the environment 100 are devices that customarily appear within the particular type of environment. For example, in a household the devices would include but not be limited to typical household devices such as a television, VCR, DVD, stereo, toaster, microwave oven, stove, oven, washing machine, dryer, and telephone. These devices are adapted to become interactive as is discussed below.
Each device communicates with the other devices of the environment 100 in this example. A first device 102 communicates with a second device 104 through a bi-directional communication path 108 . The first device 102 communicates with a third device 106 through a bi-directional communication path 110 , and the second device 104 communicates with the third device 106 through a bi-directional communication path 112 . The communication paths may be wired, wireless, or optical connections and may utilize any of the well-known physical transmission methods for communicating among devices in a relatively small relationship to one another.
The communication method used between two devices makes up a communication transport. For example, two devices may utilize the Bluetooth transport, standard infrared transport where line of sight is maintained, a UHF or VHF transport, and/or many others. Networked areas forming an environment can utilize LAN technology such as Ethernet, WAN technology such as frame relay, and the Internet. Multiple transports may be present in any single environment. As discussed below with reference to FIGS. 15 and 17 , a particular device such as an aggregator may be equipped to translate messages from one communication transport to another. Aggregators are discussed generally and in more detail below.
The details of the devices 102 , 104 , and 106 are shown in more detail in FIG. 2 . An interactive device 200 includes a processor 206 that communicates with various resources through a data bus 214 . The processor 206 may execute software stored in a memory 208 or may utilize hardwired digital logic to perform logical operations discussed below to bring about the device interaction. The processor 206 communicates with the memory 208 to apply interaction rules that govern the communications. Interaction rules specify when a particular communication should occur, the recipients of the communication, and the information to be conveyed through the communication. Memory 208 may include electronic storage such as RAM and ROM, and/or magnetic or optical storage as well.
The processor 206 communicates with a transmitter 212 and a receiver 210 to physically communicate with the other devices of the environment. The transmitter and receiver pairs discussed herein for the various embodiments may be separate or incorporated as a transceiver. When an interaction rule specifies that a communication from device 200 should occur, the processor 206 controls the transmitter 212 to cause it to send a message. The message may take various forms discussed below depending upon the intended recipients. The receiver 210 receives messages directed to the device 200 . The communications among devices may be configured so that each device to receive a message has identification data included in the message so that the processor 206 determines whether a message is relevant to the device 200 based on whether particular identification data is present.
Alternatively, other schemes may be used to communicate wherein a physical parameter of the receiver 210 controls whether a device 200 receives the message as one intended for it to be received. Examples of such physical parameters include the particular frequency at which a signal is transmitted, a particular time slot during which the message is transmitted, or the particular type of communication transport being used. The transmitter and receiver may be of various forms such as a modem, an Ethernet network card, a wireless transmitter and receiver, and/or any combination of the various forms.
The processor 206 also interacts with the intended functionality of the device 200 . The device 200 includes components 202 that provide the unique function of the device 200 . If the device 200 is a television 224 , then the components 202 include the circuitry necessary to provide the television function. One skilled in the art will recognize that the processor 206 can be separate and distinct from the processing capabilities of the components 202 or alternatively, may be wholly or in-part incorporated into the processing capabilities of the components 202 . The components 202 of many devices have digital logic such as an on-board processor of a television 224 , CD player 216 , stereo system 218 , dryer 220 , or telephone 222 .
The processor 206 can control the operations of the components to cause state changes of the device 200 . For example, the processor 206 can cause the channel to change on the television or cause the oven to preheat to a particular temperature. Thus, the processor 206 can reference interaction rules stored in memory 208 in relation to communications received through receiver 210 to determine whether a state change is necessary or can receive state change instructions through receiver 210 and implement the requested state change.
Additionally, the device 200 includes a sensor 204 for providing state change information to the processor 206 about the device 200 . The sensor 204 may be either a physical sensor such as a transducer for detecting motion or a thermocouple for detecting temperature, or the sensor 204 may be a logical sensor. The logical sensor may be a programmed function of processor 206 or the processor of components 202 or may be hardwired logic. A logical sensor may be separate and distinct from the processor 206 and/or the digital logic of components 202 and communicate through the bus 214 , or it may be incorporated wholly or in part in either the processor 206 of the processor of the components 202 . The logical sensor 204 acts as an interface to the digital logic of the components 202 for detecting the logical state of a component, such as a particular input that is active on a stereo, or a particular channel being displayed on a television.
The processor 206 receives input from the sensor 204 to determine a current state of the components 202 and thereby determine when a change of state of the device 200 occurs. As discussed below, changes of state are used to learn interaction rules and implement the rules once they have been learned. Implementing interaction rules involves controlling changes of state at device 200 and/or transmitting change of state information about device 200 to other devices or transmitting change of state instructions to other devices.
FIG. 3 shows the basic operational flow of the processor 206 for implementing device interaction to send a communication from device 200 . A state change is detected at the device 200 as described above at detect operation 302 by the sensor 204 . The state change may be a user driven event, such as a user turning the power on for the television, or an automatically occurring event such as an oven reaching a preheat temperature.
After detecting the change of state, the processor 206 references the rules of device interaction stored in the memory 208 to determine whether a communication is necessary, who should receive the communication, and the particular information to include at rule operation 304 . The processor 206 performs a look-up of the state change that has been detected to find the interaction rule that is appropriate. The processor 206 then communicates according to the appropriate interaction rule by sending a message through transmitter 212 at communicate operation 306 .
FIG. 4 shows an operational flow of a specific type of communication where a device 200 publishes its state change to all devices via a broadcast so that all devices receive the message. A broadcast to all devices is useful when devices are attempting to learn interaction rules by observing state change events occurring within the device environment 100 during a small interval of time.
The operational flow begins at detect operation 402 where the processor 206 realizes that sensor 204 has detected a change of state at device 200 . The processor 206 then determines that a broadcast is appropriate at determine operation 404 . The processor 206 may make this determination by referencing the rules of interaction to determine whether a broadcast is indicated. If learn modes are provided for the devices, as discussed below, then the processor 206 may recognize that it is operating within a learn mode where broadcasts of state change are required.
Once it is determined that a broadcast to all devices is appropriate, the processor 206 causes the broadcast to occur by triggering the transmitter 212 to send the message to all devices of the environment at broadcast operation 406 . As discussed above, messages may be addressed to specific devices by manipulation of a transmission frequency, a time slot of the transmission, or by including recipient identification data in the transmission. The message contains an identification of the device 200 and the particular state change that has been detected.
The devices of the environment receive the message at receive operation 408 . In this exemplary embodiment shown, the devices make a determination as to whether a reply is necessary at determine operation 410 . Such a determination may be made by the devices by referencing their own interaction rules or determining that a learn mode is being implemented and a reply is necessary because they have also detected their own state change recently. When a reply is necessary, the one or more devices of the environment send a reply message addressed to the device 200 at send operation 412 , and the device 200 receives the message through receiver 210 at receive operation 414 .
FIG. 5 shows an operational flow where a message is directed to a specific device of the environment from the device 200 . The processor 206 recognizes that the sensor 204 has detected a change of state of the device 200 at detect operation 502 . The processor 206 then determines from the interaction rules that a second device is associated with the state change at determine operation 504 . The second device may be a subscriber, which is a device that has noticed through a learning operation that it is related to the first device 200 through a particular state change event and that the first device should provide it an indication when the particular state change event occurs. Once it has been determined who should receive a message, the processor 206 triggers the transmitter 212 to direct a message to the second device at send operation 506 , and the message includes a notification of the state change of the first device 200 .
The processor 206 may employ additional logic when directing the message to the second device. The processor 206 may detect from the interaction rules in memory 208 whether the second device should change state in response to the detected change of state of the first device 200 at query operation 508 . If so, then the processor 206 includes an instruction in the message to the second device at message operation 510 that specifies the change of state that should be automatically performed by the second device.
FIG. 6 shows an operational flow where a request is made and a response is thereafter provided. At detect operation 602 , the processor 206 recognizes that the sensor 204 has detected a change of state of the device 200 . The processor 206 then determines that a second device is associated with the state of change at determine operation 604 . In this case, the processor 206 recognizes that a request to the second device is necessary, such as by reference to the interaction rules or due to some other reason such as a particular learn mode being implemented.
The processor 206 triggers the transmitter 212 to direct a request message to the second device at send operation 606 . The request message can specify that the second device is to respond by transmitting particular data that the second device currently possesses in memory to the device 200 . The second device receives the request message at receive operation 608 . The second device prepares a response by obtaining the required information from its memory, sensor, or components. Such information includes interaction rules, its current state, its current capabilities, or those who have subscribed to it for state change events. Once the information is obtained, the second device sends the response including the information to the first device 200 at send operation 612 .
FIG. 7 is an operational flow of a learning process of the device 200 . The device 200 may learn interaction rules that it obeys by observing activity in the environment in relation to its own state changes. Because the device may automatically learn interaction rules rather than requiring that they be manually programmed, a burden on the user is lessened. The operational flow begins by observing the environment to detect a state change message at observation operation 702 . The state change message may originate from another device of the environment and is received through the transmitter 210 . State changes of the device 200 that is learning the rule are also detected through its sensor 204 .
After detecting state change messages, the processor 206 learns the rule at learn operation 704 by associating together state changes that have occurred over a small interval of time. For example, a user may turn on one device and then shortly thereafter manipulate another device, and these two state changes are observed and associated as a rule. Particular methods of learning are discussed in more detail below with reference to FIGS. 8 and 9 . The processor 206 stores the rule in the memory 208 where it can be referenced for subsequent determinations of whether state changes should occur automatically. The rules are applied from the memory 208 at application operation 706 .
FIG. 8 shows the logical operations where the device whose state changes later in time learns the interaction rule. The operations begin at detect operation 802 where a first device detects a change of state through its state sensor. The first device determines that a broadcast is appropriate and sends the broadcast of the state change to all devices of the environment at broadcast operation 804 . All devices receive the broadcast at receive operation 806 .
After receiving the broadcast, each device of the environment monitors for its own state change. A second device that received the broadcast detects its state change at detect operation 808 within a predetermined period of time from when the broadcast was received. The second device then creates the interaction rule by associating the state change of the first device with the state change of the second device at rule operation 810 . The rule is stored in the memory of the second device so that the processor can apply the rule thereafter.
At application operation 812 , the second device receives the state change message from the first device and then applies the interaction rule that has been learned to automatically change its state accordingly. The second device applies the interaction rule by looking up the state change of the first device in its memory to see if there is an association with any state changes of the second device. The previously learned rule specifies the state change of the second device, and the second device automatically changes state without requiring the user to manually request the change.
As an example of this method of learning, the user may turn on the VCR which sends a broadcast of the state change. The user shortly thereafter tunes the TV to channel 3 to watch the VCR signal. The TV has received the broadcast from the VCR prior to the user tuning to channel 3, and therefore, the TV associates the tuning to channel 3 with the VCR being powered on to learn the interaction rule. Thereafter, when the user turns on the VCR, the TV automatically tunes to channel 3.
FIG. 9 shows an alternative method of learning where the first device to have a change of state learns the interaction rule. The logical operations begin at detect operation 902 where a first device detects its own change of state. In response to the change of state, the first device then begins monitoring for incoming state change messages at monitor operation 904 . Subsequently, a second device receives a change of state at detect operation 906 and broadcasts the change of state message to all devices at broadcast operation 908 . The broadcast is effectively a request that any device previously experiencing a state change add the second device to its subscriber list.
While monitoring, the first device receives the change of state message from the second device at receive operation 910 . Because this message was received within a predetermined amount of time from when the first device detected its own change of state, the first device creates an interaction rule at rule operation 912 . The first device creates the interaction rule by adding the second device and state change to its subscriber list that is associated with its state change. Subsequently, the first device detects its state change at detect operation 914 and then directs a message to the second device at message operation 916 in accordance with the interaction rule learned by the first device.
The message to the second device provides notification that the second device should perform a particular state change. Once the message is received at the second device, the message is interpreted, and the second device automatically performs the appropriate state change with no input from the user at state operation 918 . As an example of this method of learning, the user turns on the VCR which begins to monitor for a state change broadcast. The user tunes the television to channel 3 shortly thereafter, and the television broadcasts the state change. The VCR receives the broadcast and associates the TV to channel 3 state change with its power on state change. After the rule is created and when the user powers on the VCR, the VCR executes the rule by sending a message with instruction to the TV. The TV implements the instruction to automatically tune to channel 3.
FIG. 10 shows another alternative learning method. For this method, it is assumed that a device already has one or more interaction rules. The logical operations begin at send operation 1002 where a first device sends a request to a second device. The request is for the interaction rules stored by the second device. The rules of the second device may be relevant to the first device for various reasons such as because the first device is involved in the interaction rules of the second device or because the first device is acting as an aggregator that controls interaction of the environment. The details of the aggregator are discussed in more detail below.
After the first device has sent the request, the second device receives the request at receive operation 1004 . The second device then retrieves its interaction rules from memory at rule operation 1006 . The second device then sends a reply message to the first device at send operation 1008 that includes the interaction rules of the second device. The first device receives the reply message with the rules at receive operation 1010 and stores the rules in memory at rule operation 1012 . Thereafter, the first device can apply the rules stored in memory to control state changes upon user driven events at application operation 1014 .
Device interaction also permits additional functionality among the devices of an environment such as the control of media content to be played within the environment and the control of device settings dependent upon the particular media being played. FIG. 11 shows the logical operations of device interaction involving a device, such as an aggregator, that is in charge of the content control and/or content settings for a device environment. For example, a user may set up a parental control at one device, and the one device then becomes the instigator of content control for other media playback devices of the environment. Also, where digital rights are required for playback, the instigator of content control may manage those digital rights to prevent unauthorized playback.
The logical operations begin at content operation 1102 where a first device is attempting to play media. Here, the first device obtains content information included within the media, such as recognizing the title of a CD or DVD that is about to be played. Obtaining the content information applies for devices that support multiple media formats, such as a DVD player obtaining content information from DVDs or audio CDs during playback. Then, at query operation 1104 , the first device detects whether it has its own content rules. If so, then the first device detects whether the content is playable by comparing the content information to the associated content rules. At least two checks may be done at this point, one for content ratings and one for content rights. Content ratings are limits on the ratings of media that can be played, such as no content worse than a PG rated movie or no content with a particular type such as excessive adult language. Content rights are digital rights for playback authorization that prevent copyright or license infringement.
If the content is not playable, then the first device stops playback at stop operation 1112 . If the content is playable, then two options may occur depending upon whether the first device is configured to obey content rules from a device environment in addition to its own content rules. For example, the first device for media playback may be portable and may easily be taken to other device environments that impose more stringent restrictions on media content than the first device imposes on itself. At query operation 1107 , the first devices detects whether it is configured to obey content rules of the environment in addition to its own content rules. If the first device is configured to obey only its own content rules, then the first device begins normal playback of the media at playback operation 1108 . The first device may reference content rules at this point at settings operation 1110 to determine whether the content being played back has an associated preferred setting or setting limitation. For example, a user may have configured a rule that a particular movie is to be played back at a preferred volume setting or that the volume for playback cannot exceed a particular setting. The first device implements the preferred setting or limitation during playback.
If the first device is configured to obey its own content rules as well as the content rules of any environment where it is placed, then after determining that the media content is playable according to its own rules, operational flow transitions from query operation 1107 to send operation 1114 . Additionally, if query operation 1104 detects that the first device does not have an applicable content rule, then operational flow transitions directly to send operation 1114 .
At send operation 1114 , the first device transmits a message having the content information previously obtained to a second device that maintains content rules for the current environment where the first device is located. The second device receives the message with the content information and compares the content information to the stored content rules at rule operation 1116 . The comparison to the content rules again involves content ratings and/or rights, settings, and/or setting limitations. The details of this comparison are also shown in FIG. 11 .
The comparison begins at query operation 1126 where the second device detects whether the content is playable in relation to the content rules. The content rules may specify a maximum rating and/or whether digital rights exist for the content being played. Other limitations may also be specified in the content rules for comparison to the content information, such as a limitation on adult language present in the content that is indicated by the content information. If the content is not playable, then the comparison indicates that a stop instruction should be sent at stop operation 1130 . If the content is playable, then the comparison indicates that a play instruction should be sent along with any associated settings or setting limitations at playback operation 1128 .
Once the comparison is complete, the second device directs a message to the first device at send operation 1118 , and the message instructs the first device according to the stop instruction or playback instruction resulting from the previous comparison to the content rules. The first device receives the message and interprets the instruction at receive operation 1120 . The first device then implements the received instruction to either stop playing the media content or begin playback with any specified settings or limitations at implementation operation 1122 .
As an option, the first device may then create a content rule that associates the instruction with the content information at rule operation 1124 if the first device does not already have a local content rule. By creating the rule at the first device, the first device will at query operation 1104 detect that a content rule exists on subsequent attempts to play the same content. The first device will then handle its own content control without requiring communication with the second device.
The second device may obtain content rules through various methods. For example, the second device may receive a message from a third device at receive operation 1132 , and the message specifies a content rule. A user may have selected a content rule at the third device for media playback, and the third device then provides the rule to the second device as an automatic function or in response to a request for content rules from the second device. The second device creates the content rule by storing it in memory at rule operation 1134 .
During playback, the first device periodically repeats the comparison to environmental content rules at rule operation 1125 , as was initially done at rule operation 1116 . This operation 1126 is done periodically because if the first device is portable it may change locations after the start of playback. In that case, if the playback was initially permissible but later becomes impermissible because the first device enters a more restrictive device environment, then playback stops as indicated at stop operation 1130 .
FIG. 12 shows logical operations demonstrating the borrowing of media rights of a content rule from a device, such as an aggregator, that maintains the content rules. The logical operations begin by a first device sending a request to borrow media rights to a second device that maintains the media rights at send operation 1202 . For example, the first device may be an MP3 player and the request is for permission to play a particular song or volume of songs.
The second device receives the request and determines if the media rights to the content exist at receive operation 1204 . If so, and they are not flagged as borrowed, then the second device sends the media rights to the first device to allow the first device to play the content at send operation 1206 . The media rights are then flagged as borrowed at the second device at flag operation 1208 . Subsequently, when a third device requests authorization for media playback from the second device for the same content at send operation 1210 , the second device then checks the media rights at test operation 1212 and detects the flag. The second device then sends a stop instruction to the third device at send operation 1214 to prevent the third device from playing the content because the first device already has rights to it.
These logical operations could also be adapted to provide a count for the media rights so that more than one device can access the media rights for playback of content if multiple rights are owned for the content. Each time the media rights are borrowed by a device, the count of media rights is decremented. Once the count reaches zero, stop instructions are sent to the devices subsequently attempting playback. Furthermore, there can be a similar device exchange to unflag the digital rights or increment the count to restore capability of other devices to subsequently borrow the digital rights to media content.
The device interactions discussed above including general interaction to bring about states changes, interactive learning of interaction rules, and interactive content control become increasingly complicated as the number of devices in the environment increase. As shown in FIG. 13 , when the number of devices of an environment 1300 grows to six, the number of bi-directional communication paths grows to fifteen to ensure that every device can communicate directly with every other device. Each device uses five bi-directional paths (a first device 1302 uses paths 1314 , 1316 , 1318 , 1320 , and 1322 ; a second device 1304 uses paths 1314 , 1324 , 1326 , 1328 , and 1330 ; a third device 1306 uses paths 1316 , 1324 , 1332 , 1334 , and 1336 ; a fourth device 1308 uses paths 1318 , 1326 , 1332 , 1338 , and 1340 ; a fifth device 1310 uses paths 1320 , 1328 , 1334 , 1338 , and 1342 ; and a sixth device 1312 uses paths 1322 , 1330 , 1336 , 1340 , and 1342 ).
The complexity in coordinating the communications and interactions in such a crowded environment 1300 may result in inadequate bandwidth for the communication channels, cross-talk between the channels, and incompatible transports between devices. Furthermore, unintended rules may be learned because one or more of the devices may be unrelated to the others. For example, one person may answer the telephone shortly before another person starts the clothing dryer. There was no intended relationship but the phone or the dryer may associate the two state changes as an interaction rule, which the users never intended.
An aggregator 1402 as shown in FIG. 14 may be introduced into a crowded environment 1400 to alleviate one or more of the concerns. As shown in FIG. 14 , an aggregator 1402 can be used to reduce the number of bi-directional communications paths. For the six device environment, the aggregator has reduced the number of paths down to six (device 1414 uses path 1426 , device 1416 uses path 1428 , device 1418 uses path 1430 , device 1420 uses path 1432 , device 1422 uses path 1434 , and device 1424 uses path 1436 ). The aggregator 1402 acts as a conduit of communication from one device to another, and may also be configured to control or otherwise manage functions of a single device.
The aggregator 1402 uses a transmitter 1408 and receiver 1406 capable of communicating with the multiple devices. The transmitter 1408 and receiver 1406 may be configured to receive from all devices using various techniques known in the art. For example, frequency division multiplexing, time division multiplexing, code division multiplexing, optical multiplexing, and other multiplexing techniques may be used for a particular environment 1400 so that multiple devices can communicate with the aggregator 1402 .
The aggregator 1402 also has a processor 1404 and a memory 1410 . The processor 1404 communicates with the transmitter 1408 , receiver 1406 , and memory 1410 through a bus 1412 . The aggregator 1402 may be incorporated into a particular device of the environment as well so that the aggregator includes the additional device features such as components and a state sensor discussed in relation to FIG. 2 . The logical operations of an aggregator such as shown in FIG. 14 are discussed below.
The processor 1404 of the aggregator may be configured to perform various advanced functions for the device environment. The processor 1404 may be configured to perform periodic review of interaction rules to edit rules that are inappropriate for various reasons. For example, memory 1410 may contain a list of impermissible associations that the processor 1404 may refer to when reviewing interaction rules. If an impermissible association is found the, communication link that causes the problem may be excised from the rule. Additionally, the processor 1404 may be configured to entirely remove interaction rules that are inappropriate.
The processor 1404 may also be configured to support complex interaction rules. For example, devices may be separated into classes so that actions of one device may only affect devices within the same class. The processor 1404 may reference such class rules in memory 1410 to filter out faulty rules that might otherwise be learned, such as those where devices of different classes are involved. Furthermore, the processor 1404 may be configured to develop rules based on conditional logic or iterative logic, and perform multiple activities of a rule in series or in parallel.
As an example of conditional logic being employed, a rule may specify that a phone ringing means the volume should be decreased for several different devices but only if they are actively playing content. Then when the phone hangs up, the volume should be increased but only for those devices whose volume was decreased by the phone ringing. An example of iterative logic provides that the front porch lights should be turned on at 6 p.m. and off at 12 a.m. everyday.
An example of serial execution of interaction rules with multiple activities provides that when a light on a computer desk is turned on, the computer is then turned on, and after that the monitor is turned on followed by the computer speakers being turned on. An example of parallel execution of interaction rules with multiple activities provides that when a person is exiting a room, all devices of the room are powered off simultaneously.
FIG. 15 illustrates an embodiment of an aggregator 1502 that is additionally configured to translate among different communication transports of the device environment 1500 . Device 1518 may communicate through signals 1524 of a first communication transport while device 1520 communicates through signals 1522 of a second communication transport. For example, the first communication transport may be Ethernet while the second communication transport is fiber optical. The communication transports may differ in the physical mode of transferring signals (e.g., Ethernet versus fiber optical) and/or in the logical mode (a first data encoding scheme versus a second).
The aggregator 1502 includes a first transmitter 1508 and receiver 1506 , separate or combined as a transceiver, for communicating across the first communication transport. The aggregator may also include a second transmitter 1512 and receiver 1510 , separate or combined as a transceiver, for communicating across the second communication transport where the second communication transport differs in the physical mode of transport. A processor 1504 communicates with memory 1514 and the two transmitter-receiver pairs through a bus 1516 . Although two transmitter-receiver pairs are shown for two communication transports, one skilled in the art will recognize that any number of transmitter-receiver pairs and communication transports may be utilized, including only one, depending upon the different number of physical transports to support within the device environment.
The processor 1504 detects from the messages being received where communications should be directed. This includes determining whether the messages should be translated to a new communication transport when sending the message to the intended device. The processor 1504 may perform the same logical operations of the processor of aggregator 1402 with the addition of translation operations from one transport to another where necessary.
FIG. 16 shows the basic logical operations of an aggregator. The logical operations begin when a first device transmits a message to the aggregator at send operation 1602 . The first device may send a message to the aggregator that is intended as a broadcast to all devices, as a message directed to a specific device, or as a message intended solely for the aggregator. The aggregator receives the message at receive operation 1604 .
The aggregator then references interaction rules that it maintains in memory in relation to the message it has received at rule operation 1606 . For example, the environment may be configured so that the devices maintain no interaction rules other than to direct a message for every state change to the aggregator and rely solely on the interaction rules of the aggregator to bring about subsequent activity in the environment. The environment may alternatively be configured where the devices maintain interaction rules and provide instruction to the aggregator with each message, so that the aggregator acts upon the instruction to bring about subsequent activity.
After the aggregator has received the message and referred to the interaction rules in relation to the message, the aggregator communicates with devices of the environment in accordance with the interaction rules and any received instruction from the first device at communication operation 1608 . For example, the aggregator may possess the interaction rule that when the VCR is on, the TV should be tuned to channel 3. When the aggregator receives a power on message from the VCR, the aggregator then sends an instruction to the TV to tune to channel 3. Alternatively, the power on message may instruct the aggregator to send an instruction to the TV to tune in channel 3.
FIG. 17 shows the logical operations of an embodiment of an aggregator, such as the aggregator 1502 of FIG. 15 . The logical operations begin at detect operation 1702 where the first device detects its own state change. The first device then sends a message to the aggregator at send operation 1704 . The aggregator receives the message at receiver operation 1706 and references its interaction rules at rule operation 1708 in relation to the received message indicating the state change.
The aggregator tests whether to switch communication transports at query operation 1710 by referencing its interaction rules. The interaction rules specify how to communicate with each device. The aggregator learns the one or more devices to communicate with in response to the message from the first device by either looking up the state change of the first device in the interaction rules to find associations or by interpreting an instruction from the first device included in the message. After determining the proper device to communicate with, the aggregator can look up the device in memory to determine which communication transport to employ.
Once the aggregator has determined which transport to use for the next communication, the message from the first device or a new message from the aggregator is prepared by translating to the second communication transport appropriate for the next communication at translate operation 1712 . Where only the logical mode of communication transport differs, a second communication transport may not be needed. Furthermore, the aggregator may act as a conduit where no change in the physical or logical mode of transport should occur. As an example of where a change in transport does occur, the aggregator may receive a message from the VCR via infrared airwave signals and then prepare a message to the TV to be sent via a fiber optical connection. The aggregator sends the message to the second device at send operation 1714 . The second message may instruct the second device that the first device has changed state if the second device has its own interaction rules, or the message may provide a specific instruction to the second device.
After receiving the message, the second device implements any instruction or automatic state change dictated by its own interaction rules. The second device may respond to the aggregator if necessary at send operation 1716 . The return message may be an indication to the aggregator of the state change that the second device has performed or may be a reply to a request from the aggregator such as for current state, capabilities, or rules. The aggregator again references its interaction rules at rule operation 1718 to determine the next action after receiving the message from the second device. The aggregator then communicates with other devices of the environment as necessary at communicate operation 1720 .
The logical operations for the aggregator learning the interaction rules being applied are also shown in FIG. 17 . Several possibilities exist for learning rules at the aggregator. A user interface discussed below may be provided so that a user enters interaction rules at user operation 1722 . The aggregator may observe closely occurring state change broadcasts that are associated as interaction rules at observation operation 1724 , as was discussed above for learning with individual devices. The aggregator may request that a particular device forward its interaction rules to the aggregator where they can be stored and implemented at request operation 1726 .
After receiving the interaction rule in one of the various ways, the aggregator stores the interaction rule at rule operation 1728 . When state change messages are received at the aggregator and the aggregator references the interaction rules such as at rule operation 1708 , the aggregator compares information in the message to the stored rules at comparison operation 1730 . Through the comparison, the aggregator determines the appropriate action to take to complete communication to other devices.
Device interaction within the device environment allows the burden on the user to be lessened while the user is present within or absent from the environment. However, under certain scenarios the user is absent but needs to remain in contact with the device environment. For example, the user may need to know when the oven is finished cooking so the user can return home, or the user may need to delay the oven from automatically preheating at a certain time because the user will be late. Therefore, for these scenarios the device environment needs to communicate remotely with the user.
FIG. 18 shows one illustrative case of device communication where the messages extend beyond a closely defined area, such as a single room or household, to an external or broader area. The external area includes any destination reachable via a communications network. Thus, in this illustrative case, the device environment is not defined by proximity but by explicit definition by the user. Such explicit definition may be provided by the user in many ways, such as through a listing stored in memory that describes the devices and their address where they may be accessed through communication networks including the Internet, wireless communication network, and landline telephone network. Thus, as used herein, device environment should be understood to include both environments defined by proximity as well as explicitly defined environments.
Additionally, FIG. 18 shows an illustrative case of device communication where notification messages are passed between a notification device that is interfaced with the user and devices of the environment not otherwise interfaced with the same user. Thus, messages may be passed to the user from devices of the environment and from the user to the devices without the user interacting directly with those devices that send or receive the message. Such notification devices may be external, as discussed above, in that they are not part of the device environment through proximity but by explicit definition by the user, or the notification devices may be in close proximity and be included in the device environment on that basis.
A device 1802 such as an aggregator for sending notifications to the notification device of the user and/or for communicating to both devices defined by proximity and external devices is present in the environment 1800 . The device 1802 includes at least one transmitter 1814 and receiver 1812 for communicating with proximity based devices 1818 in the environment 1800 over a communication transport 1820 . The device 1802 of includes a memory 1806 that stores interaction rules and a processor 1804 for executing the functions of the device 1802 . The processor 1804 communicates through the bus 1816 . The memory 1806 may also store translation rules in the embodiment where communication with notification devices is supported.
The device 1802 of this embodiment also includes at least one transmitter 1810 and receiver 1808 that communicate through a remote communications transport 1828 to external devices. The remote communications transport 1828 may take various forms such as a conventional telephone network 1822 including a central office 1826 . The remote communications medium may additionally or alternatively involve a wireless network 1824 for mobile telephones or for pagers.
Communication can be established between the device 1802 and a remotely located telephone 1830 , computer 1832 , or wireless communication device 1834 such as a mobile phone or pager which is explicitly defined in memory 1806 as being part of the device environment. The device 1802 can relay information between itself or other proximity based devices of the environment 1800 and the remotely located communication devices.
In the embodiment where notification devices are supported, the user can remain in contact with the device environment 1800 by communicating through the notification devices that are either external, such as devices 1830 - 1834 , or are proximity based, such as device 1836 . For example, the device 1802 may send short messages to a mobile phone 1834 or to a proximity based portable communication device 1836 if the user is in proximity. The device 1802 may provide machine speech or text that can be interpreted by the user as a notification of a state of the environment. Similarly, the user may send machine tones, speech, or text back to the device 1802 that can be interpreted by the device 1802 as an instruction for the environment.
For example, to implement the notification process the processor 1804 may recognize a set of voice commands, tones, or text and translate those into instructions for various devices by referencing translation rules to interpret the instruction. The processor 1804 may then reference interaction rules to communicate the instruction to the appropriate device based on identification received in the message from the remote device. Likewise, the processor 1804 may choose from a set of machine voice commands, tones, or text to communicate messages from the environment back to the user when the interaction rules indicate that the remote device should be contacted.
FIG. 19 shows the logical operations for communication from the device environment to the notification device 1830 - 1834 or 1836 . The logical operations begin at detect operation 1902 where a first device of the environment detects its own state change. The first device itself or a dedicated device for remote communications such as an aggregator may then reference rules for interaction to determine whether a notification communication is necessary based on the state change at rule operation 1904 . For example, if the previously discussed content control device detects that unacceptable content playback is being attempted, a notification may be provided to the notification device 1836 or 1830 - 1834 .
The interaction rules may provide a hierarchy of communication with notification devices, or for other non-notification devices as well, so that a particular state change may require that communications cycle through a list of devices until a response is received or the list is exhausted. At detect operation 1914 , the appropriate device of the environment determines from the interaction rules the order of communication that should occur. For example, a particular state change may require that a page be left with the user followed by a call to a mobile phone if there is no response to the page within a certain amount of time.
The logical operations of FIG. 19 assume that the notification device is an external device that is explicitly defined by the user. Thus, after determining the one or more notification devices to contact, the device of the environment references translation rules at rule operation 1906 to determine how to convey the message to the remotely located notification device that should be contacted. The translation rules are typically specified by the user directly at input operation 1916 . Through a user interface, the user can specify the hierarchy and the particular translation rules to use. For example, the user can specify that a pager is contacted by dialing a specific telephone number over the ordinary telephone network, and that a text message should be left upon an answer. Rules may also include constraints such as the range of time when a particular notification device should be contacted.
The device of the environment executes the interaction rule and translation rule to communicate remotely to a second device (i.e., a notification device) at communication operation 1908 . As one exemplary option where a hierarchy is employed, the device tests whether the second device has responded at query operation 1910 . If so, then the logical operations return to await the next state change requiring remote communications. If not, then the device of the environment communicates remotely to a third device (i.e., a different notification device) as specified in the hierarchy at communication operation 1912 again with reference to the interaction and translation rules. Cycling through the devices of the hierarchy continues until query operation 1910 detects a response or the list is exhausted.
Another exemplary option is to communicate with one or more notification devices without regard to a hierarchy. After the device of the environment has provided a communication to the second notification device, then a communication is automatically provided to the third notification device at communication operation 1912 . This continues for as many remote devices as specified in the interaction rules.
FIG. 20 shows the logical operations for communications from the notification device back to the device environment. At send operation 2002 , the notification device directs a message to a first device of the environment that completes notification communications. For example, where the notification device is external to the proximity defined device environment, the first device may maintain a connection to a telephone line, and the user dials the number for the line to contact the first device. The first device answers the call and awaits data signals from the remote notification device. The remote notification device then provides the message by the user speaking or using dialing tones.
The first device receives the message at receive operation 2004 and translates the message for transport to a second device of the environment at translate operation 2006 . The first device may translate the message by referencing translation rules to convert the message into a form usable by the second device and by referencing interaction rules to determine that the second device should be contacted. For example, according to the translation rules, an initial “1” tone from the remote device may indicate that the oven should be contacted, and a subsequent “2” tone from the remote device may indicate that the oven should cancel any automatic preheating for the day.
Thus, translate operation 2006 involves determining the second device to communicate with through detecting an ID of the second device from the message of the remote device at ID operation 2020 . In the example above, the ID of the oven is an initial “1” tone. The first device receives the “1” tone and references a “1” tone in the interaction rules to determine that a message should be sent to the oven. The first device receives the “2” tone and, knowing that the message is for the oven, references a “2” tone for the oven in the translation rules to determine that a cancel preheat message to the oven is necessary. The message is communicated from the first device to the second device at communication operation 2008 .
The second device receives the message and implements the instruction at implementation operation 2010 . For the example above, the oven receives a message instructing it to cancel its pre-programmed preheat operation for the day, and it cancels the preheat operation accordingly. As an exemplary option to the logical operations, the second device may then send a message back to the first device confirming it has implemented the instruction at send operation 2012 .
The first device 2014 receives the message from the second device at receive operation 2014 , and then the first device 2014 translates the confirmation to a message that can be sent to the notification device at translate operation 2016 in the instance where the notification device is external. For example, the first device 2014 may determine from the translation rules that it should send a pattern of tones to the telephone used to place the call to signal to the user that the oven canceled the preheat operation. The first device 2014 then communicates the message to the remote notification device over the remote communication transport at communication operation 2018 to complete the notification communications.
The user may be provided a user interface to interact directly with devices of the environment such as the aggregator. As discussed above, the user may program interaction rules, translation rules, and hierarchies for remote communication through the user interface. Additionally, the user may review information about the device environment through the user interface, such as current states of devices and existing interaction rules and translation rules of the environment.
FIG. 21 shows the major components of an exemplary device 2102 establishing a user interface for the device environment. The user interface 2102 may be a separate device or may be incorporated into a device of the environment such as an aggregator. The user interface 2102 includes a processor 2104 for implementing logical operations of the user interface. The processor 2104 communicates with a memory 2106 and a display adapter 2108 through a bus 2110 . The processor 2104 references the rules stored for the environment in the memory 2106 to provide information to the user on a display screen 2112 driven by the display adapter 2108 .
The user interface 2102 may provide several mechanisms for receiving user input. As shown, a touchscreen 2112 is provided so that the user can make selections and enter information by touching the screen 2112 that displays selectable items such as text or icons. One skilled in the art will recognize that other user input devices are equally suitable, such as but not limited to a keyboard and mouse.
Several exemplary screenshots of the user interface are shown in FIGS. 22-25 . The screenshots demonstrate a graphical user interface that is icon based. However, other forms of a user interface on screen 2112 are also suitable, such as a text-based user interface. Furthermore, many variations on the graphical user interface shown are possible.
FIG. 22 shows a screenshot 2200 that contains icons that form representations of the devices present within the environment. As shown, six devices are present within the environment and the screenshot 2200 includes a television representation 2202 , a VCR representation 2204 , a microwave representation 2206 , a stove/oven representation 2208 , a washer representation 2210 , and a dryer representation 2212 . Also included in the screenshot 2200 are a rule button 2214 , a first learn mode button 2216 , and a second learn mode button 2218 .
From screenshot 2200 , the user may make a selection of a device representation to learn information about the device such as its current state. The logical operations of viewing device information are discussed in FIG. 27 . The selection may also be used to send an instruction to the device to immediately bring about a state change as may be done with an ordinary remote control. The user may select the rule button 2214 to view interaction or translation rules already stored and being executed for the environment. An example of viewing existing rules is discussed in more detail with reference to FIG. 25 .
The user may also make a selection of the first learn mode button 2216 to program an interaction or translation rule by interacting with device representations and function representations for the device. The first learn mode is discussed in more detail with reference to FIG. 23 and the logical operations of FIG. 28 . Additionally, the user may make a selection of the second learn mode button 2218 to program an interaction rule by interacting with the device itself. The second learn mode is discussed in more detail with reference to FIG. 24 and the logical operations of FIG. 26 .
FIG. 23 shows a screenshot 2300 after a user has selected the TV representation 2202 from the initial screenshot 2200 . The screenshot 2300 shows the device representation or icon 2302 and the associated function representations or icons for the functions of the TV present in the environment. The function representations include channel selection representation 2304 , volume selection representation 2306 , mute representation 2308 , power representation 2312 , and signal input representation 2310 . The user makes a selection of a particular function representation to be associated in an interaction rule and then selects another function representation of the TV or another device to complete the rule.
As described above, the user may select a power on representation for the VCR and then select the channel selection representation 2304 to indicate a channel 3 for the TV. The interaction rule is created as a result so that whenever the VCR is powered on, the TV automatically tunes to channel 3. The interaction rule may be programmed to include additional associations as well, such as setting the TV volume representation 2306 to a particular volume setting as well once the VCR is powered on. Likewise, rules may be specified for a single device, such as for example specifying that when the TV is turned on, the volume of the TV should automatically be set to a particular level.
The logical operations for the first learn mode are shown in FIG. 28 . The logical operations begin by the user interface displaying the device representations at display operation 2802 . A user selection of a first device selection is selected at input operation 2804 . The function representations of the first device are displayed on the screen for the first device at display operation 2806 . A user selection of a function representation for the first device is received at input operation 2808 .
The device selections are redisplayed and the user selects a second device representation at input operation 2810 . The function representations of the second device are displayed at display operation 2812 . A user selection of a second device selection for the second device is received at input operation 2814 . The function representation selected for the first device is associated with the function representation for the second device to create the interaction rule at rule operation 2816 .
FIG. 24 shows a screenshot 2400 that is displayed after a user selects the second learn mode button 2218 . The screenshot 2400 includes a button 2402 that is a choice to learn a first portion of the interaction rule. The user presses the button 2402 and then selects the first function on the first device itself within the environment. In response to the first device providing a message about its resulting state change, the selected function is displayed in field 2404 .
The user then presses the button 2406 that is a choice to learn a second portion of the interaction rule. The user selects the second function on the second device itself, and in response to the second device providing a message about its state change, the selected function is displayed in field 2408 . The interaction rule is created by associating the function shown in the first display field 2404 with the function shown in the second display field 2408 . In the example shown, the rule that results is if the VCR is powered on (a first received state change message), then the TV tunes to channel 3 (a second received state change message).
The development of the rule may continue as well. The user may press the button 2410 that is a choice to learn a third portion of the interaction rule. The user selects the third function on the third device itself, and in response to the third device providing a message about its state change, the selected function is displayed in filed 2412 . In the example shown, the rule that results is if the VCR is powered on, then the TV tunes to channel 3 and then the VCR begins to play. Additionally, as discussed above in relation to advanced interaction rules of the aggregator, the user may specify via buttons 2414 , 2416 whether the execution of the multiple step interaction rule should be performed in parallel or serial fashion. If in parallel, then turning the VCR on causes messages to be simultaneously instructing the TV to tune to channel 3 and the VCR to begin playing simultaneously. If in series, then the TV is instructed to turn on prior to the VCR being instructed to play.
The logical operations of an example of the second learn mode are shown in FIG. 26 . The logical operations begin at choice operation 2602 where the first choice is provided to the user for selection to initiate learning of the first portion of the interaction rule. The user selects the first choice, which is received at input operation 2604 . The user then selects the first function on the first device itself at input operation 2606 . A state change message from the first device is received at the device creating the rule at receive operation 2608 , and the message indicates the function the user selected. The function description is stored in memory.
The second choice is provided to the user for selection to initiate learning of the second portion of the interaction rule at choice operation 2610 . The user then selects the choice at input operation 2612 to initiate learning of the second portion of the interaction rule. The user then selects the second function representation on the second device at input operation 2614 . A state change message is received from the second device at the device creating the rule at receive operation 2616 , and the message indicates the function the user selected. The function description is stored in memory. Once the two function descriptions are known by the device creating the rule, the first function description is associated with the second function description at rule operation 2618 to create the reaction rule.
FIG. 25 shows a screenshot 2500 that results from the user selecting the rule button 2214 and a selection of a device that is involved in the rule. For example, the user may select the TV representation 2202 to view an interaction rule involving the TV present in the device environment. A TV representation 2502 is displayed and is connected to a function representation 2504 that indicates that the TV is being tuned to channel 3. A VCR representation 2506 is displayed and is connected to a function representation 2508 that indicates that the VCR is being powered on.
A connector 2510 is shown connecting the VCR function representation 2508 to the TV function representation 2504 . As shown, the connector 2510 is directional as an arrowhead points to the TV function representation 2504 to indicate that the TV function results from the VCR function. The corresponding interaction rule provides the association of VCR on to TV channel 3 only to automatically control the TV in response to the VCR but not the other way around. Thus, when the TV is tuned to channel 3 by the user, the VCR does not automatically turn on because the interaction rule is learned as a directional association.
Other interaction rules may involve a connector that is not directional so that the association is absolute rather than directional. For example, it may be preferred that the VCR automatically turn on when the TV is tuned to channel 3 and that the TV automatically tune to channel 3 when the VCR is turned on. Such an interaction rule would be absolute rather than directional, and the connector 2510 would lack an arrowhead or alternatively have arrowheads pointing in both directions. One skilled in the art will recognize that other visual connectors besides arrowheads and lines are suitable as well.
To view information about a specific device in the environment, the user may select the device representation from the screenshot 2200 of FIG. 22 . A screenshot such as the screenshot 2300 of FIG. 23 will be displayed. Along side each function representation, the value for that function may be displayed to inform the user of the current state of the device. For example, a 3 may appear next to the channel representation 2304 while a checkmark appears next to the mute representation 2308 to indicate that the TV is currently tuned to channel 3 but is muted.
The logical operations for obtaining information about a device through the device interface are shown in FIG. 27 . The logical operations begin by displaying a choice of device representations at display operation 2702 . A user selection of a device representation is received at input operation 2704 to select a first device. A message is then sent from the user interface, such as an aggregator, to the first device selected by the user at send operation 2706 . The message includes a request for information, such as the current status, from the first device.
The first device receives the request for information at receive operation 2708 . The first device then directs a reply back to the user interface at send operation 2710 . The reply is a response to the request for information and includes the current status information of the first device. The user interface device receives the reply from the first device at receive operation 2712 , and then the user interface displays the current status information on the screen at display operation 2714 .
Various embodiments of devices and logical operations have been discussed above in relation to communications between devices, automatic and manual learning of interaction rules, content control, aggregator functions, remote communications, and a user interface. Although these embodiments of devices and logical operations may be combined into a robust system of device interaction, it should be noted that various devices and logical operations described above may exist in conjunction with or independently of others.
Although the present invention has been described in connection with various exemplary embodiments, those of ordinary skill in the art will understand that many modifications can be made thereto within the scope of the claims that follow. Accordingly, it is not intended that the scope of the invention in any way be limited by the above description, but instead be determined entirely by reference to the claims that follow.
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Methods, systems, and products aggregate and distribute changes of state between devices. A plurality of devices communicates with an aggregator. The plurality of devices sends their respective changes of state to the aggregator. The aggregator queries a set of interaction rules to determine how the change of state is disseminated among the plurality of devices.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods of teaching, particularly teaching a person how to detect potentially incorrect answers while taking multiple-choice examinations, and more specifically, how to detect, while taking a multiple-choice examination, answers that are more likely, in comparison with other possible answers, to be incorrect.
2. Description of the Related Art
Multiple-choice examinations are commonly used for testing in different areas of knowledge. Many review courses and study aids are available on the market. They train prospective examinees in the substantive areas of knowledge and also instruct examinees by teaching helpful exam-taking techniques suitable to the multiple-choice form of examination. Commonly such instructions include, no matter what substantive area is being tested, recommending that the examinee should (i) recheck as many of his test answers as time permits after he has answered all of the questions, (ii) narrow the number of possible alternative answer-choices by some intelligent process of elimination before answering any particular multiple-choice question, and (iii) select by guessing, whenever the examinee is unable to clearly determine the correct answer based on the substantive analysis of the problem, an answer-choice from those answer-choices not eliminated.
Such processes of elimination and subsequent guessing are considered to be necessary techniques to allow an examinee to take full advantage of his or her partial knowledge of the substantive subject matter of the test. It gives knowledgeable examinees an opportunity to narrow possible alternative answer-choices and thus to increase the probability of guessing correctly thereby getting an overall higher score in comparison with an examinee who has no knowledge of the subject matter, who is unable to eliminate at least some possible alternative answer-choices, and therefore has a worse chance of guessing correctly.
While these existing methods are very helpful to students and other examinees, they do not fully exploit a systematic approach that provides a simple, efficient and effective method that could be used during a multiple-choice examination or practice session.
BRIEF SUMMARY OF THE INVENTION
I. Nature and Substance of the Invention
A multiple-choice examination is a test comprising a number of questions to be answered by an examinee, in which each such question is accompanied by a group of distinctly labeled possible answers, each said distinct label being referred to as answer-choice, wherein the examinee answers each question by selecting one of the possible answer-choices from the group of possible answers associated with that question.
Commonly, multiple-choice examinations have a fixed number of possible answer-choices. That is, the number of distinctly labeled possible answers associated with each question in the examination is the same for every question in the examination. Moreover, the distinctly labeled groups of possible answers in multiple-choice examinations are usually uniformly labeled. That is, each distinctly labeled group of possible answers is labeled with the same set of labels or answer-choices.
The present invention is applicable to multiple-choice tests that have a fixed number of uniformly labeled possible answer-choices for each multiple-choice test question, and is useful in a number of different ways including (i) aiding in the detection of answers which are more likely to be incorrect as compared with other answers already selected, (ii) helping to eliminate potentially incorrect answer-choices from the groups of labeled possible answers, and (ii) locating possible answer-choices which may have a higher probability of being correct as compared with other possible answer-choices.
One use presents itself in the situation where the examinee has finished the entire exam, either actual or practice, but still has some time left that can be used to recheck his answers. Often, the time left for rechecking will not be sufficient for rechecking of all of the answers. Thus, the examinee will face the difficult problem of choosing which answers he should be rechecking. Of course, it will be more efficient for the examinee to recheck only those answers which are more likely to be incorrect in comparison with other answers already selected (in other words, the most "suspicious" answers). In this case, the time allotted to rechecking his answers will be used most efficiently and the examinee will be able to correct as many mistakes as possible thereby improving his score to the maximum extent possible.
In order to provide the examinee with an efficient methodology for pinpointing "suspicious" answers, the present invention utilizes information about the expected distribution of the answer-choices as well as the actual distribution of the answer-choices, and employs the notion of the over-represented and under-represented answer-choices.
For example, in a test in which the correct answer-choices obey a random or uniform distribution, each of the correct answer-choices would be expected to occur approximately the same number of times as any other correct answer-choice. Specifically, each answer-choice would be expected to occur a number of times approximately equal to that number which results from dividing a numerator by a denominator where the numerator is equal to the total number of the test questions and the denominator is equal to the number of possible answer-choices for each question. Thus, any answer-choice which occurred significantly more often than this expected number of times would be an over-represented answer-choice and the examinee may consider such answer-choices as more suspicious than any others.
Still another use occurs when an examinee is faced with a question in which he is unable to easily select the best answer-choice. In this case, any answer-choice which occurred significantly less often than the expected number of times would be an under-represented answer-choice and may be considered as more likely to be correct than any other answer-choices (presuming, of course, that the examinee's substantive knowledge is insufficient to provide any other clues).
This method is particularly helpful to those examinees who have better knowledge of the subject matter, and it discourages blind guessing. This is so, because the usefulness of the method depends on the number of questions the examinee can answer correctly. That is, the actual answer distribution is reliable as a basis for the comparison with the theoretical distribution only to the extent that the actual answers are correct. The more answers that are correct, the greater the reliability and thus the usefulness of the actual answer distribution. For this reason, the present invention encourages examinee to study hard, and benefits primarily those who are well prepared, who give mostly correct answers based on a substantive analysis and who resort to guessing in relatively rare cases.
II. Objects of the Invention
It is an object of the present invention to provide a person taking a multiple-choice examination or practicing in taking such examination, with an efficient method which allows him to pinpoint answers for subsequent substantive rechecking that are more likely, in comparison with other answers, to be incorrect. In this way, the examinee will be given an opportunity to improve his score to the maximum extent possible according to the level of his knowledge and within the constraints of existing time limitations.
Another object of the present invention is to provide a person taking a multiple-choice examination with an efficient method which allows, where the substantive analysis of a question does not provide the examinee with a definite answer, said person to pinpoint and eliminate those answer-choices, if any, that are more likely, in comparison with other available alternative answer-choices, to be incorrect, so that the odds of guessing correctly will be increased.
Still another object of the present invention is to create an incentive for an examinee to study hard without becoming overwhelmed, by allowing the examinee to utilize even partial knowledge of the test's subject matter in an effective manner.
And yet another object of the present invention is to create an educational game helpful for practicing skills useful for taking multiple-choice tests.
Additional objects and advantages of the invention are set forth in the drawings, description, and claims which follow. Some objects and advantages will be apparent from the applications and combinations particularly pointed out while other objects and advantages may be learned by the practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart of a test taking sequence that illustrates the steps of creating an answer summary and answer tally to be used in a recheck procedure.
FIG. 2 is a flow chart of a test taking sequence that illustrates steps wherein an answer summary and answer tally kept on a running basis being updated after each question is answered.
FIG. 3 is a flow chart of a test taking sequence that utilizes the concepts of both over-represented and under-represented answer-choices.
DETAILED DESCRIPTION OF THE INVENTION
A method of teaching a person an efficient methodology which enables him to detect incorrect answers while taking or practicing taking a multiple-choice examination is disclosed. The following description sets forth specific details only for purposes of explanation and to provide a complete understanding of the present invention. However, it is apparent to one skilled in the art that the present invention may be practiced by application of numerous modifications obvious to those skilled in the art without making use of the specific details shown and described, and that the present invention extends beyond embodiments described herein.
In accordance with one method of the present invention, the examinee, while answering the questions of an actual examination or while practicing by taking a practice test, is taught to keep track of his answers, via an answer summary, so that by the end of examination he has available the distribution of answer-choices he selected as most likely being correct, or in other words, the actual distribution of selected answer-choices. The examinee can then total up each of his answer-choices creating an answer tally of occurrence numbers for each answer-choice (i.e. the total number of times each particular answer-choice occurs in the actual distribution) whereby he can compare the theoretically expected distribution with the actual distribution and determine the most over-represented and under-represented answer-choices.
For example, if the total number of times a particular answer-choice, say the answer choice labeled with the letter "A", occurs in the actual distribution, is less often than it is expected to occur in the theoretical distribution (i.e. its occurrence number is less than expected), then the answer-choice "A" is said to be under-represented. By the same token, if it occurs in the actual distribution more often than it is expected to occur in the theoretical distribution (i.e. its occurrence number is greater than expected), then the answer-choice "A" is said to be to be over-represented. The most over-represented answer-choice is that answer-choice with the greatest number of occurrences in the actual distribution (i.e with the greatest occurrence number). The most under-represented answer-choice is that answer-choice with the least number of occurrences in the actual distribution (i.e with the smallest occurrence number).
Based on the actual distribution, the examinee can then assign the highest priority for rechecking to those "suspicious" answers, which, if changed, would increase the total number of under-represented answer-choices and decrease the number of over-represented answer-choices in the actual distribution to the greatest extent possible, thereby making the actual distribution as close to the theoretical one as possible. Finally, after these "suspicious" answers are determined, they are rechecked by the examinee who subjects them once again to the substantive analysis.
In other words, comparison of the actual and theoretical distributions serves as a tool for detecting answers, which are more likely, in comparison with other answers, to be incorrect. The extent to which the actual distribution may become closer to the theoretical distribution as a result of possibly changing a particular answer based on a subsequent substantive analysis serves as a criterium for the selection of particular answers as being the most "suspicious" ones.
In the same manner that a method of the present invention can be used to teach a person how to efficiently pinpoint answers that are more likely, in comparison with other answers, to be incorrect at an actual test, it can also be used to help an examinee who is taking a practice exam to prepare for a real test. Thus, even during practice sessions it can help to pinpoint "suspicious" answers to be rechecked before looking up the correct answers. Used this way, the method of this invention both saves time and automatically forces test preparation to be more focused on those areas where a prospective examinee is weakest.
In accordance with another method of present invention the examinee can, for each test question and after all other means of elimination (including substantive analysis) are exhausted, detect which of the remaining possible answer-choices are more likely to be correct and which are more likely to be incorrect. This is also accomplished by a comparison of the theoretical and actual answer-choice distributions. Based on such comparison the examinee can be taught, at any time during the test, how to determine which answer-choices, if any, are over-represented and, where possible, further eliminate the over-represented answer-choices, if such elimination is not outweighed by the substantive analysis of the question. Further, the examinee can, at any time during the test, determine which answer-choices, if any, are under-represented and, if guessing is necessary, consider selecting as an answer-choice one of the under-represented answer-choices. By comparing the actual answer-choice distribution with the theoretical distribution and choosing those answers which tend to minimize this discrepancy, the examinee will be further improving his intelligent guessing strategy.
In employing this method of the present invention, it is useful to include in the answer summary an alternate group of answer-choices, for each question for which an examinee has selected an answer-choice, wherein this alternate group comprises those of the remaining possible answer-choices which the examinee is not reasonably able to determine to be incorrect. In this way the examinee can quickly search for under-represented answer-choices within the various groups of alternate answers.
Naturally, as the examinee continues to answer test questions more data will become available for entry into the answer summary and hence the answer tally. As the answer tally's data base is increased, the actual answer-choice distribution should increasingly match the expected answer-choice distribution thereby increasing the efficiency of the method of this invention. For this reason, the examinee should generally wait until he has answered a majority of the test questions before beginning any recheck procedure or using these methods to guess answers.
It should be pointed out, that the efficacy of the method of this invention depends on the extent of the examinee's familiarity with the subject matter of the test. In particular, the present invention facilitates the process of elimination and intelligent guessing, and by doing that, enables the examinee to be rewarded with partial credit for partial knowledge, and thus to get a better score in comparison with an examinee with no knowledge of a subject.
Many aspects of the above discussion are illustrated in FIG. 1 which is a block diagram of the essential sequence of processing followed in one embodiment of the method of the present invention. This processing sequence begins at Step S110 wherein the examinee begins to take a multiple-choice test. The examinee proceeds one question at a time. The examinee continues to answer each question, as indicated by Step S112, by selecting the answer-choice that he thinks is most likely to be correct. After answering a question, the examinee proceeds to Step S114 wherein he adds his selected answer-choice for that question to an answer summary. In this way, an answer summary is created and is continually updated after each question is answered. Step S116 involves a decision fork which directs the examinee to repeat the process until all of the questions are answered at which time the examinee is directed to proceed with Step S118. In Step S118, the examinee totals up the number of times each answer-choice appears in the answer summary so as to create an answer tally. This answer tally then comprises an occurrence number for each answer-choice (i.e. the total number of times each particular answer-choice occurs in the actual distribution) whereby the examinee can compare the theoretically expected distribution with the actual distribution and select an over-represented answer-choice (i.e. an answer-choice with the largest occurrence number) as indicated by Step S120. Finally, the examinee can now employ the recheck procedure of Step S122, in which he rechecks those questions for which he has previously selected as an answer-choice the most over-represented answer-choice.
Additional aspects of the present invention are illustrated by FIG. 2 which is a block diagram of the essential sequence of processing employing another embodiment of the method of the present invention. This processing sequence begins at Step S210 wherein the examinee begins to take a multiple-choice test. After the examinee answers the first question (Step S212) he updates an answer summary by including his selected answer-choice (Step S214). The examinee then proceeds to Step S216 wherein he increases the occurrence number corresponding to his selected answer-choice thereby updating an answer tally. In this way, both an answer summary and an answer tally are created and continually updated after each question is answered. In Step S218 we see that the most over-represented answer-choice is also updated after the answer summary and answer tally are updated.
Once these data bases are updated , the examinee proceeds to Step S220, in which he attempts to answer the next test question. In this step of the procedure, if the examinee has difficulty in selecting an answer-choice he should eliminate the most over-represented answer-choice and select his answer from the remaining answer-choices. The examinee then returns to Step S214 and repeats the process until he has finished answering all of the questions.
FIG. 3 is a block diagram of the essential sequence of processing employing yet another embodiment of the method of the present invention. Once again, in this example, the processing sequence begins at Step S310 wherein the examinee begins to take a multiple-choice test. After the examinee answers the first question (Step S312) he updates an answer summary by including his selected answer-choice in the answer summary (Step S314). The examinee then proceeds to Step S316 wherein he updates an amplified answer tally by (i) increasing the occurrence number corresponding to his selected answer-choice to that question, and by (ii) adding to the tally, for that question, an alternate group of answer-choices comprising those of the remaining possible answer-choices which said person was not reasonably able to determine to be incorrect in answering that question.
Additionally, the examinee (Step S318) updates his selection of the most over-represented and most under-represented answer-choice. In this way, both an answer summary and an answer tally are created and continually updated after each question is answered. In Step S320 the examinee proceeds to the next test question where once again tries to select the correct answer-choice. However, if he has difficulty in determining the correct answer, Step S320 provides for the examinee to employ an answer selection procedure. In this answer selection procedure the examinee will first eliminate as a possible answer-choice the most over-represented answer-choice. Then, if the examinee still has difficulty in determining the correct answer, he may consider selecting the most under-represented answer-choice as his best guess.
It should also be noted that, since the examinee has included in his answer tally an alternate group of answer-choices for each question, he may use this information to include a refined recheck procedure as part of this method. For example, when he is ready to recheck his answers, he may concentrate on rechecking only those questions in which his answer-choice is the most over-represented answer-choice and whose alternate group of answer-choices includes the most under-represented answer-choice.
We may further illustrate the procedures of the present invention by the following two specific examples.
EXAMPLE 1
This example illustrates how the concepts of over-represented and under-represented answer-choices can be applied in an actual test situation to help an examinee decide which questions he should give the highest priority in regards to rechecking his answers. In this example, we suppose that an examinee is taking a multiple-choice test in which the theoretical answer-choice distribution is random or uniform. Further, suppose that the test consists of 50 questions each having four different letter-choices ("A", "B", "C", and "D") as possible answers and that the examinee has already selected answer-choices for all 50 questions resulting in the following answer summary:
______________________________________1. B (A) 11. A 21. B 31. C (D) 41. D2. B B (A) 22. A A 32. B (D)3. A A13. A23. B 33. D (A)4. A (B, D) 14. A (B) 24. B (C) 34. B A 44.5. C (A) 15. C C25. D 35. D 45.6. C D (C) 26. A (B) 36. A (D) 46. A (C, D)7. A A17. C27. B 37. D 47.8. A D18. D28. D 38. B 48.9. D (B) 19. A C (B) 39. D A 49.10. B A (C) 30. A (C) 40. B A (B, C)______________________________________
This answer summary comprises, for each question for which the examinee has selected an answer-choice, (i) the selected answer-choice for that particular question and (ii) an alternate group of answer-choices comprising those of the remaining possible answer-choices which the examinee was not reasonably able to determine to be incorrect. In particular, the numbers refers to each of the 50 questions, the first letter following each number represents the examinee's answer-choice for that question, and whenever any letters appear in parentheses they represent an alternate group of probable answer-choices that the examinee was not reasonably able to determine to be incorrect. Based on this answer summary we can create the following answer tally: A: 20, B: 12, C: 7, D: 11.
This answer tally shows that the answer-choice WAN has occurred 20 times, the answer-choice "B" has occurred 12 times, etc. In this example, each answer-choice would be expected to occur approximately 12 or 13 times as the correct answer. Thus, it can be seen that the answer-choice "A" is the most over-represented. Therefore, those questions with the answer-choice "A" are more "suspect" than any other questions. Of these questions, those with probable alternative answer-choices shown in the parentheses should be examined in the first place. While examining such questions the most suspicious are those where the alternative answer-choice is "C", which is the most under-represented answer-choice. Therefore, the answers to questions 20, 30, 46, and 50 are the most "suspicious" and these questions should be selected for rechecking in the first place.
EXAMPLE 2
This example illustrates how the concepts of over-represented and under-represented answer-choices can be applied in an actual test situation to help an examinee select an answer-choice when he is not certain of the answer to a particular question. Here, we consider the same situation as in example 1, except that now we suppose that the examinee has only selected answer-choices for 45 of the 50 questions and has stopped at question 46 because he is not certain of the answer to that specific question. As in example 1, we suppose that during the test the examinee created an answer summary as follows:
______________________________________1. B 11. A 21. B 31. C 41. D2. B 12. B A22. 32. A B42.3. A 13. A A23. 33. B D43.4. A 14. A B24. 34. B A44.5. C 15. C C25. 35. D D45.6. C 16. D A26. 36. A 46.7. A 17. A C27. 37. B 47.8. A 18. D D28. 38. D 48.9. D 19. A C29. 39. D 49.10. B 20. A A30. 40. B 50.______________________________________
Again, the numbers refer to each of the 50 questions and letter following each number represents the examinee's answer-choice for that question. In this case however, we are not keeping track of any alternate possible answer-choices. Nevertheless, just as in the above example, based on this answer summary we can create the following answer tally: A: 17, B: 11, C: 7, D: 10.
If, for the purposes of this example, we assume that the examinee has ruled out answer-choice "B" based on the substantive analysis of the question, he will be left with just three possible answer-choices "A", "C", and "D". If the examinee must now "guess" the correct answer, he can improve his chances of being correct by applying the concepts of over-represented and under-represented answer-choices. In this case, of the three remaining answer-choices "A" is the most over-represented and should be eliminated prior to guessing, leaving the examinee with just two answer-choices, "C" and "D". Moreover, if the examinee is still unable to select an answer-choice, he should consider choosing the answer-choice "C" because it is the most under-represented answer-choice.
Thus, according to the above described illustrations and examples, a method of teaching a person how to detect suspicious answers on a multiple-choice examination has been disclosed. These examples have shown how the present invention allows an examinee, at the stage of rechecking his answers, to pinpoint those answers that are most likely to be incorrect, and, therefore, to spend the time left for rechecking most effectively by concentrating on these suspicious answers. These examples have also shown that the method of the present invention aids an examinee in eliminating from consideration answer-choices that are more likely, in comparison with other available answer-choices, to be incorrect.
It should be realized that in the above description, precise relationships shown may be altered in varying degrees while achieving the essential objectives of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art it is not desired to limit the invention to the exact realization and operation shown and described, and accordingly, all suitable modifications and equivalents are intended to be encompassed by the present invention, the scope of which is indicated by the appended claims.
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A method of teaching a person how to detect, while taking an actual or practice multiple-choice examination, answers that are more likely, in comparison with other answers, to be incorrect, is disclosed. This method aids an examinee in choosing those answers that are most suspicious of being in error and which should therefore be rechecked before any other answers. This method gives the examinee an opportunity to correct the suspect answers and to improve his or her score to the maximum extent possible according to the level of his or her knowledge within the constraints of existing time limitations. Moreover, in the case of a practice test, this method assures that test preparation will be more focused on those areas of the tested subject where the person is weakest. Additionally, a method of teaching a person how to eliminate, while answering a question on an actual or practice multiple-choice examination, answer-choices that are more likely, in comparison with other possible alternative answer-choices, to be incorrect, is disclosed. The method enhances the ability of an examinee to receive partial credit for partial knowledge and to obtain scores commensurate with his or her knowledge of the tested subject while discouraging blind guessing. Moreover, an educational game helpful for practicing skills useful for taking a multiple-choice test is disclosed.
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BACKGROUND OF THE INVENTION
In wire line operations, wire line retrieval and installation tools are commonly used. Most items which are installed in a tubing string are equipped with API standard fishing necks. A standard fishing neck normally includes an undercut shoulder to enable grappling by installation or retrieval tool. Quite often the API standard fishing neck will wear away so that only a stub pipe without an undercut shoulder is left. Retrieval of this sort of device is implemented by an overshot such as that manufactured by Bowen. A common drawback in the installation and retrieval tools of the past is the inability of the operator to undo the connection achieved by the tool. For instance, a wire line equipped with a Bowen overshot can be used to grasp a device installed in a tubing string in a fishing job. However, the device to be retrieved may sometimes stick and the wire line operator is unable to retrieve it on the wire line. A substantially heavier wire line may be required. The Bowen overshot is difficult to disconnect from the stub which it has engaged. Occasionally disconnection can be achieved by substantial jarring which will sometimes shear a pin. Reconstruction and reassembly of the tool at the surface is then required to repair the harm done by this step. Retrieving tools other than the named model suffer similar infirmities. Once they latch onto an item to be pulled or retrieved, substantial problems exist in selective downhole disconnection. Should a fishing job utilizing a certain weight of fishing equipment begin, it is almost impossible to disconnect the apparatus from the fish and substitute heavier equipment. As a consequence, retrieval of the fishing equipment itself compounds the problem.
The apparatus of the present invention is particularly adapted to overcome these difficulties. It can be used in a fishing job with various adaptors on the lower end to enable it to enable an API standard fishing neck, a worn fishing neck which then resembles a stub member, or an inside grappling job. In all these adaptations, the upper portion of the tool remain the same. The upper portion of the tool is able to be latched or actuated on a first jar. Should it be impossible to retrieve the fish in question, a second jar will release the fish so that the tool can be retrieved and a heavier gauge device be used.
SUMMARY OF THE INVENTION
The present invention is a wire line operated tool particularly adapted for use below a jar which incorporates an outer tubular body and an inner body. The outer body is movable in location relative to the inner body. Sliding movement of the tool actuates or reverses external and internal grapples on the lower end and a fishing neck retrieval mechanism. The tubular outer body is secured about the inner body by means of a catch mechanism. The catch mechanism has two positions, up and down. One is used to lock and the other is used to unlock the connected apparatus. The catch mechanism is preferably duplicated on opposite sides of the tool. The catch mechanism utilizes a pin on the interior of the tubular sleeve which projects inwardly into a groove which describes a closed circuit. A ball in the groove moves between selected positions to lock the pin in the up or down position.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the tool of the present invention installed with associated apparatus for running on a wire line;
FIG. 2 is an axial sectional view through the tool of the present invention particularly illustrating a catch mechanism cooperative with an outer sleeve and inner body;
FIG. 3 is a view similar to FIG. 2 contrasting the latched and unlatched position and particularly illustrating apparatus appended to the lower end which engages a fishing neck;
FIG. 4 is a detailed view of the pin and groove arrangement partly illustrated in FIG. 2 and illustrating alternative positions of the pin whereby the apparatus is latched in one of two positions;
FIG. 5 is a view similar to FIG. 4 showing a ball movable in the groove to deflect the pin to a locked position;
FIG. 6 is an alternative view showing an internal grapple mechanism; and,
FIG. 7 is a view similar to FIG. 6 showing an external grapple mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, the retrieval tool 10 is shown just above a fishing neck 11 to be retrieved. Other adaptations of the tool 10 will be described. It is connected to a threaded sub 12 which connects with a knuckle joint 13 which pivots, enabling a jar 14 to be connected thereabove. Suitable weights 15 are connected above the string of equipment. It is all adapted to be run on a wire line which connects with a wire line socket 16. The jar 14 sets and unsets the retrieval tool of the present invention. The weights 15 are helpful in running the apparatus on a wire line in a tubing string. The supportive apparatus shown is normally installed with the retrieval tool although variations in the rigging of the wire line equipment are readily accomplished.
In FIG. 2, a threaded sub 17 above a collar 18 enables the tool 10 to be joined to cooperative equipment. The collar 18 is above the neck 19 of reduced diameter. This provides a fishing neck in the event the tool 10 becomes disconnected with the cooperative apparatus. The neck 19 extends to an enlargement 20 connected to a threaded sub 21.
The sub 21 is threaded on its exterior and is joined to a tubular member 22. The outer tubular member 22 is of substantial length. It terminates at a set of threads 23 which engage a lower outer cylindrical member 24 which is of equal diameter of the outer annular member 22. The two members make up the exterior of the tool when they are threaded together. The member 24 can be removed. The tool 10 will be described as illustrated in FIG. 2, and alternative embodiments using a different sleeve attached at the threads 23 will be set forth.
The tubular member 24 provides an internal chamber where a spring 25 is positioned. The spring 25 is compressed, and bears against a solid member 26. The member 26 is generally cylindrical, although it is countersunk to receive the spring 25. The solid member 26 is threaded to or integrally formed with a set of flexible collet fingers 27. The collet fingers extend downwardly to pass over the fishing neck 11. The collet fingers extend substantially along a portion of the outer tubular sleeve 24. The collet fingers are preferably defined by uniformly spaced slots cut along the length of the tubular member which thereby defines the collet fingers. Each finger terminates at an internal enlargement 28. The enlargement 28 is undercut with an upwardly facing shoulder 29. The shoulder 29 is adapted to engage the downwardly facing shoulder on the fishing neck 11. The knuckle 28 tapers to a lower edge on its lower end. The knuckle 28 tapers to a thicker portion adjacent to the shoulder 29. This provides substantial metal in the collet fingers to engage and grasp the fishing neck 11.
The collet fingers 27 are parallel to one another and form lengthwise elements of a right cylinder. The sleeve 24 thereabout is concentrically arranged and is also a right cylinder. However, the lower end of the sleeve 24 is enlarged at 30 so as to define an internal tapering surface adjacent to the knuckles 28. The taper is about twelve degrees in the preferred embodiment although other taper angles can be utilized. The taper is gradual, and firmly engages the knuckles and forces them inwardly. In the up position of FIG. 2, the collet fingers 27 flex outwardly, thereby releasing the grasp of the tool 10 on the fishing neck 11. When the collet fingers move downwardly, the enlargement 30 contacts the knuckles 28 with the tapered surface which forces them inwardly, thereby mating the shoulder 29 against the cooperative shoulder of the fishing neck. Depth of penetration of the fishing neck in the position of FIG. 2 is limited by means of a cylindrical bumper 32. The bumper 32 is arranged near the upper end of the collet fingers.
Before completing a description of the tool shown in FIG. 2, it would be helpful to define the relative up and down positions. FIG. 2 illustrates the collet fingers 27 in the up position relative to the enlargement 30 which forces them inwardly. This is the release or engage position. In this position, the collet fingers are in their relaxed, outer position. They are unable to grasp the fishing neck 11. In contrast, FIG. 3 shows the collet fingers in the relative down position. The enlargement 30 which presents a tapered internal face forces the knuckles 28 radially inwardly toward the fishing neck 11. The shoulders lock beneath the fishing neck, thereby enabling retrieval of the fishing neck 11 and anything connected to it. FIG. 3 illustrates the relative down position, the retrieval position.
Returning to FIG. 2, the apparatus includes a catch mechanism which catches when the tool is in the up and down positions. The outer sleeve 22 supports a pin 34 which extends radially inwardly. Two identical catch mechanisms are shown. One will function adequately, or three can be used as desired. Symmetry of operation and enhanced strength is attained by duplicating the catch mechanism.
For a description of the catch mechanism 36, attention is directed to FIGS. 4 and 5. FIG. 4 is a partial face view of the exterior surface of the inner solid member 26, and includes the catch mechanism 36. A groove 37 which is parallel to the axis of the member 26 is cut in the face. The groove is sufficiently deep and wide to receive the pin 34 for lengthwise sliding movement. The groove 37 extends downwardly and deflects to the left at the portion 38. Another groove portion 39 is parallel to the groove 37. The groove portion 38 is parallel to another groove portion 40 which connects between the grooves 37 and 39. All of the grooves described in this juncture enable the pin 34 to move through the grooves.
A dead end groove portion 41 is shown in FIG. 4. It connects with the groove 39. Notweorthy, the grooves 39 and 41 are joined by an enlarged groove 42. The groove 42 is slightly wider than all the other grooves. It is wider to receive a locking ball 44. The ball 44 is limited in its movements to the groove 42. Its lowermost position is shown in FIG. 4 where locking ball 44 is in the downwardmost extent of the groove 42, and locks against a shoulder 45. The shoulder 45 catches the locking ball 44 but no other part of the mechanism described. The groove 42 extends to an upper locking shoulder 46. The shoulders 45 and 46 at the ends of the larger grooves 42 for catching the locking ball in the extremity of movement permitted to it. The ball 44 is normally found wedged against either the shoulder 45 or the shoulder 46.
The ball 44 is capable of moving to the upper shoulder 46 to lock against it. This is shown in FIG. 5. The pin 34 is also shown travelling into the groove 42. The ball is so located that the pin contacts it and is deflected to the left into the groove 41 which is a dead end. The groove 41 extends at an angle and the pin 34 is deflected at that angle into the groove 41 by the locking ball.
Viewing FIGS. 4 and 5 jointly, the pin 34 has only two permitted positions. The first is in the vertical groove 37. This coincides with the down position of FIG. 3. The pin 34 is also shown in FIG. 4 in sectional view in the dead end groove 41. This corresponds with the locked or up position of FIG. 2.
In FIGS. 4 and 5 jointly the path of the pin 34 is shown. It begins at some point in the vertical or lengthwise groove 37. When the oil jar or mechanical jar 14 above the tool is operated, the inertial upset relatively moves the outer sleeve 22 downwardly, carrying the pin 34 from the top dotted line position of FIG. 4 in the groove 37 all the way down to the groove 38. The momentum of movement of the parts is sufficient to cause the pin 34 to deflect at the angular groove 38. It moves to the bottom point of the groove 38. At this juncture, the extremes of movement have been accomplished. The pin 38 is constrained in movement. The spring 25 forces the solid member 26 relatively downward, or causes the pin 34 to move relatively upward as viewed in FIG. 4. It moves up in the groove 39. The ball 44 is in the down position, held there by gravity. The pin 34 moves in the groove 39 up against the ball. It is spring impelled in this movement. The ball 44 is quickly jammed against the upper shoulder 46. When it is jammed against that shoulder, the pin 34 continues its generally upward movement. It is limited in movement by the lock ball 44 and is deflected somewhat to the left by the round surface of the ball. When deflected to the left, it moves into the dead end groove 41. When it moves into this groove, it travels to the upper end of the groove 41 under the urging of the spring 25. It bangs against the upper end of the groove and is further limited in movement and remains there indefinitely. This is the position associated with the latched position of FIG. 3.
Later, the position of FIG. 2 is achieved as follows. The jar 14 is again operated. The inertial upset imparted to the tool forces the pin 34 downwardly in the passage or groove 41. At this time, however, the lock ball 44 is in the down position. When the pin 34 previously moved into the dead end groove 41, the ball 44 fell by gravity to the downmost position. The pin 34 moves along the passage 41 into the enlarged passage 42. After the inertial upset is terminated, the pin moves upwardly as viewed in FIG. 4. It encounters the shoulder defining the wall of the groove 40 and moves along the groove 40 back into the groove 37. It moves upwardly limited by the engagement of the tapered enlargement 30 at the lower end of the tool as shown in FIG. 3. The pin 34 does not move to the extreme upper end of the groove 37 because of this limitation. The position of the grasping mechanism on the fishing neck 11 shown in FIG. 3 is achieved when the pin 34 moves to the groove 37. Its upper travel is limited in this manner.
The groove 37 extends all the way to the upper end of the solid member 26 for ease of assembly. Separation of the parts by gravity is not permitted because of the action of the lower end of the tool as shown in FIG. 3.
From the foregoing, it will be understood how the apparatus described is able to grasp and release a fishing neck. Attention is next directed to FIG. 6 where a modified form of the tool is shown at 100. The threaded tubular member 24 is not modified. A new set of collet fingers 101 are incorporated. They do not include a single large shoulder 28, but rather several shoulders 102, 103 and 104 are included on each collet finger. When considering all of the collet fingers together, the interior describes a spiralling shoulder or helix thread. This is particularly adapted to engage a worn fishing neck, a cylindrical stub, or tubular member such as the one illustrated at 106. The several shoulders all cooperate to grasp the stub body 106. The taper 107 in the outer hollow tubular sleeve is perhaps longer to bring a greater portion of the collet fingers into contact with the worn fishing neck 106.
FIG. 7 shows an internal grapple mechanism. The solid tubular member 26 is joined to a solid lower member 121 in the tool 120. The internal grapple incorporates an external sleeve which is threaded to the upper sleeve 22. The external lower sleeve is cut into several collet fingers 122. The collet fingers collectively are externally threaded. Each collet finger carries several shoulders at 123, 124 and so on. The solid member 121 has a relatively long taper beneath the collet fingers. When the solid member 121 moves upwardly the collet fingers 122 are forced outwardly, enabling the internal grapple to grab and hold the interior of a pipe.
The tool of the present invention has been described with three connective tools appended to the lower end. The term connective tool refers to an apparatus which performs a downhole operation such as releasing or retrieval of an item with a fishing neck. It functions well in retrieval as illustrated. It is able to retrieve a fish of the sort which can be pulled free. In retrieval or fishing, it is uniquely able to engage the fish while enabling the user to pull on the wire line connected to the tool. The tool connects to the fishing neck and then releases it should a heaver line be required. Connection and release are achieved by jarring with sufficient impact or momentum to operate the catch means shown in FIGS. 4 and 5.
FIG. 7 is to be contrasted with the other drawings. The catch means, as that term is used in the claims, is inverted or upside down relative to the remainder of the tool. The catch means 200 includes a slot 201 which extends downwardly to the bottom of the solid tubular member 26. It is not necessary that it extend further. It extends to this location to enable the radially inwardly directed pin 34 to be inserted into it. The pin 34 is carried on the outer slidable tubular sleeve which terminates at the collet fingers 122. The pin is moved up through the longitudinal slot 201 on assembly of the outer tubular sleeve. The outer tubular sleeve would normally drop off the tool 120. It is kept on the tool by means of the tapered parts at the bottom which prevents the outer sleeve from sliding off the tool. It is forced downwardly by the spring at its upper end.
The pin 34 travels on a controlled route determined by the catch means. The dead end portion is found at 202. The groove has a closed route which includes the curved groove portion 203 which bends somewhat to the left. That groove portion communicates with a groove 204 which is deeper and wider, and is able to receive the lock ball 44 previously described. The lock ball is limited in travel to the deeper groove 203. It moves to the upper left to a blocking position forcing the pin 34 into the dead end groove 202. It moves by falling down and to the right, but it is not permitted to enter the longitudinal groove 201 because that groove is cut with a smaller profile. It has a more shallow depth and is more narrow.
The pin that travels into the dead end groove 203 emerges therefrom by traveling through the groove 205 and then to the groove portion 206. It is forced from the groove portion 206 downwardly into the groove 201. It travels somewhat downwardly in the groove 201 as viewed in FIG. 7 under urging of the spring, but it does not go to the bottom of that groove because the collet fingers 122 at the bottom engage the tapered mandrel 121 to stop downward movement of the outer tubular sleeve.
The cycle can be repeated indefinitely. The catch means of FIGS. 7 provides the pin with two stable locations, one in the dead end groove portion 202 and the other in the groove 201. It functions in a similar fashion to the catch means shown in other views.
The ball moves by gravity in the deeper groove 204. It moves to the left hand position where it is aligned with the dead end groove 202 and in a blocking position therefor, and it moves back to the top end of the groove 201, but it does not enter that groove as previously specified.
The catch means, as that term is used in the claims, refers to the mechanism which enables the body and surrounding mandrel to be guided in axial movement and limited to the two preferred operative positions. The two positions which are most significant are those associated with latching and unlatching, as illustrated in FIGS. 2 and 3. The latching and unlatching positions occur in any sequence. Thus, an installation job involves latching the tool 10 to a gas lift valve (as an example) at the surface which is then run into a tubing string. The valve is located and the tool 10 is unlatched and retrieved while leaving the valve in the tubing string.
A fishing job entails running the tool 10 into a tubing string to find a fish. It is jar-operated to latch onto the fish whereupon the tool and fish are both retrieved. In the event the fish is stuck and defies retrieval with the size of equipment used, the tool 10 is unlatched and retrieved. Even a third and heavier set can then be used.
The present invention thus is intended for use with downhole tasks which require latching and unlatching. The variety of downhole connective tools has not been exhausted. In particular, they include those which are slide action operated between the preferred two positions described in the foregoing description. While more modifications could be stated, the scope is determined by the claims which follow.
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A wire line oil tool adapted for multiple connectors on the bottom. It can be used as an overshot, a fishing neck grapple or an inside grapple. It incorporates an outer body which is annular about a central member. A catch mechanism locks the outer body up or down relative to the inner body. The catch mechanism enables the tool to operate on jarring. On jarring, the two parts move relatively to an up or down position. In the down position, the appendages at the bottom of the tool open to engage a fishing neck or the like. In the up position, it is latched or held. If retrieval of the tool is impeded, subsequent jarring will reverse the catch mechanism and release the fishing neck. The device is particularly adapted to be used on wire line retrieval and running operations. In the event an item is grasped which cannot be retrieved, subsequent jarring will achieve release and retrieval of the tool.
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BACKGROUND OF THE INVENTION
This invention relates generally to a fine mist sprayer having a reciprocable hollow piston stem on-which a fingertip actuated plunger is mounted for the pumping of fluid. Spin mechanics of some known type are provided for imparting a spin or swirl at a given velocity for issuance through the discharge orifice as a fine mist spray having a predetermined spray cone.
More particularly, the invention relates to a means establishing a second fluid flow path for diverting some of the fluid from the discharge passage to the spin mechanics to negate some of the spin velocity and thereby cause the spray to issue as a narrower spray cone. The second fluid path may be selectively opened and closed to regulate the size of the spray cone.
Known pump sprayers typically have some type of spin mechanics for imparting a spin or swirl to the fluid at a given velocity to issue through the discharge orifice as a fine mist spray which breaks up in the atmosphere in the form of a divergent spray cone of given size. For this purpose an orifice cup has a spin cheer coaxial with the discharge orifice, and tangential channels lead into the spin cheer. Longitudinal channels leading to the tangentials are formed between a post or a probe and the surrounding orifice cup to establish a flow path from the discharge passage formed in the hollow piston stem. The orifice cup and probe are mounted within a plunger head coupled to the stem for reciprocation of the stem upon manual depression of the head.
For certain applications it is desirable to provide a narrower spray cone using the existing spin mechanics structure, the less divergent spray cone satisfying the need for reducing the area of spray against a target of a given size to be wetted during pumping operation.
Also, it would be beneficial to selectively vary the size of the spray cone in a simple and efficient manner using existing spray mechanics without complicating the structure and avoiding the need for additional molded parts.
SUMMARY OF THE INVENTION
An object of the invention is to provide an improved fine mist sprayer capable of issuing a less divergent, narrower spray compared to the conventional sprayer in a simple and efficient yet highly effective manner by negating some of the tangential velocity imparted to the fluid at the discharge orifice.
In accordance with this general objective the spinner probe of a conventional fingertip sprayer has a through opening communicating with the stem discharge passage via an opening provided in the stem to establish a second fluid flow path to the downstream end of the tangentials at the spin cheer. Fluid from the discharge passage flows through a first fluid path in a conventional manner and swirls at a given velocity in the swirl chamber. Some of the fluid is diverted from the discharge passage into the second fluid flow path to negate some of the swirl velocity at the swirl chamber thereby causing the spray to issue from the orifice in a narrower, more divergent spray cone.
The plunger head may be rotated about the stem between a position misaligning the probe and stem openings for directing fluid through only the first fluid path to produce a normal fine mist spray of a given spin velocity, and a position aligning the probe and stem openings for directing fluid from the discharge passage through both fluid flow paths to produce a fluid spray of a reduced velocity and a narrower spray plume.
Cooperating means acting between the stem and a closure for the pump sprayer resists rotation of the stem upon head rotation.
Stop means acting between the piston stem and the plunger head limit head rotation to the misaligned and aligned positions.
And, limit stops on the head and/or the closure may be provided for limiting the reciprocation travel of the stem to thereby limit the output of the sprayer.
Other objects, advantages and novel features of the invention will become more apparent from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary vertical sectional view of a fine mist sprayer incorporating the present invention;
FIG. 2 is a fragmentary vertical sectional view of the modified piston stem of FIG. 1;
FIG. 3 is a view taken substantially along the line 3--3 of FIG. 1;
FIG. 4 is a view taken substantially along the line 4--4 of FIG. 1;
FIG. 5 is a view taken substantially along the line 5--5 of FIG. 1;
FIG. 6 is a view similar to FIG. 5 showing the plunger head rotated relative to the piston stem;
FIG. 7 is a fragmentary view of the upper end of the piston end showing one embodiment of an opening provided in the stem; and
FIG. 8 is a view similar to FIG. 7 showing another embodiment of an opening provided at the upper end of the piston stem.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings wherein like reference characters refer to like and corresponding parts throughout the several views, the pump sprayer is generally designated 10 in FIG. 1 as having a container closure 11 for mounting the sprayer on a container (not shown) of liquid product to be sprayed upon pumping.
Hollow stem 12 of the pump piston extends through a central opening in crown portion 13 of the closure for reciprocation within a pump cylinder (not shown) in the normal manner. A plunger head 14 is mounted on the stem to effect piston reciprocation upon application of a downward finger force applied to finger pad 15 of the plunger head against the spring bias of the piston return spring (not shown).
The hollow piston stem defines a fluid discharge passage 16 which communicates at its upper end with a lateral pathway 17 in head 14.
The head includes a laterally extending spinner probe 18 surrounded by an orifice cup 19 having a coaxial discharge orifice 21.
The inner front face of the orifice cup is provided with some type of known spin mechanics including a plurality of tangential channels 22 (only one shown in FIG. 1) terminating at the downstream end thereof in a central spin or swirl chamber 23. Longitudinal channels 24 formed between the orifice cup and probe 18 communicate with tangential channels 22 and form a first fluid path together with an annular opening 25 and lateral pathway 17, such path communicating with passage 16. The aforedescribed structure of spin mechanics and first fluid path is set forth in more detail in U.S. Pat. No. 4,074,861, commonly owned herewith.
During pumping operation product is discharged through passage 16 and the first fluid path as a fine mist spray via the spin mechanics which impart a swirl or spin to the fluid at a given velocity for issuance through the discharge orifice where the swirling particles break up in the atmosphere diverging as a spray cone or plume of a given conical size.
According to the invention some of the spin velocity is negated to produce a more narrow spray cone. This is effected by the provision of an opening 26 in probe 18 extending from the downstream end of the tangentials 22 at spin chamber 23 and terminating at piston stem 12. The piston stem is provided with at least one opening 27 which, in the FIGS. 1 and 5 position, is in alignment with opening 26 to establish a second fluid path communicating with passage 16.
During pumping upon reciprocation of the plunger in its relative position to the piston stem shown in FIGS. 1 and 5, fluid is discharged through passage 16 and through the first fluid flow path 17, 25, 24 as it is swirled in chamber 23 at a given velocity. And, during such pumping operation, some of the fluid is diverted from passage 16 into the second fluid path 27, 26 for negating some of the tangential velocity occurring in chamber 23 to effect a discharge of fluid through orifice 21 as a divergent spray having a cone size more narrow than the size of a spray cone produced by the pumping of fluid only through passage 16 and the first fluid flow path.
When the plunger head is rotated about the stem from its FIG. 5 position at which openings 26 and 27 are in alignment, to its FIG. 6 position at which openings 26 and 27 are out of alignment, any diversion of fluid through the second fluid flow path is blocked such that the discharge of fluid passes only through the first fluid flow path for issuing as a divergent spray having a normal cone size determined by the full spin velocity imparted to the fluid by the tangential channels.
To resist rotation of stem 12 upon plunger head rotation, the stem has one or more (three being illustrated in FIG. 3) external longitudinal ribs 28 of a given configuration mating with longitudinal grooves 29 (FIG. 4) of a corresponding shape located in central sleeve 30 which depends from crown piston 13 of closure 11.
And, limit stops are provided for limiting relative rotation of the plunger head between its FIG. 5 and its FIG. 6 positions. Such limit stops may be in the form of equally spaced lugs 31 extending radially inwardly from wall 32 of inner skirt 33 of the plunger head. The upper ends of ribs 28 of the stem contact one side of lugs 31 in the FIG. 5 position, and contact the other side of lugs 31 in the plunger head rotative position of FIG. 6.
It is to be noted that other openings 27A and 27B are provided at the upper end of stem 12 although only opening 27 in the illustration is aligned and misaligned with opening 26 upon plunger head rotation. Openings 27, 27A and 27B are equally spaced, and openings 27A and 27B are provided for facilitating the sub-assembly of the plunger head and the piston stem without the need for indexing. Thus, with three openings 27, three lugs 31 and three ribs 28, the plunger head can be initially oriented during assembly with the piston stem in the FIG. 5 or in the FIG. 6 position without the need for complicated indexing.
As seen in FIG. 7, each opening 27 may be in the form of an open notch having spaced, parallel side edges. Otherwise, an opening 33 may be formed at the upper end of the plunger stem which, as shown in FIG. 8, has a sloping bottom wall 34 to effect a partial blocking and unblocking of opening 26 upon relative head rotation. Thus, with the FIG. 8 embodiment, the second fluid flow path can be placed in service between a totally blocked position and a gradually open position for varying the spray cone within a range of that achieved by relative head rotation between a fully aligned FIG. 5 position and the fully misaligned FIG. 6 position.
Another feature according to the invention is the provision of limit stops for limiting stem reciprocation to thereby meter the volume of spray out of the orifice. For this purpose, depending lugs 35 may be provided on skirt 33 and/or upstanding legs 36 on crown portion 13 of closure 11. Lugs 35, if oriented to axially align with lugs 36, will bear against legs 36 at the end of the downward travel of the plunger head to thereby limit piston reciprocation and thereby meter the amount of discharge from the sprayer. If only lugs 35 are provided they will simply impact against crown portion 13 to limit the downward travel of the plunger head and piston. And, if only legs 36 are provided they will impact against the underside of sleeve 33 to limit downward travel of the plunger head and piston.
Obviously, many other modifications and variations of the invention are made possible in the light of the above teachings. For example, spin mechanics other than that illustrated and described can be provided within the scope of the invention. And, means other than ribs and grooves 28 and 29 could be provided for resisting stem rotation upon plunger rotation.
It is therefore to be understood that the invention may be practiced otherwise than as specifically described.
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A sprayer has a spray pattern which can be varied by the provision of a second fluid flow path which partially negates the spin velocity to produce a spray having a narrow spray cone producing spray. An opening in the spinner probe establishes the second fluid flow path from the discharge passage, and can be selectively opened and closed upon plunger rotation relative to a hollow piston stem.
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This application is a National Stage Application of PCT/FI2010/050684, filed 2 Sep. 2010, which claims benefit of Serial No. 20095911, filed 4 Sep. 2009 in Finland and which applications are incorporated herein by reference. To the extent appropriate, a claim of priority is made to each of the above disclosed applications.
FIELD OF THE INVENTION
The present invention relates to sensing technology and display technology. Especially the present invention relates to touch screens on displays, and methods for manufacturing touch screens on displays.
BACKGROUND OF THE INVENTION
Touch screens are emerging as a popular means to interact with an electronic device. Touch screens can be mechanically mated with many different display types, such as cathode ray tubes (CRTs), liquid crystal displays (LCDs), plasma displays, electroluminescent displays, or displays used for electronic paper, such as electrophoretic displays. Many touch screens operate on the principle that when the screen is touched the touch changes an electrical property, such as capacitance or resistance, in a specific location of the touch screen. An electrical signal corresponding to the location of the touch can then be read in a controller unit, to control the operation of a device connected to, for instance, a display. Based on what electrical property is affected by the touch, such touch screens are commonly categorized as e.g. capacitive touch screens or resistive touch screens.
Such touch screens rely on one or more conductive transparent layers, commonly films such as indium tin oxide (ITO) thin-films, as part of an electrical circuit whose capacitance or resistance is modified in a specific location by the touch. The conductive transparent films in known touch screen structures are deposited on a supporting substrate which must be of suitable material to enable a transparent conductive film with good optical and electrical quality to be grown or deposited.
The display devices of the prior art are typically protected by a transparent layer from the viewing side of the display (see e.g. U.S. Pat. No. 5,688,551). These protective transparent layers may be of e.g. glass or of other material, suitable for mechanically and/or chemically protecting the display and/or for supporting a transparent electrode necessary for the operation of the display. As the thin transparent film of the touch screen requires a specific substrate to be deposited on, the touch screen is fabricated as a separate module which is added and aligned on top of the display module, to form a touch display. The separate manufacturing of the touch screen module enables a suitable substrate to be chosen for the transparent conductive film (or several films) of the touch screen.
In addition to the structural support provided by the substrate a conductive transparent film commonly also requires chemical and/or physical protection from one or both sides of the film. This type of encapsulation is required to protect the potentially sensitive transparent conductive film against, for instance, water and/or oxygen or against physical damage (e.g. scratching or bending). Thus the touch screen module adds additional layers through which the image of the display must be viewed.
Due to the added optical thickness of the touch screen module, touch screens, as implemented in touch displays of the prior art, significantly degrade the optical quality/usability of the touch display. This degradation is especially detrimental in touch displays used for e-paper, such as electrophoretic (EPD) displays, which are intended to mimic the appearance of a conventional paper. On displays used for e-paper a touch screen of the prior art destroys one of the key advantages of the display; that the image appears at the surface like in traditional paper and is thus easy and comfortable to view. This disadvantageous effect of conventional touch screen structures causes a particularly unpleasant appearance for the display from wide viewing angles, i.e. when the viewing direction is far away from the direction perpendicular to the plane of the display, and in conditions that would cause high glare and/or reflection in traditional emissive displays such as LCD-displays or OLED-displays. The traditional touch screen module solution, on the other hand, gives the user the sensation of reading the e-paper through a piece of glass which is uncomfortable and unnatural to the user.
Prior art discloses some structures which attempt to integrate the touch screen to a display. E.g. U.S. Pat. No. 5,852,487 discloses a resistive touch screen on a liquid crystal display (LCD), and U.S. Pat. No. 6,177,918 discloses a touch display having the touch screen fabricated on the same side of a common substrate with the display device.
Drawbacks of the structures disclosed in U.S. Pat. No. 5,852,487 include the strict requirements for the common substrate so that the substrate would enable electrode films with suitable optical and electrical properties to be fabricated on both sides of the common substrate. The publication even suggests an approach in which the substrate between the touch screen and the display is formed by laminating separate substrates for the touch screen and the display together, after the touch screen module and the display module have been separately fabricated on their dedicated substrates.
The structures disclosed in U.S. Pat. No. 6,177,918 on the other hand requires a specific arrangement between pixels of the display and the signal generating layer of the touch screen so that the display and the touch screen could be fabricated on the same side of a common substrate. Furthermore, strict material requirements for the substrates of the transparent conductive films still remain in the structures disclosed in this publication.
There exists a need for non-complicated reliable methods and device structures that allow a touch screen to be fabricated on a display such that the optical quality of the image and readability of the display are not compromised by the touch screen.
PURPOSE OF THE INVENTION
A purpose of the present invention is to reduce the aforementioned technical problems of the prior-art by providing a new type of touch screen structure on a display and a new type of method for manufacturing a touch screen structure on a display.
SUMMARY OF THE INVENTION
A product according to the present invention is a touch screen on a display device having an upper substrate for protecting the display device from the environment, the touch screen comprising an electrically conductive transparent first layer. The first layer comprises a network of electrically conductive high aspect ratio molecular structures (HARM-structures), the first layer being embedded into the upper substrate of the display device to protect the conductive transparent first layer, for reducing the optical thickness of the structure between a viewer and the region of the display device in which the image is formed.
A method according to the present invention, for manufacturing a touch screen on a display device having an upper substrate for protecting the display device from the environment, comprises the steps of depositing an electrically conductive transparent first layer comprising a network of electrically conductive high aspect ratio molecular structures (HARM-structures) on the upper substrate of the display device in contact with the upper substrate, and pressing the first layer against the upper substrate, to embed the first layer into the upper substrate, for reducing the optical thickness of the structure between a viewer and the region of the display device in which the image is formed.
In this context the expression “transparent” should be understood as essentially transparent for visible light, preferably transmitting more than 50%, more preferably more than 80% and most preferably more than 90% of visible light. It will however be obvious for a skilled person that “transparent” layers transmitting even less than 50% of visible light can also be used, without departing from the scope of the invention.
Electrically conductive high aspect ratio molecular structures (HARM-structures), e.g. carbon nanotubes (CNTs), carbon nanobuds (CNBs), metal nanowires or carbon nanoribbons, form electrically conductive paths when the HARM-structures are deposited on a substrate. The HARM-structures do not form a film of continuous material, such as e.g. ITO, but rather a network of electrically interconnected molecules. Hence, the properties of the network of HARM-structures are not markedly sensitive to the properties of the substrate, and the substrate material can be relatively freely chosen as long as the substrate can sustain the conditions of the deposition environment. Therefore the network of HARM-structures can be deposited directly on the outer surface of the display device, which in this context is called the upper substrate.
Depositing the first layer on the upper substrate of the display device, such that the first layer resides in contact with the upper substrate, removes the need for using a dedicated substrate for depositing the first layer. This results in an optically thin design for the touch screen on the display, which improves the readability of the display under the touch screen and, therefore, the usability of the touch display. It furthermore simplifies the design and fabrication process of the whole structure as the touch screen can now be directly fabricated on the display device with good electrical and optical quality. Mechanical durability of networks of HARM-structures also results in additional advantages for the end product and enables more reliable manufacturing of the touch display. Moreover, as networks of HARM-structures need not be continuous to be conductive throughout the area of the network, as opposed to e.g. films of metal oxides such as ITO, the deposited networks of HARM-structures can be exceptionally thin while being mechanically and electrically robust. This enables the deposition of very thin networks of HARM-structures with good electrical and mechanical properties for touch screen applications, which increases transparency of the touch screen structure and thereby improves the quality of the image through the touch screen, as experienced by the user.
In one embodiment of the present invention the upper substrate is made of polymer.
In the present invention the first layer is embedded into the upper substrate to protect the conductive transparent first layer.
In yet another embodiment of the present invention the method comprises the step of applying heat to the upper substrate before and/or when pressing the first layer against the upper substrate, to embed the first layer into the upper substrate.
In one embodiment of the present invention the step of pressing the first layer against the upper substrate comprises mechanical compression or thermo-compression. In one embodiment of the present invention the mechanical compression comprises pressing without heating the upper substrate. In one embodiment of the present invention the thermo-compression comprises the use pressing and heating in order to embed the first layer into the upper substrate.
In one embodiment of the present invention the touch screen is a capacitive touch screen. In another embodiment of the present invention the touch screen is a projective capacitive touch screen.
In one embodiment of the present invention the display device is electronic paper. In another embodiment of the present invention the display device is an electrophoretic display.
An additional benefit in some embodiments of the invention is that the first layer, i.e. the network of HARM-structures, can be protected from the environment by embedding the network into the upper substrate of the display device. A network of interconnected HARM-structures is flexible and mechanically durable. This enables embedding the network of HARM-structures into the upper substrate by e.g. thermo-compression. In thermo-compression the upper substrate, which can be of e.g. polymer, is first softened by thermal treatment and subsequently the network of HARM-structures is pressed against the softened upper substrate to transfer the first layer into the upper substrate. When the first layer is encapsulated in the upper substrate in some embodiments of the invention, there is no longer a need to apply additional protective coatings on or under the first layer, which enables touch screen structures with small optical thickness to be fabricated. This further improves the readability and optical quality/usability of the touch display.
In capacitive touch screens it is beneficial, and often necessary, to protect the conductive transparent layer responsible for generating the touch-dependent electrical signal, from both sides of the layer or in a matrix of protective material. Furthermore, when the capacitive touch screen is e.g. of the projective type, the transparent conductive layers are patterned. Patterned layers are especially sensitive to e.g. mechanical or thermal disturbances, which is why their protection is important. Therefore the advantages of the present invention become pronounced in capacitive and projective capacitive touch screens.
Displays which are used for electronic paper applications such as electrophoretic displays attempt to mimic the optical appearance of conventional paper, which is why touch screen modules used on these displays should have as small an optical thickness as possible. Therefore the touch screen structure of the present invention is especially suitable for electrophoretic displays or other displays for electronic paper applications where a small optical thickness for the touch screen structure is desired or even required.
In one embodiment of the present invention the network of high aspect ratio molecular structures (HARM-structures) is a network of carbon nanotubes. In one embodiment of the present invention the network of high aspect ratio molecular structures (HARM-structures) is a network of carbon nanobud molecules having a fullerene molecule covalently bonded to the side of a tubular carbon molecule. Carbon nanotubes (CNTs) and carbon nanobuds (CNBs) are examples of HARM-structures which, when deposited on a substrate, can form a mechanically flexible and durable network which is electrically very conductive even when the deposit is very thin and transparent. Therefore these HARM-structures are well suited for the conductive transparent layers employed in touch screens. Networks of CNTs or CNBs furthermore possess a low refractive index which adds to their potential applicability to touch screens with a small optical thickness. Networks of CNTs or CNBs also exhibit a high charge storage capacity. This additional advantage, with the good electrical conductivity, can be put to use in capacitive and projective capacitive touch screens, to enable shorter response times for registering a touch on the touch screen.
In one embodiment of the invention the touch screen comprises a top substrate layer on the first layer, to protect the first layer from the environment. Under harsh operating conditions where the touch screen becomes exposed to e.g. large temperature variations, a chemically aggressive environment or repeated mechanical stress a top substrate layer may be utilized to provide additional protection for the first layer even when the first layer is embedded into the upper substrate of the display device.
The embodiments of the invention described hereinbefore may be used in any combination with each other. Several of the embodiments may be combined together to form a further embodiment of the invention. A product or a method, to which the invention is related, may comprise at least one of the embodiments of the invention described hereinbefore.
DETAILED DESCRIPTION OF THE INVENTION
In the following, the present invention will be described in more detail with exemplary embodiments by referring to the accompanying figures, in which
FIG. 1 is a schematic illustration of a touch display of the prior art,
FIG. 2 is a schematic illustration of a touch screen on a display, according to one embodiment of the invention,
FIG. 3 is a schematic illustration of a touch screen on a display, according to another embodiment of the invention,
FIG. 4 is a schematic illustration of a touch screen on a display, according to yet another embodiment of the invention,
FIG. 5 is a flow-chart illustration of a method to integrate the first layer into the upper substrate according to one embodiment of the invention,
FIG. 6 is a schematic illustration of a touch screen on a display, according to another embodiment of the invention,
FIG. 7 is a schematic illustration of a touch screen on a display, according to yet another embodiment of the invention, and
FIG. 8 is a schematic illustration of a touch screen on a display, according to yet another embodiment of the invention.
The typical projective capacitive touch display of FIG. 1 comprises a display module 1 and a touch screen module 13 laminated on the display module 1 . The display module 1 comprises a backbone 2 providing e.g. driving electronics and a substrate for the display module 1 . The display module 1 further comprises first electrodes 4 on the backbone 2 , picture elements 6 for generating the image of the display module 1 , second electrodes 8 which are transparent, on the picture elements 6 , an electrical power source connected to the picture elements 6 , and a first control cable 10 to feed the image control signal to the second electrodes 8 to selectively activate picture elements 6 . The second electrodes 8 , which may comprise a network of HARMs, and/or a transparent conductive film, are covered with a protective upper substrate 12 , which can be of e.g. glass or polymer.
The typical projective capacitive touch screen module 13 of FIG. 1 comprises two transparent substrates 14 , 20 (e.g. glass) which are laminated together, each substrate 14 , 20 having a patterned transparent conductive coating which together form a conductive transparent first layer 16 in between the two transparent substrates 14 , 20 . This first layer 16 is the touch-sensitive element of the touch screen module 13 and is connected to a control unit (not shown) via a second control cable 18 .
Sensitivity of the first layer 16 to a touch on the surface of the top substrate layer 20 is achieved by the patterned conductive coatings (electrodes) of the touch sensitive first layer 16 . These patterned coatings are fabricated from a thin film by patterning conductive transparent material such as e.g. ITO (indium tin oxide), FTO (fluorine tin oxide) or ATO (antimony tin oxide). Conductive traces (e.g. silver, copper or gold) are typically used to couple the patterned ITO, FTO or ATO film to the control unit via the second control cable 18 . The underside of the top substrate layer 20 may e.g. have horizontal Y-measuring electrodes while the top surface of the bottom substrate 14 has vertical X-measuring electrodes. The X- and the Y-electrodes together form the first layer 16 . The Y-measuring electrodes can be patterned e.g. in such a way as to minimize shielding of the X-electrodes from a touching element (e.g. a tip of a finger) which touches the touch screen module 13 on the surface of the top substrate layer 20 . Thus, in this configuration, the X and Y-electrodes are contained within the same plane. Various ways of patterning the electrodes in the touch sensitive first layer 16 are known from the prior art. In the projective capacitive touch screen of FIG. 1 , when a conductive surface, such as the tip of a finger, is brought close to, or in contact with, the top substrate layer 20 , a position-dependent perturbation in the capacitances of an RC-circuit comprising the X- and Y-electrodes is registered, and an electrical signal corresponding to the location of the touch is conveyed to the control unit (not shown) via the second control cable 18 .
Conventionally, when a touch screen is used on a display, the touch screen module 13 is placed over the display module 1 , above the upper substrate 12 through which light is emitted, and the two modules 1 , 13 are held together by a mechanical mounting means (e.g. by a frame-like construction). The display module 1 in FIG. 1 can be e.g. an LCD, a plasma display, an OLED display, an electrophoretic display, or any other display which is capable of supporting and interacting with a touch screen. The backbone 2 of the display module 1 then comprises the necessary components to drive the specific display type, e.g. power converters, backlight sources and supporting structures.
The thickness and materials in the substrates 12 , 14 , 20 and the first layer 16 can degrade the quality of the image as it passes through the structure towards the viewer. When light passes from the underlying picture elements 6 through the touch screen module 13 , the light experiences changes in the refractive index. Some light is absorbed, some light is refracted, some light is transmitted, and some light is reflected. This degrades readability, brightness, sharpness and other optical properties of the image as generated by the picture elements 6 , in the touch display of the prior art presented in FIG. 1 .
For reasons of simplicity, item numbers will be maintained in the following exemplary embodiments in the case of repeating components.
FIG. 2 presents a touch display according to one embodiment of the invention, where the touch sensitive first layer 16 is a network of HARM-structures, e.g. CNTs, nanowires, nanoribbons or CNBs, which has been patterned to incorporate the X- and the Y-electrodes. As discussed, the HARM-structures, such as CNTs or CNBs, do not grow as a film of material on a substrate, but rather as a network of molecules, and hence do not impose specific limitations on the substrate material onto which the network is deposited or on the thickness of the network of HARM-structures. Therefore the first layer 16 can be deposited directly onto the upper substrate 12 of the display module 1 to the desired layer thickness, which results in a small optical thickness for the touch screen structure. This is contrary to the touch screen structures of the prior art where the ITO, FTO or ATO films, deposited by e.g. common thin-film deposition methods such as CVD, PVD or ALD, must be grown on a substrate of specific material so that the films have good optical and electrical quality.
The thin touch screen module 13 of FIG. 2 is less visible to the user and thus enhances the performance of the display/touch screen combination. Networks of CNTs and CNBs furthermore have a low index of refraction, which adds to the advantageous reduction in the optical thickness of the touch screen module 13 .
The touch display of FIG. 2 according to one embodiment of the invention can be fabricated by depositing and patterning the first electrodes 4 on the backbone 2 of an electrophoretic display (EPD). This can be done by conventional thin-film deposition and lithographic methods. Next, a liquid polymer layer containing e-ink capsules is deposited on the first electrodes to form the picture elements 6 and transparent second electrodes 8 are formed on the picture elements 6 . The first 4 and the second 8 electrodes are connected to an electrical power source which generates an electric field between the electrodes. The electric field over each individual picture element is controlled by the first control cable 10 , which is attached to the control unit (not shown) controlling the voltage of each individual second electrode 8 . A protective upper substrate 12 made of polymer is assembled on the second electrodes 8 . The touch sensitive first layer 16 of the touch screen module 13 can be deposited directly and patterned on the upper substrate 12 at many alternative stages of the process flow. The first layer 16 can be e.g. deposited before or after the upper substrate 12 is assembled to the display module 1 . Correspondingly, the top substrate layer 20 can be assembled on the first layer 16 before or after the upper substrate 12 is assembled to the display module 1 . In another embodiment of the invention the first layer 16 can also be deposited on the top substrate layer 20 first, and subsequently the first layer 16 residing on the substrate layer 20 can be deposited in contact with the upper substrate 12 which is already assembled onto the display module 1 . The top substrate layer 20 is used to mechanically support the underlying structure and to protect the first layer 16 e.g. mechanically and chemically from the environment.
Details of a gas-phase synthesis process for HARM-structures and a process which can be used to deposit a network of CNTs (or CNBs) on a substrate are disclosed in e.g. patent application publications WO2005/085130, WO2007/101906 and WO2007/101907 which are included as references herein. Details of a patterning process to pattern a network of HARM-structures are disclosed in patent application publication WO2009/000969 which is included as a reference herein.
According to some embodiments of the present invention the processes disclosed in the references above can be employed to fabricate the patterned X-electrodes and the Y-electrodes comprising the HARM-structures in the first layer 16 . Electrical connection of the second control cable 18 to the HARM-structures of the first layer 16 (formed of e.g. CNTs or CNBs) can be accomplished with methods known from the prior art and these methods are obvious for a skilled person. Such methods are discussed in e.g. patent application publication US2005/0148174, which is included as a reference herein.
As an example of how to deposit the network of HARM-structures on the upper substrate 12 according to one embodiment of the invention, SWCNTs (single walled carbon nanotubes) were synthesized in an aerosol laminar flow (floating catalyst) reactor using carbon monoxide and ferrocene as a carbon source and a catalyst precursor, respectively. SWCNT mats were then collected directly from the gas phase downstream of the reactor by filtering through a 2.45 cm diameter nitrocellulose (or silver) disk filters (Millipore Corp, USA). The filter, in this embodiment, takes the role of a preliminary substrate. The deposition temperature on the filter surface (preliminary substrate) was measured to be 45° C. The layer thickness of SWCNT networks formed on the preliminary substrate was controlled by the deposition time, which could be altered from a few minutes to several hours depending on the desired network thickness. In this way, networks of SWCNTs of different thicknesses were obtained on the preliminary substrate, and measurement results showed that the deposits were randomly oriented networks of SWCNTs. Subsequently, in this embodiment of the invention, physical compression and heating (thermo-compression) was used to transfer the SWCNT networks from the preliminary substrate onto the upper substrate 12 . Thermo-compression was carried out by applying a force between two parallel heated plates between which the preliminary substrate and the upper substrate 12 were placed, such that the network of SWCNTs was sandwiched in between the preliminary substrate and the upper substrate 12 . The heated compression plates naturally also caused heating of the preliminary substrate, the SWCNT-network, and upper substrate 12 .
As an example, SWCNT networks were transferred to 10 μm thick medium-density polyethylene (PE) polymer films (MetsäTissue Ltd, Finland), which served the purpose of the upper substrate 12 . This material is flexible, optically essentially transparent, has a melting temperature t m of about 125° C. and a glass transition temperature t g of about −125° C. After thermo-compression, the preliminary substrate was removed from contact with the SWCNT-network. Finally, the transferred network of SWCNTs was densified on the upper substrate 12 by an intercalation material (ethanol or water), to form the first layer 16 .
To evaluate optical transparency of the SWCNT networks, an uncoated polymer film was used as a reference. The transparency of the SWCNT networks deposited onto the polymer film varied from approximately 60% to 95% for a CNT network having a thickness ranging from 500 to 24 nm, respectively.
In the embodiment of the invention presented in FIG. 3 the touch sensitive first layer 16 is embedded into an upper substrate 12 (made of polymer) of the display module 1 . Embedding the first layer 16 diminishes the need to have an additional protective top substrate layer 20 or a separate encapsulation layer to protect the touch sensitive first layer 16 , as the touch sensitive electrodes of the first layer 16 are protected and encapsulated in this embodiment of the invention by the upper substrate 12 . This structure results in a further decrease in the optical thickness of the touch screen and thereby improves the readability and usability of the touch display. Although the first layer 16 is well protected by the upper substrate 12 into which the first layer 16 is embedded, under harsh operating condition there may still exist a need for additional protection. Where the touch screen becomes exposed to e.g. large temperature variations, a chemically aggressive environment or repeated mechanical stress, a top substrate layer 20 may be deposited on the first layer 16 to provide additional protection for the first layer 16 . This embodiment of the invention is presented schematically in FIG. 4 . The embedded structure of FIG. 3 or FIG. 4 is difficult to achieve with transparent conductive materials other than a network of HARM-structures in the touch sensitive first layer 16 . Examples of these other materials include conductive polymers and the films of metal oxides mentioned above.
The first layer 16 comprising the network of HARM-structures, e.g. CNTs or CNBs, can be embedded directly into the upper substrate 12 of the EPD display module (or any other suitable display module) by e.g. thermo-compression. The details of a thermo-compression method were discussed above and can also be found in patent application publication WO2009/000969 which is included as a reference herein.
To enable the integration of the first layer 16 into the upper substrate 12 according to FIG. 3 or FIG. 4 the first layer 16 is first deposited onto the upper substrate 12 from the preliminary substrate e.g. as discussed above. After removal of the preliminary substrate from contact with the first layer 16 , thermo-compression is used again to press the first layer 16 residing on the upper substrate 12 into the upper substrate 12 . This time the temperature of the compression plates discussed above is increased close to the melting temperature of the material of the upper substrate 12 . This will cause the viscosity of the upper substrate to decrease and the applied compression force will press the first layer 16 into the upper substrate 12 to integrate the first layer 16 into the polymer material of the upper substrate 12 , i.e. into a polymer matrix. Details of the process parameters needed to realize the integration are interrelated and they will depend on e.g. the composition of the upper substrate 12 . Suitable process parameters can be readily found by the skilled professional in light of this specification. A method to integrate the first layer 16 into the upper substrate 12 according to one embodiment of the invention is presented as a flow-chart in FIG. 5 .
In one embodiment of the present invention the first layer 16 is embedded into the upper substrate 12 by mechanical compression. In this embodiment the first layer 16 deposited on the upper substrate 12 is pressed against the upper substrate without the use of heat to embed the first layer 16 into the upper substrate 12 .
The touch sensitive display structure schematically illustrated in FIG. 6 according to yet another embodiment of the invention comprises an electrically conductive transparent second layer 22 on the top substrate layer 20 . The second layer 22 like the first layer 16 is a network of HARM-structures. The structure also comprises an optional top coating 24 on the second layer 22 to protect the second layer 22 from the environment. The structure of FIG. 6 can be fabricated as disclosed above and by fabricating the transparent electrically conductive layers comprising a network of HARM-structures, i.e. the first layer 16 and the second layer 22 , on each side of the transparent top substrate layer 20 . The “two-layer” touch screen module 13 of FIG. 6 , comprising the first layer 16 on one side of the top substrate layer 20 ; the second layer 22 on the other side of the top substrate layer 20 ; optionally the top coating 24 on the second layer 22 ; and the top substrate layer 20 in between the first layer 16 and the second layer 22 , can then be assembled on the upper substrate 12 of the display module 1 such that the first layer 16 is deposited in contact with the upper substrate 12 . The transparent protective coating 24 , which can be of e.g. PET or other polymer, can be deposited on the second layer 22 before or after the aforementioned touch screen module 13 is assembled onto the upper substrate 12 .
The additional electrically conductive transparent second layer 22 in FIG. 6 comprises X- and Y-electrodes, like in the first layer 16 , which are electrically connected to a control unit (not shown) via a third control cable 21 . The electrodes in the first layer 16 are capacitively coupled with the electrodes in the second layer 22 , and when the touch screen module 13 is touched on (or brought close to) the exposed surface, the touching conductive surface, e.g. the tip of a finger, is capacitively coupled to the electrodes of the second layer 22 . Hence, two capacitive couplings are formed in series, the third electrode being a touching conductive surface. As known by the skilled person a series connection of capacitors, such as the one in the touch screen module 13 of FIG. 6 , can be used to improve the accuracy and sensitivity of the touch screen module 13 .
In another embodiment of the invention illustrated schematically in FIG. 7 the first layer 16 is embedded into the upper substrate 12 of the display module 1 and the second layer 22 is embedded into the top substrate layer 20 . The embedding of the first 16 and the second 22 layer can be achieved by e.g. the thermo-compression method disclosed above, and this will be obvious for a skilled person in light of this specification. The touch screen module 13 of FIG. 7 also comprises the optional transparent protective coating 24 .
Another embodiment of the invention, illustrated schematically in FIG. 8 , presents how the first layer 16 and the second layer 22 can be both embedded in the top substrate layer 20 , while the first layer 16 retains contact with the upper substrate 12 as it is not completely surrounded by the material of the top substrate layer 20 . The second layer 22 is also not completely surrounded by the material of the top substrate layer 20 , but remains exposed to the environment or, in case the protective coating 24 is employed, in contact with the protective coating 24 . In the embodiment of FIG. 8 the embedding of the first 16 and the second 22 layer can be achieved by e.g. the thermo-compression method disclosed above, and this method will be obvious for a skilled person in light of this specification.
As is obvious for a skilled person, other ways of embedding the first 16 and the second 22 layer into the upper substrate 12 and/or the top substrate layer 20 may also be conceived, and features of the different embodiments of the invention discussed above can be combined in light of this specification to form another embodiment of the invention.
Although the examples above describe the invention in the context of a projective capacitive touch screen, the same inventive idea can be used in other types of touch screen structures as well; e.g. in resistive touch screens and in non-projective, “regular”, capacitive touch screens. The modifications required for the invention to be utilized in these touch screen structures will be obvious for a skilled person in light of this disclosure of the invention. Also other deposition methods to deposit or pattern the first layer 16 and/or the second layer 22 comprising HARM-structures can be conceived by the skilled professional in light of this specification.
As is clear for a person skilled in the art, the invention is not limited to the examples described above but the embodiments can freely vary within the scope of the claims.
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A touch screen ( 13 ) on a display device ( 1 ), and a method for manufacturing a touch screen ( 13 ) on a display device ( 1 ). The display device ( 1 ) has an upper substrate ( 12 ) for protecting the display device ( 1 ) from the environment, the touch screen ( 13 ) comprising an electrically conductive transparent first layer ( 16 ). The first layer ( 16 ) comprises a network of electrically conductive high aspect ratio molecular structures (HARM-structures), the first layer ( 16 ) being embedded into the upper substrate ( 12 ) of the display device ( 1 ) to protect the conductive transparent first layer ( 16 ), for reducing the optical thickness of the structure between a viewer and the region of the display device ( 1 ) in which the image is formed.
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REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 11/075,792 filed 9 Mar. 2005 now U.S. Pat No. 7,504,087, which is a continuation-in-part of U.S. patent application Ser. No. 10/800,531 filed 15 Mar. 2004, which is a continuation-in-part of Ser. No. 09/864,011 filed May 23, 2001 now U.S. Pat. No. 6,706,254 filed 23 May 2001, which is a continuation-in-part of Ser. No. 09/484,322 filed Jan. 18, 2000 now U.S. Pat. No. 6,395,257 filed 18 Jan. 2000, each of which is expressly incorporated by reference herein it is entirety.
FIELD OF INVENTION
This invention relates generally to compositions of cyanine and indocyanine dye bioconjugates with bioactive molecules for diagnosis and therapy, and particularly for visualization and detection of tumors.
BACKGROUND
Several dyes that absorb and emit light in the visible and near-infrared region of electromagnetic spectrum are currently being used for various biomedical applications due to their biocompatibility, high molar absorptivity, and/or high fluorescence quantum yields. The high sensitivity of the optical modality in conjunction with dyes as contrast agents parallels that of nuclear medicine, and permits visualization of organs and tissues without the undesirable effect of ionizing radiation.
Cyanine dyes with intense absorption and emission in the near-infrared (NIR) region are particularly useful because biological tissues are optically transparent in this region (B. C. Wilson, Optical properties of tissues. Encyclopedia of Human Biology, 1991, 5, 587-597). For example, indocyanine green, which absorbs and emits in the NIR region, has been used for monitoring cardiac output, hepatic functions, and liver blood flow (Y-L. He, et al., Measurement of blood volume using indocyanine green measured with pulse-spectrometry: Its reproducibility and reliability. Critical Care Medicine, 1998, 26(8), 1446-1451; J. Caesar, et al. The use of Indocyanine green in the measurement of hepatic blood flow and as a test of hepatic function. Clin. Sci. 1961, 21, 43-57), and its functionalized derivatives have been used to conjugate biomolecules for diagnostic purposes (R. B. Mujumdar, et al., Cyanine dye labeling reagents: Sulfoindocyanine succinimidyl esters. Bioconjugate Chemistry, 1993, 4(2), 105-111; U.S. Pat. No. 5,453,505; WO 98/48846; WO 98/22146; WO 96/17628; WO 98/48838).
A major drawback in the use of cyanine dye derivatives is the potential for hepatobiliary toxicity resulting from the rapid clearance of these dyes by the liver (G. R. Cherrick, et al., Indocyanine green: Observations on its physical properties, plasma decay, and hepatic extraction. J. Clinical Investigation, 1960, 39, 592-600). This is associated with the tendency of cyanine dyes in solution to form aggregates, which could be taken up by Kupffer cells in the liver.
Various attempts to obviate this problem have not been very successful. Typically, hydrophilic peptides, polyethyleneglycol or oligosaccharide conjugates have been used, but these resulted in long-circulating products, which are eventually still cleared by the liver. Another major difficulty with current cyanine and indocyanine dye systems is that they offer a limited scope in the ability to induce large changes in the absorption and emission properties of these dyes. Attempts have been made to incorporate various heteroatoms and cyclic moieties into the polyene chain of these dyes (L. Strekowski, et al., Substitution reactions of a nucleofugal group in hetamethine cyanine dyes. J. Org. Chem., 1992, 57, 4578-4580; N. Narayanan, and G. Patonay, A new method for the synthesis of heptamethine cyanine dyes: Synthesis of new near infrared fluorescent labels. J. Org. Chem., 1995, 60, 2391-2395; U.S. Pat. Nos. 5,732,104; 5,672,333; and 5,709,845), but the resulting dye systems do not show large differences in absorption and emission maxima, especially beyond 830 nm where photoacoustic diagnostic applications are very sensitive. They also possess a prominent hydrophobic core, which enhances liver uptake. Further, most cyanine dyes do not have the capacity to form starburst dendrimers, which are useful in biomedical applications.
For the purpose of tumor detection, many conventional dyes are useful for in vitro applications because of their highly toxic effect on both normal and abnormal tissues. Other dyes lack specificity for particular organs or tissues and, hence, these dyes must be attached to bioactive carriers such as proteins, peptides, carbohydrates, and the like to deliver the dyes to specific regions in the body. Several studies on the use of near infrared dyes and dye-biomolecule conjugates have been published (G. Patonay and M. D. Antoine, Near-Infrared Fluorogenic Labels: New Approach to an Old Problem, Analytical Chemistry, 1991, 63:321A-327A and references therein; M. Brinkley, A Brief Survey of Methods for Preparing Protein Conjugates with Dyes, Haptens, and Cross-Linking Reagents, Perspectives in Bioconjugate Chemistry 1993, pp. 59-70, C. Meares (Ed), ACS Publication, Washington, D.C.; J. Slavik, Fluorescent Probes in Cellular and Molecular Biology, 1994, CRC Press, Inc.; U.S. Pat. No. 5,453,505; WO 98/48846; WO 98/22146; WO 96/17628; WO 98/48838). Of particular interest is the targeting of tumor cells with antibodies or other large protein carriers such as transferrin as delivery vehicles (A. Becker, et al., “Transferrin Mediated Tumor Delivery of Contrast Media for Optical Imaging and Magnetic Resonance Imaging”, Biomedical Optics meeting, Jan. 23-29, 1999, San Jose, Calif.). Such an approach has been widely used in nuclear medicine applications. Its major advantage is the retention of a carrier's tissue specificity, since the molecular volume of the dye is substantially smaller than the carrier. However, this approach does have some serious limitations in that the diffusion of high molecular weight bioconjugates to tumor cells is highly unfavorable, and is further complicated by the net positive pressure in solid tumors (R. K. Jain, Barriers to Drug Delivery in Solid Tumors, Scientific American 1994, 271:58-65. Furthermore, many dyes in general, and cyanine dyes, in particular, tend to form aggregates in aqueous media that lead to fluorescence quenching.
Therefore, there is a need for dyes that could prevent dye aggregation in solution, that are predisposed to form dendrimers, that are capable of absorbing or emitting beyond 800 nm, that possess desirable photophysical properties, and that are endowed with tissue-specific targeting capability.
SUMMARY
The invention is directed to compositions, as well as methods of preparing such compositions, of low molecular weight biomolecule-dye conjugates. These bioconjugates may be utilized, for example, to enhance tumor detection. Compositions of the present invention preserve the fluorescence efficiency of the dye molecules, do not aggregate in solution, form starburst dendrimers, are capable of absorbing and/or omitting light in the near infrared region (beyond 800 mm), and can be rendered tissue-specific.
In one aspect, the present invention relates to a composition including a cyanine dye of general formula 1
wherein W 1 and X 1 may be the same or different and are selected from the group consisting of —CR w R x , —O—, —NR y , —S—, and —Se—; Q 2 is a single bond or is selected from the group consisting of —O—, —S—, —Se—, and —NR 5 ; a 1 and b 1 independently vary from 0 to 5; a and c are independently from 1 to 20; b and d are independently from 1 to 100; Y 1 is a constituent selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —N(R y )—(CH 2 ) b —CONH-Bm, (CH 2 ) a —N(R y )—(CH 2 ) c —NHCO-Bm, —(CH 2 ) a —N(R y )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —N(R y )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—CH 2 —(CH 2 OCH 2 ) d —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Bm, —(CH 2 ) a —NR y R z , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR y R z ; Z 1 is a constituent selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —(CH 2 ) a —N(R y )—(CH 2 ) b —CONH-Dm, (CH 2 ) a —N(R y )—(CH 2 ) c —NHCO-Dm, —(CH 2 ) a —N(R y )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —N(R y )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—CH 2 —(CH 2 OCH 2 ) d —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Dm, —(CH 2 ) a —NR y R z , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR y R z ; R w , R x , R y , R z , and R 1 to R 9 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, glucose derivatives of R groups, cyano, nitro, halogen, saccharide, peptide, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; and Bm and Dm are independently selected from the group consisting of a peptide, a protein, a cell, an antibody, an antibody fragment, a saccharide, a glycopeptide, a peptidomimetic, a drug, a drug mimic, a hormone, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent. At least one of Y 1 , Z 1 , R w , R x , R y , R z , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and R 9 is preferably a constituent including Bm or Dm. Further, it is preferred that at least one Bm or Dm of the cyanine dye is selected from the group consisting of a peptide, a protein, a cell, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent. For instance, in one preferred family of embodiments, at least one of Y 1 , Z 1 , R w , R x , R y , R z , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and R 9 is a constituent including Bm or Dm, and at least one of Bm and Dm is a peptide such as Octreotide, Octreotate, Bombesin, Cholecystokinin, or Neurotensin. In another exemplary family of preferred embodiments, at least one of Y 1 , Z 1 , R w , R x , R y , R z , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 R 7 , R 8 and R 9 is a constituent including Bm or Dm, and at least one of Bm and Dm is a photosensitizer for phototherapy.
In another aspect, the present invention relates to a composition including an indocyanine dye of general formula 2
wherein W 2 and X 2 may be the same or different and are selected from the group consisting of —CR 1 R 2 , —O—, —NR 3 , —S—, and —Se—; Q 2 is a single bond or is selected from the group consisting of —O—, —S—, —Se—, and —NR 5 ; a 2 and b 2 independently vary from 0 to 5; a and c are independently from 1 to 20; b and d are independently from 1 to 100; Y 2 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH-Bm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO-Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 2 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH-Dm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO-Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —N(R 3 )—CH 2 —CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; R 1 to R 5 , and R 16 to R 28 are constituents independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, glucose derivatives of R groups, cyano, nitro, halogen, saccharide, peptide, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; and Bm and Dm are independently selected from the group consisting of a peptide, a protein, a cell, an antibody, an antibody fragment, a saccharide, a glycopeptide, a peptidomimetic, a drug, a drug mimic, a hormone, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent. At least one of Y 2 , Z 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 16 , R 17 , R 18 , R 19 , R 20 , R 21 , R 22 , R 23 , R 24 , R 25 , R 26 , R 27 and R 28 is preferably a constituent including Bm or Dm. Further, it is preferred that at least one Bm or Dm of the indocyanine dye is selected from the group consisting of a peptide, a protein, a cell, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent. For instance, in one preferred family of embodiments, at least one of Y 2 , Z 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 16 , R 17 , R 18 , R 19 , R 20 , R 21 , R 22 , R 23 , R 24 , R 25 , R 26 , R 27 and R 28 is a constituent including Bm or Dm, and at least one of Bm and Dm is a peptide such as Octreotide, Octreotate, Bombesin, Cholecystokinin, or Neurotensin. In another exemplary family of preferred embodiments, at least one of Y 1 , Z 1 , R w , R x , R y , R z , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and R 9 is a constituent including Bm or Dm, and at least one of Bm and Dm is a photosensitizer for phototherapy.
In yet another aspect, the invention relates to a composition including a cyanine dye of general formula 3
wherein W 3 and X 3 may be the same or different and are selected from the group consisting of —CR 1 R 2 , —O—, —NR 3 , —S—, and —Se; Y 3 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH-Bm, —(CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO-Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 3 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH-Dm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO-Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 1 is a single or a double bond; B 1 , C 1 , and D 1 may the same or different and are selected from the group consisting of —O—, —S—, —Se—, —P—, —CR 1 R 2 , —CR 1 , alkyl, NR 3 , and —C═O; A 1 , B 1 , C 1 , and D 1 may together form a 6- to 12-membered carbocyclic ring or a 6- to 12-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 3 and b 3 independently vary from 0 to 5; R 1 to R 4 , and R 29 to R 37 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, glucose derivatives of R groups, cyano, nitro, halogen, saccharide, peptide, —CH 2 (CH 2 OCH 2 ) b —CH 2 ——OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of a peptide, a protein, a cell, an antibody, an antibody fragment, a saccharide, a glycopeptide, a peptidomimetic, a drug, a drug mimic, a hormone, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent; a and c are independently from 1 to 20; and b and d are independently from 1 to 100.
In still another aspect, the invention is directed to a composition including an indocyanine dye of general formula 4
wherein W 4 and X 4 may be the same or different and are selected from the group consisting of —CR 1 R 2 , —O—, —NR 3 , —S—, and —Se; Y 4 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH-Bm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO-Bm, —(CH 2 ) a —N(R 13 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 4 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH-Dm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO-Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 2 is a single or a double bond; B 2 , C 2 , and D 2 may be the same or different and are selected from the group consisting of —O—, —S—, —Se—, —P—, —CR 1 R 2 , —CR 1 , alkyl, NR 3 , and —C═O; A 2 , B 2 , C 2 , and D 2 may together form a 6- to 12-membered carbocyclic ring or a 6- to 12-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 4 and b 4 independently vary from 0 to 5; R 1 to R 4 , and R 45 to R 57 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, glucose derivatives of R groups, cyano, nitro, halogen, saccharide, peptide, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of a peptide, a protein, a cell, an antibody, an antibody fragment, a saccharide, a glycopeptide, a peptidomimetic, a drug, a drug mimic, a hormone, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent; a and c are independently from 1 to 20; and b and d are independently from 1 to 100.
Yet another aspect of the present invention relates to a composition including a cyanine dye of general formula 5
wherein W 5 and X 5 may be the same or different and are selected from the group consisting of —CR 1 R 2 , —O—, —NR 3 , —S—, and —Se; Y 5 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH-Bm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO-Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 5 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH-Dm, (CH 2 ) a —N(R 3 )—(CH 2 ) n —NHCO-Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 3 is a single or a double bond; B 3 , C 3 , and D 3 may be the same or different and are selected from the group consisting of —O—, —S—, —Se—, —P—, —CR 1 R 2 , —CR 1 , alkyl, NR 3 , and —C═O; A 3 , B 3 , C 3 , and D 3 may together form a 6- to 12-membered carbocyclic ring or a 6- to 12-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 5 is independently from 0 to 5; R 1 to R 4 , and R 58 to R 66 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, glucose derivatives of R groups, cyano, nitro, halogen, saccharide, peptide, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of a peptide, a protein, a cell, an antibody, an antibody fragment, a saccharide, a glycopeptide, a peptidomimetic, a drug, a drug mimic, a hormone, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent; a and c are independently from 1 to 20; and b and d are independently from 1 to 100.
Still yet another aspect of the present invention is directed to a composition including an indocyanine dye of general formula 6
wherein W 6 and X 6 may be the same or different and are selected from the group consisting of —CR 1 R 2 , —O—, —NR 3 , —S—, and —Se; Y 6 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH-Bm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO-Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 6 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H—(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH-Dm, (CH 2 ) a —N(R 3 )—(CH 2 ) n —NHCO-Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 4 is a single or a double bond; B 4 , C 4 , and D 4 may be the same or different and are selected from the group consisting of —O—, —S—, —Se—, —P—, —CR 1 R 2 , —CR 1 , alkyl, NR 3 , and —C═O; A 4 , B 4 , C 4 , and D 4 may together form a 6- to 12-membered carbocyclic ring or a 6- to 12-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 6 is independently from 0 to 5; R 1 to R 4 , and R 67 to R 79 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, glucose derivatives of R groups, cyano, nitro, halogen, saccharide, peptide, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —OH or —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of a peptide, a protein, a cell, an antibody, an antibody fragment, a saccharide, a glycopeptide, a peptidomimetic, a drug, a drug mimic, a hormone, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent; a and c are independently from 1 to 20; and b and d are independently from 1 to 100.
A chelate such as ethylenediaminetetraacetic acid (EDTA), diethylenetriamine-pentaacetic acid (DPTA), 1,4,7,10 tetraazacyclododecane-tetraacetic acid (DOTA), or their derivatives, can be attached to the compounds of Formulas 1-6 as one or more R groups. These structures are expected to be highly water soluble.
The invention will be further appreciated in light of the following figures, detailed description, and examples.
BRIEF DESCRIPTION OF THE FIGURES
The file of U.S. patent application Ser. No. 10/800,531 (filed Mar. 15, 2004), which is hereby incorporated by reference, contains color versions of FIGS. 7A-11 below. Copies of that patent application with color drawing(s) may be provided by the Patent and Trademark Office upon request and payment of the necessary fee.
FIG. 1 shows the reaction pathway for the synthesis of bis-carboxylic acid cyanine dyes.
FIG. 2 shows the reaction pathway for the synthesis of tetracarboxylic acid cyanine dyes.
FIG. 3 shows the reaction pathway for the synthesis of polyhydroxycarboxylic acid dyes.
FIG. 4 shows the reaction pathway for the synthesis of non-aggregating cyanine dyes.
FIG. 5 shows the reaction pathway for the synthesis of long wavelength absorbing dyes.
FIG. 6 shows the reaction pathway for the synthesis of cyanine dye bioconjugates.
FIGS. 7A-F represent images at 2 minutes and 30 minutes post injection of indocyanine green (ICG) into rats with various tumors.
FIGS. 8A-B show a comparison of the uptake of ICG ( FIG. 8A ) and Cytate 1 ( FIG. 8B ) in rats with the pancreatic acinar carcinoma (CA20948).
FIGS. 9A-B show images of rats with the pancreatic acinar carcinoma (CA20948) 45 minutes ( FIG. 9A ) and 27 hours ( FIG. 9B ) post injection of Cytate 1.
FIG. 10 is an image of individual organs taken from a rat with pancreatic acinar carcinoma (CA20948) about 24 hours after injection with Cytate 1.
FIG. 11 is an image of bombesinate in an AR42-J tumor-bearing rat 22 hours after injection.
FIG. 12 is the clearance profile of Cytate 1 from the blood of a normal rat.
FIG. 13 is the clearance profile of Cytate 1 from the blood of a pancreatic tumor-bearing rat.
FIG. 14 is the clearance profile of Cytate 2 from the blood of a normal rat.
FIG. 15 is the clearance profile of Cytate 2 from the blood of a pancreatic tumor-bearing rat.
FIG. 16 is the clearance profile of Cytate 4 from the blood of a normal rat.
DETAILED DESCRIPTION
The dyes of formulas 1 to 6 as compounds, compositions, and in methods of imaging offer significant advantages over conventional dyes known in the art. These inventive dyes form starburst dendrimers which prevent aggregation in solution by preventing intramolecular and intermolecular ordered hydrophobic interactions, and have multiple attachment sites proximal to the dye chromophore for ease of forming bioactive molecules. The presence of rigid and extended chromophore backbone enhances their fluorescence quantum yield and extends their maximum absorption beyond 800 nm. Conjugation of biomolecules to these dyes is readily achievable.
The inventive bioconjugates of the present invention also exploit the symmetric nature of the cyanine and indocyanine dye structures by incorporating one to ten receptor-targeting groups in close proximity to each other, such that the receptor binding can be greatly enhanced due to a cooperative effect. Accordingly, several cyanine dyes containing one or more targeting domains have been prepared and tested in vivo for biological activity.
The inventive dye-bioconjugates of formulas 1 to 6 are useful for various biomedical applications. These include, but are not limited to, tomographic imaging of organs, monitoring of organ functions, coronary angiography, fluorescence endoscopy, detection, imaging, and therapy of tumors, laser guided surgery, photoacoustic methods, and sonofluorescent methods.
Specific embodiments to accomplish some of the aforementioned biomedical applications are given below. The dyes of the present invention are prepared according to methods well known in the art as illustrated in the exemplary synthetic schemes of FIGS. 1-5 .
FIG. 1 illustrates the synthetic scheme for bis-carboxylic acid cyanine dyes, where A=CH 2 or CH 2 OCH 2 ; R═COOH; R′═COOH, NHFmoc; CO 2 t-Bu; SO 3 − ; R 1 ═R 2 ═H (Formula 1) or R 1 , R 2 =fused phenyl (Formula 2).
FIG. 2 illustrates the synthetic scheme for tetracarboxylic acid cyanine dyes, where A=CH 2 or CH 2 OCH 2 ; R 1 ═R 2 ═H (Formula 1) or R 1 , R 2 =fused phenyl (Formula 2).
FIG. 3 illustrates the synthetic scheme for polyhydroxy-carboxylic acid cyanine dyes.
FIG. 4 illustrates the synthetic scheme for non-aggregating cyanine dyes.
FIG. 5 illustrates the synthetic scheme for long wavelength-absorbing tunable cyanine dyes.
In one aspect, dyes of the invention have the Formula 1, wherein W 1 and X 1 may be the same or different and are selected from the group consisting of —CR w R x , —O—, —NR y , —S—, and —Se—; Q 2 is a single bond or is selected from the group consisting of —O—, —S—, —Se—, and —NR 5 ; a 1 and b 1 independently vary from 0 to 5; a and c are independently from 1 to 20; b and d are independently from 1 to 100; Y 1 is a constituent selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —N(R y )—(CH 2 ) b —CONH-Bm, (CH 2 ) a —N(R y )—(CH 2 ) n —NHCO-Bm, —(CH 2 ) a —N(R y )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —N(R y )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—CH 2 —(CH 2 OCH 2 ) d —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Bm, —(CH 2 ) a —NR y R z , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR y R z ; Z 1 is a constituent selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —(CH 2 ) a —N(R y )—(CH 2 ) b —CONH-Dm, (CH 2 ) a —N(R y )—(CH 2 ) c —NHCO-Dm, —(CH 2 ) a —N(R y )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —N(R y )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—CH 2 —(CH 2 OCH 2 ) d —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R y )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Dm, —(CH 2 ) a —NR y R z , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR y R z ; R w , R x , R y , R z , and R 1 to R 9 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, glucose derivatives of R groups, cyano, nitro, halogen, saccharide, peptide, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; and Bm and Dm are independently selected from the group consisting of a peptide, a protein, a cell, an antibody, an antibody fragment, a saccharide, a glycopeptide, a peptidomimetic, a drug, a drug mimic, a hormone, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent.
With regard to preferred cyanine dyes of Formula 1, at least one of Y 1 , Z 1 , R w , R x , R y , R z , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and R 9 is preferably a constituent including Bm or Dm. Further, it is preferred that at least one Bm or Dm of the dye of Formula 1 is selected from the group consisting of a peptide, a protein, a cell, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent. For instance, in one preferred family of embodiments, at least one of Y 1 , Z 1 , R w , R x , R y , R z , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and R 9 is a constituent including Bm or Dm, and at least one of Bm and Dm is a peptide such as Octreotide, Octreotate, Bombesin, Cholecystokinin, or Neurotensin.
In another family of preferred embodiments of the dyes of Formula 1, at least one of Y 1 , Z 1 , R w , R x , R y , R z , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and R 9 is a constituent including Bm or Dm, and at least one of Bm and Dm is a photosensitizer for phototherapy. For example, in one preferred embodiment, at least one of Y 1 , R w , R x , R y , R z , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 1 and R 9 is a constituent including Bm, and Z 1 is a constituent including Dm. In such a preferred embodiment, one of Bm and Dm is a peptide, and the other of Bm and Dm is a photosensitizer for phototherapy.
In still another family of preferred embodiments of the dyes of Formula 1, at least one of Y 1 , Z 1 , R w , R x , R y , R z , R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and R 9 is a constituent including Bm or Dm. However, in this preferred family, Bm and/or Dm is selected from the group consisting of a protein, a cell, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent.
Turning to a second aspect of the invention, some indocyanine dyes of the invention have the Formula 2, wherein W 2 and X 2 may be the same or different and are selected from the group consisting of —CR 1 R 2 , —O—, —NR 3 , —S—, and —Se—; Q 2 is a single bond or is selected from the group consisting of —O—, —S—, —Se—, and —NR 5 ; a 2 and b 2 independently vary from 0 to 5; a and c are independently from 1 to 20; b and d are independently from 1 to 100; Y 2 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH-Bm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO-Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 2 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —(CH 2 ) a —N(R 3 )—(CH 2 ) b —CONH-Dm, (CH 2 ) a —N(R 3 )—(CH 2 ) c —NHCO-Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —N(R 3 )—CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —N(R 3 )—CH 2 —(CH 2 OCH 2 ) d —NHCO-Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; R 1 to R 5 , and R 16 to R 28 are constituents independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, glucose derivatives of R groups, cyano, nitro, halogen, saccharide, peptide, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; and Bm and Dm are independently selected from the group consisting of a peptide, a protein, a cell, an antibody, an antibody fragment, a saccharide, a glycopeptide, a peptidomimetic, a drug, a drug mimic, a hormone, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent.
With regard to preferred indocyanine dyes of Formula 2, at least one of Y 2 , Z 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 16 , R 17 , R 18 , R 19 , R 20 , R 21 , R 22 , R 23 , R 24 , R 25 , R 26 , R 27 and R 28 is a constituent including Bm or Dm. Further, it is preferred that at least one Bm or Dm of the indocyanine dye is selected from the group consisting of a peptide, a protein, a cell, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent. For instance, in one preferred family of embodiments, at least one of Y 2 , Z 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 16 , R 17 , R 18 , R 19 , R 20 , R 21 , R 22 , R 23 , R 24 , R 25 , R 26 , R 27 and R 28 is a constituent including Bm or Dm, and at least one of Bm and Dm is a peptide such as Octreotide, Octreotate, Bombesin, Cholecystokinin, or Neurotensin.
In another family of preferred embodiments of the dyes of Formula 2, at least one of Y 2 , Z 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 16 , R 17 , R 18 , R 19 , R 20 , R 21 , R 22 , R 23 , R 24 , R 25 , R 26 , R 27 and R 28 is a constituent including Bm or Dm, and at least one of Bm and Dm is a photosensitizer for phototherapy. For example, in one preferred embodiment, at least one of Y 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 16 , R 17 , R 18 , R 19 , R 20 , R 21 , R 22 , R 23 , R 24 , R 25 , R 26 , R 27 and R 28 is a constituent including Bm, and Z 2 is a constituent including Dm. In such a preferred embodiment, one of Bm and Dm is a peptide, and the other of Bm and Dm is a photosensitizer for phototherapy.
In still another family of preferred embodiments of the indocyanine dyes of Formula 2, at least one of Y 2 , Z 2 , R 1 , R 2 , R 3 , R 4 , R 5 , R 16 , R 17 , R 17 , R 18 , R 19 , R 20 , R 21 , R 22 , R 23 , R 24 , R 25 , R 26 , R 27 and R 28 is a constituent including Bm or Dm. However, in this preferred family, Bm and/or Dm is selected from the group consisting of a protein, a cell, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent.
A third aspect of the invention is preferably directed to cyanine dyes of Formula 3, wherein W 3 and X 3 may be the same or different and are selected from the group consisting of —C(CH 3 ) 2 , —C((CH 2 ) a OH)CH 3 , —C((CH 2 ) a OH) 2 , —C((CH 2 ) a CO 2 H)CH 3 , —C((CH 2 ) a CO 2 H) 2 , —C((CH 2 ) a NH 2 )CH 3 , —C((CH 2 ) a NH 2 ) 2 , C((CH 2 ) a NR 3 R 4 ) 2 , —NR 3 , and —S—; Y 3 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 3 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 1 is a single or a double bond; B 1 , C 1 , and D 1 are independently selected from the group consisting of —O—, —S—, NR 3 , (CH 2 ) a —CR 1 R 2 , and —CR 1 ; A 1 , B 1 , C 1 , and D 1 may together form a 6- to 10-membered carbocyclic ring or a 6- to 10-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 3 and b 3 are independently from 0 to 3; R 1 to R 4 , and R 29 to R 37 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 12 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyhydroxyalkyl, C 5 -C 12 polyhydroxyaryl, C 1 -C 10 aminoalkyl, mono- or oligosaccharide, peptide with 2 to 30 amino acid units, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of peptide containing 2 to 30 amino acid units, an antibody, a mono- or oligosaccharide, a glycopeptide, a metal chelating agent, a radioactive or nonradioactive metal complex, and an echogenic agent; a and c are independently from 1 to 10; and b and d are independently from 1 to 30.
Yet a fourth aspect of the invention is preferably directed to indocyanine dyes having the general Formula 4, wherein W 4 and X 4 may be the same or different and are selected from the group consisting of —C(CH 3 ) 2 , —C((CH 2 ) a OH)CH 3 , —C((CH 2 ) a OH) 2 , —C((CH 2 ) a CO 2 H)CH 3 , —C((CH 2 ) a CO 2 H) 2 , —C((CH 2 ) a NH 2 )CH 3 , C((CH 2 ) a NH 2 ) 2 , —C((CH 2 ) a NR 3 R 4 ) 2 , —NR 3 , and —S—; Y 4 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 4 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 2 is a single or a double bond; B 2 , C 2 , and D 2 are independently selected from the group consisting of —O—, —S—, NR 3 , (CH 2 ) a —CR 1 R 2 , and —CR 1 ; A 2 , B 2 , C 2 , and D 2 may together form a 6- to 10-membered carbocyclic ring or a 6- to 10-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 4 and b 4 are independently from 0 to 3; R 1 to R 4 , and R 45 to R 57 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 12 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyhydroxyalkyl, C 5 -C 12 polyhydroxyaryl, C 1 -C 10 aminoalkyl, mono- or oligosaccharide, peptide with 2 to 30 amino acid units, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of a peptide containing 2 to 30 amino acid units, an antibody, a mono- or oligosaccharide, a glycopeptide, a metal chelating agent, a radioactive or nonradioactive metal complex, and an echogenic agent; a and c are independently from 1 to 10; and b and d independently from 1 to 30.
Still a fifth aspect of the invention includes cyanine dyes preferably having the general Formula 5, wherein W 5 and X 5 may be the same or different and are selected from the group consisting of —C(CH 3 ) 2 , —C((CH 2 ) a —H)CH 3 , —C((CH 2 ) a —H) 2 , —C((CH 2 ) a —O 2 H)CH 3 , —C((CH 2 ) a —O 2 H) 2 , —C((CH 2 ) a —H 2 )CH 3 , —C((CH 2 ) a NH 2 ) 2 , —C((CH 2 ) a NR 3 R 4 ) 2 , —NR 3 , and —S—; Y 5 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH—NHCO-Bm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 5 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —H 2 NR 3 R 4 ; A 3 is a single or a double bond; B 3 , C 3 , and D 3 are independently selected from the group consisting of —O—, —S—, NR 3 , (CH 2 ) a —CR 1 R 2 , and —CR 1 ; A 3 , B 3 , C 3 , and D 3 may together form a 6- to 10-membered carbocyclic ring or a 6- to 10-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 5 is from 0 to 3; R 1 to R 4 , and R 58 to R 66 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 12 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyhydroxyalkyl, C 5 -C 12 polyhydroxy aryl, C 1 -C 10 aminoalkyl, mono- or oligosaccharide, peptide with 2 to 30 amino acid units, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of a peptide containing 2 to 30 amino acid units, an antibody, a mono- or oligosaccharide, a glycopeptide, a metal chelating agent, a radioactive or nonradioactive metal complex, and an echogenic agent; a and c are independently from 1 to 10; and b and d are independently from 1 to 30.
Still a sixth aspect of the invention is directed to indocyanine dyes preferably having the general Formula 6, wherein W 6 and X 6 may be the same or different and are selected from the group consisting of —C(CH 3 ) 2 , —C((CH 2 ) a OH)CH 3 , —C((CH 2 ) a OH) 2 , —C((CH 2 ) a CO 2 H)CH 3 , —C((CH 2 ) a CO 2 H) 2 , —C((CH 2 ) a NH 2 )CH 3 , C((CH 2 ) a NH 2 ) 2 , C((CH 2 ) a NR 3 R 4 ) 2 , —NR 3 , and —S—; Y 6 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —NR 1 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; Z 6 is selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 20 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyalkoxyalkyl, C 1 -C 20 polyhydroxyalkyl, C 5 -C 20 polyhydroxyaryl, C 1 -C 10 aminoalkyl, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Dm, —(CH 2 ) a —NHCO-Dm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Dm, —(CH 2 ) a —NR 3 R 4 , and —CH 2 (CH 2 OCH 2 ) b —CH 2 NR 3 R 4 ; A 4 is a single or a double bond; B 4 , C 4 , and D 4 are independently selected from the group consisting of —O—, —S—, NR 3 , (CH 2 ) a —CR 1 R 2 , and —CR 1 ; A 4 , B 4 , C 4 , and D 4 may together form a 6- to 10-membered carbocyclic ring or a 6- to 10-membered heterocyclic ring optionally containing one or more oxygen, nitrogen, or sulfur atom; a 6 is from 0 to 3; R 1 to R 4 , and R 67 to R 79 are independently selected from the group consisting of hydrogen, C 1 -C 10 alkyl, C 5 -C 12 aryl, C 1 -C 10 alkoxyl, C 1 -C 10 polyhydroxyalkyl, C 5 -C 12 polyhydroxy aryl, C 1 -C 10 aminoalkyl, mono- or oligosaccharide, peptide with 2 to 30 amino acid units, —CH 2 (CH 2 OCH 2 ) b —CH 2 —OH, —(CH 2 ) a —CO 2 H, —(CH 2 ) a —CONH-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —CONH-Bm, —(CH 2 ) a —NHCO-Bm, —CH 2 —(CH 2 OCH 2 ) b —CH 2 —NHCO-Bm, —(CH 2 ) a —OH and —CH 2 —(CH 2 OCH 2 ) b —CO 2 H; Bm and Dm are independently selected from the group consisting of a peptide containing 2 to 30 amino acid units, an antibody, a mono- or oligosaccharide, a glycopeptide, a metal chelating agent, a radioactive or nonradioactive metal complex, and an echogenic agent; a and c are independently from 1 to 10; and b and d are independently from 1 to 30.
This invention is also related to the method of conjugating the inventive dyes to peptides or biomolecules by solid phase or solution synthesis methods. Accordingly, the term “dye” or the like herein shall refer to the compounds representatively illustrated in Formulas 1-6, including described bioconjugates of such compounds. For example, in some preferred bioconjugates of the invention, one or more of the constituents represented by Y groups, Z groups, and R groups of Formulas 1-6 is a constituent including Bm or Dm, wherein Bm and Dm may each be any of a peptide, a protein, a cell, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent. In one preferred family of embodiments of Formulas 1-6, one or more of the constituents represented by Y groups, Z groups, and R groups is a constituent including Bm or Dm, and at least one of Bm and Dm is a peptide such as Octreotide, Octreotate, Bombesin, Cholecystokinin, or Neurotensin. In another preferred family of embodiments of Formulas 1-6, one or more of the constituents represented by Y groups, Z groups, and R groups is a constituent including Bm or Dm, and at least one of Bm and Dm is a photosensitizer for phototherapy. For example, one preferred dye of one of Formulas 1-6 has two Y, Z, and/or R group constituents of which a Bm is a part. In this preferred dye, one Bm is a photosensitizer, and the other Bm is a peptide. In still another preferred family of embodiments of Formulas 1-6, one or more of the constituents represented by Y groups, Z groups, and R groups is a constituent including Bm or Dm, and Bm and/or Dm is selected from the group consisting of a protein, a cell, a metal chelating agent, a radioactive or nonradioactive metal complex, a photosensitizer for phototherapy, and an echogenic agent.
FIG. 6 illustrates the synthetic scheme for bioconjugates incorporating the cyanine dyes of FIGS. 1-5 , using automated peptide synthesis in a solid support, where A=CH 2 or CH 2 OCH 2 ; R 1 ═R 2 ═H (Formula 1) or R 1 , R 2 =fused phenyl (Formula 2); AA=amino acids; R═CONH peptide; R′═R (bis conjugate) or COOH (mono conjugate);
or absence depends on R′ definition.
This invention is also related to the method of preventing fluorescence quenching. It is known that cyanine dyes generally form aggregates in aqueous media, leading to fluorescence quenching. Where the presence of a hydrophobic core in the dyes leads to fluorescence quenching, the addition of a biocompatible organic solvent, such as 1-50% dimethylsulfoxide (DMSO) for example, restored fluorescence by preventing aggregation and allowed in vivo organ visualization. Large fluorescence enhancement of dyes have been observed under the condition where the dye is encapsulated in, i.e. forms an inclusion complex with, cyclodextrins (W. R. Bergmark et al., Dramatic fluorescence effects for coumarin laser dyes coincluded with organic solvents in cyclodextrins. J. Phys. Chem., 1990, 94, 50208-5022). However, in vivo fluorescence enhancement of dyes coinjected with biocompatible organic solvents has not been previously described. Suitable organic solvent include, but are not limited to dimethylsulfoxide (DMSO), ethyl alcohol, isopropyl alcohol, glycerol, and other biocompatible polyols such as sorbitol, mannitol, xylitol, lactitol, erythritol, polydextrose, sucrose, fructose, maltose, hydrogenated starch hydrolysate (HSH), isomalt (palitinit), polyglycerol, hyperbranched polyglycerol, acetylated polyols, maltodextrine, cyclodextrine, dianhydosorbitol, starches, polysaccharides, etc. as known to one skilled in the art.
The dye-biomolecule conjugates are used for optical tomographic, endoscopic, photoacoustic, phototherapeutic, and sonofluorescent applications for the detection and treatment of tumors and other abnormalities. The phototherapeutic photosensitizers may include those operating via direct (Type 1) mechanism as described by Rajagopalan et al. (U.S. Pat. No. 6,485,704, and U.S. patent application Ser. Nos. 09/766,347, and 09/898,887, incorporated herein by reference in their entirety), or by photodynamic (PDT or Type II) mechanism as described by Jori et al. (Tumour photosensitizers: approaches to enhance the selectivity and efficiency of photodynamic therapy, Journal of Photochemistry and Photobiology B: Biology 36 (1996) 87-93; Novel Therapeutic Modalities Based on Photosensitized Processes, EPA Newsletter No. 60, (July 1997) 12-18; Far-red-absorbing photosensitizers: their use in the photodynamic therapy of tumours, J. Photochem. Photobiol. A: Chem., 62 (1992) 371-378; and Second Generation Photosensitizers for the Photodynamic Therapy of Tumours, Light in Biology and Medicine, Vol. 2, (1991) 253-266), incorporated herein by reference in their entirety. Type 1 photosensitizers are those moieties that produce reactive intermediates such as free radicals, nitrenes, carbenes, and the like upon photoactivation. These include azides, peroxides, disulfides, sulfenates, and the like. Type II sensitizers are those that produce singlet oxygen species upon photoactivation. These include phthalocyanines, porphyrins, and the like. Incidentally, U.S. Pat. No. 6,217,848 is also herein incorporated by reference in its entirety.
The bioconjugates of the present invention are prepared by the standard bioconjugate chemistry methods known in the art as illustrated in the forthcoming examples. Typically, the coupling between the dyes and the photosensitizers of the present invention is achieved by reacting the carboxyl group in one of the two aforementioned components with the aminogroup of the other component that results in the formation of the amide bond between the two units. Alternatively, if the two components contain either an amino or a hydroxyl group, the coupling would result in the formation of ester, urea, thiourea, carbamate, or carbonate species. Indeed, in one preferred family of embodiments, the compounds of formulas 1-4 have at least one constituent that includes at least one of Bm and Dm. In one preferred subfamily of such embodiments, at least one of Bm and Dm is a photosensitizer that may be utilized in phototherapy.
The inventive composition may be administered for imaging by more than one modality. As one example, a paramagnetic metal ion such as gadolinium or manganese may be included in the chemical formula and the composition may be imaged by optical imaging alone, by magnetic resonance imaging (MR) alone, or by both optical and MR modalities. As another example, the composition may be imaged by optical imaging alone, by nuclear imaging alone, or by both optical and nuclear imaging modalities when a radioactive isotope is included in the chemical formula, such as replacing a halogen atom with a radioactive halogen, and/or including a radioactive metal ion such as Tc 99 , In 111 , etc.
It will also be appreciated that the inventive compositions may be administered with other contrast agents or media used to enhance an image from a non-optical modality. These include agents for enhancing an image obtained by modalities including but not limited to MR, ultrasound (US), x-ray, positron emission tomography (PET), computed tomography (CT), single photon emission computed tomography (SPECT), etc. Both optical and non-optical agents may be formulated as a single composition (that is, one composition containing one, two or more components, for example, an optical agent and a M agent), or may be formulated as separate compositions. The inventive optical imaging contrast agent and the non-optical contrast agent are administered in doses effective to achieve the desired enhancement, diagnosis, therapy, etc., as known to one skilled in the art. The inventive compositions, either alone or combined with a contrast agent, may be administered to a patient, typically a warm-blooded animal, systemically or locally to the organ or tissue to be imaged. The patient is then imaged by optical imaging and/or by another modality. As one example of this embodiment, the inventive compounds may be added to contrast media compositions. As another example, the inventive compositions may be co-administered with contrast media, either simultaneously or within the same diagnostic and/or therapeutic procedure (for example, administering the inventive composition and administering a contrast agent then performing optical imaging followed by another imaging modality, or administering the inventive composition and administering a contrast agent then performing another imaging modality followed by optical imaging, or administering the inventive composition and optical imaging, then administering a contrast agent and MR, US, CT, etc. imaging, or administering a contrast agent and imaging by MR, US, CT, etc., then administering the inventive composition and optical imaging, or administering the inventive composition and a contrast agent, and simultaneously imaging by an optical modality and MR, US, CT, etc.). As another example, an optical imaging agent may be added as an additive or excipient for a non-optical imaging modality. In this embodiment, the optically active component, such as the dyes disclosed herein, could be added as a buffering agent to control pH or as a chelating agent to improve formulation stability, etc. in CT contrast media, M contrast media, x-ray contrast media, US contrast media, etc. The CT, MR, x-ray, US contrast media would then also function as an optical imaging agent. The information obtained from the modality using the non-optical contrast agent is useful in combination with the image obtained using the optical contrast agent.
Dye-biomolecule conjugates of the invention are also used for localized therapy. This may be accomplished by attaching a porphyrin or photodynamic therapy agent to a bioconjugate, shining light of appropriate wavelength for detection and treatment of the abnormality.
The inventive conjugates can also be used for the detection of the presence of tumors and other abnormalities by monitoring the blood clearance profile of the conjugates, for laser assisted guided surgery for the detection of small micrometastases of, e.g., somatostatin subtype 2 (SST-2) positive tumors, upon laparoscopy, and for diagnosis of atherosclerotic plaques and blood clots.
The compositions of the invention can be formulated into diagnostic and therapeutic compositions for enteral or parenteral administration. These compositions contain an effective amount of the dye along with conventional pharmaceutical carriers and excipients appropriate for the type of administration contemplated. For example, parenteral formulations advantageously contain the inventive agent in a sterile aqueous solution or suspension. Parenteral compositions may be injected directly or mixed with a large volume parenteral composition for systemic administration. Such solutions also may contain pharmaceutically acceptable buffers and, optionally, electrolytes such as sodium chloride.
Formulations for enteral administration may vary widely, as is well known in the art. In general, such formulations are liquids, which include an effective amount of the inventive agent in aqueous solution or suspension. Such enteral compositions may optionally include buffers, surfactants, thixotropic agents, and the like. Compositions for oral administration may also contain flavoring agents and other ingredients for enhancing their organoleptic qualities.
In one embodiment, the agents may be formulated as micelles, liposomes, microcapsules, or other microparticles. These formulations may enhance delivery, localization, target specificity, administration, etc. of the agents. Preparation and loading of these are well known in the art.
As one example, liposomes may be prepared from dipalmitoyl phosphatidylcholine (DPPC) or egg phosphatidylcholine (PC) because this lipid has a low heat transition. Liposomes are made using standard procedures as known to one skilled in the art (e.g., Braun-Falco et al., (Eds.), Griesbach Conference, Liposome Dermatics , Springer-Verlag, Berlin (1992), pp. 69-81; 91-117 which is expressly incorporated by reference herein). Polycaprolactone, poly(glycolic) acid, poly(lactic) acid, polyanhydride or lipids may be formulated as microspheres. As an illustrative example, the optical agent may be mixed with polyvinyl alcohol (PVA), the mixture then dried and coated with ethylene vinyl acetate, then cooled again with PVA. In a liposome, the optical agent may be within one or both lipid bilayers, in the aqueous between the bilayers, or with the center or core. Liposomes may be modified with other molecules and lipids to form a cationic liposome. Liposomes may also be modified with lipids to render their surface more hydrophilic which increases their circulation time in the bloodstream. The thus-modified liposome has been termed a “stealth” liposome, or a long-lived liposome, as described in U.S. Pat. No. 6,258,378, and in Stealth Liposomes Lasic and Martin (Eds.) 1995 CRC Press, London, which are expressly incorporated by reference herein. Encapsulation methods include detergent dialysis, freeze drying, film forming, injection, as known to one skilled in the art and disclosed in, for example, U.S. Pat. No. 6,406,713 which is expressly incorporated by reference herein in its entirety.
The agent formulated in liposomes, microcapsules, etc. may be administered by any of the routes previously described. In a formulation applied topically, the optical agent is slowly released over time. In an injectable formulation, the liposome, capsule, etc., circulates in the bloodstream and is delivered to the desired site.
The diagnostic compositions are administered in doses effective to achieve the desired enhancement. Such doses may vary widely, depending upon the particular dye employed, the organs or tissues to be imaged, the imaging equipment being used, and the like. The diagnostic compositions of the invention are used in the conventional manner. The compositions may be administered to a patient, typically a warm-blooded animal, either systemically or locally to the organ or tissue to be imaged, and the patient then subjected to the imaging procedure.
The inventive compositions and methods represent an important approach to the synthesis and use of novel cyanine and indocyanine dyes with a variety of photophysical and chemical properties. The combination also represents an important approach to the use of small molecular targeting groups to image tumors by optical methods. The invention is further detailed in the following Examples, which are offered by way of illustration and are not intended to limit the scope of the invention in any manner.
EXAMPLE 1
Synthesis of Bis(ethylcarboxymethyl)indocyanine Dye
( FIG. 1 , R 1 , R 2 =fused phenyl; A=CH 2 , n=1 and R═R′═CO 2 H)
A mixture of 1,1,2-trimethyl-[1H]-benz[e]indole (9.1 g, 43.58 mmoles) and 3-bromopropanoic acid (10.0 g, 65.37 mmoles) in 1,2-dichlorobenzene (40 mL) was heated at 110° C. for 12 hours. The solution was cooled to room temperature and the red residue obtained was filtered and washed with acetonitrile:diethyl ether (1:1) mixture. The solid obtained was dried under vacuum to give 10 g (64%) of light brown powder. A portion of this solid (6.0 g; 16.56 mmoles), glutaconaldehyde dianil monohydrochloride (2.36 g, 8.28 mmoles) and sodium acetate trihydrate (2.93 g, 21.53 mmoles) in ethanol (150 mL) were refluxed for 90 minutes. After evaporating the solvent, 40 mL of a 2 N aqueous HCl was added to the residue. The mixture was centrifuged and the supernatant was decanted. This procedure was repeated until the supernatant became nearly colorless. About 5 mL of water:acetonitrile (3:2) mixture was added to the solid residue and lyophilized to obtain 2 g of dark green flakes. The purity of the compound was established with 1 H-NMR and liquid chromatography-mass spectroscopy (LC-MS).
EXAMPLE 2
Synthesis of Bis(pentylcarboxymethyl)indocyanine Dye
( FIG. 1 , R 1 , R 2 =fused phenyl: A=CH 2 , n=4 and R′═R′═CO 2 H)
A mixture of 1,1,2-trimethyl-[1H]-benz[e]indole (20 g, 95.6 mmoles) and 6-bromohexanoic acid (28.1 g, 144.1 mmoles) in 1,2-dichlorobenzene (250 mL) was heated at 110° C. for 12 hours. The green solution was cooled to room temperature and the brown solid precipitate formed was collected by filtration. After washing the solid with 1,2-dichlorobenzene and diethyl ether, the brown powder obtained (24 g, 64%) was dried under vacuum at room temperature. A portion of this solid (4.0 g; 9.8 mmoles), glutaconaldehyde dianil monohydrochloride (1.4 g, 5 mmoles) and sodium acetate trihydrate (1.8 g, 12.9 mmoles) in ethanol (80 mL) were refluxed for 1 hour. After evaporating the solvent, 20 mL of a 2 N aqueous HCl was added to the residue. The mixture was centrifuged and the supernatant was decanted. This procedure was repeated until the supernatant became nearly colorless. About 5 mL of water:acetonitrile (3:2) mixture was added to the solid residue and lyophilized to obtain about 2 g of dark green flakes. The purity of the compound was established with 1 H-NMR and LC-MS.
EXAMPLE 3
Synthesis of Bisethylcarboxymethylindocyanine Dye
( FIG. 1 , R 1 ═R 2 ═H; A=CH 2 , n=1 and R═R′═CO 2 H)
This compound was prepared as described in Example 1 except that 1,1,2-trimethylindole was used as the starting material.
EXAMPLE 4
Synthesis of Bis(hexaethyleneglycolcarboxymethyl)indocyanine Dye
( FIG. 1 , R 1 ═R 2 =fused phenyl; A=CH 2 OCH 2 , n=6 and R═R′═CO 2 H)
This compound was prepared as described in Example 1 except that □-bromohexaoxyethyleneglycolpropiolic acid was used in place of bromopropanoic acid and the reaction was carried out in 1,2-dimethoxypropane.
EXAMPLE 5
Synthesis of Bisethylcarboxymethylindocyanine Dye
( FIG. 2 , R 1 ═R 2 =fused phenyl, A=CH 2 , and n=0)
A solution of 50 ml of dimethylformamide and benzyl bromoacetate (16.0 g, 70 mmol) was stirred in a 100-mL three-neck flask. Solid potassium bicarbonate (7.8 g, 78 mmol) was added. The flask was purged with argon and cooled to 0° C. with an ice bath. To the stirring mixture was added dropwise a solution of ethanolamine (1.9 g, 31 mmol) and 4 ml of dimethylformamide over 5 minutes. After the addition was complete the mixture was stirred for 1 hour at 0° C. The ice bath was removed and the mixture stirred at room temperature overnight. The reaction mixture was partitioned between 100 ml of methylene chloride and 100 ml of saturated sodium bicarbonate solution. The layers were separated and the methylene chloride layer was again washed with 100 ml of saturated sodium bicarbonate solution. The combined aqueous layers were extracted twice with 25 ml of methylene chloride. The combined methylene chloride layers were washed with 100 ml of brine, and dried over magnesium sulfate. The methylene chloride was removed with aspirator vacuum at about 35° C., and the remaining dimethylformamide was removed with vacuum at about 45° C. The crude material was left on a vacuum line overnight at room temperature.
The crude material was then dissolved in 100 ml of methylene chloride at room temperature. Triphenylphosphine (8.91 g, 34 mmol) was added and dissolved with stirring. An argon purge was started and the mixture was cooled to 0° C. with an ice bath. The N-bromosuccinimide (6.05 g, 34 mmol) was added portionwise over two minutes. The mixture was stirred for 1.5 hours at 0° C. The methylene chloride was removed with vacuum and gave purple oil. This oil was triturated with 200 ml of ether with constant manual stirring. During this time the oil became very thick. The ether solution was decanted and the oil was triturated with 100 ml of ether. The ether solution was decanted and the oil was again triturated with a 100 ml portion of ether. The ether was decanted and the combined ether solution was allowed to stand for about two hours to allow the triphenylphosphine oxide to crystallize. The ether solution was decanted from the crystals and the solid was washed with 100 ml of ether. The volume of the combined ether abstracts was reduced with vacuum until a volume of about 25 ml was obtained. This was allowed to stand over night at 0° C. Ether (10 ml) was added to the cold mixture, which was mixed to suspend the solid. The mixture was percolated through a column of 45 g of silica gel and eluted with ether; 75 ml fractions were collected. The fractions that contained product, as determined by thin layer chromatography, were pooled and the ether was removed with vacuum. This yielded 10.1 g of crude product. The material was flash chromatographed on silica gel with hexane, changing to 9:1 hexane:ether. The product-containing fractions were pooled and the solvents removed with vacuum. This yielded 7.4 g (57% yield) of pure product.
A mixture of 10% palladium on carbon (1 g) and a solution of the benzyl ester (10 g) in 150 ml of methanol was hydrogenolyzed at 25 psi for two hours. The mixture was filtered over celite and the residue was washed with methanol. The solvent was evaporated to give viscous oil in quantitative yield.
Reaction of the bromide with 1,1,2-trimethyl-[1H]-benz[e]indole was carried out as described in Example 1.
EXAMPLE 6
Bis(ethylcarboxymethyldihydroxyl)indocyanine Dye (FIG. 3 )
The hydroxy-indole compound is readily prepared by a known method (P. L. Southwick, et al., One pot Fischer synthesis of (2,3,3-trimethyl-3-H-indol-5-yl)-acetic acid derivatives as intermediates for fluorescent biolabels. Org. Prep. Proced. Int. Briefs, 1988, 20(3), 279-284). Reaction of p-carboxymethylphenylhydrazine hydrochloride (30 mmol, 1 equiv.) and 1,1-bis(hydroxymethyl)propanone (45 mmole, 1.5 equiv.) in acetic acid (50 mL) at room temperature for 30 minutes and at reflux for one minute gives (3,3-dihydroxymethyl-2-methyl-3-H-indol-5-yl)-acetic acid as a solid residue. The reaction of 3-bromopropyl-N,N-bis(carboxymethyl)amine, which was prepared as described in Example 5, with the intermediate indole and subsequent reaction of the indole intermediate with glutaconaldehyde dianil monohydrochloride (see Example 1) gives the desired product.
EXAMPLE 7
Synthesis of Bis(propylcarboxymethyl)indocyanine Dye (FIG. 4 )
The intermediate 2-chloro-1-formyl-3-hydroxymethylenecyclohexane was prepared as described in the literature (G. A. Reynolds and K. H. Drexhage, Stable heptamethine pyrylium dyes that absorb in the infrared. J. Org. Chem., 1977, 42(5), 885-888). Equal volumes (40 mL each) of dimethylformamide (DMF) and dichloromethane were mixed and the solution was cooled to −10° C. in acetone-dry ice bath. Under argon atmosphere, phosphorus oxychloride (40 mL) in dichloromethane was added dropwise to the cool DMF solution, followed by the addition of 10 g of cyclohexanone. The resulting solution was allowed to warm up to room temperature and refluxed for six hours. After cooling to room temperature, the mixture was poured into ice-cold water and stored at 4° C. for twelve hours. About 8 g of yellow powder was obtained after filtration. Condensation of the cyclic dialdehyde with the indole intermediate is carried out as described in Example 1. Further functionalization of the dye with bis isopropylidene acetal protected monosaccharide was accomplished by the method described in the literature (J. H. Flanagan, et al., Near infrared heavy-atom-modified fluorescent dyes for base-calling in DNA-sequencing application using temporal discrimination. Anal. Chem., 1998, 70 (13), 2676-2684).
EXAMPLE 8
Synthesis of Bis(ethylcarboxymethyl)indocyanine Dye (FIG. 5 )
These dyes are prepared as described in Example 7. These dyes absorb in the infrared region. The typical example shown in FIG. 5 has an estimated absorption maximum at 1036 nm.
EXAMPLE 9
Synthesis of Peptides
The procedure described below is for the synthesis of Octreotate. The amino acid sequence of Octreotate is: D-Phe-Cys'-Tyr-D-Trp-Lys-Thr-Cys'-Thr (SEQ ID NO:1), wherein Cys' indicates the presence of an intramolecular disulfide bond between two cysteine amino acids. Other peptides of this invention were prepared by a similar procedure with slight modifications in some cases.
The octapeptide was prepared by an automated fluorenylmethoxycarbonyl (Fmoc) solid phase peptide synthesis using a commercial peptide synthesizer from Applied Biosystems (Model 432A SYNERGY Peptide Synthesizer). The first peptide cartridge contained Wang resin pre-loaded with Fmoc-Thr on 25-μmole scale. Subsequent cartridges contained Fmoc-protected amino acids with side chain protecting groups for the following amino acids: Cys(Acm), Thr(t-Bu), Lys(Boc), Trp(Boc) and Tyr(t-Bu). The amino acid cartridges were placed on the peptide synthesizer and the product was synthesized from the C- to the N-terminal position. The coupling reaction was carried out with 75 μmoles of the protected amino acids in the presence of 2-(1H-benzotriazol-1-yl)-1,1,3,3-tetramethyluronium hexafluorophosphate (HBTU)/N-hydroxybenzotriazole (HOBt). The Fmoc protecting group was removed with 20% piperidine in dimethylformamide. After the synthesis was complete, the thiol group was cyclized with thallium trifluoroacetate and the product was cleaved from the solid support with a cleavage mixture containing trifluoroacetic acid (85%):water (5%):phenol (5%):thioanisole (5%) for 6 hours. The peptide was precipitated with t-butyl methyl ether and lyophilized with water:acetonitrile (2:3) mixture. The peptide was purified by HPLC and analyzed with LC/MS.
Octreotide, D-Phe-Cys'-Tyr-D-Trp-Lys-Thr-Cys'-Thr-OH (SEQ ID NO:2), wherein Cys' indicates the presence of an intramolecular disulfide bond between two cysteine amino acids, was prepared by the same procedure.
Bombesin analogs were prepared by the same procedure except that cyclization with thallium trifluoroacetate was not needed. Side-chain deprotection and cleavage from the resin was carried out with 50 μL each of ethanedithiol, thioanisole and water, and 850 μL of trifluoroacetic acid. Two analogues were prepared: Gly-Ser-Gly-Gln-Trp-Ala-Val-Gly-His-Leu-Met-NH 2 (SEQ ID NO:3) and Gly-Asp-Gly-Gln-Trp-Ala-Val-Gly-His-Leu-Met-NH 2 (SEQ ID NO:4).
Cholecystokinin octapeptide analogs were prepared as described for Octreotate without the cyclization step. Three analogs were prepared: Asp-Tyr-Met-Gly-Trp-Met-Asp-Phe-NH 2 (SEQ ID NO:5); Asp-Tyr-Nle-Gly-Trp-Nle-Asp-Phe-NH 2 (SEQ ID NO:6); and D-Asp-Tyr-Nle-Gly-Trp-Nle-Asp-Phe-NH 2 (SEQ ID NO:7) wherein Nle is norleucine.
A neurotensin analog, D-Lys-Pro-Arg-Arg-Pro-Tyr-Ile-Leu (SEQ ID NO:8), was prepared as described for Octreotate without the cyclization step.
EXAMPLE 10
Synthesis of Peptide-Dye Conjugates (FIG. 6 )
The method described below is for the synthesis of Octreotate-cyanine dye conjugates, but a similar procedure is used for the synthesis of other peptide-dye conjugates.
Octreotate was prepared as described in Example 9 but the peptide was not cleaved from the solid support and the N-terminal Fmoc group of Phe was retained. The thiol group was cyclized with thallium trifluoroacetate and the Phe was deprotected to liberate the free amine. Bisethylcarboxymethylindocyanine dye (53 mg, 75 μmoles) was added to an activation reagent consisting of a 0.2 M solution of HBTU/HOBt in DMSO (375 μL), and 0.2 M solution of diisopropylethylamine in DMSO (375 μL). The activation was complete in about 30 minutes and the resin-bound peptide (25 μmoles) was added to the dye. The coupling reaction was carried out at room temperature for three hours. The mixture was filtered and the solid residue was washed with DMF, acetonitrile and THF. After drying the green residue, the peptide was cleaved from the resin and the side chain protecting groups were removed with a mixture of 85% trifluoroacetic acid, 2.5% water, 2.5% thioanisole and 2.5% phenol. The resin was filtered and cold t-butyl methyl ether (MTBE) was used to precipitate the dye-peptide conjugate, which was dissolved in acetonitrile:water (2:3) mixture and lyophilized. The product was purified by HPLC to give the monoOctreotate-Bismethylcarboxymethylindocyanine dye (Cytate 1, 80%) and the bisOctreotate-Bismethylcarboxymethylindocyanine dye (Cytate 2, 20%). The monoOctreotate conjugate is obtained almost exclusively (>95%) over the bis conjugate by reducing the reaction time to two hours. However, this also leads to incomplete reaction, and the free Octreotate must be carefully separated from the dye conjugate in order to avoid saturation of the receptors by the non-dye conjugated peptide.
Octreotate-bispentylcarboxymethylindocyanine dye was prepared as described above with some modifications. Bispentylcarboxymethylindocyanine dye (60 mg, 75 μmoles) was added to an activation reagent consisting of a 0.2 M solution of HBTU/HOBt in DMSO (400 μL), and 0.2 M solution of diisopropylethylamine in DMSO (400 μL). The activation was complete in about 30 minutes and the resin-bound peptide (25 μmoles) was added to the dye. The reaction was carried out at room temperature for three hours. The mixture was filtered and the solid residue was washed with DMF, acetonitrile and THF. After drying the green residue, the peptide was cleaved from the resin and the side chain protecting groups were removed with a mixture of 85% trifluoroacetic acid, 2.5% water, 2.5% thioanisole and 2.5% phenol. The resin was filtered and cold t-butyl methyl ether (MTBE) was used to precipitate the dye-peptide conjugate, which was dissolved in an acetonitrile:water (2:3) mixture and lyophilized. The product was purified by HPLC to give Octreotate-1,1,2-trimethyl-[1H]-benz[e]indole propanoic acid conjugate (10%), monoOctreotate-bispentylcarboxymethylindocyanine dye (Cytate 3, 60%) and bis Octreotate-bispentylcarboxymethylindocyanine dye (Cytate 4, 30%).
EXAMPLE 11
Formulation of Peptide-Dye Coniugates in Dimethyl Sulfoxide (DMSO)
The dye-peptide conjugates are sparingly soluble in water and require the addition of solubilizing agents or co-solvents. Addition of 1-20% aqueous ethanol to the conjugates partially quenched the fluorescence intensity in vitro and the fluorescence was completely quenched in vivo (the conjugate was not detected by the charged coupled device (CCD) camera). Addition of 1-50% of DMSO either re-established or increased the fluorescence intensity of the conjugates in vitro and in vivo. The dye fluorescence remained intense for over one week. The DMSO formulations were well tolerated by experimental animals used for this invention.
EXAMPLE 12
Imaging of Pancreatic Ductal Adenocarcinoma (DSL 6A) with Indocyanine Green (ICG)
A non-invasive in vivo fluorescence imaging apparatus was employed to assess the efficacy of contrast agents developed for tumor detection in animal models. A LaserMax Inc. laser diode of nominal wavelength 780 nm and nominal power of 40 mW was used. The detector was a Princeton Instruments model RTE/CCD-1317-K/2 CCD camera with a Rodenstock 10 mm F2 lens (stock #542.032.002.20) attached. An 830 nm interference lens (CVI Laser Corp., part # F10-830-4-2) was mounted in front of the CCD input lens such that only emitted fluorescent light from the contrast agent was imaged. Typically, an image of the animal was taken pre-injection of contrast agent. This image was subsequently subtracted (pixel by pixel) from the post injection images. However, the background subtraction was never done once the animal had been removed from the sample area and returned at a later time for images taken several hours post injection.
DSL 6A tumors were induced in male Lewis rats in the left flank area by the introduction of material from a solid (donor) implant and the tumors were palpable in approximately 14 days. The animals were anesthetized with xylazine; ketamine; acepromazine 1.5:1.5:0.5 at 0.8 mL/kg via intramuscular injection. The area of the tumor (left flank) was shaved to expose tumor and surrounding surface area. A 21 gauge butterfly equipped with a stopcock and two syringes containing heparinized saline was placed into the later tail vein of the rat. Patency of the vein was checked prior to administration of the ICG via the butterfly apparatus. Each animal received 500 mL of a 0.42 mg/mL solution of ICG in water.
FIGS. 7A-B are tumor images of two minutes ( FIG. 7A ) and 30 minutes ( FIG. 7B ) post bolus injection of a 0.5 ml aqueous solution of ICG (5.4 μm). Tetracarboxylic acid cyanine dyes were synthesized as shown in FIG. 2 , with A=CH 2 or CH 2 OCH 2 ; R 1 ═R 2 ═H (Formula 1) or R 1 , R 2 =fused phenyl (Formula 2).
The Figures are false color images of fluorescent intensity measured at the indicated times, with images constrained to the tumor and a small surrounding area. As is shown, the dye intensity in the tumor is considerably diminished 30 minutes post-ICG injection.
EXAMPLE 13
Imaging of Prostatic Carcinoma (R3327-H) with Indocyanine Green (ICG)
The imaging apparatus and the procedure used are described as in Example 12. Prostrate tumors (Dunning R3327-H) were induced in young male Copenhagen rats in the left flank area from a solid implant. These tumors grow very slowly and palpable masses were present 4-5 months post implant. FIGS. 7C-D are images of a rat with an induced prostatic carcinoma tumor (R3327-H) imaged at two minutes ( FIG. 7C ) and 30 minutes ( FIG. 7D ) post injection.
The Figures are false color images of fluorescent intensity measured at the indicated times, with images constrained to the tumor and a small surrounding area. As is shown, the dye intensity in the tumor is considerably diminished 30 minutes post-ICG injection.
EXAMPLE 14
Imaging of Rat Pancreatic Acinar Carcinoma (CA20948) with Indocyanine Green (ICG)
The imaging apparatus and the procedure used are described in Example 12. Rat pancreatic acinar carcinoma expressing the SST-2 receptor (CA20948) was induced by solid implant technique in the left flank area, and palpable masses were detected nine days post implant. The images obtained at 2 and 30 minutes post injection are shown in FIG. 7E-F . FIGS. 7E-F are images of a rat with an induced pancreatic acinar carcinoma (CA20948) expressing the SST-2 receptor imaged at two minutes ( FIG. 7E ) and 30 minutes ( FIG. 7F ) post injection.
The Figures are false color images of fluorescent intensity measured at the indicated times, with images constrained to the tumor and a small surrounding area. As is shown, the dye intensity in the tumor is considerably diminished and almost absent 30 minutes post-ICG injection.
EXAMPLE 15
Imaging of Rat Pancreatic Acinar Carcinoma (CA20948) with Cytate 1
The imaging apparatus and the procedure used are described in Example 12 except that each animal received 500 μl of a 1.0 mg/mL solution of Cytate 1 solution of 25% dimethylsulfoxide in water.
Rat pancreatic acinar carcinoma expressing the SST-2 receptor (CA20948) were induced by solid implant technique in the left flank area, and palpable masses were detected 24 days post implant. Images were obtained at various times post injection. Uptake into the tumor was seen at two minutes but was not maximal until about five minutes.
FIGS. 8A-B show a comparison of the uptake of ICG and Cytate 1 at 45 minutes in rats with the CA20948 tumor cell line. By 45 minutes the ICG has mostly cleared ( FIG. 8A ) whereas the Cytate 1 is still quite intense ( FIG. 8B ). This dye fluorescence remained intense in the tumor for several hours post-injection.
EXAMPLE 16
Imaging of Rat Pancreatic Acinar Carcinoma(CA20948) with Cytate 1 Compared with Imaging with Indocyanine Green
Using indocyanine green (ICG), three different tumor lines were imaged optically using a CCD camera apparatus. Two of the lines, DSL 6/A (pancreatic) and Dunning R3327H (prostate) indicated slow perfusion of the agent over time into the tumor and reasonable images were obtained for each. The third line, CA20948 (pancreatic), indicated only a slight but transient perfusion that was absent after only 30 minutes post injection. This indicated no non-specific localization of ICG into this line compared to the other two tumor lines, suggesting a different vascular architecture for this type of tumor (see FIGS. 7A-F ). The first two tumor lines (DSL 6/A and R3327H) are not as highly vascularized as CA20948 which is also rich in somatostatin (SST-2) receptors. Consequently, the detection and retention of a dye in this tumor model is a good index of receptor-mediated specificity.
Octreotate is known to target somatostatin (SST-2) receptors, hence, cyano-Octreotates (Cytate 1 and Cytate 2) was prepared. Cytate 1 was evaluated in the CA20948 Lewis rat model. Using the CCD camera apparatus, localization of this dye was observed in the tumor (indicated by arrow) at 45 minutes post injection ( FIG. 9A ). At 27 hours post injection, the animal was again imaged ( FIG. 9B ). Tumor visualization was easily observed (indicated by arrow) showing specificity of this agent for the SST-2 receptors present in the CA20948 tumor line.
Individual organs were removed at about 24 hours post Cytate 1 administration and imaged. As shown in FIG. 10 , high uptake of Cytate 1 was observed in the pancreas, adrenals and tumor tissue, while heart, muscle, spleen and liver indicated significantly lower uptake. These data correlate well with radiolabeled Octreotate in the same model system (M. de Jong, et al. Cancer Res. 1998, 58, 437-441).
EXAMPLE 17
Imaging of Rat Pancreatic Acinar Carcinoma (AR42-J) with Bombesinate
The AR42-J cell line is derived from exocrine rat pancreatic acinar carcinoma. It can be grown in continuous culture or maintained in vivo in athymic nude mice, SCID mice, or in Lewis rats. This cell line is particularly attractive for in vitro receptor assays, as it is known to express a variety of hormone receptors including cholecystokinin (CCK), epidermal growth factor (EGF), pituitary adenylate cyclase activating peptide (PACAP), somatostatin (SST-2) and bombesin.
In this model, male Lewis rats were implanted with solid tumor material in a similar manner as described for the CA20948 rat model. Palpable masses were present seven days post implant, and imaging studies were conducted on animals at 10-12 days post implant when the mass had achieved about 2-2.5 g.
FIG. 11 is an image of bombesinate in an AR42-J tumor-bearing rat, as described in Example 16, at 22 hours post injection of bombesinate. As shown in FIG. 11 , specific localization of the bioconjugate in the tumor (indicated by arrow) was observed.
EXAMPLE 18
Monitoring of the Blood Clearance Profile of Peptide-Dye Conjugates
A laser of appropriate wavelength for excitation of the dye chromophore was directed into one end of a fiber optic bundle and the other end was positioned a few millimeters from the ear of a rat. A second fiber optic bundle was also positioned near the same ear to detect the emitted fluorescent light and the other end was directed into the optics and electronics for data collection. An interference filter (IF) in the collection optics train was used to select emitted fluorescent light of the appropriate wavelength for the dye chromophore.
Sprague-Dawley or Fischer 344 rats were used in these studies. The animals were anesthetized with urethane administered via intraperitoneal injection at a dose of 1.35 g/kg body weight. After the animals had achieved the desired plane of anesthesia, a 21 gauge butterfly with 12″ tubing was placed in the lateral tail vein of each animal and flushed with heparinized saline. The animals were placed onto a heating pad and kept warm throughout the entire study. The lobe of the left ear was affixed to a glass microscope slide to reduce movement and vibration.
Incident laser light delivered from the fiber optic was centered on the affixed ear. Data acquisition was then initiated, and a background reading of fluorescence was obtained prior to administration of the test agent. For Cytates 1 or 2, the peptide-dye conjugate was administered to the animal through a bolus injection, typically 0.5 to 2.0 ml, in the lateral tail vein. This procedure was repeated with several dye-peptide conjugates in normal and tumor bearing rats. Representative profiles as a method to monitor blood clearance of the peptide-dye conjugate in normal and tumor bearing animals are shown in FIGS. 12-16 . The data were analyzed using a standard sigma plot software program for a one compartment model.
In rats treated with Cytates 1 or 2, the fluorescence signal rapidly increased to a peak value. The signal then decayed as a function of time as the conjugate cleared from the blood stream. FIG. 12 shows the clearance profile of Cytate 1 from the blood of a normal rat monitored at 830 nm after excitation at 780 nm. FIG. 13 shows the clearance profile of Cytate 1 from the blood of a pancreatic tumor (CA20948)-bearing rat also monitored an 830 nm after excitation at 780 nm.
FIG. 14 shows the clearance profile of Cytate 2 from the blood of a normal rat, and FIG. 15 shows the clearance profile of Cytate 2 from the blood of a pancreatic tumor (CA20948)-bearing rat, monitored at 830 nm after excitation at 780 nm.
FIG. 16 shows the clearance profile of Cytate 4 from the blood of a normal rat, monitored at 830 nm after excitation at 780 nm.
It should be understood that the embodiments of the present invention shown and described in the specification are only specific embodiments of inventors who are skilled in the art and are not limiting in any way. Therefore, various changes, modifications, or alterations to those embodiments may be made or resorted to without departing from the spirit of the invention in the scope of the following claims. The references cited are expressly incorporated by reference herein in their entirety.
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Cyanine and indocyanine dye compounds and bioconjugates are disclosed. The present invention includes several cyanine and indocyanine dyes, including bioconjugates of the same, with a variety of bis- and tetrakis (carboxylic acid) homologues. The compounds of the invention may be conjugated to bioactive peptides, carbohydrates, hormones, drugs, or other bioactive agents. The small size of compounds of the invention allows favorable delivery to tumor cells as compared to larger molecular weight imaging agents. Further, use of a biocompatible organic solvent such as dimethylsulfoxide may be said to assist in maintaining the fluorescence of compounds of the invention. The compounds and bioconjugates herein disclosed are useful in a variety of medical applications including, but not limited to, diagnostic imaging and therapy, endoscopic applications for the detection of tumors and other abnormalities, localized therapy, photoacoustic tumor imaging, detection and therapy, and sonofluorescence tumor imaging, detection and therapy.
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BACKGROUND OF THE INVENTION
The present invention concerns an air guide box for the drying section of a high-speed paper machine where the paper web to be dried meanders together with a backing belt forming a continuous backing belt loop across drying cylinders, and at that, alternately across drying cylinders that are located outside and inside the backing belt loop. An air guide box of the categorial type is known from the German patent document No. 32 36 576 which is equivalent to U.S. Pat. No. 4,502,231.
In a drying section using such air guide boxes, as is generally known, the drying cylinders are arranged in two tiered rows. The paper web and a continuous backing belt run alternately across cylinders of an upper and a lower row. The cylinders arranged in the one row, preferably the top row, are contained outside the continuous backing belt loop, whereas the cylinders of the other row, preferably the bottom row, are arranged within the continuous backing belt loop. The air guide box is always arranged on a backing belt section running from an outside (preferably top) to an inside (preferably bottom) cylinder.
The expression "cylinder" respectively "drying cylinder" is to be understood here quite generally, i.e., it covers not only steam-heated drying cylinders with a smooth cylinder surface but also guide rolls with a smooth, profiled or perforated surface which, when needed, may be fashioned as suction rolls. This is because the inventional air guide box is suitable for drying sections of various designs. In a preferable design, both the outside and inside cylinders are fashioned as steam-heated drying cylinders. In another preferred drying section design, only the outside cylinders are fashioned as steam-heating drying cylinders, whereas the inside cylinders, i.e., preferably those of the bottom row, are designed as guide rolls or as suction guide rolls.
Forces of various types act in the drying section of a high-speed paper machine on the paper web and the backing belt; as the paper web and the backing belt pass through the paper machine, these forces cause at increasing speed phenomena such as web flutter, web liftoff and wrinkling. These phenomena, which possibly may even lead to a break of the paper web, are to be avoided as much as possible.
This objective was extensively accomplished already with the air guide box according to the German patent document No. 32 36 576, which is known also by the name "web stabilizer". But specific examinations of the air flows, for one, and practical experience, for another, have shown that the prior air guide box can be optimized further in view of the requirements imposed on it.
In the practical operation of high-speed paper machines using air guide boxes according to the German patent document No. 32 36 576, the following was noticed at increasing machine speeds: There is a risk that the backing belt, which together with the paper web meanders across the drying cylinders, will at times brush against the air guide box. Such a contact occurs specifically on the so-called boundary layer stripper arranged on the entrance (preferably upper) end of the first box wall (also called "foil wall"). But an undesirable contact with the backing belt may occur also on the foil wall. Attempts were made at circumventing these problems by adjusting a greater space between the trajectory of the backing belt and the foil wall. But this approach was not satisfactory either because it invited the risk that--at least at times--the foil effect is lost, i.e., that an appreciable vacuum is no longer created in the gap between the backing belt and the air guide box.
Considered also was a replacement of the mechanical boundary layer stripper by a blowing air jet (air scraper) directed at the backing belt; refer to column 6, lines 14 and 15, of the German patent document No. 32 36 576. But this has the disadvantage that the consumption of blowing air increases considerably. Besides, there is the risk that the blowing air jet directed at the backing belt will penetrate the backing belt and cause the paper web to lift off the backing belt. But the objective is exactly the opposite, namely causing the paper web to safely adhere to the backing belt.
Previously known is an arrangement such that the entrance edge of the foil wall of the air guide box, on which the boundary layer stripper is mounted, is arranged in the area where the backing belt separates from the upper cylinder. This arrangement would result in the case of the prior air guide box when the vertical distance between the upper cylinder row and the lower cylinder row is smaller than illustrated in the German patent document No. 32 36 576. Such an arrangement, in principle, is known already in the case of a large vertical cylinder spacing. The length of the air guide box--viewed in cross-section--is in this case enlarged accordingly. But this increases also the risk of a contact between the backing belt and the foil wall of the air guide box and, thus, the risk of wear on these elements.
The problem underlying the present invention is therefore to so modify the design of the prior air guide box that the risk of wear is eliminated or at least reduced on the backing belt and on the air guide box itself, which is in no way to adversely affect the stability of the run of the paper web in contact with the backing belt, but rather to improve it further, thereby enabling in the future machine speeds that are higher yet than heretofore. This problem is solved by the present invention.
In other words, this means that the so-called foil wall of the air guide box is no longer of flat design such as before, but is adapted to the curved course of the backing belt that adjusts itself operationally. This adaptation is to be such that now as before (i.e., despite the curved course of the backing belt) the gap between the backing belt and the air guide box diverges gradually in the running direction of the backing belt, thereby ensuring the foil effect of the air guide box across its entire length, viewed in cross-section.
The inventional design takes into account that the course of the backing belt and the paper web deviate more or less from the theoretical, straight running course tangent to the two cylinder surfaces as the machine speed increases, with said course more or less bowing out toward the air guide box. The adaptation of the foil wall to this bow-out ensures that the backing belt and the foil wall will not make contact even at high machine speeds and that the entrance and edge of the foil wall--despite a large vertical cylinder spacing (and thus a great length of the air guide box--viewed in cross-section) --can be arranged at the point where the paper web and the backing belt are still in contact with the upper cylinder. In other words, the entrance end edge of the foil wall can be safely arranged in the area of the departure point of the backing belt from the upper cylinder and even before it (relative to the running direction). This latter variant will be explained below.
Thus, it is inventionally possible to always make use of the possibility of adjusting between the entrance end, on which now as before a boundary layer stripper is arranged, and the backing belt an exactly definable small spacing. This makes it possible for the boundary layer stripper to preferably work in noncontact fashion. This is true not only for the case when the boundary layer stripper is fashioned as a blowing air jet (air scraper), but it applies specifically also in the preferred case where a mechanical boundary layer stripper is concerned (felt strip, brush slat or similar). This eliminates also the risk that the seam that makes the backing belt continuous and is thicker than the backing belt itself will make contact with the boundary layer stripper. Additionally, there is now always the previously known advantage that the effect of the air guide box, namely the creation of a vacuum in the gap between the backing belt and the air guide box, begins already at the point where the paper web and the backing belt depart from the upper drying cylinder. This counteracts the tendency of the paper web to continue, at the departure point, clinging for a short distance to the cylinder surface of the drying cylinder and only then settle again on the backing belt.
As already indicated though, the boundary layer stripper need not be arranged exactly at the departure point of the backing belt from the upper drying cylinder. Rather, the invention makes it possible to extend the air guide box somewhat further upward so that the boundary layer stripper is situated within the so-called looping zone in which the paper web and the backing belt touch the curved cylinder surface of the upper drying cylinder. This is advantageous because stripping the boundary air layer carried by the backing belt is more effective in this area. This utilizes the phenomenon that a vacuum is created in the radially inner area of an air boundary layer proceeding along a curved course, so that the air in the radially inner partial layer is thinner than in the radially outer partial layers.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully explained hereafter with the aid of the drawing:
FIG. 1 shows schematically a section of a drying section of a paper machine;
FIG. 2 shows an inventional air guide box, in cross-section and scaled up relative to FIG. 1; and
FIG. 3 shows a partial cross-section of an embodiment differing from FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The five drying cylinders 10 through 14 illustrated in FIG. 1 form a drying group of a drying section. Another drying cylinder, marked 15, is an integral part of a subsequent drying group. The drying cylinders 10, 12 and 14 are arranged in an upper row, the cylinders 11 13 and 16 in a bottom row. The paper web 16 to be dried meanders in the direction of arrows 17 across the drying cylinders. Within the first drying group 10 through 14, the web is constantly accompanied by the continuous, air-permeable backing belt (drying screen) 18, which from the cylinder 14 returns again to the first cylinder 10 via guide rolls 9. The drying cylinders 10, 12 and 14 of the top row are situated outside the loop formed by the backing belt 18, whereas the cylinders 11 and 13 of the bottom row are situated within the loop. The paper web 16 extends thereby in the area of the upper cylinders 10, 12 and 14 between their cylinder surfaces and the backing belt 18. In the area of the bottom cylinders 11 and 13, conversely, the paper web 16 is located on the outside of the backing belt 18 bearing on these cylinders. On the free sections between the cylinders 12 through 14, the paper web 16 is supported by the backing belt 18. A free paper train exists for the first time between the cylinders 14 and 15. In the following drying groups, each cylinder row has a backing belt 19 of its own.
Provided on the common course of the paper web 16 and the backing belt 18, from one of the upper drying cylinders 10 respectively 12 to one of the lower cylinders 11 respectively 13, is an air guide box 20 each, on the side of the backing belt. Rigid and having a length equal to the web width or less, each of the air guide boxes 20 extends transverse to the drying section. Shorter air guide boxes are preferably arranged in the marginal areas of the paper web.
True for all embodiments is that the air guide box with the illustrated cross-sectional shape extends normally crosswise through the entire drying section, that is, from the backing belt edge on the tending side to that of the drive side and still somewhat farther beyond these edges. But it is also possible to provide two relatively short air guide boxes only in the area of the two edges, since it may at times be sufficient to suck only the paper web edges to the backing belt.
An air guide box 20 is described hereafter in more detail. Essentially closed on all sides, the air guide box 20 has a first wall 21 which hereafter will be referred to as foil wall and which, viewed in the cross-section of the air guide box 20, extends along the backing belt 18 up to the inlet gore formed by it and the free cylinder surface of the lower drying cylinder 11 respectively 13. This leaves between the foil wall 21 and the backing belt 18 a gap 23 that diverges toward the inlet gore.
The air guide box described thus far is the object of the German patent document No. 32 36 576. Different from it, the air guide box according to the present invention extends considerably farther in the direction toward the upper half of the cylinder surface of the respective upper drying cylinder 10 respectively 12, and the foil wall 21 is with regard to the divergence of the gap 23 of the real web curve designed accordingly.
This air guide box 20 will be more fully described with the aid of FIG. 2. Illustrated in FIG. 2 are an upper drying cylinder 10, 12 and a lower drying cylinder 11, 13. The paper web 16 and the backing belt 18 separate from the upper drying cylinder 10, 12 and run to the lower drying cylinder 11, 13. On condition of a low speed and proper backing belt tension, the paper web 16 and the backing belt 18 would each respectively approach tangentially along an ideal curve I. Due to, e.g., dead weight and centrifugal forces and due to the vacuum created between the backing belt 18 and the air guide box 20 though, this trajectory bows out toward the air guide box 20.
The extent of this bow-out is determined, among others, by the longitudinal tension which is present in the backing belt 18, which customarily can be adjusted by means of a tensioning roll 9' (see FIG. 1). At any rate, an arcuate (real) trajectory R occurs between the upper 10, 12 and lower drying cylinders 11, 13. This real trajectory R, in the final analysis, corresponds to the shape of the paper web 16 and the backing belt 18 enroute from the delivering cylinder 10, 12 to the receiving cylinder 11, 13 and the foil wall 21 of the air guide box is adapted approximately to this trajectory R, and at that, with the proviso that the gap 23 between the trajectory R and the departure point A from the delivering cylinder 10, 12 to the approach point Z of the receiving cylinder 11, 13 diverges, and thus increases across the length of the first wall.
According to the illustration in FIG. 2, the gap 23 is realized by a polygonal design of the foil wall 21. In a first area 21.1 bordering on the departure point A, the foil wall 21 extends about parallel to the trajectory R; in a second, subsequent area 21.2, the foil wall 21 extends, viewed in the running direction 17, under conical divergence relative to the trajectory R; and in a third area 21.3 the foil wall 21 extends again approximately parallel with the trajectory R. Due to this diverging gap 23, the above mentioned vacuum is generated across the entire length of the foil wall 21, favoring the adhesion between the paper wall 16 and the air-permeable backing belt 18.
The air guide box 20 as a whole, in detail, is designed as follows. Arranged on the upper edge 24 of the foil wall 21 is a boundary layer stripper 25 which extends toward the backing belt 18. Consisting of a felt strip or a plastic brush or also a so-called air scraper, this boundary layer stripper 25 extends close (space a of about 2 mm) to the free surface of the backing belt 18 and provides noncontact stripping of the air boundary layer carried by the belt. To avoid backups in the area of the boundary layer stripper 25, the invention provides for setting the wall 40 of the air guide box bordering in this area on the foil wall 21 at an acute angle. This makes for an easier separating sweep of the air (arrow 41).
Additionally, the air guide box 20 has a second wall 26 which, forming a gap 27 relative to the cylinder surface of the lower drying cylinder 11 respectively 13, meets in the area of the inlet gore 22 with the foil wall 21. Provided there is an aerodynamic rounding 42, from the foil wall 21 to the second wall 26. As compared with the air guide box according to the German patent document No. 32 36 576, the air flowing through the gap 23 toward the inlet gore 22 can transfer to the gap 27 on the cylinder side along a path shorter than before (and thus with lower flow losses).
Second wall 26, in its area on the gore end, features a slot-shaped opening 29 for the discharge of air. This opening 29 extends in the longitudinal direction of the air guide box 20. Facultatively, the opening 29 is bridged by spaced connecting strips so as to secure in the case of very long air guide boxes 20 the stability of the sections of the second wall 26 which are located on both sides of the opening. As can be seen in FIG. 2, the blowing direction of the opening 29 extends at an acute angle to the second wall 26 and essentially opposite to the running direction 35 of the cylinder 11, 13.
The air guide box 20 is connected, on its end, to a blowing air line 30. Located inside the air guide box 20, in the path of the blowing air flow from the feed line 30 to the slot-shaped opening 29, is a baffle 31. This latter extends across the entire box length and defines, together with the second wall 26, a cross-sectionally nozzle-shaped space 32 that extends into the slot-shaped opening 29. Additionally, a curved channel 33 may be provided between the foil wall 21 and the second wall 26, connecting the gap 23 on the backing belt side and the gap 27 on the cylinder side with each other. The curvature of this channel is such that it extends, viewed in the running direction 17, at an acute angle to the trajectory R and at an acute angle to the surface of the lower drying cylinder 11, 13. The channel 33--so as not to prevent the flow of blowing air from the feed line 30 to the slot-shaped opening 29--is designed as a number of curved pipes 34 extending in the longitudinal direction of the air guide box 20. The end of the channel 33, on the backing belt side, is located in the bottom third of the foil wall 21. Viewed in the running direction (arrow 35) of the lower drying cylinder 11 respectively 13, the mouth of the channel 33 on the cylinder side is located closely before the slot-shaped opening 29. The second wall 26 diverges from the lower drying cylinder 11, 13 so that the gap 27 undergoes opposite to the running direction of the lower drying cylinder 11, 13 (arrow 35) a widening which favors the flow conditions.
The flow conditions prevailing around the air guide box 20 and in the air guide box itself present themselves as follows. The blowing air proceeding to the air guide box 20 negotiates on its way to the slot-shaped opening a choke gap 37 which is defined by the foil wall 21 and the baffle 31 and which causes the pressure of the air to be evenly distributed across the length of the air guide box 20. In the nozzle-shaped space 32, the blowing air undergoes an acceleration so that it enters the gap 27 at high speed and opposite to the running direction (arrow 35) of the lower drying cylinder 11 respectively 13. In the course of its flow path through the gap 27 on the cylinder side, the blowing air stripe the air boundary layer that is carried by the lower drying cylinder 11, 13 and prevents it from being carried into the inlet gore 22.
The boundary layer stripper 25 on the entrance side edge 24 of the foil wall 21 deflects a considerable part of the air boundary layer from the backing belt 18 across the mentioned wall 40. Due to the previously described divergence of the gap 23 on the backing belt side toward the inlet gore 22, a vacuum is created in this gap 23 (and thus the so-called "foil effect"). This vacuum tends to equalize itself by sucking air through the backing belt 18, causing the intended settling of the paper web 16 on the backing belt 18. Additionally, a considerable increase of the vacuum occurs yet on account of the ejector effect of the blowing air in the gap 27 on the cylinder side. This is because air is siphoned off both from the inlet gore 22 and through the channel 33 from the gap 23 on the backing belt side, by this blowing air. In this respect, reference is made explicitly to the illustration in FIG. 2, where the arrows show clearly the air flows described.
Illustrated in the embodiment according to FIG. 3 is an air guide box 20a where the upper edge 24a of the foil wall 21a with the boundary layer stripper 25 is located above the departure point A of the backing belt 18 from the upper cylinder 10, 12. The boundary layer stripper 25 is thus located within the looping zone of the paper web 16 and backing belt 18, thereby favoring the stripping of the air boundary layer.
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Air guide box 20 for a paper machine where the paper web 16 to be dried runs together with the backing belt 18 across drying cylinders 10 through 14. The air guide box 20 extends from a point A where the backing belt 18 departs from a cylinder 10, 12 toward a point Z where the backing belt runs on the following cylinder 11, 13. A diverging gap 23 remains between the air guide box 20 and the backing belt 18. The air guide box 20 has in the area of the departure point A a mechanical air boundary layer stripper 25. Facing toward the backing belt 18 and diverging in its running direction from the contact screen, the wall 21 of the air guide box 20 is shaped in accordance with the operationally occurring curved trajectory of the contact screen 18, is composed, preferably in polygon fashion, from flat wall elements 21.1, 21.2 and 21.3.
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BACKGROUND OF THE INVENTION
The invention concerns a device for the prevention of the abuse of a dry-plate clutch for a motor vehicle with a manual gearbox, wherein the device acts jointly with a hydraulic master cylinder and a related slave cylinder in the operation of the clutch.
The use of a device of the above-mentioned type prevents the transfer of an excessive torque gradient (torque change per time unit) to the transmission due to a too rapid release of the clutch pedal during the engagement of the clutch. Such abuse of the clutch is especially risky when starting in, first gear or in reverse gear, as well as when moving through the lowest gears when driving forwards. The sudden forces acting on the transmission during such a rapid engaging of the clutch often result in damage to the differential gears, the crown wheel and the pinion of the rear axle transmission unit, the drive shaft and the gearbox, but damage has also been found in engines due to frequent abuse of the clutch. There are previously known devices for counteracting the abuse of the clutch, where the devices are not included in the hydraulic clutch system, but comprise levers and rods which are connected to the clutch pedal or the clutch master cylinder's piston rod or the clutch disengagement arm, and are effective shock absorber. These mechanical systems must be manufactured with fine tolerances, are difficult to instal, expensive and dampen the clutch movement every time it is engaged, even when the clutch pedal is released in the correct manner.
Another known system for counteracting the abuse of the clutch works hydraulically via a choke device with a non-return valve installed in a bypass pipe. When the clutch is engaged the non-return valve closes, thus causing all the hydraulic fluid to flow via the choke device, thereby providing a damping during the entire return movement of the clutch pedal. In this case too a damping takes place each time the clutch is engaged, irrespective of whether the clutch pedal is moved rapidly or slowly. Since the damping takes place during the entire return movement, a rapid gear change is virtually impossible, a fact which is particularly critical and awkward when changing gear at low temperatures since the damping increases and the clutch can slip.
For this reason, in another embodiment of this system an electromagnetically controlled valve is incorporated which engages the device only when the clutch is used in connection with first gear and reverse gear. Thus there is no protection against abuse of the clutch in the other gears.
From DE1600184, DE3031262 and FI842051 there are known devices of the above-mentioned type where a valve ensures that a pressure-based clutch can be engaged rapidly until a predetermined pressure has built up in the hydraulic fluid, whereupon a delay occurs. Apart from this no consideration is given to whether the clutch is operated rapidly or slowly. Thus this solution is not suitable for spring-based dry-plate clutches.
The object of the invention is to provide a device of the type described in the introduction which is not encumbered by the above-mentioned disadvantages.
SUMMARY OF THE INVENTION
To achieve this object, the invention provides in a device for the prevention of the abuse of a dry-plate clutch for a motor vehicle with a manual gearbox due to too rapid an engagement of the clutch, wherein the device acts jointly with a hydraulic master cylinder and a related slave cylinder for operation of the clutch, and the device includes a valve unit that is installed hydraulically in series with and between the master cylinder and the slave cylinder, the valve unit having a valve body and a valve housing having a valve seat for the valve body and a first and a second valve housing chamber located on each side of the valve seat and arranged to face the slave cylinder and the master cylinder respectively, the valve unit opening when there is movement of the valve body from the valve seat and into the first valve housing chamber of the valve unit, the improvement comprising a first passage directly connecting the first and second valve chambers of the valve unit with each other to permit restricted fluid flow between the chambers when the valve body sits on the valve seat and the valve unit is closed, means for forcibly opening the valve unit when the clutch is located in a position between a position of maximum disengagement and a second position located close to the position in which the clutch begins to engage, and a spring arranged to exercise a force on the valve body to bias the valve body away from the valve seat, wherein the force exercised by the spring is greater than the force exercised on the valve body by the hydraulic fluid when the fluid flows towards the master cylinder during a predetermined normal rate of engagement of the clutch, but wherein the force exercised by the spring is less than the force exercised on the valve body by the hydraulic fluid when the clutch is engaged more rapidly than at said predetermined rate.
The characteristic features of the device according to the invention will now be described in more detail with reference to the drawings which illustrates schematically an embodiment of a device according to the invention.
FIG. 1 is a sketch of a hydraulic system for operating a clutch of a motor vehicle, wherein some of the components are shown in section, a clutch pedal is located in its rest position and a clutch of the dry-plate type is engaged.
FIG. 2 is a longitudinal section through the device where it is located in its rest position.
DETAILED DESCRIPTION OF THE INVENTION
In the following description the indications of direction should be understood with reference to the figures unless otherwise specified.
As illustrated in FIG. 1 a system for operating a clutch 1 comprises a clutch pedal 2 which the driver of the vehicle can move with his foot, a hydraulic master cylinder 3 and a slave cylinder 4. The clutch pedal 2 is linked to the piston 5 of the master cylinder 3 via a piston rod 6 which projects from one end of the master cylinder's cylinder part 7. The master cylinder 3 communicates with the slave cylinder 4 by means of a conduit 8.
The slave cylinder's piston 9 is linked via a piston rod 10 which projects from one end of the slave cylinder's cylinder part 11 to a rotatably mounted lever 12, whereby the clutch's thrust bearing 13 and spring means 15 can be moved. Thus by depressing the pedal 2 the clutch plates can be moved in the known manner towards the right in FIG. 1 to disengage the clutch and vice versa.
At the end of the master cylinder 3 which is provided hydraulically closest to the slave cylinder 4 there is installed a valve unit 20 which constitutes an abuse device for the clutch 1, i.e. a device for counteracting the abuse of the clutch. This valve unit 20 comprises a preferably cylindrical Valve housing 21 one end of which is connected to the master cylinder's cylinder part 7 via e.g. flange sections 23, 24 of the valve unit 20 or the master cylinder 3, the flange sections being capable of being connected to each other by means of screws 25 or the like, as indicated by chain-dotted lines. The valve unit 20 and the master cylinder 3 are preferably coaxial.
The master cylinder 3 and the valve unit 20 communicate with each other via through-going passages 26 which are provided in a transverse end wall 27 at the right hand end of the valve housing 21. The conduit 8 whereby the slave cylinder 4 and the valve unit 20 communicate with each other is screwed into a threaded bore 28 at the other end of the valve housing 21.
In a radially extending circular shoulder section 30 which faces the bore 28, and which projects into the valve housing, there is provided a seat 31 for a valve body 32, which is supported by an axially and centrally extending valve rod 33. This is slidably passed into a sleeve 34 which in turn is slidably passed into a central bore in the end wall 27. The valve rod 33 projects into the master cylinder and is closed with an end plate 35, a threaded end section of the valve rod 33 being screwed into a threaded hole in the end plate.
The sleeve 34 comprises a first and a second sleeve section 36 and 37 which extend coaxially to each other and are permanently connected to each other by means of a threaded joint in order to permit the installation of the sleeve. The first sleeve section 36 has an end flange 38 and a stem section 39. The outer diameter of the end flange 38 and the second sleeve section 37 are larger than the diameter of the bore in the end wall 27, and the outer diameter of the stem section 39 is adapted to the diameter of the bore in the end wall 27, thus enabling the stem section 39 to be moved slidably to the right and the left in this bore, the sleeve's movement to the left thus being restricted by the second sleeve section 37 abutting against the right side of the end wall 27. The sleeve's inner diameter is adapted to the diameter of the valve rod 33, thus enabling it to be moved to the right and the left in relation to the sleeve 34, since such movement of the valve rod 33 can be restricted by the valve body 32 abutting against the end flange 38 of the first sleeve section 36 or by the end plate 35 abutting against the right end surface of the second sleeve section 37.
A first helical spring 40 which is provided around the sleeve's 34 stem section 39 and between the end flange 38 and the end wall 27 attempts to move the sleeve to the left in relation to the valve housing 21. A second helical spring 41 which is provided around the valve rod 33 and extends between the end plate 35 and the second sleeve section 37 attempts to move the valve body 32 and the valve rod 33 to the right in relation to the sleeve 34.
When the valve body 32 abuts against its seat 31, it divides the valve housing 21 into a first valve housing chamber 51 which faces the slave cylinder, and a second valve housing chamber 52 which faces the master cylinder. By means of at least one axially extending passage 53 through the valve body 32 communication is provided between these valve housing chambers 51, 52 even when the valve housing 32 abuts against its seat. Furthermore the valve body has a cylindrical piston section 54 whose outer diameter is only slightly smaller than the inner diameter of the first valve housing chamber 51. In the piston section 54 there is provided at least one axially extending, through-going, second passage 55. When the valve body is only affected by the springs 40, 41, an opening 56 is formed between the valve body 32 and the valve seat 31.
Furthermore the diameter of the valve body 32 is so much smaller than the inner diameter of the valve housing chamber 51 that the radially extending opening between these components does not cause any significant flow resistance for the fluid. When the valve body does not abut against its seat, fluid will thus preferably flow through this radial opening rather than flowing through the first passage 53.
The method of operation of the device is as follows.
In order to disengage the clutch 1 the clutch pedal 2 is first depressed, and the master cylinder's piston 5 is thereby moved to the left in the cylinder part 7. Hydraulic fluid is then forced through the passages 26 in the end wall 27 and on through the opening 56 and the passage 55 in the valve body. From there the fluid flows on to the slave cylinder. Since these passages 26, 55 and the opening 56 are large, there is little flow resistance.
After some movement of the piston 5, means are provided for forcibly opening the valve unit. As embodied, this means comprises valve rod 33 and its end plate 35, piston 5 abutting against the end plate 35, whereupon the piston also moves the valve body 32 to the left via the valve rod 33. If the diameter of the first valve chamber 51 which constitutes a cylinder for the piston section 54 corresponds to the inner diameter of the master cylinder's cylinder part 7, no fluid will flow through the passage 55, since the amount of fluid flowing out of the first valve housing chamber 51 corresponds to the amount of fluid being forced into it from the master cylinder via the passage 26. The clutch will preferably be disengaged and brought into its maximum disengaged position without the end plate 35 having abutted against the right hand end of the second sleeve section 37.
If the clutch subsequently has to be engaged, the clutch pedal 2 is first released, thereby moving the master cylinder's piston 5 to the right. Oil flows thereby from the slave cylinder 4 and into the master cylinder 3 via the valve unit 20. By means of the second spring 41 the end plate 35 will thereby be pressed against the master cylinder's piston 5 and force the valve body 32 to follow its movement. Since for the above-mentioned reason oil too preferably does not flow through the passage 55 in the valve body piston section 54 during this movement, the valve body 32 will not offer any significant resistance to the fluid flow.
When the valve body 32 abuts against the end flange 38 of the first sleeve section 36, the end plate 35 is prevented from following the further movement of the piston 5 to the right. During this first phase of engagement the clutch has been moved from a position of maximum disengagement to a position close to that in which the clutch plates begin to engage.
During the subsequent, second phase of engagement and continued movement of the piston 5 to the right, an amount of fluid corresponding to that which is displaced by the slave cylinder's piston 9 will be forced through the second passage 55 because the valve body 32 is now at rest. If the clutch is then correctly engaged, i.e. at the correct speed, the differential pressure which is created over the piston section 54 due to the fluid's being choked in this second passage 55 and in the opening 56, will not be sufficiently great to create a force which is exercised on the valve body 32, and which is greater than the force which is exercised by the first spring 40. The valve body therefore remains at rest.
The second phase is concluded immediately after the clutch plates are engaged with full force.
During a third final phase the clutch pedal is thereafter moved all the way back, during which the piston 5 of the master cylinder 3 is moved to the position it had before the disengagement of the clutch started. Even if the clutch pedal is moved somewhat more rapidly during this final third phase than during the second phase, the valve body will still not abut against its seat, thus making normal, correct engagement of the clutch possible.
However, if the clutch pedal should be moved so rapidly during the second phase that a corresponding rapid engagement of the clutch could cause damage to the transmission, the differential pressure which is created over the valve body 32 due to the increased fluid flow through the second passage 55 and the opening 56, will cause the force which is exercised on the valve body 32 to the right to become greater than the force which is exercised on it by the first spring 40 in the opposite direction, thus causing the valve body 32 to be moved to the right and to abut against the valve seat 31. In this case the fluid has to pass through the first passage 53. The fluid flow is thereby considerably more choked, which leads to a reduction in the speed of the piston 9 of the slave cylinder 4 and thereby a restriction of the increase per time unit for the torque which is transferred by the clutch. By means of an optimum restriction of this kind, damage due to abuse of the clutch can be avoided, thus increasing reliability of operation. Furthermore the transmission can be dimensioned correspondingly, i.e. it can be designed to be smaller, lighter and thus substantially cheaper to produce.
With the invention the object is achieved of dividing the engagement process into a first rapid phase and a second, slow phase, and of effecting a damping in the case of too rapid engagement. This means that the clutch pedal can be moved rapidly during the first phase which constitutes approximately 50% of the total distance it can cover. Only immediately before the clutch's engagement point and if the engagement speed exceeds a critical value, does a damping of the engagement speed occur, i.e. in the case of abuse of the clutch and only during the actual engagement.
If the diameter of the piston section 54 and thus the inner diameter of the first valve chamber 51 is significantly smaller than the piston 5 of the master cylinder 3, the rate of fluid flow to the right during the first phase of the engagement of the clutch will be greater in the first valve chamber 51 than in the master cylinder 3. The fluid will then attempt to move the valve body to the right but is prevented from doing so by the end plate 35 which abuts against the piston 5. Some of the fluid which is displaced by the slave cylinder therefore has to flow through the passage 55, but can be so extensively choked here that the movement of the piston 5 becomes slow. If the fluid is cold this effect is reinforced because the choking is added to the flow resistance in the conduit 8.
Instead of the valve body being adapted to cooperation with the piston 5 of the master cylinder, in a second embodiment of the device according to the invention, the valve body can be adapted to cooperation with the slave cylinder's piston. Movement of this piston too is slow if the diameter of the piston section 54 is significantly smaller than the diameter of the piston.
In these cases the driver will notice that the clutch pedal becomes unpleasantly sluggish and does not follow the foot movement. It is therefore advantageous for the diameter of the valve body's valve 54 to be equal to or only slightly smaller than the diameter of the piston 5 or 9 with which the valve body is connected.
If the speed of the master cylinder's piston 5 is required to be greater during the third phase than during the second phase, the characteristics of the first spring 40 can, for example, be adapted to the characteristics of the spring device which is included in the clutch 1 and which attempts to engage it in such a way that the valve body 32 is moved away from its seat 31 by the spring 40 after the clutch 1 has been engaged. If the force exercised by the clutch's spring in relation to the force exercised by the first spring is thereby reduced during the third phase in relation to the second phase, the differential pressure exercised on the closed valve body would be able to be so small that the valve unit opens once again and the first passage no longer chokes the oil flow.
It should be noted that even though it was stated in the described embodiment of the device that the passage 53 extends through the valve body, it should be understood that the same effect can be obtained if a corresponding passage is provided in the seat section area of the valve housing, provided that it ensures communication between the valve housing chambers 51 and 52 even after the valve body abuts against the valve seat.
It should further be noted that even though the movement of the valve body 32 and the valve rod 33 in relation to the sleeve 34 can instead be restricted by the end plate's 35 abutment against the second sleeve section 37, which in turn restricts the clutch pedal's and the clutch's movement, this restriction possibility will not normally be used, since the movement of the pedal and the clutch will preferably be restricted in another way, e.g. by means of a stopper which is attached to the body against which the pedal abuts.
Furthermore the valve body's piston section 54 can be omitted. The valve body will then be moved to the closed position due to the differential pressure over this as a result of the drop in pressure which is caused by the fluid flowing through the opening 56. However, this is less advantageous because the shape of this opening will be decisive for the extent of the pressure difference, which will, e.g., require an extremely accurate setting of the axial distance between the valve body and the valve seat during the installation of the valve unit.
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A device for the prevention of the abuse of a dry-plate clutch (1) for a motor vehicle with a manual gearbox, wherein the device acts jointly with a hydraulic master cylinder (3) and a related slave cylinder (4) in the operation of the clutch (1). The device comprises a valve unit (20) which is installed hydraulically in series with and between the master cylinder (3) and the slave cylinder (4). The valve unit opens when the valve body (32) is moved towards the slave cylinder (4). A first passage (53) which extends in the valve body (32) or in the valve housing (21) permits restricted fluid flow through the valve (20) when the valve unit (20) is closed. A device (33,35,41) keeps the valve unit (20) open when the clutch is located in positions between a position of maximum disengagement and a second position located close to the position in which the clutch begins to engage. During an engagement of the clutch which is so rapid that there is a risk of damage to the transmission, the force of a spring (40) which attempts to open the valve unit (20) becomes less than the force exercised by the hydraulic fluid on the valve body (32) and attempts to close the valve unit (20), thus causing it to be moved towards its seat (31), whereupon the fluid is forced to flow through the passage (53).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to bearing structures and, more particularly, to bearing and seal assemblies for rotatably mounting and supporting an open end of a clothes dryer drum.
2. Description of the Related Art
A typical clothes dryer of the domestic type includes a box-like cabinet which houses a horizontally rotatable clothes-containing drum. The cabinet includes a door to permit user-access to the drum via its open front end.
Generally, two methods have been used to rotatably support the open front end of the dryer drum. The first method employs roller-type supports beneath the drum, while the second method provides a bearing and seal assembly, typically in contact with the inner periphery of the front end of the drum. The bearing and seal assembly is located between the drum and a circular flange provided by a front panel of the cabinet to rotatably and sealably support the drum.
With reference to U.S. Pat. No. 3,399,464, the disclosure of which is expressly incorporated herein by reference, a ring-like bearing and seal assembly for rotatably supporting the front end of a dryer drum is shown. The bearing and seal assembly includes a pair of plastic bearing pads that are fixed to an upper portion of a circular support flange extending inwardly from the front panel of the dryer cabinet. The circular flange surrounds the access opening provided by the front panel of the cabinet. The front end of the drum provides a circular lip that rides on and bears against the two noted bearing pads, the circular support flange being coaxially nested within the open front end of the drum. The annular space between the drum lip and the support flange that is not occupied by the pair of bearing pads is filled with lengths of felt material constituting a seal for minimizing air leakage between the lip and the flange.
A more recently developed bearing and seal assembly, which comprises separate felt and split-ring bearings, is disclosed in U.S. Pat. No. 4,430,809. The felt bearing is mounted to a support ring inwardly adjacent the access opening in the front of the dryer and constitutes an air seal. The split ring bearing, which is made of a wear resistant material such as polytetrafluoroethylene (hereafter PTFE) or nylon, is mounted to the dryer drum via a series of resilient tab-like fasteners. The inner periphery of the split-ring bearing rides against the outer surface of the felt bearing.
Another bearing and seal assembly is disclosed in the commonly assigned U.S. patent application Ser. No. 07/852,574, the disclosure of which is expressly incorporated herein in its entirety. In this assembly, the bearing and seal is comprised of a ring of felt-like material having an upper portion of relatively dense felt and a lower portion of relatively less dense felt. The upper portion includes wear-resistant glide members or bearing pads upon which bears the weight of the rotatable drum.
While bearing and seal assemblies of the above-described types may adequately provide rotatable support for the front end of the dryer drum, undesirable noise transmission to the dryer cabinet can occur via the bearing pads or bearing ring due to a rotating non-concentric dryer drum. Also, plastic or wear resistant material, such as nylon or PTFE, used to form the bearing ring or pads is relatively expensive and, thus, increases the cost of the resulting product.
Therefore, there exists a need in the art for a bearing and seal assembly which reduces or eliminates the transmission and generation of noise, and which does so at a reduced cost.
SUMMARY OF THE INVENTION
In accordance with the invention, a ring of felt material is fixed to an inwardly extending circular flange provided by the front panel of a dryer cabinet. The upper arcuate surface of the felt ring is powder-coated with a wear resistant material such as PTFE. A circular lip at the open front end of the dryer drum slidably engages the powder-coated surface. The circular flange is coaxially nested within the circular lip of the drum to rotatably support the drum.
In further accordance with the present invention, most of the felt ring, which also provides an air seal between the drum and the circular flange, is made of relatively low density, low cost felt material. The remaining portion of the felt ring provides the upper arcuate powder-coated surface which is slidably engaged by the drum and is formed of higher density felt material to resist compaction due to the weight of the rotating drum bearing thereupon. The higher density felt material also acts as a shock absorbing element between the rotating drum and the circular flange which underlies the felt ring, thereby minimizing the generation and transmission of noise.
The use of felt material having an integral PTFE powder-coated surface simultaneously provides an effective air seal between the drum and cabinet, and eliminates the noise transmission and generation problems associated with separate or additional bearing pads, while reducing material, production, and labor costs.
BRIEF DESCRIPTION OF THE DRAWINGS
A fuller understanding of the invention may be had by referring to the following description and claims, taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a front perspective view of a domestic clothes dryer in an open door condition;
FIG. 2 is a rear exploded perspective view of a front portion of the clothes dryer of FIG. 1 which includes a bearing and seal assembly in accordance with the present invention; and,
FIG. 3 is a side elevational view, in cross section, of the bearing and seal assembly of the present invention, with portions cut away.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a clothes dryer 10 of the domestic type which incorporates the present invention is illustrated. The clothes dryer 10 has a box-like cabinet formed from painted sheet metal, as is well known in the art. The dryer 10 includes a horizontal top panel 12 with a control console 14 extending along its rear edge. The control console allows the user to regulate the operation of the clothes dryer 10 to provide drying of clothes placed within the dryer in a predetermined manner. The dryer 10 further includes a pair of vertical side panels 16 and 18, and a vertical rear panel (not shown).
A vertical front panel 20 provides an access opening 22 which is normally closed by a door 24 that is hinged along its left edge, as shown, for movement about a vertical axis. When the door 24 is open as shown in FIG. 1, a user can reach through the access opening 22 and into the interior of the clothes dryer 10 to insert clothing therein or remove clothing therefrom.
Turning to FIG. 2 of the drawings, the clothes dryer discussed with regard to FIG. 1 can be seen to include, in addition to the front panel 20, a drum support panel 30, a bearing and seal assembly 40 in accordance with the present invention, and a dryer drum 60 that, in operation, rotates on a horizontal axis 70.
The front panel 20 provides an inner surface 21 having an inner periphery 21a which defines, in part, the access opening 22 (see FIG. 1). The front panel 20 also provides a seat against which the door 24 seals during operation of the dryer 10. A conventional switch (not shown) is provided adjacent the front panel to preclude operation of the dryer without closure of the door 24 against the front panel 20.
The drum support panel 30 has a generally planar, plate-like front portion 32 that is fixed by suitable mechanical means to the inner surface 21 of the front panel 20. Centrally located in the plate-like front portion 32 is an aperture constituting, in part, the access opening 22 (FIG. 1). With further reference to FIG. 2, the drum support panel 30 includes, in addition to the plate-like front portion 32, a transition ring 33 that is generally annular in shape with a circular outer periphery and a generally rectangular inner periphery 33a, as illustrated.
The transition ring 33 has extending horizontally from its outer circular periphery a circular drum support flange 34 which is inwardly spaced from the plate-like front portion 32. The transition ring 33 extends inwardly from the plate-like portion 32 to support the circular drum support flange 34 at a relatively inwardly displaced position. When assembled, by welding or suitable mechanical fastening means, the front panel 20 and the drum support panel 30, including its elements 32, 33, and 34, are fixed in position relative to each other and constitute a unitary structure.
The bearing and seal assembly 40, in accordance with the invention, rotatably supports the front end 62 of the dryer drum 60, the rear end (not shown) of the drum 60 being supported by conventional means. The assembly 40 preferably includes an upper felt member 42 of a high density felt material and a lower felt member 44 of a relatively lower density felt material.
The high density material comprising the upper felt member 42 helps to prevent compression or compaction of the felt member due to the load or weight of the front end 62 of the dryer drum 60. The lower felt member 44 is formed from relatively lower density material because it does not support the load of the dryer drum 60 and, hence, is not susceptible to similar compressive forces.
As can be seen best in FIGS. 2 and 3, the front end 62 of the dryer drum 60 includes an annular front wall 64. The annular front wall 64 provides, at its inner periphery, a horizontally extending circular or annular lip 66 that generally surrounds the bearing and seal assembly 40 and the support flange 34. The annular lip 66 rides or bears upon, and is vertically supported by, the outer or upper surface 46 of the upper felt member 42.
The felt members 42 and 44 combine to provide a generally continuous ring of felt-like material that is fixed to the exterior of the circular flange 34 by, for example, a suitable adhesive material or mechanical fastening means. Alternatively, the upper and lower felt members 42 and 44 can be attached or adhered to an integral elastic ring which, in turn, is elastically mounted or fit over the annular flange 34.
It can be seen that the upper felt member 42 constitutes approximately 25% of the circumferential extent of the ring of felt-like material while the lower felt member 44 constitutes approximately 75% thereof. The combination of high density and low density felt material in this manner provides a relatively low cost drum support and air seal, as the amount of high density felt, which is relatively more expensive than the low density felt, is reduced. Naturally, if product expense is no consideration, the entire ring could be formed of a high density material. The upper felt member 42 has deposited upon its upper or outer surface 46 a powder coating of wear resistant material such as PTFE, the powder being identified by reference numeral 48 in FIG. 3.
According to the method currently employed and contemplated by applicant to manufacture the high density felt member 42, the PTFE powder 48 is applied to the upper or outer surface 46 of the high density felt member 42 in a continuous fashion. The powder 48, which preferably has a particle size of between about 1.5 and 4 microns with a bulk density of about 475 to 550 grams/liter and a specific gravity of about 2.2, is preferably applied at a rate of about 8.7 to 10.0 grams per square yard. After being deposited on the surface of the upper felt member 42, the PTFE powder 48 is mechanically rubbed or worked into the interstices of the upper felt member 42 to create a zone 50 of PTFE powder impregnated felt. As shown best in FIG. 3, the zone 50 of PTFE powder impregnation, which is delimited from the remainder of the felt material by a dashed line, extends downwardly a short distance from the outer or upper surface 46 of the upper felt member 42.
With continued reference to FIG. 3, wherein the drum 60 with its associated circular lip 66, the felt members 42 and 44, and the circular flange 34 are shown in their normal positions when the dryer drum is rotating, it can be seen that the smaller diameter circular flange 34 is coaxially nested within the larger diameter circular lip 66 of the drum 60. The annular space between the flange 34 and the lip 66 is substantially filled by the felt-like material constituted by felt members 42 and 44 so as to establish an air seal therebetween. The PTFE powder-coated upper surface 46 of the upper felt member 42 is adjacent to and supports the drum 60 and, more specifically, is in engagement with the circular lip 66.
It has been found that, as the drum 60 rotates and bears upon the powder-coated surface 46 of the upper felt member 42, an amount of PTFE is transferred to the circular lip 66 of the drum 60 and forms a thin PTFE layer or coating thereon. Applying the powder 48 to the upper surface 46 of the high density upper felt member 42 significantly reduces friction produced by engagement of the drum 60 with the upper felt member 42 during operation of the clothes dryer drum, while providing an effective and inexpensive air seal. Also, rotational engagement of the powder-coated surface 46 with the lip 66 of the drum 60 does not produce or transmit noise, as was the case with the bearing pads used in the prior art.
As can be seen from the above, a simple, low-cost dryer drum bearing and seal assembly has been provided. A lower density, reduced cost, lower felt member 44 which functions primarily as an air seal member between the drum 60 and the support flange 34 constitutes a major portion (i.e., approximately 75%) of the ring-like felt material between the drum 60 and the flange 34. The upper felt member 42, which is formed of relatively high density material that can bear the weight of the front end of the drum 60, is carried on the upper portion of the circular flange 34. This higher density material includes, adjacent its upper surface 46, a coating or zone 50 of PTFE powder 48 which, due to sliding engagement with the lip 66 of the drum 60, produces or creates a thin layer or coating of PTFE on the lip 66 and thereby reduces the frictional interference between the bearing and seal assembly 40 and the lip 66. The upper felt member 42 performs both an air sealing function and a weight bearing function.
It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. For example, it is disclosed that the ring of felt-like material is adhered or attached to the circular flange 34 and the PTFE powder-coated surface 46 is in engagement with the circular lip 66 of the drum 60. However, it is contemplated that this structure could be modified to have the bearing and seal assembly 40 adhered or attached to the drum's circular lip 66 such that a downwardly or inwardly directed PTFE powder-coated surface is in engagement with the circular flange 34. Moreover, if the diameter of the drum is close to the size of the access opening 22, the lip of the dryer drum 60 which engages the bearing and seal assembly 40 could be directly formed or provided on the inner periphery of the cylindrical shell of the drum 60, thereby eliminating the need for the annular front wall 64 and further reducing product costs. Therefore, it should be clear that the present invention is not to be limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.
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A bearing and seal assembly for rotatably supporting an open front end of a clothes dryer drum includes a ring of felt-like material positioned between the circular open front end of the drum and a circular support flange of smaller diameter coaxially nested within the end of the drum. The felt-like material is fixed to the flange and substantially fills an annular space between the drum and the flange to preclude air leakage therebetween. The upper or outer surface of the felt seal, which is in engagement with the circular open front end of the drum, is powder coated with a wear-resistant material such as polytetrafluoroethylene. The powder-coated surface is slidably engaged by the drum and bears the weight of the end of the drum. The felt-like material acts as a sound dampener and shock absorber between the rotating drum and the fixed flange to preclude transmission or generation of undesirable noise caused by rotation of the drum.
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BACKGROUND OF THE INVENTION
The invention relates to the modification of water flows, particularly at bifurcations in water channels. Such bifurcations occur in natural river channels and tidal waterways as well as in artificial basins, docks, canals etc.
It has been observed in nature that in many circumstances an eddy current is generated as a result of flow separation immediately within the entrance to a bifurcation (see FIG. 1) and leads to the deposition of sediment. In uni-directional flows, i.e. rivers, the water level changes in height only slowly and such eddy systems, in which the flow rotates about a vertical axis, are set up at bifurcations due to flow separations induced by sharp changes in the orientation of the bank. Such separations are enhanced by velocity gradients between the water in the river channel passing the entrance to the branch and the branch itself, where the velocity, in the case of blind-ending branches, may be zero.
In simple river channels with no tidal effect there is no superimposed advection of water through the eddy system to fill the branch. In tidal waters eddy rotation is supplemented by advection of water into the basin on a rising tide. In either case, a portion of the water drawn into the eddy may eventually escape and enter the side branch whilst another portion may escape and return to the main stream.
In bidirectional or tidal flows, the water level changes in height regularly and in relative terms, rapidly. On rising stages of the tide in these situations it has been observed that a quantity of water larger than that strictly necessary to fill a branch basin at high tide may be exchanged at the entrance to the bifurcation. This implies that the eddy is both drawing in water to fill the basin on the rising tide and also exchanging water back into the main flow. The quantity of water exchanged is difficult to estimate, but in some cases may be two or three times the tidal volume of the basin. (The tidal volume is the surface area multiplied by the tidal range). The strength and persistence of the eddy and also the volume of water which passes through the eddy contribute to its efficiency in trapping and depositing sediment.
In blind-ending bifurcations, such as harbour basins in tidal waters, the importance of the eddy current depends in part on the size and extent of the harbour basin. In small harbour basins the eddy current may occupy the whole area of the basin, whilst in larger basins the eddy may occupy only the entrance to the basin.
The rotary motion in such eddy currents may, in itself, be undesirable in that the strong cross-currents induced may present control difficulties for vessels, of necessity moving slowly whilst entering the branch, but it is also known that large quantities of sediment frequently accumulate on the channel bed beneath such eddy currents. Deposition arises as a result of the so-called "tea-cup effect": as a result of the pressure gradients and the velocity distribution within a rotating eddy, sediment is drawn into its axial region. Such sediment cannot readily escape from the centre of the eddy with the result that a certain proportion of it is deposited. In small harbour basins, with or without a tidal influence, where the eddy fills the entire basin, the entirety of the sedimentation occurring arises from this so-called tea-cup effect. In large harbour basins, with a tidal influence, it has been observed that up to 50% of the sedimentation occurring arises from the tea-cup effect and deposition is concentrated just within the harbour entrance. At waterway bifurcations without blind-ends, such as the branches of rivers or canals, the tea-cup effect is still present and leads to such sediment as is deposited being concentrated in the zone beneath the eddy.
Sedimentation caused by eddy currents in any of the cases described above and in the quantities specified results in high costs for dredging and maintaining navigable waterways. Costs are enhanced when such material is highly contaminated by pollutants and has to be transported long distances or placed in special containment or spoil-disposal areas ashore.
OBJECT OF THE INVENTION
The object of the present invention is to provide means for breaking down or preventing the formation of such eddy currents so as to reduce the quantity of sediment deposited or at least to spread it as a thinner layer over a wider area. Both of these factors would give rise to a major benefit, either from a reduction in the quantity of sediment to be removed or in the frequency with which dredging operations have to be carried out. For example, in one example of a bifurcated channel from which data is available, the average annual sediment deposition is close to 600,000 m 3 , of which half occurs in close association with the eddy at the entrance. If the destruction of the eddy were to lead to an improvement of only 50% in the amount of deposition in this region a decrease in the annual dredging need for the basin of 150,000 m 3 would result.
BRIEF STATEMENT OF THE INVENTION
Accordingly the invention provides, in a bifurcated channel comprising a main channel carrying a water flow and a branch channel bifurcating from said main channel, flow deflecting means located adjacent the upstream corner of the bifurcation relative to the direction of said water flow and arranged to deflect a minor proportion of said water flow into the branch channel so as to oppose the formation of eddies in the branch channel in the region of said bifurcation.
In effect, the flow deflecting device of the invention tends to set up an eddy which would rotate in the opposite sense from that induced in the main flow from the main channel into the branch channel and hence counteracts the main eddy so that eddying at the bifurcation is at least reduced if not entirely prevented.
In preferred embodiments of the invention, the flow deflecting means comprise a passive device which, once installed, requires no supplementary operating energy but simply harnesses the natural energy of the flowing water. In other words, it involves no running costs. To this end, the flow-deflecting means may consist of a wall which defines a deflection channel extending adjacent the upstream corner of the bifurcation and having an inlet in the main channel and an outlet in the branch channel. The wall may extend the full depth of the water or only part of this depth in which case it may be located in the upper or the lower part of the water channel and it may be constructed from concrete, metal, wood or other materials as appropriate.
The provision of the deflecting wall will narrow the entrance to the branch channel if no other changes are made but this is compensated for, in navigational terms, by the reduction of the strong cross-currents at the entrance. Depending on the configuration of the bifurcation, the upstream corner of the bank around which the deflection channel is formed may, in any case, be modified; a sharp corner may, for example, be cut away so that the deflection channel follows a smooth curve arount it, or a subsidiary wall may be built up around the corner itself or so as to project from the corner into the branch channel to deflect water in the deflection channel towards the centre of the channel rather than parallel to the bank.
It will be appreciated that the structure of the flow-deflecting means and the proportion of the main flow directed into the branch channel can be varied widely according to the configuration of a bifurcation and the flow criteria operating there but some specific embodiments of the invention will now be described by way of example, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic plan view of an eddy system generated by flow separation at a bifurcation;
FIG. 2 is a schematic plan view of the bifurcation of FIG. 1 according to a first embodiment of the invention.
FIG. 3 is a schematic plan view of the bifurcation of FIG. 1 according to a second embodiment of the invention.
FIG. 4 is a schematic plan view of the bifurcation of FIG. 1 according to a third embodiment of the invention.
FIG. 5 a a partial side elevational view of a flow deflecting wall according to a fifth embodiment of the invention;
FIG. 6 is a schematic plan view of the upstream corner of a channel bifurcation modified by the provision of flow-deflecting means according to a sixth embodiment of the invention;
FIG. 7 is a cross-section taken along the line VII--VII of FIG. 6;
FIG. 8 is a schematic plan view of the upstream corner of a channel bifurcation modified by the provision of flow-deflecting means according to a seventh embodiment of the invention;
FIG. 9 is a cross-section taken on line IX--IX of FIG. 8;
FIG. 10 is a schematic plan view of the upstream corner of a channel bifurcation modified by the provision of flow-deflecting means according to an eighth embodiment of the invention;
FIG. 11 is a section taken on lines XI--XI of FIG. 10; and
FIG. 12 is a schematic plan view of a channel bifurcation modified by a further embodiment of flow-deflection means according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1 of the drawings a main water channel is shown at 1 and contains water flowing in the direction of the arrows 2 in an upstream to downstream direction. A branch channel 3 bifurcates from the channel 1 and water on entering the branch channel 3 from the main channel 1 forms eddies indicated by the arrows 4. The bank of the main channel is indicated 101a upstream of the bifurcation and 101b downstream of the bifurcation while the bank of the branch channel 3 which continues from the bank 101a is indicated 103a, the opposite bank being indicated 103b. The corner joining the banks 101a and 101b is indicated 12 and is termed an upstream corner of the entrance to the branch while the corner joining banks 101b and 103b is termed a downstream corner.
FIG. 2 shows a modification of the bifurcation of FIG. 1 by the provision of a flow-deflecting channel 5 at the bifurcation, around the upstream corner 12 from the main channel 1 to the branch channel 3. The channel 5 is formed by rounding of the corner 12 as shown at 6 and by the building of a vertical wall 7, spaced from the corner 6, and extending from the channel 1 into the channel 2. The wall may, for example, be a sheet-piled steel wall and extends the full depth of the water in the two channels 1 and 3 and confines the flow-deflecting channel 5 between it and the curved corner 6, such that the channel 5 has its inlet in the main channel 1 and its outlet in the branch channel 3. The channel 5 thus deflects a small proportion of the water flow 2 from the channel 1 into the channel 3, as indicated by the arrows 8. This flow counters the main flow from the channel 1 into the branch channel 3, indicated by the arrow 2a, to reduce eddying at the bifurcation.
As shown in FIG. 2, the flow deflection channel 5 is of uniform section but its shape could be modified as required at a particular bifurcation by changing the curve of the bank at 6 or the line of the wall 7. In particular it can be useful to narrow the exit of the channel 5 compared with its inlet to increase the speed of the water flow through the channel 5.
With reference to FIG. 3 of the drawings, in this embodiment the flow deflecting means include a flow-deflecting wall similar to the wall 7 of FIG. 2, indicated by the same reference numeral and bounding a flow deflecting channel again indicated 5. In this embodiment, however, the opposite bank of the channel 5 is formed not by cutting away of the original corner 12 but by the addition of a curved spur wall, indicated 9, which extends from the corner 12 into the channel 3. The gap between the ends of the wall 9 and the bank 103a is closed by a further wall or by complete infilling of the space between the bank 103a and the wall 9.
In FIG. 3 the channel 5 is shown tapering towards its outlet but this configuration may be changed according to requirements. The channel 5 serves the same purpose as that shown in FIG. 2 and the eddy current which would normally tend to form at the bifurcation, and which is opposed by the current 8, is shown by broken arrows at 4.
FIG. 4 shows a variation on the arrangement of FIG. 3. Here, the single wall 7 is replaced by two overlapping walls 7a and 7b which define a narrow, subsidiary channel 13 between them, in addition to the main flow-deflection channel 5, the entrance to the channel 13 being within the channel 5. The purpose of this subsidiary channel is to stop the development of additional, smaller eddies in the boundary area between the main channel 1 and the branch channel 3, in the lee of the wall 7. A comparable effect may be achieved by forming apertures or "windows" in a deflecting wall 7, as shown at 14 in FIG. 5.
If desired, the wall 7 can be designed so that only certain layers in the upper and/or lower region of the water body are deflected into the deflection channel 5, while still stopping the development of the major eddy. To this end, a wall occupying only part of the overall depth of the water may be built on the channel bed or supported above it by means of piles or floats.
With reference to FIGS. 6 and 7, these show the positioning of a low guiding wall, or underwater groyne, 15 of roughly conical section in front of the entrance to the flow-deflection channel 5 in order to deflect bedload and highly concentrated suspended matter which moves just above the main channel bed and prevent this from entering the channel 5. The groyne 15 extends from the foot of the wall 7 at the entrance to the channel 5 in a direction upstream and across the entrance to meet the upstream bank 101a of the main channel 1. The height, cross-sectional shape and line of the groyne 15 will depend on the particular morphological and current condtions at a given bifurcation.
FIG. 8 shows a variant of the embodiment of FIG. 2, in which an additional wall 16 has been built up around the curve 6 and the channel 5 has been roofed over by a flat roof 17 supported by the walls 7 and 16. The structure may thus be used as a wharf and a ship 18 is shown schematically alongside the wall 7. The shape of the channel 5 may be modified is explained above.
FIG. 10 shows an embodiment in which the channel 5 is defined, not by vertical walls as in the previous embodiments, but by a large-diameter pipe 19. This may extend through the corner 12, as shown in FIG. 10 and may be encased in a wharf structure as shown at 20 in FIG. 11.
With reference to FIG. 12, this shows schematically an embodiment in which the positions of a deflecting wall 7 and/or of a spur wall 9 can be adjusted by means, for example, of respective actuators 21 to vary the geometry of the entrances to the branch channel 3 and the deflection channel 5. This has the object of optimising the direction of the current 8 and the percentage of the cross-section of the branch 3 to be blocked. In FIG. 12 the spur-wall 9 and wall 7 are shown in full outline at one extreme position of their movements and in broken outline at the opposite extremes of their movements.
The invention thus deals with the prevention of unwanted eddy currents in bifurcations such as harbour basins, canals etc. by the positioning of current deflecting walls near the point of bifurcation to a branch channel to separate part of the stream and direct a counter-current to prevent the formation of a major eddy at the entrance to the branch. Arising from the intrinsic variability of natural waterways and artificial harbours the precise shape, dimensions and position of the CDW channel must be tailored to take account of local conditions in order to provide the optimal alignment of the counter-current and minimise unwanted sediment deposition.
The implication is that field data must be collected and a physical or other model constructed on each occasion to enable an appropriate current deflecting wall 7 to be built and any other modifications to be made.
Certain criteria have been established from physical model tests upon which to base the design of a flow deflection channel 5 at the entrance to a harbour basin. A formula has been developed as follows: ##EQU1## S FD =Cross-sectional area of FD channel 5 (m 2 ) A HBR =Surface area of harbour (m 2 )
TR=Tidal Range (m)
V FD =Cross-sectional depth mean velocity during flood tide (m/sec)
D F =Duration of flood tide (sec)
Assuming that the flow pattern created by the deflection channel blocks the bifurcation, as has been proved possible by physical model tests, the purpose of the formula is to permit the scaling of the flow deflection channel in tidal waters in such a way that the volume of water passing through it is just sufficient to fill the blind-ending basin completely (i.e. the tidal volume) at high water. For non-tidal situations the objective of design is to produce sufficient energy in the counter-current just to overcome the kinetic energy in the rotating major eddy. From a consideration of the forces responsible for driving the rotating major eddy in the branch channel, it has been shown by calculation that these are zero when the current vector at the mouth of the branch channel is parallel to the sides of the channel. This condition is satisfied over a significant proportion of the flood tide provided: ##EQU2## TP=Tidal period (sec) φ=Phase lag between slack water and low water (degrees)
θ=Angle between branch and mainstream (degress)
V MAX =Maximum value of cross-sectional mean current velocity (m/sec)
The two formulae given for the cross-sectional area of the current deflection channel agree to within 20% for all cases. Consequently, the current deflection acts in two ways to reduce the strength of the entrance eddy:
(i) it minimises the energy transfered into the eddy
(ii) it dissipates some or all of the energy which is concentrated in the eddy.
In order to achieve a smooth channel for both walls of the deflection channel it may be desirable to reform or re-align the original junction, or corner, between the main flow and the branch at its "upstream" end i.e. the flow separation point, by for example cutting away the corner as shown at 6 in FIG. 2. Practical factors such as the cost or the need to maintain the maximum size opening to the bifurcation or basin must, however, be taken into account.
Alternatively, if calculations demonstrate that the bifurcation is wider than the optimal size and practical considerations permit, the revised inner curve can be designed to project into the branch at the point of bifurcation, thus restricting the cross-sectional area of the entrance to the branch, as shown in the embodiment of FIG. 3. The additional spur-wall extends over the full water depth and has a shape, when viewed from above, of a truncated hydrofoil. The spur-wall serves the twin purposes of aligning the flow in the channel 5 and "tuning" the cross-sectional area of the branch to its optimum. Other modifications such as those indicated in other embodiments described above may also be included as appropriate.
It will be appreciated that the use of Formula I above will permit the specification of a flow deflection channel for tidal situations. In non-tidal situations the preferred cross-section of the channel has been found from model tests to lie roughly in the region 10% of the total cross-sectional area of the branch. This is found to generate sufficient kinetic energy to overcome the major eddy current.
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An arrangement for opposing the formation of eddies and diminishing the deposition of sediment at the junction of a branch channel with a main, water carrying channel. The upstream corner of the intersection of the channels is provided with a deflector to divert some of the main channel water into the branch channel. The deflector is in the form of a curved, vertically disposed wall extending the full depth of the water.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation application of U.S. application Ser. No. 11/140,100 filed May 27, 2005, which application is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
The present invention relates to an improved icemaker for freezer or icemaking compartments.
The prior art icemakers suffer from a variety of issues relative to operation, ice formation, ice harvest without water spillage, quality issues, attachment issues to the inside of the refrigerator compartment, etc. These problems have been exasperated by the fact that a significant design effort has not been overtaken by the industry for many years. While the industry has seen some incremental changes to the icemaker design, they have focused mainly on components outside the icemaker mold as the mold portion is very expensive to redesign and place into production. In general, the industry has taken an attitude that the current icemakers work well enough.
Unfortunately, the prior art icemakers do not work well. Ice is often formed with many trapped air bubbles forming “white” instead of clear ice. Additionally, production of ice cubes is slow and icemakers take up a significant portion of the freezer capacity. Moreover, service calls resulting from prior art icemaker malfunctions are high and detract from the bottom line of a company.
The present invention solves or minimizes these problems and others as evident in the following specification and claims.
BRIEF SUMMARY OF THE INVENTION
The foregoing objectives may be achieved with an improved icemaker having an ice mold.
A further feature of the present invention is an improved icemaker having an ice stripper that protects ice from falling back into the ice cavities after the ice is ejected but yet minimizes the amount of obstruction along a wall of the ice mold from cold freezer air used to freeze the water. The ice stripper may also include vertically extending ribs that help assist in creating convective air.
A further feature of the present invention is an icemaker that may be positioned on different sides of the storage compartment without compromising the effectiveness of the icemaker.
A further feature of the improved icemaker is multiple means of mounting the icemaker including plate mounting, button style mounting, and impingement duct mounting.
A further feature of the present invention includes a control system that does not permit an external fan to blow while a heating coil is engaged.
A further feature of the present invention is an externally mounted thermostat that sandwiches the thermostat between a control housing of the icemaker and the mold to firmly hold the thermostat in place for effective contact against the first ice cavity of the ice mold.
A further feature of the present invention is an improved thermal cutoff switch location that is positioned to contact an extension member of the ice mold placed within the control housing.
A further feature of the present invention is a modular bale arm that operates at a pivot point of the control housing.
A further feature of the present invention is an icemaker heating coil clenching method that firmly positions the heating coil to the bottom of the ice mold.
A further feature of the present invention are longitudinal running bottom fins that effectively transfer heat across the bottom of the ice mold in low air flow conditions from a convectional vent at the rear of the freezer department.
A further feature of the present invention is an icemaker that has raised walls for a non-spill feature in conditions in which the icemaker is misplaced plus/minus 5.6 degrees from front to back and plus/minus 10.2 degrees from side to side.
A further feature of the present invention is a tilted forward ice cube tray that positions the ice mold approximately 1.5 degrees higher at the back end than at the door end of the icemaker to ensure that the ice cube cavity closest to the thermostat is filled with water.
A further feature of the present invention is the inclusion of two lower front weirs that assure that the ice cube portion nearest the control housing is filled with water.
A further feature of the present invention is an improved ice ejector that does not interfere with the crown of ice that is formed during the normal freezing process.
A further feature of the present invention is a mold with a center weir opening to assure that the ice mold is filled regardless of the mounting orientation of the mold within the storage compartment.
A further feature of the present invention are wire ready mold hooks that permit a icemaker cord to be wrapped around the hooks to reduce its length to accommodate a variety of different positions within a freezer compartment.
A further feature of the present invention is a fill cup funnel inlet that is splayed outward to facilitate more accurate installation and thereby reduce potential for water to be spilled within the ice storage compartment.
A further feature of the present invention is an impingement duct which accelerates the formation of ice within the ice mold.
A further feature of the present invention is a water fill location at the center or one end of the ice mold to facilitate the thermostat being able to better determine that it is proper to eject ice from the cavities.
A further feature of the present invention is multiple water fill level sensors to better determine the optimum fill volume of the ice cavities.
A further feature of the present invention is an ice mold having a larger cube near the temperature sensor to better facilitate control of the ice ejector of the icemaker.
A further feature of the present invention is individual fill of ice mold cavities to assure proper filling of all ice mold cavities.
A further feature of the present invention is a straight shot of fill water down the mold lower rear side to assure that all ice cavities are filled with water.
A still further feature of the present invention is a step mold icemaker that reduces the amount of problems an ice mold may have as a result of unlevel mounting.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the icemaker of the present invention within a storage compartment of the refrigerator.
FIG. 2 is a top perspective view of the icemaker of the present invention.
FIG. 3A is a perspective view of the icemaker of the present invention being installed upon a bottom plate for mounting within the refrigerator wall.
FIG. 3B is a perspective view of a refrigerator having mounting buttons upon a wall of the refrigerator for mounting the icemaker.
FIGS. 4A-C show different aspects of the button mounting for the icemaker.
FIGS. 5A and 5B illustrate different mounting bracket configurations for the icemaker.
FIGS. 6A-C illustrate a mounting method of placing the icemaker upon button mountings.
FIG. 7 is a perspective view of the icemaker in use within a specialty icemaking compartment (icebox).
FIGS. 8-14 illustrate aspects of the icemaker's thermostat and thermal cutoff sensor.
FIG. 15 illustrates a side view of the icemaker and its modular bale arm.
FIG. 16 is a bottom view of the icemaker illustrating the crimping of the heating element.
FIG. 17 is a side cross sectional view of the icemaker.
FIG. 18 is a side view of the icemaker within the freezer compartment showing the 1.5 degree forward tilt of the icemaker.
FIG. 19 is a cross sectional view of the icemaker showing the weir configuration and the positioning of the ice ejector arm.
FIG. 20 is a sectional view of a weir of the icemaker.
FIG. 21 is a side view of the icemaker showing the wire cable and wire mounting hooks.
FIGS. 22 and 23 illustrate the impingement duct in use with the icemaker of the present invention.
DETAILED DESCRIPTION
Overview
With initial reference to FIG. 1 , a refrigerator, generally indicated by numeral 10 , includes a cabinet 12 within which is defined a storage compartment 14 . Storage compartment 14 may be selectively accessed through the pivoting of door 16 . As shown, refrigerator 10 is a side-by-side style unit. However, it should be understood that the refrigerator may be a top freezer refrigerator, a bottom freezer refrigerator, a stand alone freezer, a stand alone refrigerator with a specialty icemaker compartment, a bottom freezer having a specialty ice making compartment in the refrigerator compartment, or other refrigerators known in the art.
Arranged within the storage compartment 14 is an icemaker 22 . The icemaker 22 has positioned underneath it an ice storage bin 24 . The icemaker 22 is shown to include a bale arm 26 which is rotatable upward and downward based on the amount of ice retained in the ice storage bin 24 .
The icemaker 22 includes an ice mold 28 . The icemaker 22 receives water directed to the ice mold 28 through a fill tube 30 .
As seen more clearly in FIG. 18 , the fill tube 30 may be positioned adjacent a fill cup 32 which prevents the water from spilling or splashing into the storage compartment. The fill cup 32 may receive the fill tube 30 from a rear opening 34 or a top opening 36 . The fill cup 32 directs the water into the ice mold 28 . The ice mold 28 has weirs 38 partitioning the ice mold 28 into individual cube cavities 42 . The weirs 38 have an opening 40 which permits water to move from the fill cup 32 into individual cavities for forming ice cubes. In use, the water is turned into ice primarily through either conductive or convective heat exchange within the storage compartment 14 .
A control housing 44 is attached to the ice mold 28 . The control housing 44 contains the electromechanical components of the icemaker 22 . An on/off switch 46 is provided on the outside of the control housing 44 . A cord 48 is provided for power and/or control commands to be routed to the control housing 44 . A plug 50 is provided at the end of the cord 48 to mate with a socket placed within a wall or ceiling of the storage compartment 14 . The cord 48 may be held in place against the ice mold 28 by at least one routing hook 51 .
The control housing encloses a motor to activate an ejector arm 54 . The ejector arm 54 has fingers 56 for each cavity 42 . The control housing also encloses a thermostat 58 and a thermal cut-off unit 60 (See FIGS. 11 and 12 ).
The thermostat 58 is positioned in contact with the ice mold next to the cavity 42 nearest the control housing. The thermostat 58 is selected to close an electrical circuit at a designated temperature to engage the motor powering the ejector arm 54 and thus initiate an ice harvest. Under normal operating conditions which has some degree of inconsistent convection, this temperature registered by the thermostat is selected to be 15°-17° F.; however, under low or repentable airflow conditions the thermostat may be selected to send a signal at temperatures as high as 30°-31° F. In any event, the thermostat should not initiate the ejector arm when any of the cavities have liquid within them. When only one thermostat is being used, it is preferred that the icemaker is biased such that the cavity to which the thermostat is in contact has water in it that freezes last. Alternatively, multiple thermostats may be used and a control system utilized that only initiates the ejector arm 54 when all thermostats are below a set-point temperature.
The thermal cut-off unit 60 is provided as a safety measure. The icemaker utilizes a high wattage heating coil 57 ( FIG. 17 ) to heat the underside of the ice mold 28 . The thermal cut-off unit 60 is provided to cut power to the high wattage heating coil 57 in the event that the high wattage heating coil 57 malfunctions. During a malfunction, the high wattage heating coil 57 remains on creating a temperature rise outside normal operating parameters.
In normal operation, the water in the cavities 42 is frozen, the heating coil 57 turned on, and the motor engaged to release ice cubes. The motor moves the ejector arm 54 to rotate the fingers 56 through notches in the ice stripper 62 to engage the ice and remove them from the ice mold 28 . The ice stripper 62 prevents ice from reentering into the ice mold 28 . The ejector arm 54 returns to its starting position after two revolutions and engages a switch which indicates that water may again fill the ice mold 28 .
Improved Ice Stripper
As seen in the FIG. 2 , the ice stripper 62 has a small strip skirt 63 . The strip skirt 63 slides upon a longitudinal rail of the ice mold 28 . The strip skirt 63 permits the side of the ice mold 28 to be exposed for heat transfer. This is in sharp contrast to the prior art which had a skirt that extended substantially down along the side of the icemaker and consequently heat exchange from cool air hitting the icemaker 22 did not transfer to the ice mold 28 .
An additional improvement to the ice stripper 62 may include upward extending fins (not shown). The ice stripper 62 as shown in FIG. 2 has ribs that extend over the cavities 42 . These ribs are separated by notches through which the ejector fingers 56 pass through. Each rib may have an upward extending fin (not shown). These fins are centered upon the rib. The rib's midline is preferably centered upon each of the weirs 38 thus placing the fins directly above the weirs 38 . The fins enhance airflow and improve the rate that ice is formed.
Icemaker Positioning
The icemaker 22 may be positioned in the storage compartment 14 at different positions. The present icemaker assembly permits positioning upon various sides of the storage compartment 14 . Moreover, the icemaker unit 22 may be positioned within different compartments of the refrigerator including a top mount freezer, a side-by-side freezer, a bottom mount freezer, and within an ice box.
Icemaker Mounting
The icemaker unit may be attached to the storage compartment 14 with different mountings. These mountings may include hangers, platforms and/or compartments. Mounting brackets are provided upon the icemaker assembly. The brackets are typically integrally formed with the ice mold 28 .
a. Plate Mounting
As seen in FIG. 3A , the icemaker 22 may be mounted to a plate 70 . The plate 70 may then be attached to a wall of the storage compartment 14 .
b. Button Style Mounting
As seen in FIG. 4A , a button 72 A may be attached to the inner surface of a storage compartment 14 . The button 72 A may be attached by a screw as previously done by Maytag Corporation. The button 72 A is used primarily with refrigerators 10 that are retrofit to include an icemaker.
An improved button 72 B may be provided as illustrated in FIGS. 4B-4C for refrigerators that come preassembled with an icemaker 22 . In this scenario, it is more industrious to provide button 72 B which does not include a separate threaded fastener but rather utilizes a twist and lock fastener 74 . During the manufacture of the refrigerator storage compartment 14 a lateral slit is provided in the wall 18 . A twist and lock fastener 74 has a lateral dimension greater than its longitudinal dimension. Therefore, the twist and lock fastener 74 may be inserted into the lateral slit on wall 18 when its lateral dimension is aligned with the lateral slit. The twist and lock fastener 74 is then fully inserted into the wall until a back plate 76 of the button 72 B strikes the wall 18 .
The back plate 76 has a square top 78 . As the user is putting this in sideways, the shape difference between the flat square top 78 and a rounded bottom 84 provides a reference for the user to turn button 72 B to place it in an optimal position such that the twist and lock fastener 74 may not come out of the lateral slit. The user may use a hex fitting to assist in rotating the button 72 B into a locked position.
The button, either 72 B or 72 A, has a small inner diameter 80 and a larger outer diameter 82 . Two buttons together cooperate with brackets 64 upon the icemaker unit 22 . As seen in FIG. 2 , the brackets 64 may both be designed with a longitudinal opening.
As seen in FIG. 5A , the bracket 64 A may be designed to have a first diameter (D 1 ) which accommodates insertion of the outer diameter 82 of the button and then have the button slide up the bracket 64 to a portion that has a second diameter (D 2 ) that engages the inner diameter 80 . Alternatively as seen in 5 B, the bracket 64 B may be a longitudinal channel having a diameter (D 3 ) which is less than the outer diameter 82 . When installing the icemaker having the bracket 64 A, the bracket is moved laterally over the button 72 and then slid downward upon the button. Using the bracket 64 B, the user is able to slide the bracket down over the button, without moving the bracket laterally over the button prior to downward movement of the bracket 64 B.
An alternative form of the brackets is seen in FIG. 6A-C . In these figures, two different types of brackets are provided, namely a first bracket 64 with longitudinal channel a second bracket 66 with a lateral channel. The lateral channel bracket 66 is of a position on the icemaker that is away from the installer. As seen in FIG. 6A , the installer inserts the lateral channel bracket 66 upon the button 72 laterally. Then, as seen in 6 B, the user rotates the icemaker assembly downward such that the longitudinal channel bracket 64 comes down upon another button 72 .
c. Impingement Duct Mounting
FIG. 7 illustrates a third way of mounting the icemaker within a storage compartment 14 by placing it within an ice box 86 . The icemaker 22 is fastened to an assembly that includes a fan assembly 88 , an impingement duct 90 connected to the fan assembly 88 and positioned beneath the ice mold 28 , and an auger assembly 92 . The impingement duct 90 has an integrally molded rail (not shown) that slides within a guide 94 upon the side of the ice box 86 . The icemaker 22 is attached to the impingement duct 90 and held within the ice box 86 by virtue of the molded rail upon the impingement duct 90 .
Control of External Fan
As shown in FIG. 7 , the fan assembly 88 is used to blow air onto the mold body. A control system may be provided for the icemaker 22 which controls when the fan assembly 88 operates. Using such a control system, the fan assembly 88 is not permitted to turn on when the icemaker is harvesting ice because at this time heat is applied to the icemaker mold body during harvest through a heating coil 57 . If cold freezer air is not forced to the mold body during an ice harvest, the mold body heats up faster, allowing a faster ice harvest rate. It should be noted that the control system may be used to control the freezer's evaporator or other fan not illustrated in FIG. 7 .
Externally Mounted Thermostat
As seen in FIG. 8-12 , the externally mounted thermostat 58 is positioned between the control housing 44 and the mold 28 . The mold 28 in FIGS. 8 and 9 is illustrated with only components that are integrally molded together. The mold is preferably made from aluminum or other heat conductive material.
As most clearly illustrated in FIG. 8 , the thermostat 58 is placed within an orifice 100 . Opposite the orifice 100 , a flat surface of the mold 28 is provided to press against the thermostat 58 and hold it firmly in place. As seen in FIG. 10 , the back side of the thermostat 58 has electrical connectors extending through the orifice 100 . A cross section of the thermostat 58 within the orifice illustrates that a thin gap 102 may be present between the thermostat 58 and the mold 28 . The gap 102 may be filled with a conductive grease-like material to facilitate effective heat transmission from the mold 28 to the thermostat 58 . This improvement is in contrast to the prior art which used a spring to push the thermostat into intimate contact with the mold; in sharp contrast, the externally mounted thermostat 58 is locked between the control housing 22 and the mold 28 .
Improved Thermal Cut-Off Location
As also in FIG. 8-10 , 13 - 14 , the thermal cut-off switch 60 is positioned to contact mold 28 at an integrally formed extension member 104 . The extension member 104 is inserted into the control housing 44 through an opening 106 . The thermal cut-off switch (TCO) 60 is a safety element. The thermal cut-off switch 60 is a fuse that melts if the mold body temperature rises above 160° F. When the TCO melts, the current flow stops and cuts off power to the icemaker or the heater coil from the icemaker thus preventing excessive temperature rise.
As seen in FIGS. 13-14 , the thermal cut-off switch 60 is held in contact with the extension member 104 by a finger 108 biased toward the opening 106 . As opposed to the prior art that positions the thermal cut-off switch 60 within the opening 106 , the improved thermal cut-off location protects the switch 60 from damage within the control housing and forms better contact with the mold 28 by contacting the extension member 104 . Additionally, the prior art requires the use of a conductive grease-like material to facilitate effective heat transmission as opposed to applicant's thermal cut-off switch 60 which is positioned in intimate contact with the extension member without a conductive grease-like material. It should be noted that applicant's invention may use a conductive grease-like material as an additional precaution.
Modular Bale Arm
As seen in FIG. 15 , the modular bale arm 26 is mounted to the control housing 44 by a rotating base 110 . The bale arm 26 is comprised of three different formed portions. When in a lowered position these portions are identified as a first portion that angles downward from the rotating base 110 , a second, center portion that is parallel relative the icemaker, and a third portion that angles upward from the second portion. The bale arm 26 pivots for movement in a vertical plane between a lowered position in which ice is permitted to be made and an upper position in which ice production is stopped.
Icemaker Heating Coil
The bottom side of the icemaker 22 is illustrated in FIG. 16 . Along the bottom of the mold 28 , the individual ice cube cavities 42 have a bottom side that is slightly curved as it approaches the weirs 38 . Each weir 38 bottom side is shown with a slight indentation.
A heating coil 57 runs along the channel defined by an outer ridge 122 and an inner ridge 120 . The heating coil 57 has side portions that have a higher wattage than the end away from the control housing. This difference in wattage prevents the ice cube portion 42 furthest from the control housing 44 from melting faster than the other cubes. The heating coil is held within this channel by a series of crimps 124 . The crimps 124 are preferably located over the weirs 38 . Alternatively, the crimps 124 may be located upon the ice cube cavities 42 . These crimps 124 assist in conduction of energy from the heating coil to the ice mold 28 . Thermally conductive grease or mastic may be provided between the heating coil and the bottom of the mold 28 to further enhance heat conduction.
In normal operation, the last cube to be frozen should be the ice cube portion in contact with the thermostat 58 because as soon as the thermostat 58 registers that ice has been formed in that ice cube portion the thermostat will trigger the ejector arm 54 to empty the ice mold 28 . If the ice cube portion nearest the control housing 44 were to freeze prior to the others, the ejector arm may be operated when the other ice cubes have not been completely formed, thus causing a spill.
In the prior art, only one or two crimps are formed through a clinching process on the side wall of the icemaker 10 to press it against the heat exchanger. The prior art crimps were designed to basically hold the heat exchanger against the bottom of the icemaker 22 . However, having only one or two crimps causes inconsistent hot spots and excess residual water.
Longitudinal Running Bottom Fins
As further seen in FIG. 16 , the icemaker 22 has fins 126 on the bottom of the mold 28 . The fins 126 promote convective heat transfer away from the bottom of the ice mold 28 and more rapid freezing of water within ice cavities 42 .
As seen in FIG. 17 , the fins are tapered from a wide portion away from the control housing 44 to a narrow portion near the control housing. The shape is particularly useful should the icemaker 22 be used with a refrigerator with a conventional vent at the rear of the freezer compartment. The fins 126 make a marked improvement by directing this air along a pathway along the bottom of the icemaker mold.
Raised Walls for Non-Spill Feature
As further seen in FIGS. 7 and 8 , the icemaker 22 is provided with side walls 27 , 29 and end walls 31 , 33 which cooperate to have a no-spill feature that prevents water from going over the side of the icemaker 22 and into the ice storage bin 24 . At least the side wall 27 and the end wall 31 extend above the tops of the weirs 38 . The side and end walls of the ice mold 28 cooperate to have a minimum continual wall height about the periphery based on end user potential alignments. For example, an icemaker 22 may be mounted incorrectly or the refrigerator may be placed on uneven ground. Specifically, the walls provide the icemaker with tolerances which permits the icemaker to be positioned +/−5.6 from front to back and +/−10.2 from side to side.
Tilted Forward Ice Cube Tray
As seen in FIG. 18 , the icemaker 22 may be positioned with the control housing 44 mounted toward the front of the cabinet 12 and plugged into a ceiling of the cabinet 12 . As illustrated the icemaker 22 is mounted at an angle such that the ice mold 28 is approximately 1.5° higher at the back end than at the door end of the icemaker.
During a fill cycle, water enters into the fill cup 32 and flows along the ice mold 28 . An angled icemaker 22 helps assure that the ice cube cavity 42 nearest the control housing 44 is filled so that the thermostat 58 will get an accurate reading. The thermostat reads the temperature in the ice cube cavity 42 and controls the function of the ice ejector 54 to release ice from the ice cube cavities 42 . The ice cube tray 16 is 1.5° higher at the back of the ice mold 28 than at the front end of the ice mold 28 . This orientation assures that the ice cube portion 42 nearest the control housing 44 is filled so that an accurate measurement of the temperature is recorded by the thermostat 58 .
Additionally, the 1.5° tilt allows extra aluminum 24 to be added at a back end of the icemaker 22 (see FIG. 2 ) to provide greater heat transfer to the back ice cube portions to enable them to freeze prior to the ice cube portion 42 in contact with the thermostat 58 .
Lower Front Weirs
Preferably, the weirs 38 are of different heights to accommodate the 1.5° tilt. An alternate icemaker may have the first 1-2 weirs from the control housing having a bottom point opening lower than the weirs farthest from the control housing 44 . This configuration assures that water enters into the ice cube cavity 42 nearest the control housing 44 and adjacent the thermostat 58 .
Improved Ice Ejector
As seen in the cross section of the icemaker FIG. 19 , an ejector arm 54 having fingers 56 is used to eject ice from the ice mold 28 . The ejector arm 54 is located approximately 0.5″ above the lowermost opening of the weir 38 and turns in a circular path about a central axis. The present invention's ejector arm 54 is positioned and turns such that the ejector arm 54 does not interfere with the crown of ice that is formed during the normal freezing process. The present ejector arm 54 is in contrast with prior art ejector arms that are mounted lower, or are offset or eccentrically mounted so as to turn in a non-circular or elliptical path.
Mold with Center Weir Opening
As seen in both FIGS. 19 and 20 , the weir 38 has a bottom point 130 of the opening 40 located along the weir centerline. This placement of the weir bottom point 130 allows the maximum side to side angle flexibility. The weirs as illustrated permit an ice mold 28 to function properly at angles between +/−5.6° about the lateral axis in between +/−10.2° about the longitudinal axis. This is in contrast to the prior art icemakers that position the weir openings 40 significantly off to one side of the ice mold 28 .
Wire Routing Mold Hooks
As seen in FIG. 21 , the icemaker 22 has wire routing hooks 51 . These hooks 51 are integrally formed with the ice mold 28 . These hooks 51 together form a runway for the cable 48 . These hooks 51 are particularly useful because they permit a single length cord 48 to be preassembled to the icemaker 22 and used for many different refrigerator models despite the icemaker 22 being positioned at different locations in the ice storage compartment 14 for these models. The cord 48 fits a variety of different icemakers but because it must be longer to accommodate some icemakers and shorter for others, portions of it are wrapped around the hooks 51 .
Fill Cup Funnel Inlet
As further seen in FIG. 21 , the fill cup 32 may be provided with a funnel inlet that is outwardly splayed to permit easier installation of the icemaker upon a production line or for a consumer to install a retrofit icemaker within a freezer. The funnel inlet solves the problem associated with a water inlet tube missing the fill cup 32 during installation and causing water to fill the ice storage compartment 14 as opposed to the ice mold 28 .
Impingement Duct
As seen in FIGS. 7 , 22 and 23 , the impingement duct or manifold 90 is provided directing an array of air jets 140 to the ice mold. As shown in FIG. 7 , the impingement duct 90 can be mounted under applicant's improved icemaker 22 or under a prior art icemaker as illustrated in FIG. 22 . The icemaker 22 using the impingement duct 90 produces ice two to three times faster than an icemaker without an impingement duct. Thus, the impingement duct 90 is particularly useful for refrigerators having a compact icemaker or rapid ice production feature.
As seen in FIG. 23 , the impingement duct 90 has a rectangular base 142 from which the air jets 140 extend upward. As illustrated, the air jets 140 have a diameter between 0.2-0.25 inches. There are eight rows of air jets 140 that are directed under each of the eight ice cavities. These eight rows may be further divided into four columns, two outer rows 144 and two inner rows 146 . The outer rows 144 are higher than the inner rows 146 to follow the shape of the ice cavity 42 . It is understood that the number of rows and columns of air jets may be varied without departing from the scope of the invention.
The air jets 140 are specifically designed to disrupt the thin boundary layer of air that is warmed by the water freezing in the ice mold 28 and to provide a continuous supply of freezer temperature air. The configurations of the nozzles are either round, slotted or the like. The actual diameter of the nozzles, the space between adjacent nozzles, and distance between the surface of icemakers and nozzles are optimally designed to obtain the largest heat transfer coefficient for an airflow rate.
An air channel or plenum 148 is beneath the air jets 140 . The air channel has a wide end 150 that receives air from a fan assembly 88 and than tapers to a closed end 152 . The taper permits a balanced airflow distribution to all air jets 140 .
The cooling capacity of the air jets is provided from the freezer itself. The fan assembly 88 has an AC or DC power supply with a small power consumption of up to 3-5 watts in order to reduce impact of heat from the fan motor in the refrigerated space.
Water-Fill Location at the Sensor End of the Icemold
The icemaker 22 may be altered to have the water fill tube 30 fill the ice cavity 42 in contact with the thermostat 58 first. This fill location is significant because it increases the probability that the thermostat 58 will measure a properly filled ice cavity 42 .
Icemakers that fill the ice mold 28 from the opposite end of the mold in relation to the sensor may leave the cube nearest the thermostat unfilled. This is particularly a problem in low water fill situations such as homes with low water pressure and may result in quality problems and service calls. When the cube nearest the thermostat is not properly filled, the ejector arm 54 is likely to be engaged while some of the ice cavities 42 still contain liquid.
Multiple Temperature and Water Fill Level Sensors
The icemaker 22 may be altered to include multiple temperature sensors. Icemakers that initiate an ice harvest based upon a single temperature sensor are subject to a variety of failures that are caused by the combination of water quantity, air flow/heat transfer, levelness of the icemaker, temperature sensor location, and other. Essentially, the icemaker 22 may be determined to be too long with respect to the location of a single temperature sensor.
The icemaker 22 may incorporate multiple water level sensors positioned along the length the row of ice cavities 42 . Using two or more water level sensors will provide information about the fill volume and levelness condition of the icemaker. This information can be used in an icemaker control algorithm to provide the optimum fill volume and the correct harvest initiation. The use of multiple water level sensors results in reliable ice production with conventional water supply technology, conventional temperature sensing means, and typical airflow/heat transfer, and typical installation parameters.
Icemold Having a Larger Ice Cavity Near Temperature Sensor
The icemaker 22 may be altered to include a larger ice cavity 42 near the thermostat 58 . Such a larger ice cavity 42 would produce a large ice cube that would freeze slower than the rest of the ice cubes. As the thermostat registers the temperature of the large ice cube, this would prevent premature ice harvest, one reason for failures and service calls on refrigerators containing icemakers in their freezer portion. The larger ice may have a modified dispensing system and may require slightly longer ejector fingers 56 .
This inventive feature is in contrast to icemakers with symmetrical compartments for all ice cubes. The prior art thermostat controlled icemakers often have a time delay or other active means to compensate for the possibility for a hollow ice problem (where the center of the ice cube is still liquid water). In the present invention, the large ice cube portion located next to the thermostat passively delays the activation of the thermostat and subsequent harvest mechanism. This has the potential to be an energy savings and the modification is passive requiring no other energy to be expended. This invention is particularly useful to applications that require increased ice harvest rates.
Individual Fill of Ice Mold Cavities
The icemaker 22 may be altered to include multiple water fill tubes. Such a configuration permits more uniform distribution of water to each cavity 42 . One such method of accomplishing this is through the utilization of a supply manifold.
In contrast, current icemakers use a single point in which the mold body is filled with supply water. As the mold body is filled, the supply water over flows the dividing walls (weirs 38 ) of the individual ice cube cavities with the intent of filling the entire mold with supply water. An unlevel installation creates problems for this type of design. The tilt of the icemaker may not allow the supply water to sufficiently fill the cavities on the high end of the mold body, and/or may cause too much water in cavities on the low end. This can lead to an overflow of the icemaker and/or problems with ice harvesting such as hollow cubes, excessive wetting, and ejector arm stalls.
Straight Shot of Fill Water Down the Mold Lower Weir Side
As seen in FIGS. 19 and 20 , the ice mold 28 has one side of the weir 38 open for water flow. The icemaker 22 may be altered to position the fill tube 30 in alignment with this opening so that water flowing from the fill tube takes a direct path.
The prior art icemakers provides a fill tube that directs water flowing into the mold body along a circuitous path that slows the entry of the water into the ice cavities 42 . As proposed, this may be improved upon by getting water to flow in a direct path down the open side of the weir 38 and thereby allowing momentum to minimize water surface tension and its effects upon water flow and filling of the individual ice cube cavities.
Stepped Mold
The icemaker 22 may be altered to included a stepped ice mold to improve the ability of the icemaker to operate correctly when installed in an unlevel condition. The icemaker mold is given a stepped orientation in which the mold fills from the top, and cascades into each lower cube. The harvest or fill sensor can be located at any cube, but top and/or bottom are thought to be the preferred sensor locations. The stepped orientation of the ice mold would make the icemaker no more sensitive to unlevelness than any single cube. The slope of the icemaker steps must be greater than the largest degree of unlevelness that the icemaker will see.
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An improved icemaker is provided for a refrigerator. The improvements include tilting the ice mold to assure that the ice cavity nearest the thermostat is filled with water; controlling air flow to the mold to promote rapid freezing of water in the mold cavities; raising the perimeter walls of the mold to minimize water spillage; and providing hooks on the mold for routing electrical wires.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part from continuation-in-part application Ser. No. 10/837,213, filed Apr. 30, 2004, which is a continuation-in part application of divisional application Ser. No. 10/731,315 filed Dec. 8, 2003, now U.S. Pat. No. 7,025,532 which was a divisional application of application Ser. No. 10/453,673 filed on Jun. 3, 2003 that matured into U.S. Pat. No. 6,722,818 B1 issued on Apr. 20, 2004, which itself was a continuation-in-part of parent U.S. application Ser. No. 10/316,756 filed Dec. 11, 2002 that matured into U.S. Pat. No. 6,692,186 B1, issued Feb. 17, 2004. The specification and disclosures of U.S. Pat. No. 6,692,186 B1, of U.S. Pat. No. 6,722,818 B1, and co-pending divisional application Ser. No. 10/731,315 are incorporated by reference into this document.
FIELD OF TECHNOLOGY
The apparatus and method disclosed and claimed in this document pertain generally to a system for draining and transporting fluids, including water, and fluid mixtures and admixtures containing undesirable solids, gases, trash, dirt, toxins, contaminants, and a wide range of other solids, fluids, gases and other undesirable matter (collectively, in this document, “undesirable fluids and materials”) to a containment, collection, or disposal location (collectively, a “containment area”). More particularly, the new and useful interlockable drainage system disclosed and claimed in this document provides inexpensive, light, portable, light-resistant, ultra-violet light-resistant, inter-connectable drainage liner sections that, when assembled, transport undesirable fluids and materials away from both land and structures on land, thus avoiding the adverse results of the presence of undesirable fluids and materials. The interlockable drainage system is particularly, but not exclusively, useful for drainage control in commercial and residential areas, and for solving diverse and complex conservation and water management problems.
BACKGROUND
Both stationary undesirable fluids and materials may adversely affect commercial and residential land and structures. Both the land and structures may be adversely affected by the action of undesirable fluids and materials in, against and under structures. The undesirable fluids and materials also may contaminate the land. Structures may be adversely affected by seepage of undesirable fluids and materials beneath structures because, to the extent that seepage occurs in the vicinity of concrete and other materials used to construct foundations and other components of structures, the structure may be adversely affected as more particularly described below. In addition, undesirable fluids and materials may erode open land, as well as land on which structures are constructed, adversely affecting the use, value and utility of land and structures.
Since time immemorial, a common way to both transport water and to drain undesirable fluids and materials has been the use of ditches. The term “ditch” as used in this document means any excavation dug in the earth, or any structure partially or completely installed above earth, that may be referred to as a drain, channel, canal or acequia, whether lined or unlined, that usually but not always relies on principles of gravity and gravity flow to transport fluids such as water along descending elevations of the ditch.
Since the introduction and use of combinations of Portland cement and aggregate to the construction industries, concrete-lined ditches have been used to transport fluids such as water through ditches. Examples of such installations of concrete lined ditches are shown in FIGS. 1A–1B . Concrete seemed useful because it could be formed to fit varying slopes and directions of earthen ditches. Water, however, whether freestanding or moving, that seeps into and against concrete in concrete-lined ditches often adversely affects commercial and residential structures. Examples are shown in FIGS. 1C–1D . Concrete, unfortunately, has inherent brittle tendencies to crack, and is difficult to repair in remote and challenging terrain due in part to the weight of concrete and the weight of hauling and installing equipment and vehicles. Concrete repair also may disrupt landscapes due to heavy equipment needed. Accordingly, corrosion mitigation systems, particularly in connection with concrete, are a significant goal in the construction industries.
Concrete drains manufactured from Portland cement and various aggregates are subject to deleterious damage caused at least in part by alkali-silica reactivity (“ASR”). ASR is a chemical reaction between Portland cement concrete and aggregates that in some environments, and under some conditions, may cause severe damage to concrete ditches. ASR also may expedite other reactions that in turn cause damage, such as freeze-thaw or corrosion related damage. The phenomenon has been recognized since at least 1940, but neither the mechanisms of ASR, nor solutions, yet are clearly understood.
It is known, however, that deterioration of a concrete structure such as a concrete-lined ditch is due at least in part to water absorption by a gel that forms in concrete. The term “gel” as used in connection with concrete fabrication refers to a naturally occurring silica gel that is a colloidal silica resembling course white sand, but has many fine pores, a condition that causes the gel to be extremely adsorbent. Soluble alkalis also are present in cement, and may be affected by undesirable moisture. Vulnerable sites in the silica structure may be attacked by fluid-induced activity, converting the silica to a silica gel that absorbs water or other fluids.
An important property of concrete is its tensile strength, or its ability to react to longitudinal stress. Liquids, however, are known to adversely affect tensile strength in concrete. If the tensile strength of concrete is exceeded, cracks will form and propagate from one or more alkali-silica reaction sites, weakening the concrete structure. Many if not all of these problems generally associated with ASR may be seen in concrete-lined ditches that have been constructed in situ for any length of time. In addition, concrete becomes ever more expensive, and is difficult to install and maintain.
Suggested alternatives to concrete-lined ditches or drains are apparatus manufactured of one or more metals. Metal ditch liners, however, have proven to be neither cost effective nor durable in the presence of moving or stationary fluids, particularly undesirable fluids and materials.
A need exists in the industry, therefore, for a new, useful interlockable drainage system capable of removing undesirable fluids and materials from both open land as well as land adjacent to structures, in which the components of the interlockable drainage system may be installed in unlined ditches as well as over existing concrete-lined ditches or even other ditch liners; a system that is not susceptible to alkali-silica reactivity or to other deleterious affects associated with concrete; and a system that is flexible, light-weight, long-lived, easily installed, easily maintained or replaced, and inexpensive both to install and to maintain.
SUMMARY
The interlockable drainage system for transporting undesirable fluids and materials is insertable into a ditch that is either lined or unlined. The interlockable drainage system includes two or more liner sections. In one embodiment of the system, the two or more liner sections have a generally V-shaped cross-section. The two or more liner sections are flexible, allowing horizontal and vertical displacement due to small shifts caused, for example, by tectonic events. Molding manufacturing processes, of course, allow production of liner sections for an interlockable drainage system in various geometries and sizes to accommodate any number of circumstances and conditions. Each liner section includes a plurality of corrugations. The corrugations are formed between opposing ends of the liner sections. In one embodiment of the interlockable drainage system the plurality of corrugations are asymmetrical. The asymmetrical corrugations are formed of asymmetrical plates. The terms “asymmetrical” and “asymmetrical plates” mean that the corrugations are formed of quadrilateral plates joined by alternating substantially parallel ridges and nonparallel grooves; that each quadrilateral plate includes at least two substantially right angles formed adjacent the substantially parallel ridge; and that each quadrilateral plate also includes at least two angles adjacent the nonparallel groove that are neither right angles nor equal angles.
The interlockable drainage system also includes a flared channel. The flared channel extends from opposing edges of the liner sections. The flared channel not only is useful for reducing erosion and seepage adjacent the ditch, but also provides a device for inserting anchors that secure the liner sections in place.
Shoulders are formed in the opposing ends of the liner sections. A plurality of bosses is formed on each shoulder. The plurality of bosses on a shoulder is compressibly connectable to the plurality of bosses on an opposing shoulder in another liner section, thus providing the ability to connect one liner section to another liner section in a simple, quick and effective manner. A range of alternative means may be used to connect the plurality of bosses.
It will become apparent to one skilled in the art that the claimed subject matter as a whole, including the structure of the apparatus, and the cooperation of the elements of the apparatus, combine to result in a number of unexpected advantages and utilities. The structure and co-operation of structure of the interlockable drainage system will become apparent to those skilled in the art when read in conjunction with the following description, drawing figures, and appended claims.
The foregoing has outlined broadly the more important features of the invention to better understand the detailed description that follows, and to better understand the contributions to the art. The interlockable drainage system is not limited in application to the details of construction, and to the arrangements of the components, provided in the following description or drawing figures, but is capable of other embodiments, and of being practiced and carried out in various ways. The phraseology and terminology employed in this disclosure are for purpose of description, and therefore should not be regarded as limiting. As those skilled in the art will appreciate, the conception on which this disclosure is based may be used as a basis for designing other structures, methods, and systems. The claims, therefore, include equivalent constructions. Further, the abstract associated with this disclosure is intended neither to define the interlockable drainage system, which is measured by the claims, nor intended to limit the scope of the claims.
SUMMARY OF DEFINTIONS
The following terms have the following meanings in this document:
The term “drain” and “drainage” as used in this document refers at least to the planned installation of a system components disclosed and claimed in this document to route, carry, and move undesirable fluids and materials at a desirable rate of flow from one location to another.
The term “containment area” and terms of similar import mean any outflow area where the undesirable fluids and materials no longer pose an unacceptable threat to land and structures.
The term “concrete-lined ditches” means any concrete-lined ditch, drain, or culvert.
The term “undesirable fluids and materials” means fluids, including water, and fluid mixtures and admixtures containing undesirable solids, gases, trash, dirt, toxins, contaminants, and a wide range of other solids, fluids, gases and other undesirable matter.
The term “ditch” means any excavation dug in the earth, or any structure partially or completely installed above earth, that may be referred to as a drain, channel, canal or acequia, whether lined or unlined, that usually but not always rely on principles of gravity and gravity flow to transport fluids such as water along descending elevations of the ditch.
The term “asymmetrical” and “asymmetrical plates” means that the corrugations are formed of quadrilateral plates joined by alternating substantially parallel ridges and nonparallel grooves; that each quadrilateral plate includes at least two substantially right angles formed adjacent the substantially parallel ridge; and that each quadrilateral plate also includes at least two angles adjacent the nonparallel groove that are neither right angles nor equal angles, as perhaps best shown diagrammatically in FIG. 7 .
The novel features of the interlockable drainage system are best understood from the accompanying drawing, considered in connection with the accompanying description of the drawing, in which similar reference characters refer to similar parts, and in which:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1A is a perspective view of a representative environment in which ditches exist;
FIG. 1B is a top view of the view of a representative environment shown in FIG. 1A with contour lines;
FIG. 1C is an end cut-away end view of a concrete ditch liner installed in a ditch;
FIG. 1D is an end cut-away end view of a hillside showing water flow from rain passing two concrete ditch liners;
FIG. 2A is a perspective view of an uninstalled interlockable drainage system about to be installed in a concrete lined ditch;
FIG. 2B is a perspective view of one embodiment of a hub assembly of the interlockable drainage system;
FIG. 2C is a perspective exploded view of the hub assembly of the interlockable drainage system and cut-away portion of ditch liner connectable to the hub assembly;
FIG. 2D is a perspective view of an alternative embodiment of two hub assemblies;
FIG. 3A is an cut-away view of a ditch liner of the interlockable drainage system installed in a concrete ditch shown without bosses to emphasize other features of the liner components;
FIG. 3B is an end view showing greater detail of an anchor inserted through a liner section;
FIG. 4 is a perspective end view showing an anchor inserted through a liner section shown without bosses to emphasize other features of the liner components;
FIG. 5A is an end view of a liner section shoulder showing a plurality of bosses formed on the shoulder of the liner section;
FIG. 5B is an end view of a liner section shoulder showing a plurality of bosses formed on the shoulder of the liner section and an alternative embodiment of a anchors;
FIG. 6 is a cut-away side view of bosses connectable by a connector; and
FIG. 7 is a diagrammatic view of the asymmetrical plates used for forming the corrugations of the liner sections of the interlockable drainage system.
DETAILED DESCRIPTION
To the extent that subscripts to numerical designations include the lower case letter “n,” as in “a–n,” the letter “n” is intended to express a number of repetitions of the element designated by that numerical reference and subscripts.
As shown in FIGS. 1A–7 , an interlockable drainage system 10 is provided that in its broadest context includes two or more liner sections 12 a–n insertable into a lined or unlined ditch 14 as shown in FIGS. 1A–1B . Liner sections 12 a–b as perhaps best shown in FIG. 2A include a plurality of corrugations 16 a–n formed between opposing ends 18 a–d of liner sections 12 a–b that in one embodiment are asymmetrical quadrilateral plates 20 a–n joined by alternating parallel ridges 22 a–n and nonparallel grooves 24 a–n best shown in FIG. 7 .
Interlockable drainage system 10 also includes a flared channel 26 a–b that extends from opposing edges 28 a–b of liner sections 12 a–b as best shown in FIG. 2A . Flared channel 26 a–b is useful not only for reducing erosion adjacent ditch 14 in which interlockable drainage system 10 is installed, but also provides means 30 ′ for inserting one or more anchors 30 a–n for securing liner sections 12 a–b in place as best shown in FIGS. 3B–5B .
As best shown by cross-reference between FIGS. 2 C and 5 A– 5 B, a shoulder 32 a–n is formed in opposing ends 18 a–b of liner sections 12 a–b . A plurality of bosses 34 is formed on shoulder 32 a–b . Plurality of bosses 34 a–n on one shoulder 32 a is provided for compressibly connecting plurality of bosses 34 to another shoulder 32 b , thus interlocking one liner section 12 a to another liner section 12 b . A connector 36 , best shown in FIG. 6 , may be used for interconnecting plurality of bosses 34 .
More specifically, as shown by cross-reference between FIGS. 2A and 3A , interlockable drainage system 10 includes two or more liner sections 12 a–b . Each liner section 12 a–b of interlockable drainage system 10 is formed with a spaced-apart open span 38 defined by opposing edges 28 a–n that are substantially parallel to the longitudinal axis of each of two or more liner sections 12 a–b . In the embodiment shown in FIGS. 2A and 3A , two or more liner sections 12 a–b are formed with a generally V-shaped cross-section. The generally V-shaped cross-section is to accommodate and fit into a pre-existing concrete ditch liner 40 formed with a V-shaped cross-section as shown by cross-reference between FIGS. 2A–5B . As will be evident to one skilled in the art, interlockable drainage system 10 may be shaped to accommodate or fit into a variety of ditches 14 regardless of cross-section shape. As shown, two or more liner sections 12 a–b is molded from polyethylene with anti-ultra violet resistant characteristics and fire-resistant characteristics. The material also is chosen to provide excellent friction factors in connection with water movement. Because of the materials used to manufacture the liner sections and methods of manufacture, the two or more liner sections 12 a–b may be colored to match different terrains and environments to enhance the aesthetics of an installation.
In the embodiment shown in FIGS. 2A and 3A , two or more liner sections 12 a–b are thermoformed polyethylene liner sections. Two or more liner sections are formed of Medium Density Polyethylene (“MDPE”) material. Polyethylene and similar thermoplastic materials are unpalatable to rodents that otherwise might bore holes through two or more liner sections 12 a–b . Thermoplastic materials also are highly resistant to heat and fire. Such materials also contribute to rigidity, force resistance, lightness, and environmental acceptance. Nova Chemical NOVAPOL™ provides at least one commercial formulation of the polyethylene. TR-0535-UGhexene MDPE. As a person skilled in the art will also appreciate, however, two or more liner sections 12 a–b made of other materials also may be appropriate in other circumstances, environments, and conditions. Accordingly, a variety of resins, plastics, and other materials may be used as materials in making interlockable drainage system 10 .
As indicated, two or more liner sections 12 a–b may be formed by thermoforming. Thermoforming is a method of manufacturing plastic and resin products by preheating a flat sheet of plastic, then bringing the sheet in contact with a mold whose shape the sheet takes. This may be done by vacuum, pressure, or direct mechanical force. Injection molding also may be used by heating pellets or granules of plastic until melted. The melted material is forced into a split-die chamber, or mold, and allowed to cool and cure into desired shapes. The mold then is opened and the part ejected. As a person skilled in the art also will appreciate, however, two or more liner sections 12 a–b may be made by any number of other methods, including rotational molding. The method of manufacturing of two or more liner sections 12 a–b is not a limitation of this disclosure or of the claims.
Plurality of corrugations 16 is formed between opposing ends 18 a–b of two or more liner sections 12 a–b . In the embodiment shown by cross-reference between FIGS. 2A and 7 , plurality of corrugations 16 includes asymmetrical quadrilateral plates 20 a–n . As also shown perhaps best in the embodiment shown in FIGS. 3A and 7 , plurality of asymmetrical quadrilateral plates 20 a–n have a leading border 42 and a trailing border 44 . Asymmetrical quadrilateral plates 20 a–n are sequentially joined at leading border 42 and trailing border 44 by substantially parallel ridges 22 a–n and substantially nonparallel grooves 24 a–n . More specifically, plurality of asymmetrical quadrilateral plates 20 a–n also is joined at sequentially alternating substantially parallel ridges 20 a–n and substantially nonparallel grooves 24 a–n.
Plurality of asymmetrical quadrilateral plates 20 a–n includes at least two substantially right angles. The at least two substantially right angles A and B are formed adjacent substantially parallel ridges 22 a–n , shown diagrammatically in FIG. 7 as Angles A and B. As also shown, plurality of asymmetrical quadrilateral plates 20 - a–n includes at least two angles that not only are not right angles, but also are not equal angles, as shown diagrammatically in FIG. 7 as Angles C and D. The use of corrugations 16 formed as asymmetrical quadrilateral plates 20 a–n contributes to the mechanical advantages of interlockable drainage system 10 . The mechanical advantages include at least dampening rapid flow of undesirable fluid and materials through interlockable drainage system 10 . Another mechanical advantage is interrupting or trapping the flow of silt, dirt, and similar matter within corrugations 16 , while also providing alternating scoops 46 a–n to slow the rate of movement of such matter by providing a means for gradual passage of the matter through and over alternating scoops 46 a–n aligned transversely to the longitudinal axes through interlockable drainage system 10 . Asymmetrical quadrilateral plates 20 a–n also affect the coefficient of friction otherwise provided by two or more liner sections 12 a–n , and accordingly the rate of flow through interlockable drainage system 10 .
The inner surface 48 a–b of two or more liner sections 12 a–b is thus formed for flow enhancement and control by selection of the proper combination of materials and the configuration of corrugations 16 . The term “flow enhancement and control” as used in this document refers to the fact that inner surface 48 a–b of one or more liner sections 12 a–b is shaped and formed to permit passage across and through interlockable drainage system 10 of undesirable fluids and materials sought to be conveyed from one location to another. The term “flow enhancement and control” also means that inner surface 48 of a liner section 12 is shaped and formed to inhibit flow blockage across and through interlockable drainage system 10 that might otherwise be caused by solid materials ceasing to flow through the interlockable drainage system 10 for any reason.
A flared channel 26 a–b is provided in interlockable drainage system 10 . In the embodiment shown by cross-reference between FIGS. 2A–5B , flared channel 26 a–b monolithically extends from opposing edges 28 a–b of one or more liner sections 12 a–b . Flared channel 26 a–b includes a substantially L-shaped arm 50 a–b as perhaps best shown in FIGS. 3A and 3B . Flared channel 26 a–b also includes a foot 52 extending from substantially L-shaped arm 50 a–b . Flared channel 26 a–b includes an angled flange 54 extending from foot 52 . Flared channels 26 a–b provide the mechanical advantage of a duct 56 into which dirt and other materials may be mounded and compressed to provide a barrier for resisting seepage and erosion of soil adjacent concrete liner 40 , as best shown in FIGS. 3A–4 , and because L-shaped arm 50 a–b is designed to tuck over the lip 58 of concrete liner 40 before backfill of the dirt and other materials.
In the embodiment shown in FIGS. 2 A and 3 A– 4 , flared channel 26 a–b also includes an inclined bracket 60 a–n formed with a hole 62 . Inclined bracket 60 a–n formed with a hole 62 is shown in FIGS. 3A and 3B as installed at the intersection of the angle formed between foot 52 and angled flange 54 . The angle formed between foot 52 and angled flange 54 a–b is shown diagrammatically in FIG. 3A as Angle E. Inclined bracket 60 a–n formed with hole 62 provides the mechanical advantage of including an opening provided by hole 62 through which anchor 30 may be aligned and guided for insertion through one or more liners 12 a–b . Inclined bracket 60 a–n formed with hole 62 also provides the mechanical advantage of a guide facet 64 . Guide facet 64 is angled for properly inserting anchor 30 at the most effective angle through inclined bracket 60 a–n into soil or other material adjacent concrete liner 40 . The soil or other material adjacent concrete liner 40 is perhaps best shown by cross-reference between FIGS. 3A–5B as a crosshatched pattern. As will be evident to one skilled in the art, and as shown in FIG. 4 , inclined bracket 60 a–b in opposing flared channels 26 a–b are aligned in different orientations, thus providing a more movement resistant installation on insertion of anchors 30 shown in FIG. 4 as anchors 30 c–d.
In the embodiment shown in FIG. 5A , one or more anchors 30 is insertable through the flared channel 26 a–b and inclined bracket 60 a–n for securing two or more liners 12 a–b in concrete ditch liner 40 . In the embodiment shown in FIG. 5A , one or more anchors 30 e–f is an earth anchor. The term “earth anchor” refers to an anchor manufactured under the trademark PLATIPUS® by Platipus Anchors Limited located in Surrey, England. As will be evident to one skilled in the art, any of a variety of anchors 30 may be used. In the embodiment shown in FIG. 5B , for example, one or more anchors 30 a–n is a rod 66 a–b . Rod 66 a–b is shown to include a stopper 68 . Stopper 68 a–b not only secures rod 66 a–b against guide facet 64 a–b of inclined bracket 60 a–b , but also contributes to orienting the angle of incidence of rod 66 a–b at the proper angle for insertion through inclined bracket 60 a–b , shown diagrammatically in FIG. 5B as Angle F and F′.
As shown in FIGS. 2A–2B and 5 A– 5 B, in one embodiment of interlockable drainage system 10 shoulders 32 a–b are formed in opposing ends 18 a–d of two or more liner sections 12 a–b . A plurality of bosses 34 a–n is monolithically formed on shoulder 32 a–b in opposing ends 18 a–b of two or more liner sections 12 a–b . A connector 70 as best shown in FIG. 6 is provided for interconnecting plurality of bosses 34 a–n . As shown in FIG. 6 , connector 70 may be threadably inserted through exterior surface 72 a and through exterior surface 72 b using a connector 70 that does not make contact with or puncture any other portion of liner sections 12 a–n . In the embodiment shown in FIGS. 2C and 6 , plurality of bosses 34 is substantially hollow. Plurality of bosses 34 also is formed with an exterior surface 72 and an interior surface 74 . Exterior surface 72 of plurality of bosses 34 is slidably and compressibly connectable and engageable with interior surface 74 of bosses in an opposing shoulder 32 b.
The mechanical advantage of a slidably connectable and engageable interior surface 74 and exterior surface 72 includes at least providing means for quickly, easily, and compressible interconnecting bosses 34 a–n for a secure fit that avoids seepage or leakage from interlockable drainage system 10 . As shown in FIG. 2B , plurality of bosses 34 a–n is formed as a substantially frusto-conical member formed with a recess 75 . But as will be evident to one skilled in the art, the shape of plurality of bosses 34 a–n is not a limitation of interlockable drainage system 10 , and may include not only a frusto-conical member, but include a variety of cross-sectional variations including, by way of a non-exclusive example, a hexagonal cross-section.
Alternative means for compressibly connecting opposing ends 18 a–b of liner sections 12 a–b are available but not shown. Alternative connecting means include a first locking channel segment monolithically formed substantially adjacent one end of the two or more flexible liner sections. Connecting means also includes a second locking channel segment monolithically formed substantially adjacent the other end of the two or more flexible liner sections, and further wherein the second locking channel segment is detachably connectable to the first locking channel segment. The alternative means for compressibly connecting opposing ends of liner sections is shown and claimed in U.S. Pat. No. 6,692,186 B1 issued to one of the named inventors named in this document on Feb. 17, 2004, shown in FIGS. 3A–3C and at column 13 , lines 8 – 16 , column 13 , lines 61 – 64 , and column 14 , lines 38 – 46 , the provisions of which are incorporated by reference into this document.
Yet another means for compressibly connecting opposing ends of liner sections 12 a–b is available. Means for compressibly connecting opposing ends of liner sections includes a first locking channel segment monolithically formed substantially adjacent one end of the two or more flexible liner sections. Means also includes a second locking channel segment monolithically formed substantially adjacent the other end of the two or more flexible liner sections, and further wherein the second locking channel segment is detachably connectable to the first locking channel segment. The alternative means for compressibly connecting opposing ends of liner sections is shown and claimed in U.S. Pat. No. 6,722,818 B1 issued to one of the named inventors named in this document on Apr. 20, 2004, at FIGS. 4–6 , and in column 9 , lines 23 – 37 , column 10 , lines 1 – 12 , and column 10 , lines 50 – 64 , the provisions of which are incorporated by reference into this document.
In the embodiment shown in FIG. 2A , an adjustable elbow unit 76 is included with interlockable drainage system 10 . Adjustable elbow unit 76 is removably connectable to opposing ends 18 a–b of two or more sequential liner sections 12 a–b in an interlocked interlockable drainage system 10 for changing the direction of flow of the undesirable fluids and materials through interlockable drainage system 10 . Adjustable elbow unit includes a pleat 78 . Pleat 78 provides the resiliency and flexibility of a living hinge in the form of a band 80 that interrupts the sequence of asymmetrical corrugations 20 a–n , and is but one embodiment that may or may not be corrugated. Pleat 78 in adjustable elbow unit 76 provides the mechanical advantage of flexibility and bendability to accommodate changes in direction of an installed interlockable drainage system 10 either along the longitudinal axes of liner sections 12 a–b joined by adjustable elbow unit 76 or along the transverse direction substantially perpendicular to the longitudinal axes. As shown, pleat 78 in adjustable elbow unit 76 provides the desired flexibility and bendability to alter direction of an installed interlockable drainage system 10 , but the mechanism for doing so may be any of a variety of mechanisms. One such alternative mechanism may be a crinkled accordion configuration (not shown). Another such alternative mechanism may be a series of uniform variously shaped corrugations formed in pleat 78 (not shown).
Other embodiments are shown in FIGS. 2B–2D for changing the direction of flow of the undesirable fluids and materials through interlockable drainage system 10 . As shown in FIG. 2C , interlockable drainage system 10 includes a hub 82 . Hub 82 includes one or more passages 84 a–d formed with a distal end 86 a–n . A shoulder extension 88 a–n adjacent distal end 86 a–n is formed in one or more passages 84 a–d extending a distance D 1 from distal end 86 a–n toward center 88 of hub 82 as shown in FIG. 2D . A plurality of bosses 34 ′ a–n is monolithically formed on shoulder extension 88 a–n for slidably interconnecting plurality of bosses 34 a–n on shoulders 32 a–n of liner sections 12 a–n to plurality of bosses 34 ′ a–n formed on shoulder extension 88 a–n . Connector 70 as shown in FIG. 7 may be used to further connect plurality of bosses 34 a–n on shoulders 32 a–n of liner sections 12 a–n to plurality of bosses 34 ′ a–n on sho extension 88 a–n.
As also shown in FIGS. 2B–2D , hub 82 may be provided with a varying number of passages 84 a–d for affecting the direction of flow through interlockable drainage system 10 . FIG. 2D , for example, shows one hub 82 with four passages 84 a–d connectable to a second hub 82 ′ having three passages 84 e–g . Hub 82 ′ also is shown with a means 90 for splitting or interrupting the flow of undesirable fluids and materials through interlockable drainage system 10 . As shown, means 90 is a wedge 90 ′ extending toward center 88 of a second hub 82 ′ from a closed end 92 of hub 82 ′. The flow of undesirable fluids and materials, for example, from passage 84 f in the direction of passage 84 e may be slowed, interrupted, and redirected by wedge 90 ′. As will be evident to one skilled in the art, wedge 90 ′ is only one of several means 90 for affecting the direction of flow through interlockable drainage system 10 . It also will be evident to one skilled in the art that alternative means may be used other than bosses 34 ′ a–n for compressibly connecting opposing ends 18 a–n of two or more liner sections 12 a–n . Such alternative means have been described in this document by reference to U.S. Pat. No. 6,692,186 B1, issued Feb. 17, 2004, and to U.S. Pat. No. 6,692,186 B1, issued Feb. 17, 2004.
The interlockable drainage system 10 shown in drawing FIGS. 1 through 7 is at least one embodiment that is not intended to be exclusive, but merely illustrative of the disclosed but non-exclusive embodiments. Claim elements and steps in this document have been numbered and/or lettered solely as an aid in readability and understanding. Claim elements and steps have been numbered solely as an aid in readability and understanding. The numbering is not intended to, and should not be considered as intending to, indicate the ordering of elements and steps in the claims. Means-plus-function clauses in the claims are intended to cover the structures described as performing the recited function that include not only structural equivalents, but also equivalent structures. Thus, although a nail and screw may not be structural equivalents, in the environment of the subject matter of this document a nail and a screw may be equivalent structures.
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The specification and drawing figures describe and show an interlockable drainage system insertable into a ditch that includes two or more liner sections. Each liner section includes a plurality of corrugations that are asymmetrical. The interlockable drainage system also includes a flared channel extending from opposing edges of the liner sections. A shoulder is formed in the opposing ends of the liner sections. A plurality of bosses is formed on the shoulder. The plurality of bosses on one shoulder is compressibly connectable to the plurality of bosses on an opposing shoulder, thus connecting one liner section to another. A connector is provided for added interconnectability of the plurality of bosses. This abstract is provided to comply with rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure, but this abstract is not to be used to interpret or limit the scope or meaning of any claim.
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This is a division of Application Ser. No. 967,227 filed Dec. 7th, 1978 and now U.S. Pat. No. 4,240,479.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to tool handles and in particular to a novel, unbreakable handle for a sledge hammer.
2. Brief Description of the Prior Art
In the past, many attempts have been made to provide a flexible coupling between a tool, such as a hammer head, and a handle for manipulating the tool. Such prior art attempts have included the use of a flat, leaf-type spring, a coil spring, and many other types of connectors. The provision of flexible elements within hammer handles was believed to add to the usefulness of the handle since it would accept a certain amount of shock and prevent the transmission of this shock to the user. However, it has been found that in order to eliminate shock, the connector becomes extremely flexible, and therefore, difficult to use as a hammer.
German Patent No. 525282, issued May 21, 1931, discloses the use of a section of wire rope between the handle portion and the end in which the tool is mounted. However, the present invention provides an improvement in the art by providing a novel apparatus and method of securing the respective elements to the ends of a wire rope section.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a new and useful tool handle which is substantially unbreakable in its intended use.
It is another object of the present invention to provide a connecting means for securely mounting the tool, such as a hammer head, to a conventional handle, such as a wooden handle, for preventing relative rotation of the tool with the handle during use.
It is yet another object of the present invention to provide a method for making a sledge hammer in which a wire rope connector portion greatly reduces the breakage of handles during normal use.
An unbreakable sledge hammer handle includes a conventional, wood or other rigid lower handle portion and a wire rope connector for mounting the hammer head on the top end of the hammer. A pair of collars are fit on the opposite ends of the wire rope connector and secured thereto by applying extreme pressure to the collar which deforms and cold works the interior diameter to fill in the gaps between the wire segments. The sledge hammer head is provided with a cylindrical mounting aperture which is smaller in diameter than the outside diameter of the collar. The hammer head is subsequently heat shrunk onto the collar. The opposite end of the wire rope connector is secured to the wooden handle portion by a sleeve which extends a substantial length over the exterior of the handle portion. The sleeve is riveted to the wooden handle portion and spot welded to the collar.
The foregoing and other objects of the present invention will become apparent from the following detailed description of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a sledge hammer, partially shown in section, made in accordance with the concepts of the present invention;
FIG. 2 is a top plan view of the upper end of the handle mounted within the hammer head;
FIG. 3 is a vertical section of the connection between the handle and the hammer head taken generally along line 3--3 of FIG. 2;
FIG. 4 is a cross-sectional view, similar to FIG. 3, showing schematically the step of hydraulically deforming a collar onto the wire section;
FIG. 5 is a top plan view of a hammer head having a cylindrical mounting aperture;
FIG. 6 is a vertical section showing the connection of the wire rope connector to the hammer head and the wooden handle;
FIG. 7 is a top plan view of the prior art; and
FIG. 8 is a vertical section of the prior art taken generally along line 8--8 of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A tool handle, particularly adapted for use with an impact tool, such as a sledge hammer, made in accordance with the concepts of the present invention, is shown in FIG. 1 and indicated by the reference numeral 10. While the tool handle 10 of the present invention can be used with many types of tools, and in particular, impact tools, it is shown and described herein with reference to its application on a sledge hammer without limiting the nature and scope of the invention. The handle 10 includes a conventional generally elongated wooden handle portion 12 and a connection means 14 which secures the handle to a tool, such as the sledge hammer head 16.
The connection means 14 includes a wire rope section 18, an upper fastening means, generally designated 20, for connecting the head 16 to one end thereof, and a lower fastening means 22 for connecting the other end of the wire rope 18 to the elongated handle portion 12. Prior attempts to utilize a wire rope section for an impact tool resulted in several deficiencies, the structural differences of which are shown in FIGS. 7 and 8 hereof. In particular, the prior art utilized a wire rope section such as the section 26 in which six outer wires are wrapped about an inner wire in a generally spiral fashion. The prior art devices, such as shown in the above-referenced German patent and in U.S. Pat. No. 2,619,860 provide a cylindrical connector 28 which was connected to the end of the wire rope 26. However, because of the outer diameter of the wire rope 26, defined by the largest circumscribing circle of the six outer wire portions, there is very little contact between the sleeve 28 and the wire rope itself, only six, theoretical lines of contact. This factor left many vacancies, such as the six generally triangular voids 30 between the inner wall of the sleeve 28 and the wire rope. In a side elevational view, these vacancies 30 can be seen to extend along substantial lengths between the wire rope 26 and the sleeve 28. These voids and vacancies 30, in addition to the theoretical point or line contact between the elements 26 and 28 greatly reduces the strength and rigidity of the connection. When such a connection is applied to an impact tool, such as a sledge hammer, were very high forces and stresses are applied at the juncture, the head would tend to loosen and, particularly, possibly twist due to torsional forces if an exact hit were not accomplished by the user. The present invention solves this particular problem as described in detail hereinafter.
The wire rope section 18 may be of a standard or conventional type. The particular type of wire rope selected for use in the present invention is designated a 6×25 filler wire. Each of the six outer strands of the filler wire includes a central wire about which six identically sized wires are wrapped, followed by six substantially smaller wires which fill the gaps about the six, followed by an outside layer of twelve identically sized wires. The top view of FIG. 2 shows the end view of the 6×25 filler wire 18 in its assembled form in the hammer head.
The first step in manufacturing the tool handle is the attachment of the upper fastening means 20 to the wire rope 18, as shown in FIG. 4. The upper fastening means 20 includes a generally cylindrical collar 34 which has an internal diameter approximately equal to the diameter of the wire rope 18, and a substantially larger outer diameter. One end of the collar 34 includes a chamfer which defines a shoulder 36. The collar 34 is preferably manufactured of cold rolled steel so that it can be cold worked and maintain a deformed position. In one method contemplated by the present invention, referring to FIG. 4, the collar 34 is fit on one end of the wire rope 18 and the assembly is inserted into the jaws 38 of a hydraulic pressuring device. Then, hydraulic pressure of approximately 600 tons is applied in the direction of the arrows A to compress the collar 34 causing the internal diameter or the interior surfaces thereof to become cold worked and fill in the gaps 40 along the length of the wire with material from the collar itself. In the top view, the filled in, generally triangular shaped areas 40 have been darkened with respect to the collar to emphasize the filling in of the vacancies 30 of the prior art by cold working of the collar 34 itself. This tremendous hydraulic pressure has also been found to cause the external diameter of the wire to be reduced by a significant amount, also indicating that the end of the wire rope within the collar 34 has been compressed to an even greater degree than in its normal form. Thus, the collar 34, in one method, is securely fastened to the end of the wire rope by compressive forces which solidly connect the end of the wire rope 18 to the collar 34. It is also possible that a plurality of compression rings or grooves 43 may be impressed on the exterior of the collar 34 to create additional stress, friction, and facilitate the filling of the voids along the length of wire rope 18. Although only two grooves are shown in FIG. 4, it is contemplated that as many as ten or more grooves may be appropriate.
In an alternative form of the present method, the end of the wire rope 18 can be prepared in a manner similar to that used for zinc plating and the collar 34 can be secured to the end of the wire rope 18 by simultaneously press fitting the collar 34 on the end while filling all of the gaps adjacent the collar, and gaps within the wire rope 18 itself, with molten metal, such as zinc itself. In both methods, the binding of the end of the wire prevents any unraveling, and in fact, adds rigidity to the wire rope section itself.
The upper fastening means is then secured to a tool, such as a sledge hammer head 16. The pressurizing step described above maintains a cylindrical outside diameter for the collar 34, and therefore the collar can fit within a cylindrical aperture in a tool handle. Prior art sledge hammer heads always require an expensive, oblong aperture for mounting a wood handle. However, in the present application, an oblong aperture is not required. The sledge hammer head 16 is provided with a cylindrical aperture 44 and is heated prior to assembly which causes the aperture 44 to become larger due to expansion. The collar 34 may be chilled prior to insertion into the aperture 44 of the heated head 16 by a press fit. After the head is permitted to reach room temperature, very substantial compressive forces will be generated which maintain the head securely on the collar 34. In addition, to further secure the head, the upper surface of the aperture 44 is provided with a chamfered edge 46 and the steel collar 34 is flared, as at 48, shown in FIG. 3. The compressive forces of the pressurizing or hydraulic crimping step and the cooling of the head 16 will generate compressive forces on the wire rope 18 which are greatest in the center of the head as shown by arrow B which forces taper off from the center toward the ends.
Referring to FIG. 6, the flaring of the upper end of the collar 34 is shown more clearly by the arrows and, in this enlarged view, the filled in areas 40 are shown in cross section with the collar.
The lower fastening means 22 which secure the opposite end of the wire rope to the wooden handle 12 is slightly different than the upper fastening means 20. Referring to FIG. 6 in particular, a collar 50 is similarly secured to the opposite end of the wire rope 18. This opposite end may or may not include the shoulder 36 as on the top collar 34. Again, the pressurizing step deforms a portion of the collar to fill the gaps within the areas adjacent the wire rope 18. The lower collar 50 is then secured to the wooden handle portion 12 by an elongated sleeve 52. The internal diameter of the sleeve 52 is substantially identical to the outer diameter of the collar 50 on one end and may be tapered to fit snugly on the exterior of a preshaped wooden handle portion 12. The upper end of the sleeve 52, the end adjacent the hammer head, is secured to the sleeve by a plurality of spot welds 56 shown in FIG. 6. The lower portion of the sleeve 52 is secured to the wooden portion of the handle by a plurality of rivets 60. Thus, the rivets secure the sleeve 52 on the end of the wooden shank 12 and the spot welds 56 secure the collar 50 to the upper end of the sleeve 52. This construction completes the assembly of the tool handle and its connection to, in this case, a hammer head. Preferably, the length of the sleeve 52 which overlaps the wooden handle portion 12 is approximately 4 times the length that overlaps or encloses the collar 50.
Many alternate constructions of the present invention are possible without departing from the spirit and scope thereof. For example, the length of the wire rope 18 can be of any suitable length to provide more or less rigidity and weight balance in the handle portion itself. In addition, during assembly of the collars 34 and 50 (which may be done simultaneously) on the opposite ends of the wire 18, the wire may be twisted in the direction of the wrap of the individual components to assure that all gaps or other loose areas within the wire are themselves eliminated. This construction provides an extremely rigid, usable tool handle which is not susceptible to many of the normal breaking problems associated with wooden tools. For example, when attempting to drive a 1/8" steel plate into the ground to form a barrier wall or when using wedges to split logs, for example, a slight miscalculation of the user which causes the hammer head 16 to miss its target and forces the handle to absorb the shock as it engages the work piece, will normally cause a wooden sledge hammer handle to break. The particular advantage, and that which makes the handle unbreakable, of the present invention, is that the wire rope portion 18 will not be broken. The invention disclosed herein could easily be incorporated in any device having one elongated handle without departing from the spirit and scope of this invention. For example, this invention could be used on tennis racquets, golf clubs and other sporting equipment as well as other tools, such as screwdrivers, torque wrenches, or the like.
Many other advantages and other uses of the present invention will become obvious in view of this disclosure and therefore, the foregoing detailed description has been given for clearness of understanding only and no unnecessary limitations should be understood therefrom as some modifications will be obvious to those skilled in the art.
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An unbreakable sledge hammer handle includes a conventional, wood or other rigid lower handle portion and a wire rope connector for mounting the hammer head on the top end of the hammer. A pair of collars are fit on the opposite ends of the wire rope connector and secured thereto by applying extreme pressure to the collar which deforms and cold works the interior diameter to fill in the gaps between the wire segments. The sledge hammer head is provided with a cylindrical mounting aperture which is smaller in diameter than the outside diameter of the collar. The hammer head is subsequently heat shrunk onto the collar. The opposite end of the wire rope connector is secured to the wooden handle portion by a sleeve which extends a substantial length over the exterior of the handle portion. The sleeve is riveted to the wooden handle portion and spot welded to the collar.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to liquid spreading devices and more particularly to a manually manipulatable mechanism for spraying a molten asphalt seal coating on selected areas of paved surfaces.
2. Description of the Prior Art
In the art of highway maintenance, it is a common practice to periodically renew the surface of the pavement by applying what is referred to as a chip seal coat on the existing paved surface. After the repair of damaged areas, such as the filling of cracks and chuck holes, a seal coating of molten asphalt is sprayed on the entire paved surface and a coating of crushed rocks, referred to in the industry as chips, is spread on the asphalt while it is still hot. The surface is then rolled with a special roller vehicle which embed the chips in the asphalt seal coating.
The equipment used in this type of highway maintenance is very large and expensive to operate. For example, the spray application of the molten asphalt seal coat is normally accomplished by using a large truck which is provided with heaters, agitators, asphalt pumps and various other devices which condition the molten asphalt and supply it under pressure from a molten asphalt supply tank to a spreader bar assembly which is carried transversely at the rear of the truck. The spreader bar usually includes a fixed central portion whose length is established by the laws which govern the maximum width of vehicles that are operated on highways. To overcome this width limitation, foldable extension spreader bars are mounted on the opposite ends of the central portion and in this way, a substantial portion of a highway is coated with each pass of the truck.
Since the entire surface of a highway, or other paved surface, is being renewed by the above described maintenance procedure, the large size of the various pieces of equipment needed to accomplish this task, such as the hereinbefore described asphalt spray truck, is needed, and the operating expenses of such equipment are justified.
However, when spot road repair work is needed, such as filling chuck holes, repairing damaged shoulders, and the like, the above mentioned equipment is much to large and expensive to use. Spot repair is, therefore, normally accomplished in a different manner. For example, a chuck hole, after being cleaned out, is filled with a hot asphalt-aggregate mix, leveled by hand and then rolled with a hand operated roller. Since no equipment for applying a molten asphalt seal coat and a chip coat is available, or suitable for such spot repair work, the chip seal coating is simply omitted. In the absence of a chip seal coating, the repaired areas are subject to relatively rapid deterioration due to traffic and environmental damage.
To the best of our knowledge, no equipment has been devised or suggested which is suitable for use in applying a seal coating of molten asphalt in relatively small areas where spot repair work is being accomplished on paved surfaces. Therefore, a need exists for a manually manipulatable mechanism for spreading a molten asphalt seal coating on selected areas of a paved surface.
SUMMARY OF THE INVENTION
In accordance with the present invention, a new and useful manually manipulatable mechanism is disclosed for spraying molten asphalt on selected areas of a paved surface.
The spray mechanism is an application device and as such is designed to work in conjunction with a suitable molten asphalt supply apparatus which is configured to contain a supply of molten asphalt, maintain the asphalt in its molten state and supply it under pressure to the spray mechanism. Apparatus suitable for this purpose are well known in the art, with an example of such an apparatus being fully disclosed in U.S. Pat. No. 4,159,877, issued on July 3, 1979.
When in use, the spray mechanism of the present invention is coupled to the suitable molten asphalt supply apparatus by a supply hose and a return hose. When the spray mechanism is in an operator selected inoperative state, as is needed from time to time, such as, for example, to move the spray mechanism from one application area to another, the molten asphalt is received under pressure from the supply apparatus and is moved through the spray mechanism and recirculatingly returned to the supply apparatus. This recirculation capability allows the supply apparatus to maintain the asphalt in its molten state which, in the absence of this capability could cool and solidify in the spray mechanism during prolonged inoperative periods thereof. When the spray mechanism is switched by the operator to its operative state, the received molten asphalt is prevented from returning to the supply apparatus and is sprayingly applied on the paved surface.
The spray mechanism includes a wheeled carriage which supportingly carries a conduit assembly having a flow switching valve therein, with the conduit assembly supportingly carrying a spray bar, so that it transversely spans the intended movement path of the mechanism. The conduit assembly is provided with a pair of coupling means to which the previously mentioned supply hose and return hose are connected for coupling the spray mechanism to the molten asphalt supply apparatus.
The spray bar is an elongated dual channel enclosure having a plurality of spray nozzles arranged in spaced increments along its length. The spray nozzles are interconnected by a gang linkage for simultaneous opening and closing thereof, and the gang linkage is connected to a control lever so that the operator of the spray mechanism can manually accomplish the opening and closing of the spray nozzles as needed.
When the spray mechanism is in its inoperative, or stand by state, the spray nozzles of the spray bar will, of course, be closed, and the flow switching valve is positioned so that the received molten asphalt will pass through part of the conduit assembly into and through the spray bar, through another part of the conduit assembly which directs it through the return hose back to the molten asphalt supply apparatus.
When the spray mechanism is switched to its operative state, by virtue of the operator manually moving the control lever, the spray nozzles of the spray bar will open and the flow switching valve is repositioned so that the received molten asphalt will be directed to the spray bar and that portion of the conduit assembly which is in communication with the return hose is closed.
The flow switching valve is coupled to the control lever by which the operator controls the position of the spray nozzles. Thus, when the spray nozzles are closed to place the spray mechanism in the inoperative state, the flow switching valve will simultaneously and automatically be positioned to recirculatingly direct the flow of molten asphalt through the spray mechanism back to the molten asphalt supply apparatus. Likewise, when the spray mechanism is switched by the operator to its operative state, the spray nozzles will open and the flow switching valve will automatically and simultaneously be repositioned to close the asphalt return portion of the conduit assembly.
The conduit assembly and the flow switching valve, in conjunction with the spray bar, are configured so that when the spray mechanism is in the inoperative state, the molten asphalt will flow through the spray bar in one direction. However, when the spray mechanism is switched to its operative state, the flow of molten asphalt into the spray bar is in two counter flowing directions which insures an even flow of asphalt to all of the spray nozzles.
The length of the spray bar and the number of spray nozzles are such that the spray pattern is ideal for most uses in spot application work on paved surfaces. However, in some instances, this spray pattern may be larger than is needed. For this reason, each of the spray nozzles are demountably connected to the gang linkage. Thus, by simply disconnecting the desired number of spray nozzles from the ganged linkage, the spray pattern can be adjustably reduced in size as needed.
Accordingly, it is an object of the present invention to provide a new and useful manually manipulatable molten asphalt spray mechanism for applying a seal coating of asphalt on selectable areas of a paved surface.
Another object of the present invention is to provide a spray mechanism of the above described character, having an operator selected inoperative stand by state wherein molten asphalt is recirculatingly directed in a flow path wherein it passes through the mechanism to prevent cooling and solidification of the molten asphalt therein.
Another object of the present invention is to provide a spray mechanism of the above described character having an operator selected operative state wherein molten asphalt is directed in a supply flow path wherein it is supplied in counter flowing directions to insure an even flow distribution.
Another object of the present invention is to provide a new and useful spray mechanism of the above described character, wherein the flow of molten asphalt is simultaneously and automatically switched between its recirculating flow path and its supply flow path when the spray mechanism is switched between its inoperative and operative states.
Still another object of the present invention is to provide a spray mechanism of the above described character wherein the size of the spray pattern is adjustable.
The foregoing and other objects of the present invention as well as the invention itself, will be more fully understood from the following description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the manually manipulatable molten asphalt spray mechanism of the present invention showing the various features thereof.
FIG. 2 is an enlarged side elevational view of the mechanism.
FIG. 3 is a diagrammatic illustration showing the recirculating flow path of the molten asphalt when the mechanism of the present invention is in the inoperative, stand by state.
FIG. 4 is a diagrammatic illustration similar to FIG. 3 but showing the supply flow path of the molten asphalt when the mechanism is in its operative state.
FIG. 5 is an enlarged fragmentary sectional view taken along the line 5--5 of FIG. 1 to show the internal configuration of the spray bar of the spray mechanism and a typical one of the plural spray nozzles.
FIG. 6 is an enlarged fragmentary plan view of the illustration of FIG. 5 showing the demountable connection of a typical spray nozzle to the gang linkage which interconnects the plural spray nozzles.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings, FIGS. 1 and 2 show the manually manipulatable molten asphalt spray mechanism of the present invention which is indicated generally by the reference numeral 10. As will hereinafter be described in detail, the spray mechanism 10 includes the major components of a wheeled carriage 12, a conduit assembly 14, a flow switching valve 16, a spray bar 18 and a control mechanism 20.
The wheeled carriage 12 has a single axle 22 with a pair of wheels 23 journalled for rotation at the opposite ends thereof. The carriage 12 also includes a bar 24 integrally attached to the axle 22 intermediate its opposite ends, and the bar extends from the axle and is fixedly attached to the conduit assembly 14. Thus, the wheeled carriage 12 supportingly carries all the other components of the spray mechanism 10 as will become apparent as this description progresses. A stand 25 is mounted on the conduit assembly so as to depend therefrom. This stand is employed for parking of the spray mechanism 10 and to prevent the spray bar 18 from being moved to close to the surface which is being sprayed by the spray mechanism.
The conduit assembly 14 includes a molten asphalt input conduit 26 having a swivel joint fitting 27 on one end thereof which couples a 90° elbow 28 thereto. A flexible molten asphalt input hose 29 is shown as being suitably mounted on the elbow 28 for supplying molten asphalt under pressure to the spray mechanism 10 from a suitable supply apparatus (not shown). As hereinbefore described, any of several well known supply mechamism can be employed for this purpose, with a specific example being fully disclosed in the hereinbefore referenced U.S. Patent. The opposite end 30 of the input conduit 26 is fixedly attached to the spray bar 18, such as by welding. The conduit assembly 14 also includes a crossover conduit 32 having one of its ends fixedly attached to the input conduit 26 as at 33 and having its other end connected to the molten asphalt input port 34 of the flow switching valve 16. In addition to the input conduit 26 and the crossover conduit 32, the conduit assembly 14 also includes a return conduit 36 and a reversible flow conduit 38. The reversible flow conduit 38 is coupled to the molten asphalt supply port 39 of the flow switching valve 16 and extends therefrom to the spray bar 18 and is fixedly connected thereto as at 40, such as by welding. The return conduit 36 is connected to the molten asphalt return port 42 of the flow switching valve 16 and its opposite end has a swivel joint fitting 43 and a 90° elbow 44 mounted thereon. The elbow 44 is shown as having a flexible molten asphalt return hose 46 connected thereto which is for returning molten asphalt to the supply apparatus (not shown). The asphalt flow paths through the above described conduit assembly 14 will hereinafter be described in detail.
As shown, the asphalt return conduit 36 is bent as at 48 and a handle assembly 50 is fixedly attached to that conduit at the bend 48 so as to extend therefrom. The handle assembly 50 includes an extending bar 51 with a transverse crossbar 52 on its extending end to provide handle grips by which an operator may push and manually manipulate the spray mechanism 10 in the conventional and well known manner.
The asphalt input conduit 26 and the reversible flow conduit 38 are fixedly attached to the spray bar 18 as hereinbefore described, and those conduits supportingly carry the spray bar so that it is parallel to the axle 22 of the wheeled carriage and thus, is disposed transverse of the intended movement path of the spray mechanism.
The spray bar 18 includes an elongated box beam housing 54 which is closed at its opposite ends and is provided with an internal chamber having a longitudinally extending partition wall 55 and a divider partition wall 56 therein. As seen best in FIGS. 3 and 4, the longitudinally extending partition wall 55 is vertically disposed and positioned between the front and back walls 57 and 58 of the spray bar housing 54 with its opposite ends being spaced from the closed end walls of the housing 54 to provide openings 59 and 60. The divider partition wall 56 is also vertically disposed and it extends normally from the longitudinally extending partition wall 55 to the back wall 58 of the spray bar housing 54.
The partition walls 55 and 56 divide the internal chamber of the spray bar housing 54 into a first molten asphalt flow passage 62 which is in communication with one end of a second flow passage 64 by means of the opening 59 with the other end of the flow passage 64 being in communication with a third flow passage 66 by means of the opening 60.
The end 30 of the molten asphalt input conduit 26 opens into the first flow passage 62 and the end 40 of the reversible flow conduit 38 opens into the third flow passage 66 as seen best in FIGS. 3 and 4.
The spray bar 18 is provided with a plurality of liquid spray nozzles 70 which are spacedly arranged along the length of the spray bar housing 54. The spray nozzles 70 are identical structures and the following description of a typical one thereof will be understood to apply to all of the nozzles.
As seen best in FIG. 5, the typical asphalt spray nozzle 70 includes a hollow elongated cylindrical valve body 71 which is mounted in the spray bar housing 54 so as to pass vertically through the second flow passage 64 thereof and is sealingly secured in the top and bottom walls of the housing, such as by welding. The valve body 71 has at least a pair of relatively large openings 72 and 73 formed in its sides so that molten asphalt moving through the second flow passage 64 of the housing 54 is free to flow into the bore 74 of the valve body. The depending end of the valve body 71 extends below the bottom wall of the housing 54 and is internally threaded as at 75 to sealingly receive a plug 76 therein. The plug 76 is formed with an externally threaded shank portion 77 and a head portion 78 in the form of a nut. An axial bore 79 is drilled or otherwise formed through the plug 76, with the upwardly disposed end of the shank 77, which circumscribes the axial bore 79, serving as a valve seat 80, and with the downwardly disposed end of the axial bore being internally threaded to sealingly receive an orifice plug 82 which has an axial bore 83 formed therethrough. A slide valve 84 is mounted in the body 71 and is axially movable in the bore 74 thereof. The slide valve 84 includes an elongated valve stem 85 having its upper end threaded as at 86, with the upper end extending axially from the valve body 71. A valve head assembly 88 is mounted on the other end of the valve stem 85 for movement with the stem into and out of seated engagement with the valve seat 80. The valve head assembly 88 includes a tubular sleeve 89 which is concentrically and slidably mounted on the depending end of the valve stem 85 with a ball 90, or other suitably configured head, welded or otherwise affixed to the extending end of the tubular sleeve 89. The valve head assembly 88 is captively retained on the depending end of the valve stem 85, and its axial slidable movement is limited by a pin 92 which is transversely carried in the end of the stem 85 so that each of its oppositely extending ends are positioned in a different one of a pair of elongated slots 94 provided in diametrically opposed sides of the tubular sleeve 89. A compression spring 96 is disposed within the tubular sleeve 89 so as to bear against the end of the valve stem 85 and to bear against the ball 90. In this manner, the valve head assembly 88 is yieldably biased to its axially extended position.
The control mechanism 20, as seen best in FIGS. 1 and 2, includes an L-shaped lever 100 which is pivotably carried on a trunnion 102 which extends laterally from the extending bar 51 of the handle assembly 50. The lever 100 is provided with a hand grip member 103 on one end thereof which is adjacent the crossbar 52 of the handle assembly 50 so as to be conveniently within reach of the operator of the spray mechanism 10. The other end of the L-shaped lever is connected to one end of a tie-rod 104 by means of a clevis 105 provided on the tie-rod. The opposite end of the tie-rod 104 is similarly provided with a clevis 106 which is attached to the laterally offset extending end of an operating lever 108 of the flow switching valve 16 for reasons which will hereinafter be described in detail.
The operating lever 108 of the flow switching valve 16 has one end of an adjustable connecting rod 110 attached thereto, with the opposite end of the connecting rod 110 being connected to a clevis 112 which is fixedly carried on a rock shaft 114. The rock shaft 114 is suitably journalled for rotation in bearing blocks 115 which are fixedly carried atop the spray bar housing 54. The rock shaft 114 is disposed to extend substantially along the length of the spray bar 18 in upwardly spaced relationship with respect to the top surface thereof, so that it is proximate each of the plurality of liquid spray nozzles 70.
Each of the plurality of liquid spray nozzles 70 is demountably connected to the rock shaft 114 by a connection block assembly 116. Each of the block assemblies 116 is identical, thus, the following description of a typical one of the those connection block assemblies 116 will be understood to also apply to the other block assemblies.
As seen best in FIGS. 5 and 6, a typical one of the connection block assemblies 116 includes a first block 118 which is fixedly carried on the rock shaft 114, such as by welding, for rotation therewith. The first, or fixed, block 118 has a latching lever 120 attached thereto by the pivot pin 121. Immediately adjacent the fixed block 118 is a second block 122 which demountably couples the liquid spray nozzles 70 to the fixed block 118 and thus, to the rock shaft 114. The second, or coupling block 122, has a bore 123 formed therethrough and the rock shaft 114 passes loosely through this bore 123. In this manner, the coupling block 122 is held in position by the rock shaft but is not in and of itself tied to the rock shaft for rotation therewith. The coupling block 122 has a slot 125 formed in one end thereof which is alignable with the latching lever 120 of the fixed block 118. As seen in FIG. 6, manual movement of the latching lever 120 to its latching position, as shown in solid lines, will place the lever within the slot 125 of the coupling block 122. When in this latched position, the first and second blocks 118 and 122 will be demountably connected to each other and will thus rotatably move as a single entity upon rocking movement of the rock shaft 114. When the latching lever 120 is manually moved to the unlatched position thereof, as shown in dashed lines in FIG. 6, the connection between the blocks 118 and 122 is broken and the coupling block 122 will no longer respond to rocking movements of the rock shaft. The other end of the coupling block 122 has a cutout 127 formed therein and one end of a plate 128 is disposed in the cutout and is connected to the coupling block by means of a pivot pin 129. The extending end of the plate 128 has a hole 130 formed therethrough with the threaded end 86 of the valve stem 85 passing through the hole. Suitable nuts 131 are carried on the uppermost end of the valve stem 85 so that rocking movement of the rock shaft 114 in the direction of arrow 132 will be transmitted through the coupling block assembly 116, when the blocks 118 and 122 are latchingly interconnected in the manner described above, and the plate 128 will lift the slide valve 84 off of its seat 80 and thus move the liquid spray nozzle 70 from its closed to its open position. Similarly, rocking movement of the rock shaft in the direction opposite to the arrow 132 will move the slide valve 84 into seated engagement with the valve seat 80, thus closing the spray nozzle.
With all of the plurality of spray nozzles 70 demountably coupled to the rock shaft 114 in the hereinbefore described manner, it will be appreciated that the spray bar 18 will emit molten asphalt in a spray pattern having a given width dimension. In many instances however, this width of spray pattern will be in excess of that needed to properly spot repair a paved surface. Therefore, by decoupling one or more of the spray nozzles 70 from the rock shaft 114, the width of the spray pattern can be reduced as needed.
As hereinbefore mentioned, the tie-rod 104 of the control mechanism 20 is connected to the operating lever 108 of the flow switching valve 16. Therefore, when the operator of the spray mechanism 10 moves the L-shaped lever 100 to change the mechanism between an operating mode, i. e., opens the spray nozzles 70, and an inoperative or stand by mode, i. e., spray nozzles 70 closed, the flow switching valve 16 will automatically and simultaneously be repositioned.
When the spray mechanism 10 is in its inoperative state, the flow switching valve 16, as seen in FIG. 3, is positioned so that the molten asphalt received under pressure from the suitable supply apparatus (not shown) passes through the input conduit 26 into the first flow passage 62 of the spray bar housing 54. The molten asphalt then exits the flow passage 62 through the opening 59 into one end of the second flow passage 64, passes the full length of the second passage 64 and enters the third flow passage 66 via the opening 60. The reversible flow conduit 38 directs the molten asphalt from the third flow passage 66 of the spray bar housing 54 to the flow switching valve 16 which directs it to the return conduit 36 which returns the molten asphalt to the supply apparatus (not shown).
Thus, when the spray mechanism 10 is in its inoperative, or stand by state, it will be seen that the flow of molten asphalt is in a recirculating flow mode which prevents the asphalt from cooling and solidifying in the spray mechanism 10.
When the operator switches the spray mechanism 10 to the operating state thereof, the spray nozzles 70 will be opened and the flow switching valve 16 will be automatically and simultaneously repositioned as hereinbefore described and the resulting molten asphalt flow path is shown in FIG. 4. The molten asphalt under pressure is received in the input conduit 26 and passes into the first flow passage 62 of the spray bar housing 54, and it also flows through the crossover conduit 32, through the repositioned flow switching valve 16, through the reversible flow conduit 38 into the third flow passage 66 of the spray bar housing 54. In this manner, molten asphalt under pressure is in the molten asphalt supply flow mode, in that it is received simultaneously in the first and third flow passages 62 and 66 of the spray bar housing 54 and will flow through the openings 59 and 60 into both ends of the second flow passage 64. By supplying molten asphalt to the opposite ends of the second flow passage 64, an evenly distributed supply of the asphalt will be delivered to all of the plurality of spray nozzles 70 of the spray bar 18.
The flow switching valve 16, which may be any of several well known devices, is shown as including a body 136 having the previously mentioned ports 34, 39 and 42 by which the flow switching valve is mounted and connected into the conduit assembly 14 of the spray mechanism. As seen best in FIG. 2, the operating lever 108 of the flow switching valve 16 is suitably connected to a valve positioning shaft 138 to rotate that shaft when the lever 108 is repositioned as hereinbefore described. The shaft 138 extends from the valve body 136 and is suitably journalled for rotation therein in the well known manner for rotatably repositioning a rotary valve 140 as shown schematically in FIGS. 3 and 4. The rotary valve 140 is provided with flow passage 142 which passes diametrically therethrough and a branch flow passage 144 which transversely intersects the diametrically extending passage. In this manner, when the flow switching valve 16 is positioned so that the flow of molten asphalt is in the recirculating mode, the rotary valve 140 is positioned so that the diametrically disposed passage 142 interconnects the reversible and return conduits 38 and 36 respectively, and the branch passage 144 is closed. When the flow switching valve 16 is repositioned to achieve the molten asphalt supply flow mode, the rotary valve 140 is positioned so that one end of the diametrically disposed passage 142 is blocked with the other end, in conjunction with the branch passage 144, interconnecting the crossover and reversible flow conduits 32 and 38 respectively.
While the principles of the invention have now been made clear in an illustrated embodiment, there will be immediately obvious to those skilled in the art, many modifications of structure, arrangements, proportions, the elements, materials, and components used in the practice of the invention, and otherwise, which are particularly adapted for specific environments and operation requirements without departing from those principles.
Although the spray mechanism of the present invention is herein described as being primarily for use in applying spray coatings of molten asphalt, it will be understood that this specific use is not intended as a limitation of the present invention. Virtually any liquid can be applied by the mechanism with a specific example, which also relates to the highway repair art, being emulsified asphalt which, as is known, is not a molten liquid but is asphalt containing an asphalt solvent, such as kerosene.
The appended claims are therefore intended to cover and embrace any such modifications within the limits only of the true spirit and scope of the invention.
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A manually manipulatable spray mechanism for connection to a supply apparatus having a source of molten asphalt under pressure for applying a sprayed coating of molten asphalt on selected areas of a paved surface. The spray mechanism is configured so that its asphalt spray pattern may be adjusted to suit the job being accomplished, and, to provide for recirculatingly returning the molten asphalt to the supply apparatus when the spray mechanism is in the inoperative or stand by state.
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This application claims priority under 35 U.S.C.§119( e ) from U.S. Provisional Application 60/348,237 dated Oct. 23, 2001, titled REMOTE MONITORING AND SOFTWARE DISTRIBUTION SYSTEM FOR SERVICING INSERTER SYSTEMS, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
The present invention relates to a system for upgrading and updating software for use on a network of mutually monitored and controlled inserter systems.
BACKGROUND
Systems for mass producing mail pieces are well known in the art. Such systems are typically used by organizations such as banks, insurance companies and utility companies for producing a large volume of specific mailings like billing statements, or promotional offers. The starting point for the document production process is a stream of print data generated by the organization wishing to create the mailing. The print streams are usually produced by older, legacy, computer systems that are not easily adapted to do more than provide raw print data that is output as a result of the legacy computer systems' business logic.
The raw print stream data may be manipulated using known print stream manipulation software, such as the Streamweaver™ product of Pitney Bowes Inc. Print stream manipulation software allows users to change the look and content of documents, without requiring changes to the legacy computer systems.
Once print stream manipulation is complete, the print stream may be sent to a high volume printer. Such high volume printing results in large rolls or stacks of documents, usually connected in a continuous web. The webs of documents are transported to an inserter machine to be separated into individual pages and turned into mail pieces. Examples of such inserter systems are the 8 series and 9 series inserter systems available from Pitney Bowes Inc. of Stamford Conn.
In many respects the typical inserter system resembles a manufacturing assembly line. Sheets and other raw materials (other sheets, enclosures, and envelopes) enter the inserter system as inputs. A plurality of different modules or workstations in the inserter system work cooperatively to process the sheets until a finished mail piece is produced. The exact configuration of each inserter system depends upon the needs of each particular customer or installation.
Typically, inserter systems prepare mail pieces by gathering collations of documents on a conveyor. The collations are then transported on the conveyor to an insertion station where they are automatically stuffed into envelopes. After being stuffed with the collations, the envelopes are removed from the insertion station for further processing. Such further processing may include automated closing and sealing the envelope flap, weighing the envelope, applying postage to the envelope, and finally sorting and stacking the envelopes.
Each collation of documents processed by the inserter system typically includes a control document having coded control marks printed thereon. Scanners are located throughout the inserter system to sense the presence of the control document and to allow control for processing of a particular mail piece. The coded marks may be bar codes, UPC code, or the like.
The inserter system control system is coupled to each of the inserter system's modular components. The control system stores data files identifying how individual mail pieces should be processed. These data files are typically linked to individual mail pieces by the coded marks included on the control documents. As a collation passes through the inserter system, the coded marks on the control document are scanned and the control system directs the modular components to assemble the mail piece as appropriate. Mail pieces such as billing statements will often include a reply document and/or a return envelope that is pre-addressed for delivery back to the originator of the mail piece. Such reply documents and return envelopes may be used to send back payments, or acceptances of offers, or the like.
Once a finished mail piece has been formed by the inserter system, it may be stacked and provided to a carrier service, such as the U.S. Postal Service, for delivery. Often, in order to receive postal discounts, it is advantageous to sort the outgoing mail in accordance postal regulations. Such output sorting devices are well known. Examples of output sorting devices are available from MailCode, Inc.
The inserter control system also collects data about the efficiency and functioning of the inserter system. For example, the control system can monitor and keep statistics about the speed at which the system is operating, and the rate of errors that occur. Such monitoring may utilize data from tracking mail piece control documents through the inserter system. Additional sensors may also be used to provide further information. For example, optical sensors and scanners may be located at input and output locations for the inserter systems to further monitor and record data concerning inserter processing.
Recently, systems have been developed to monitor and control multiple inserter systems, such as those described above, from remote locations on a network. As such, operation of multiple geographically separate inserter systems can be observed from a centralized control center. Thus, a bank with mail production facilities in Newark and Atlanta can monitor bank statement production activities from its headquarters office in New York City.
SUMMARY OF THE INVENTION
The present invention provides enhancement to such existing systems by providing the ability to receive data files from remote inserter systems, and to transfer files to remote inserter systems, from a central repository. This transfer of files is preferably to upload software updates to the remote inserter machines and to download inserter and mail production data from the remote inserter machines. Control of the transfer of files to and from the central repository can be accomplished through a control website that may be accessed anywhere with Internet access. Such transfers can be scheduled for immediate execution of for any time in the future. The present invention will also notify the originator when such downloads/uploads are complete.
The present invention provides benefits, including archiving of files from remote inserter systems without physically traveling to them; upgrading of software on remote inserter systems without having to physically visit them; scheduling transfer of files anytime without having to physically visit them; transferring files to and from multiple inserter systems at one or more locations simultaneously; supporting multiple protocols for different kinds of machines; and automatic notification to the user when tasks are completed.
SUMMARY OF THE FIGURES
FIG. 1 depicts an exemplary embodiment of an inserter control network for use with the present invention.
FIG. 2 depicts an exemplary form for use with the present invention in carrying out the desired upload and download functionality.
DETAILED DESCRIPTION
In FIG. 1 , a system for implementing remote monitoring and software distribution system is depicted. Remote monitoring and software distribution functionality are preferably handled from a command center 100 , which may or may not be geographically proximal to the site where documents are being created and formed into mail pieces. Preferably the command center 100 will be capable of monitoring document production sites, e.g. 130 and 140 , at a plurality of remote and local locations. Terminal 101 within the command center 100 allow users to interface with the remote monitoring and software distribution system through a command intranet 103 . Alternately, a remote terminal 102 may communicate to the command infrastructure 110 through a network 104 , such as the Internet.
The command infrastructure 110 is preferably comprised of a command web server 113 to handle communications and data transfer with remote and local network locations. A monitoring application server 114 includes the computer hardware and software for transferring data too and from the command infrastructure 110 , and for providing a control and monitoring interface for users. Monitoring data downloaded from the inserter sites 130 and 140 data are stored at the command location in the command database 111 . Database 111 may also include the necessary software update information to be provided to the remote inserter sites 130 and 140 .
The monitoring application server 114 includes a transfer files job handler 115 for coordinating the uploading and downloading the monitoring data and software updates respectively. A notification handler 116 provides for notification messages to the sent to users to notify them when predetermined events relating to the uploading and downloading of information have occurred.
A remote inserter site 130 (linked via the Internet 104 ) is preferably comprised of a site infrastructure 120 and to one or more inserter machines 145 . The site infrastructure 120 and local inserters 145 are linked via a site intranet 126 . The site infrastructure 120 includes a web server 124 for communicating with the remote command infrastructure 110 . Site infrastructure 120 further includes a data concentrator 125 that prepares the respective upload and download data for transfer. Within, or associated with, the one or more inserters 145 , an inserter web server 151 provides communications capabilities to and from the inserter. Finally inserter applications 150 control the ongoing operation of the inserters 145 in the formation of mail pieces. It is inserter applications 150 that must be periodically updated to provide the latest versions of control software, so that the inserter machine may be run to provide optimal mail piece creation functionality.
The present invention provides file transfer between the command infrastructure 110 and the one or more inserter sites 130 , 140 . File upload from the command infrastructure 110 is necessary for updating applications 150 in the inserter 145 . Such applications may be .exe files, .dll files, or .mdb files.
File downloads from the inserter sites 130 , 140 are needed to allow retrieval of files including but not limited to log files, configuration files and mail piece logs generated at the inserters 145 .
An authorized user logged onto command center terminal 101 or remote terminal 102 can initiate and control the transfer of files to and from one or more inserter sites 130 , 140 . In the preferred embodiment all file transfers are implemented using standard ftp client/server communications. All file transfers are initiated from the command infrastructure 110 , although the user/controller may be logged into the system from a remote location 102 .
The user initiates a file transfer by filling out and submitting a form 200 , as depicted in FIG. 2 . The information in form 200 is verified and used to create a transfer request. When the transfer request is accepted, the transfer is scheduled for the requested time. Upon the requested time, the files are transferred and the user is notified. A transfer job is created from information gathered from form 200 . A unique job ID is assigned to uniquely identify the job
A download request portion of a job is created pursuant to the download portion 220 of the transfer form 200 . A download request is preferably an XML file and contains a list of inserter machines 145 at the various remote locations and files, as well as a time to perform the transfer. The files are downloaded via FTP to the data concentrators 125 serving the remote inserters 145 . A scheduler thread is created for each inserter 145 in the download request. The file information is saved and the thread information sleeps until the given download time.
At the given download time the thread wakes up and increments the data concentrator 125 “FTP Request Flag” for a corresponding inserter 145 . When an “FTP Accepted” message is received the files are transferred from the inserter 145 . If execution of a file before downloading has been selected by the user, the thread may further send an “Execute File” command to the inserter 145 . After all is complete, completion status is reported back to the command infrastructure via an XML file.
Similarly if a user wants the transfer job to include uploading activity, an upload request is created for each data concentrator 125 associated with the job. The upload request is an XML file and contains a list of inserters 145 and files and a time to perform the transfer. The upload request is transferred to the appropriate data concentrators 125 . The file information is saved and the thread sleeps until the designated upload time.
At the designated upload time the thread wakes up and increments the “FTP Request Flag” for the inserter 145 . The inserter 145 accepts the FTP request and the thread then sends an “Execute File” command. The inserter 145 runs the file and returns and “Execute Done” message. The upload files are transferred to the inserter 145 until all identified upload files are transferred. Completion status is reported back to the command infrastructure 110 via an XML file.
As discussed above, FIG. 2 depicts an exemplary operator interface 200 to be used in conjunction with a web browser. The upload files section 210 includes designations and options for users to define the aspects of jobs relating to uploads. The “machines” field 211 includes a list of customers, sites and inserters that can be designated for upload transfers. A user will select one or more inserters from the “machines” field 211 . The “upload” list box 212 contains a list of pre-configured upload jobs. The selections are retrieved from the command database 111 . Each selection in the “upload” list box includes a corresponding list of file and directory pairs to upload. One or more upload jobs can be selected in upload field 212 . The “additional files” field 213 allows the user to enter additional files that are not included in pre-configured jobs in field 212 . Entries in field 213 must include the full path and file specifications, but may contain wildcard characters. The “upload to directory” field 314 specifies the directory on the inserter 145 where the uploaded files are to be copied. The “execute before upload” field 215 specifies a file (executable, batch file, etc.) that is executed on the inserter 145 before the files are uploaded.
The download files section 220 includes designations and options for users to define the aspects of jobs relating to downloads. The “machines” field 221 includes a list of customers, sites and inserters that can be designated for download transfers. A user will select one or more inserters from the “machines” field 221 . The “download” list box 222 contains a list of pre-configured download jobs. The selections are retrieved from the command database 111 . Each selection in the “download” list box 222 includes a corresponding list of files to down load and the destination directory for each file. One or more upload jobs can be selected in “download” field 222 . The “download from directory” field 223 includes the identification of the directory, or directories, from which files should be downloaded. The “other download files” field 224 allows the user to enter additional files to download. Entries in field 224 must include the full path and filed specifications, but may contain wildcard characters. The “execute after download” field 225 specifies a file (executable, batch file, etc.) that is executed on the inserter 145 after the files are downloaded.
The setup section 230 includes designations and options for users to define how the upload and download jobs should be performed. The “notification” list box 231 contains a list of notification methods that may be retrieved from database 111 . Notification methods include email, fax, pager, or a screen message that will alert the user that an upload or download event has occurred pursuant to the defined job. The “time to transfer” field 232 is where the date and time for performing the defined transfer is designated. An “interval for retry” field 233 is used to indicate how often frequently a transfer attempt should be retried if an inserter 145 is busy and cannot accept a transfer at a designated time. The “number of retries” field 234 indicates how many retries should be attempted.
The “coordinate transfers” selection box 235 includes several options for coordinating upload and download activity. “None” is used when there is a transfer only in one direction or if no coordination is required (uploads and downloads will occur simultaneously). The “Job Upload Before Download” option forces all uploads on all machines to finish before any download starts. The “Job Download Before Upload” option forces all downloads on all machines to finish before any upload starts. The “Machine Upload Before Download” option forces all uploads on a machine to finish before the download for that machine starts. The “Machine Download Before Upload” option forces all downloads on a machine to finish before the upload for that machine starts.
Upon completion of the form 200 , the submit button 240 may be pressed and a corresponding transfer job will be created and stored.
Events occurring during a transfer job are asynchronous. Since multiple sites 130 , 140 and multiple inserters 145 may be included in the transfer the error handling is done on an inserter by inserter basis. A status condition of each transfer job on each inserter is maintained in the database 111 . Each error condition is handled on an individual basis. An error only affects the entire job as it affects the completion of a task to be performed before a subsequent task is started (i.e. if the “complete download before upload” condition is set and there is an error on the download then the upload cannot proceed.).
If the command infrastructure 110 is unable to transfer a file to or from a data concentrator 125 , a thread is created to sleep and retry. The retry time and count from the form 200 are used. If the command infrastructure 110 tries the maximum amount of times without success, a failure status is stored in the database 111 for each inserter 145 involved on that data concentrator 125 . The user may be notified via the notification handler 216 in accordance with the method selected from field 231 on form 200 .
Similarly, if a data concentrator 125 is unable to transfer a file to or from an inserter 145 , a thread is created to sleep and retry. The retry time and count from the form 200 are used. If the data concentrator 125 tries the maximum amount of times without success, a failure status is stored in the database 111 for each inserter 145 involved on that data concentrator 125 . The user may be notified via the notification handler 116 in accordance with the method selected from field 231 on form 200 .
Thus, although the invention has been described with respect to a preferred embodiment thereof, it will be understood by those skilled in the art that the foregoing and various other changes, omissions and deviations in the form and detail thereof may be made without departing from the scope of this invention, as further described in the following claims.
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A method for controlling transfer of files in a network of inserters at a plurality of sites from a remote command center. The method retrieving inserter data stored at the plurality of inserter sites and storing the data at the command center. The command center further uploading software updates to the plurality of inserters in accordance with a predefined upload/download scheme. The upload/download scheme defined at the command center via a graphical interface. The upload/download scheme identifying one or more of the plurality of inserters for the file transfer transaction, identifying inserter data from the selected one or more inserters to upload to the command center, identifying software updates to download from the command center to the one or more selected inserters, identifying a time for the file transfer transaction, identifying a sequence for the upload and download portions of the transfer transaction; and executing the defined file transfer transaction.
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BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to motorized window shades.
[0003] 2. Description of the Related Art
[0004] A roll-up window shade is well known. The shade can be moved manually up or down in front of a window to control the light level, room temperature, light flow, or to provide privacy. The known roll-up shade is relatively inexpensive and is easy to install. If the shade is damaged, a new shade can be replaced easily. These types of shades are sold in retail stores and do-it-yourself centers across the U.S. The shades are typically stocked in 3, 4, 5 and 6 foot widths. The shade can easily be cut to the proper width with a cutting device either at the point of sale or at installation time. The installer or homeowner can measure and install the shade on the same site visit.
[0005] The conventional roll-up shade has a first pin end and a second spring end with a rectangular barb extending outwardly. The pin end is inserted into a circular hole in a bracket. The spring end is mounted in a similar shaped bracket with a slot designed to keep the barb from rotating. The brackets are designed to be mounted inside a window frame i.e., inside the jamb, or along the outside of a window frame. The user pulls the roll-up shade down by a hem bar located along the bottom edge of the shade until the desired amount of shade material is showing. The user then eases up on the hem bar until the pawl mechanism in the spring end of the shade locks the shade into position. As the shade is being pulled down, the spring is being wound up.
[0006] When the user wants to put the shade up, the user pulls down on the hem bar slightly to disengage the pawl mechanism and then guides the hem bar upward as the spring pulls the fabric upward. If the user lets go of the shade as the shade is traveling upward the spring in the shade will cause the shade to travel upward out of control. The hem bar will continue to rotate around the roller until it stops. The setting of multiple shades at the same relative position can be a very time consuming process. The manually-operated shades are not capable of receiving inputs from time clocks, photo sensors, occupant sensors or infrared hand held transmitters.
[0007] It is known to replace the spring mechanism described above with a motor, typically a tubular motor, to allow the window shade to be rolled and unrolled (opened and closed) by remote control. Installation of these systems typically requires a skilled craftsman. The installer usually will need to make one visit to measure the window and another separate visit to install the system. In some systems, the hem bar located at the bottom of the shade travels in channels secured to the sides of the window opening, thus, decreasing the amount of light that can enter through the window when the shade is up. The motor is typically connected to a nearby power source with line voltage or low-voltage wiring.
[0008] A typical motorized roller shade is secured to the window opening with two mounting brackets. The single roller shade is custom made with a fabric of choice. The motor is installed inside the roller tube at the factory and line or low voltage wiring connects the motor to a nearby power source. If the unit fails, the unit must typically be returned to the manufacturer or a technician must visit the job site.
[0009] Multiple units can be grouped together by wiring the multiple units to each other or to a common control system. Installation of such wiring is beyond the capabilities of most homeowners, and thus, such units must be installed by a professional installer.
[0010] The prior art devices generally suffer from a number of disadvantages including the inability to communicate with other devices, lack of intelligent control, e.g. by a microprocessor, and thus, having inability to be programmed easily, bulky size causing difficulty in installation, an unattractive appearance and maintenance problems as well as inability to easily retrofit to existing manually actuated shades. Moreover, prior art systems have using mounting brackets that place an undesirably-large gap between the edge of the shade and the window casing. These problems have severely limited the market for motorized rollup window shades.
SUMMARY
[0011] The system and method disclosed herein solves these and other problems by providing a remotely-controllable, self-powered, user-installable motorized window shade. In one embodiment, a mounting system allows the window shade material to be placed relatively close to the edge of the window casing, thus reducing the size of the gap between the window shade and the window casing. In one embodiment, the motorized roll-up window shade includes a controller, a tubular motor provided to the controller. The tubular motor is configured to raise and lower the window shade. A first power source is provided to the controller and a two-way wireless communication system is provided to the controller. The controller is configured to control the motor in response to a wireless communication received from a group controller or central control system. The motorized shades can be used to produce a desired room temperature during the day and to provide privacy at night.
[0012] In one embodiment, the electronically-controlled motorized shade includes a light sensor. In one embodiment, the electronically-controlled motorized shade includes a temperature sensor. In one embodiment, the electronically-controlled motorized shade includes a second power source. In one embodiment, the electronically-controlled motorized shade includes a solar cell configured to charge the first power source. In one embodiment, the electronically-controlled motorized shade includes a shade position sensor. In one embodiment, the electronically-controlled motorized shade includes a turns counter to count turns of the tubular motor.
[0013] In one embodiment, the controller is configured to transmit sensor data according to a threshold test. In one embodiment, the threshold test includes a high threshold level, a low threshold level, and/or a threshold range.
[0014] In one embodiment, the controller is configured to receive an instruction to change a status reporting interval. In one embodiment, the controller is configured to receive an instruction to change a wakeup interval. In one embodiment, the controller is configured to monitor a status of one or more electronically-controlled motorized shades.
[0015] In one embodiment, the controller is configured to communicate with a central controller. In one embodiment, the central controller communicates with an HVAC system. In one embodiment, the central controller is provided to a home computer. In one embodiment, the central controller is provided to a zoned HVAC system. In one embodiment, the central controller cooperates with the zoned HVAC system to use the motorized shade to partially control a temperature of a desired zone.
[0016] In one embodiment, the controller is configured to use a predictive model to compute a control program. In one embodiment, the controller is configured to reduce power consumption by the tubular motor. In one embodiment, the controller is configured to reduce movement of the tubular motor.
[0017] In one embodiment, a group controller is configured to use a predictive model to compute a control program for the motorized shade. In one embodiment, the group controller is configured to reduce power consumption by the motorized shade. In one embodiment, the group controller is configured to reduce movement of the motorized shade.
[0018] In one embodiment, the shade material includes a plurality of conductors provided to the controller. In one embodiment, the shade material includes a connector for connecting a charger to the controller to provide power to recharge the power source. In one embodiment, the shade material includes a solar cell.
[0019] In one embodiment, the motorized shade system can easily be installed by a homeowner or general handyman. In one embodiment, the motorized shade system is used in connection with a zoned or non-zoned HVAC system to control room temperatures throughout a building. The motorized shade can also be used in connection with a conventional zoned HVAC system to provide additional control and additional zones not provided by the conventional zoned HVAC system. The motorized shade can be installed in place of a conventional manually-controlled window treatment.
[0020] In one embodiment, the motorized shade includes an optical sensor to measure the ambient light either inside or outside the building. In one embodiment, the motorized shade opens if the light exceeds a first specified value. In one embodiment, the motorized shade closes if the light exceeds a second specified value. In one embodiment, the motorized shade is configured to partially open or close in order to maintain a relatively constant light level in a portion of the building.
[0021] In one embodiment, the motorized shade is powered by an internal battery. A battery-low indicator on the motorized shade informs the homeowner when the battery needs replacement. In one embodiment, one or more solar cells are provided to recharge the batteries when light is available.
[0022] In one embodiment, one or more motorized shades in a zone communicate with a group controller. The group controller measures the temperature of the zone for all of the motorized shades that control the zone. In one embodiment, the motorized shades and the group controller communicate by wireless communication methods, such as, for example, infrared communication, radio-frequency communication, ultrasonic communication, etc. In one embodiment, the motorized shades and the group controller communicate by direct wire connections. In one embodiment, the motorized shades and the group controller communicate using powerline communication.
[0023] In one embodiment, one or more group controllers communicate through a central controller.
[0024] In one embodiment, the motorized shade and/or the group controller includes an occupant sensor, such as, for example, an infrared sensor, motion sensor, ultrasonic sensor, etc. The occupants can program the motorized shade or the group controller to bring the zone to different temperatures when the zone is occupied or to provide privacy (e.g., by closing the shade) when the zone is occupied. In one embodiment, the occupants can program the motorized shade or the group controller to bring the zone to different temperatures and/or light levels depending on the time of day, the time of year, the type of room (e.g., bedroom, kitchen, etc.), and/or whether the room is occupied or empty. In one embodiment, various motorized shades and/or group controllers through a composite zone (e.g., a group of zones such as an entire house, an entire floor, an entire wing, etc.) intercommunicate and change the temperature setpoints according to whether the composite zone is empty or occupied.
[0025] In one embodiment, the home occupants can provide a priority schedule for the zones based on whether the zones are occupied, the time of day, the time of year, etc. Thus, for example, if zone corresponds to a bedroom and zone corresponds to a living room, zone can be given a relatively lower priority during the day and a relatively higher priority during the night. As a second example, if zone corresponds to a first floor, and zone corresponds to a second floor, then zone can be given a higher priority in summer (since upper floors tend to be harder to cool) and a lower priority in winter (since lower floors tend to be harder to heat). In one embodiment, the occupants can specify a weighted priority between the various zones.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 shows a typical home with windows and ductwork for a heating and cooling system.
[0027] FIG. 2 shows one example of a motorized shade mounted in a window.
[0028] FIG. 3 is a block diagram of a self-contained motorized shade.
[0029] FIG. 4A is a block diagram of a motorized shade with a fascia having a solar cell.
[0030] FIG. 4B is a block diagram of a motorized shade with a shade material having a solar cell.
[0031] FIG. 5 shows one embodiment of a motorized shade with fascia having a solar cell.
[0032] FIG. 6 is a block diagram of a system for controlling one or more motorized shades.
[0033] FIG. 7A is a block diagram of a centrally-controlled motorized shade system wherein the central control system communicates with one or more group controllers and one or more motorized shades independently of the HVAC system.
[0034] FIG. 7B is a block diagram of a centrally-controlled motorized shade system wherein the central control system communicates with one or more group controllers and the group controllers communicate with one or more motorized shades.
[0035] FIG. 8 is a block diagram of a centrally-controlled motorized shade system wherein a central control system communicates with one or more group controllers and one or more motorized shades and, optionally, controls the HVAC system.
[0036] FIG. 9 is a block diagram of an efficiency-monitoring centrally-controlled motorized shade system wherein a central control system communicates with one or more group controllers and one or more motorized shades and, optionally, controls and monitors the HVAC system.
[0037] FIG. 10 is a block diagram of a motorized shade configured to operate with a powered coil mounted on a window sill.
[0038] FIG. 11 is a block diagram of a basic group controller for use in connection with the systems shown in FIGS. 6-9 .
[0039] FIG. 12 is a block diagram of a group controller with remote control for use in connection with the systems shown in FIGS. 6-9 .
[0040] FIG. 13 shows one embodiment of a central monitoring system.
[0041] FIG. 14 is a flowchart showing one embodiment of an instruction loop for a motorized shade or group controller.
[0042] FIG. 15 is a flowchart showing one embodiment of an instruction and sensor data loop for a motorized shade or group controller.
[0043] FIG. 16 is a flowchart showing one embodiment of an instruction and sensor data reporting loop for a motorized shade or group controller.
[0044] FIG. 17 is a block diagram of a control algorithm for controlling the motorized shades.
[0045] FIG. 18 shows one embodiment of a motorized shade with internal batteries
[0046] FIG. 19 shows one embodiment of a motorized shade with internal batteries and a fascia.
[0047] FIG. 20 shows one embodiment of a window shade roller that includes a low-profile mounting system.
[0048] FIG. 21 shows one embodiment of a modular window shade roller that includes a low-profile mounting system.
[0049] FIG. 22 is an exploded view of the modular window shade roller from FIG. 21 .
[0050] FIG. 23 shows details of a low-profile mounting system for coupling to a motor.
[0051] FIG. 24 shows details of a low-profile mounting system for coupling to a window shade roller.
[0052] FIG. 25 shows one embodiment of a motor mounting.
[0053] FIG. 26 (consisting of FIGS. 26A-26C ) shows mounting a window shade using the low-profile mounting.
[0054] FIG. 27 shows an alternate embodiment of the low profile mounting that further facilitates adapting the roller shade to different windows.
DETAILED DESCRIPTION
[0055] FIG. 1 shows a home 100 with ducts for heating and cooling and windows on various sides of the house. For example, the home 100 includes north-facing windows 150 , 151 , an east-facing window 180 , south-facing windows 160 , 161 , and a west-facing window 170 . In the home 100 , an HVAC system provides heating and cooling light to the system of windows. In a conventional system, a thermostat monitors the air temperature and turns the HVAC system on or off. In a zoned system, sensors 101 - 105 monitor the temperature in various areas (zones) of the house. A zone can be a room, a floor, a group of rooms, etc. The sensors 101 - 105 detect where and when heating or cooling is needed. Information from the sensors 101 - 105 is used to control motors that adjust the flow of air to the various zones. The zoned system adapts to changing conditions in one area without affecting other areas. For example, many two-story houses are zoned by floor. Because heat rises, the second floor usually requires more cooling in the summer and less heating in the winter than the first floor. A non-zoned system cannot completely accommodate this seasonal variation. Zoning, however, can reduce the wide variations in temperature between floors by supplying heating or cooling only to the space that needs it.
[0056] FIG. 2 shows one example of a motorized shade 200 . The shade material 201 rolls on a tube 202 . A motor (not shown) rotates the tube 202 to raise and lower the shade material 201 to control the amount of light that passes through the window. The tube 202 is mounted to (or near) a window frame 250 .
[0057] FIG. 3 is a block diagram of a self-contained motorized shade as one embodiment of the motorized shade 200 . In the motorized shade shown in FIG. 3 , a mount 301 mounts the tube 202 to the window frame 250 (or near the window frame 250 ). The tube 202 includes a controller 301 . The controller 301 provides control for communications, power management, and other control functions. A motor 303 , such as, for example, a tubular motor with a gearbox, is provided to the controller 301 . In one embodiment, the motor 301 includes an internal turns counter and limit switches to limit the revolutions and set the stop points of the motor. In one embodiment, a turns counter 304 is provided to the controller 301 . A first power source 305 is provided to the controller 301 . In one embodiment, the first power source 305 includes a stack of batteries. In one embodiment, the batteries are rechargeable batteries. In one embodiment, the batteries are non-rechargeable batteries.
[0058] A radio-frequency transceiver 302 is provided to the controller. In one embodiment, an InfraRed (IR) and/or light sensor receiver is provided to the controller 301 . In one embodiment, a light-guiding apparatus 360 is provided to direct light to the IR receiver 308 . The light-guiding apparatus 360 can include, for example, a light-pipe, a mirror, a plastic light guide, etc. In one embodiment, at least a portion of the light-guiding apparatus 360 is provided to the mount 301 to reflect (or direct) IR light into the tube 202 and/or IR receiver 308 .
[0059] In one embodiment, an optional capacitor 306 is provided to the controller 301 . The controller 301 can extend the life of the first power source 305 by drawing power relatively slowly, and/or at relatively low voltage from the first power source 305 to charge the capacitor 306 . In one embodiment, the capacitor 306 is used, at least in part, to provide power for the controller 301 , the transceiver 302 , and/or the motor 303 .
[0060] In one embodiment, a solar cell 307 is provided to the controller 301 . In one embodiment, an RFID tag 309 is provided to the controller 301 .
[0061] In one embodiment, the IR receiver 308 is used to provide control inputs to the controller 301 . In one embodiment, IR control is used in lieu of RF control, and the RF transceiver 302 is omitted. In one embodiment, the IR receiver 308 is configured as a transceiver to allow two-way IR communications between the motorized shade and a controller. In one embodiment, IR control is used for programming the controller 301 (e.g., for inserting or reading an identification code) and RF control is used to raise and lower the blinds.
[0062] One or more attachments 350 are provided to attach the shade material 201 to the roller tube 202 . In one embodiment, the attachments 350 include a channel in the tube 202 and the upper end of the shade material 201 is configured to slide into the channel and be held in place by the channel. In one embodiment, the attachments 350 include one or more glue joints. In one embodiment, the attachments 350 include one or more capture devices that clamp onto the shade material.
[0063] In one embodiment, the shade material 201 includes one or more electrical conductors, such as, for example, (wires, wire meshes, metal foil, conductive polymers, etc.) In one embodiment, one or more of the attachments 350 are configured to make electrical contact with the one or more conductors in the shade material 201 . In one embodiment a power connector is provided to the one or more conductors in the shade material to allow a power source (e.g., a battery charger) to be connected to the powered shade to recharge the batteries 305 . In one embodiment, the power connector is provided to a lower portion of the shade material. In one embodiment, the one or more conductors in the shade material provide connections to power sources, such as, for example, solar cells (see e.g., FIG. 4 b ), pickup coils (see e.g., FIG. 10 ), etc.
[0064] In one embodiment, the tube 202 is made from aluminum or other conductive material, and a slot-type RF aperture is provided in the tube 202 to allow the RF transceiver 302 to communicate. In one embodiment, an RF antenna connection from the RF transceiver 302 is provided to the mount 301 to allow the mount and/or fascia to act as an antenna or portion of an antenna. In one embodiment, an RF antenna connection from the RF transceiver is provided to the tube 202 to allow the tube 202 to act as an antenna or portion of an antenna. In one embodiment, an RF antenna connection from the RF transceiver 302 is provided to one or more conductors in the shade material 301 to allow the one or more conductors to act as an antenna or portion of an antenna.
[0065] The controller 301 typically operates in a sleep-wakeup cycle to conserve power. The controller 301 wakes up at specified intervals and activates the transceiver 302 to listen for commands from a remote control or other control device or to send status information (e.g., fault, low battery, etc.).
[0066] FIG. 4A is a block diagram of an embodiment of a motorized shade as one embodiment of the motorized shade 200 that includes a solar cell 404 provided to the mount 301 . In one embodiment, the mount 301 includes a fascia as shown in FIG. 5 and the solar cell 404 is mounted to the outside of the fascia in order to receive sunlight. The motorized shade shown in FIG. 4A includes the other elements shown in FIG. 3 , including the tube 202 , the controller 301 , the motor 303 , the transceiver 302 , etc.
[0067] FIG. 4B is a block diagram of an embodiment of a motorized shade as one embodiment of the motorized shade 200 that includes a solar cell 504 provided to the shade material 201 . The solar cell 504 can be mounted to the shade material 201 and/or integrated into the shade material 201 . When the solar cell 504 is provided to the shade material 201 , then one or more of the attachments 350 are configured to provide electrical contact between the controller 301 and the solar cell 504 .
[0068] FIG. 5 shows one embodiment of a motorized shade with the solar cell 404 provided to a fascia 502 . As shown in FIG. 5 , the solar cells 404 and 504 are not mutually exclusive and can be used together if desired.
[0069] FIG. 6 is a block diagram of a system for controlling one or more motorized shades 200 . The system 600 allows the motorized shades 200 to be controlled in groups (where a group can be one motorized shade or a plurality of motorized shades). FIG. 6 shows five groups of motorized shades, labeled groups 650 - 654 . Groups 650 - 652 each have three or more motorized shades, group 653 has two shades, and group 654 has one motorized shade. One or more group controllers 607 , 608 can be used to control one or more groups of shades. The group controllers 607 , 608 can be hand-held remote-control type devices and/or wall-mounted controllers. A central control system 601 includes a processor 603 , a clock/calendar module 604 , and an RF transceiver 602 . In one embodiment, the central control system 601 is provided to an HVAC interface to a zoned or non-zoned HVAC system. In one embodiment, a sunlight sensor 610 is provided to the control system 601 . In one embodiment, the sunlight sensor 610 detects the amount of sunlight. In one embodiment the sunlight sensor 610 detects the amount and direction of the sunlight.
[0070] One or more group controllers 607 , 608 can be provided to various rooms in the house, such as for example, the bedrooms, kitchen, living room, etc. In one embodiment, the controllers 607 , 608 can be used to control any of the shades in the house. In one embodiment, a display on the group controller 607 , 608 allows the user to select which group of shades to control from a list of shade groups.
[0071] The central control system 601 is provided to a computer system (e.g., a personal computer system) by an interface 605 such as, for example, a USB interface, a firewire interface, a wired local area network (LAN) interface, a wireless local area network interface, a powerline networking interface, etc. The computer system 606 can be used to program and monitor the central control system 601 and to instruct the control system 601 as to the number of motorized shades, the identification codes for the shades, the location of the shades, the amount of privacy desired, how to interact with the HVAC system, etc. For example, if a window faces the street or other public areas, then the computer system 606 can be used to instruct the central control system 601 to provide a relatively high level of privacy for that window. By contrast, if a window faces a barrier of trees or bushes, then the computer system 606 can be used to instruct the central control system 601 to provide a relatively lower level of privacy for that window.
[0072] In one embodiment, a compass direction of each window (e.g., south facing, northwest facing, compass angle of the direction the window faces, etc.) corresponding to a motorized shade is provided to the central control system 601 . Thus, for example, the control system 601 will know that south-facing windows receive relatively more sunlight than north-facing windows. The central control system 601 can close the shades on south-facing windows in order to reduce cooling and reduce fading of carpets and furniture caused by sunlight. Alternatively, the central control system 601 can open the shades on south-facing windows in order to reduce heating loads during cold periods. In one embodiment, the central control system 601 can open the motorized shades during the day to let in sunlight, and close the motorized shades during the night to provide privacy. In one embodiment, the central controller 601 is configured to partially open or close the motorized shades to let in a desired amount of light. In one embodiment, the central controller 601 is configured to open and close shades in a particular group by the same amount for aesthetic purposes.
[0073] In one embodiment, the group controllers 607 , 608 can be used to control one or more groups of motorized shades. In one embodiment, the group controllers 607 , 608 send control signals directly to the motorized shades. In one embodiment, the group controllers 607 , 608 send control signals to the central controller 601 which then sends control signals to the motorized shades 200 .
[0074] The motorized shades 200 can be used to implement a motorized shade system. The motorized shades 200 can also be used as a remotely control motorized shade in places where the window is located so high on the wall that it cannot be easily reached. In one embodiment, the motorized shades 200 are self-powered and controlled by wireless communication. This greatly simplifies the task of retrofitting a home by replacing one or more manual window treatments with the motorized shades 200 .
[0075] The controller 301 controls the motor 303 . In one embodiment, the motor 303 provides position feedback to the controller 301 . In one embodiment, the controller 301 reports shade position to the central control system 601 and/or group controllers 607 , 608 . The motor 303 provides mechanical movements to control the light through the window. In one embodiment, the motor 303 includes a motor to control the amount of light that flows through the motorized shade 400 (e.g., the amount of light that flows from the window into the room). In one embodiment, the system 601 allows a user to set the desired room temperature and/or lighting. An optional sensor 404 is provided to the controller 301 .
[0076] In one embodiment, the motorized shade 200 includes a flashing indicator (e.g., a flashing LED or LCD) when the available power from the power source 305 drops below a threshold level.
[0077] The home occupants use the group controllers 607 , 608 or computer 606 to set a desired temperature, privacy, or lighting for the vicinity of the motorized shade 200 . If the room temperature is above the setpoint temperature, and the window light temperature is below the room temperature, then the controller 301 causes the motorized shade 200 to open the shade. If the room temperature is below the setpoint temperature, and the window light temperature is above the room temperature, then the controller 301 causes the motorized shade 200 to open the window. Otherwise, the controller 301 causes the motorized shade 200 to close the shade. In other words, if the room temperature is above or below the setpoint temperature and the temperature of the light in the window will tend to drive the room temperature towards the setpoint temperature, then the controller 301 opens the window to allow light into the room. By contrast, if the room temperature is above or below the setpoint temperature and the temperature of the light in the window will not tend to drive the room temperature towards the setpoint temperature, then the controller 301 closes the window.
[0078] In one embodiment, the controller 301 is configured to provide a few degrees of hysteresis (often referred to as a thermostat deadband) around the setpoint temperature in order to avoid wasting power by excessive opening and closing of the window.
[0079] The controller 301 conserves power by turning off elements of the motorized shade 400 that are not in use. The controller 301 monitors power available from the power sources 305 , 306 . When available power drops below a low-power threshold value, the motorized shade 200 informs the central controller 601 . When the controller senses that sufficient power has been restored (e.g., through recharging of one or more of the power sources, then the controller 301 resumes normal operation).
[0080] In one embodiment, the motorized shades 200 communicates with each other in order to improve the robustness of the communication in the system. Thus, for example, if a first motorized shade is unable to communicate with the group controller 601 but is able to communicate with a second motorized shade 200 , then the second motorized shade 200 can act as a repeater between the first motorized shade 200 and the group controller 601 .
[0081] The motorized shade system shown in FIG. 6 can be used in connection with a zoned or non-zoned HVAC system. For example, in winter, the system 600 can be used to open the shades of southerly windows on sunny days to provide some measure of solar heating. By contrast, in winter, the system 600 can be used to close the window shades windows in the evening in order to reduce heat loss and to provide privacy. For example, in winter, the system 600 can be used to close the shades of southerly windows on sunny days to reduce solar heating. By contrast, in summer, the system 600 can be used to open the window shades windows in the evening in order to radiate heat (reducing cooling loads).
[0082] Using the system 600 , the homeowner can select the relative priority of light, temperature, and privacy for each group of shades. The relative priorities can be adjusted based on day of the week, time of day, time of year, etc. In one embodiment, the system 600 is provided with an override switch (not shown) to change the relative priorities (e.g., temperature, privacy, light) based on whether the homeowner is at home or away from home. Thus, for example, while away from home, the homeowner can instruct the system 600 to minimize privacy and maximize HVAC efficiency; by contrast, when at home, the homeowner can instruct the system 600 to use different priorities that provide relatively more privacy.
[0083] In one embodiment, the user can use the computer system 606 to specify the relative desired privacy, temperature, and light levels, and the relative priorities of privacy, temperature, and light, for each group of shades in the house. In one embodiment, the settings can be specified as a matrix of settings according to the day of the week and/or the hour of the day and/or the time of year, etc.
[0084] In one embodiment, the user can create various “profiles” using the computer system. Thus, for example, the user can create a privacy profile, a summer profile, a morning profile, and evening profile, a default profile, a standard profile, a winter profile, etc. Thus, for example, the user can create a privacy profile wherein the various settings of the shade control system are adjusted to provide relatively more privacy. The user can create a summer profile wherein the various settings of the shade control system are adjusted to provide setting the user desires during summer (e.g., efficient use of cooling). The user can create a winter profile wherein the various settings of the shade control system are adjusted to provide settings the user desires during winter (e.g., efficient use of heating). In one embodiment, the system comes configured with a default profile that is configured to provide a balance of privacy, temperature, and light, summer cooling, winter heating, evening privacy, etc. In one embodiment, the default profile is computed by the shade control system according to the geographical location of the house.
[0085] In one embodiment, the control system 601 is an adaptive system (as shown, for example in FIG. 17 ) configured to learn and adapt. Thus, for example, the control system 601 , when provided with temperature data from a room corresponding to particular group of shades, can adapt to change in room temperature as that group of shades is raised and lowered.
[0086] In one embodiment, the user can create a standard profile that includes the user's standard desired settings for the system. The use of profiles allows the user to quickly and easily change the many operating parameters of the shade control system (e.g., using the controls 607 , 608 ) on a group-by-group, room-by-room basis, or on a whole-house basis.
[0087] Any number of independent groups can be controlled by the system 600 . FIG. 7A is a block diagram of a centrally-controlled zoned heating and cooling system wherein a central control system 710 communicates with one or more group controllers 707 708 and one or more motorized shades 702 - 705 . In the system 700 , the group controller 707 measures the temperature and/or light of a zone 711 , and the motorized shades 702 , 703 are used to regulate light to the zone 711 . The group controller 708 measures the temperature and/or light of a zone 712 , and the motorized shades 704 , 705 regulate light to the zone 712 . A central thermostat 720 controls the HVAC system 721 .
[0088] FIG. 7B is a block diagram of a centrally-controlled motorized shade system 750 that is similar to the system 700 shown in FIG. 7A . In FIG. 7B , the central system 710 communicates with the group controllers 707 , 708 , the group controller 707 communicates with the motorized shades 702 , 703 , the group controller 708 communicates with the motorized shades 704 , 705 , and the central system 710 communicates with the motorized shades 706 , 707 . In the system 750 , the motorized shades 702 - 705 are in zones that are associated with the respective group controller 707 , 708 that controls the respective motorized shades 702 - 705 . The motorized shades 706 , 707 are not associated with any particular group controller and are controlled directly by the central system 710 . One of ordinary skill in the art will recognize that the communication topology shown in FIG. 7B can also be used in connection with the system shown in FIGS. 8 and 9 .
[0089] The central system 710 an example of one embodiment of the central control system 601 . The central system 710 controls and coordinates the operation of the zones 711 and 712 , but the system 710 does not control the HVAC system 721 . In one embodiment, the central system 710 operates independently of the thermostat 720 . In one embodiment, the thermostat 720 is provided to the central system 710 so that the central system 710 knows when the thermostat is calling for heating, cooling, or fan.
[0090] The central system 710 coordinates and prioritizes the operation of the motorized shades 702 - 705 . In one embodiment, the home occupants and provide a priority schedule for the zones 711 , 712 based on whether the zones are occupied, the time of day, the time of year, etc. Thus, for example, if zone 711 corresponds to a bedroom and zone 712 corresponds to a living room, zone 711 can be given a relatively lower priority during the day and a relatively higher priority during the night. As a second example, if zone 711 corresponds to a first floor, and zone 712 corresponds to a second floor, then zone 712 can be given a higher priority in summer (since upper floors tend to be harder to cool and have different privacy requirements) and a lower priority in winter (since lower floors tend to be harder to heat and my require less privacy). In one embodiment, the occupants can specify a weighted priority between the various zones.
[0091] FIG. 8 is a block diagram of a centrally-controlled motorized shade system 800 . The system 800 is similar to the system 700 and includes the group controllers 707 , 708 to monitor the zones 711 , 712 , respectively, and the motorized shades 702 - 705 . The group controllers 707 , 708 and/or the motorized shades 702 - 705 communicate with a central controller 810 . In the system 800 , the thermostat 720 is provided to the central system 810 and the central system 810 controls the HVAC system 721 directly. The central system 810 an example of one embodiment of the central control system 601 .
[0092] Since the controller in FIG. 8 also controls the operation of the HVAC system 721 , the controller is better able to call for heating and cooling as needed to maintain the desired temperature of the zones 711 , 712 . If all, or substantially, all of the home is served by the group controllers and motorized shades, then the central thermostat 720 can be eliminated.
[0093] FIG. 9 is a block diagram of an efficiency-monitoring centrally-controlled motorized shade system 900 . The system 900 is similar to the system 800 . In the system 900 , a controller 910 includes an efficiency-monitoring system that is configured to receive sensor data (e.g., system operating temperatures, etc.) from the HVAC system 721 to monitor the efficiency of the HVAC system 721 . The central system 910 an example of one embodiment of the central control system 601 .
[0094] FIG. 10 is a block diagram of a motorized shade 1000 configured to operate with a powered coil mounted on a window sill. The motorized shade 1000 is one embodiment of the motorized shade 200 . The motorized shade 1000 includes the elements shown in FIG. 3 , and, in addition, the motorized shade 1000 includes a coil 1001 . The coil 1001 is provided to the controller 301 . In one embodiment, the coil 1001 is provided to the controller 301 through a conductive coupling 350 a and a conductive coupling 350 b. A powered coil 1002 is provided to a window sill such that when the shade 1000 is lowered to the window sill, the coil 1001 is in proximity to the coil 1002 . In one embodiment, alternating current power is provided to the coil 1002 from a power source 1003 . In one embodiment, the power source 1003 is provided to a wall outlet to receive standard household AC power. When the shade lowered, the coil 1001 electromagnetically couples to the coil 1002 to form a transformer such that power is provided from the coil 1002 to the coil 1001 . The power received by the coil 1001 is provided to the controller 301 and the controller 301 can store the received power in the optional capacitor 306 or in a rechargeable battery 305 . In one embodiment, one or both of the coils 1001 , 1002 include a core of magnetic material. In one embodiment, the magnetic field produced by the powered coil 1002 attracts the magnetic core of the coil 1001 to help hold the bottom of the shade material in place.
[0095] In one embodiment, the coil 1002 is continuously powered by the power source 1003 . In one embodiment, the controller 301 sends a pulse of power to the coil 1001 , which pulse is then coupled to the coil 1002 and provided by the coil 1002 to the power source 1003 . The power source 1003 , upon sensing the pulse from the controller 301 , then provides power to the coil 1002 in response to the power pulse from the controller 301 . In one embodiment, the controller 301 sends a second pulse to the coil 1001 to instruct the controller 1003 to de-power the coil 1002 .
[0096] In one embodiment, the power source 1003 senses the impedance of the coil 1002 (on a continuous or periodic basis) and provides power to the coil 1002 when the impedance of the coil 1002 indicates that the coil 1001 is in proximity to the coil 1002 .
[0097] Power provided to the coil 1002 will magnetically attract a magnetic core of the coil 1001 . In one embodiment, the motor 303 can provide sufficient torque to overcome such magnetic attraction and raise the shade. In one embodiment, the controller 301 sends a reverse current pulse to the coil 1001 to cause the magnetic field of the coil 1001 to substantially cancel the magnetic field of the coil 1002 in order to release the shade and allow the shade to then be raised by the motor 303 .
[0098] In one embodiment, the controller 301 automatically lowers the shade 1000 when available power from the battery pack 305 and/or capacitor 306 falls below a specified value. In one embodiment, the system controllers (e.g., the controllers 710 , 810 , 910 , etc.) instruct the controller 301 to lower the shade 1000 when the available power from the battery pack 305 and/or capacitor 306 falls below a specified value.
[0099] In one embodiment, a plurality of coils 1001 and/or 1002 are provided along the lower portion of the shade material 201 and the window sill respectively.
[0100] FIG. 11 is a block diagram of a basic group controller 1100 for use in connection with the systems shown in FIGS. 6-9 . In the group controller 1100 , an optional temperature sensor 1102 is provided to a controller 1101 . User input controls 1103 are also provided to the controller 1101 to allow the user to select a shade and specify a setpoint shade opening. A visual display 1110 is provided to the controller 1101 . The controller 1101 uses the visual display 1110 to show the current shade group, setpoint, power status, etc. The communication system 1181 is also provided to the controller 1101 . The power source 404 and, optionally, 405 are provided to provide power for the controller 1100 , the controls 1101 , the sensor 1103 , the communication system 1181 , and the visual display 1110 .
[0101] In systems where the central controller 1101 is used, the communication method used by the group controller 1100 to communicate with the motorized shade 1000 need not be the same method used by the group controller 1100 to communicate with the central controller 1101 . Thus, in one embodiment, the communication system 1181 is configured to provide one type of communication (e.g., infrared, radio, ultrasonic) with the central controller, and a different type of communication with the motorized shade 1000 .
[0102] In one embodiment, the group controller is battery powered. In one embodiment, the group controller is configured into a standard light switch and receives electrical power from the light switch circuit.
[0103] FIG. 12 is a block diagram of a group controller 1200 with remote control for use in connection with the systems shown in FIGS. 6-9 . The group controller 1200 is similar to the group controller 1100 and includes, the temperature sensor 1103 , the input controls 1102 , the visual display 1110 , the communication system 1181 , and the power sources 404 , 405 . In the group controller 1200 , the remote control interface 501 is provided to the controller 1101 .
[0104] In one embodiment, an occupant sensor 1201 is provided to the controller 1101 . The occupant sensor 1201 , such as, for example, an infrared sensor, motion sensor, ultrasonic sensor, etc., senses when the zone is occupied. The occupants can program the group controller 1101 to bring the zone to different temperatures and privacy levels when the zone is occupied and when the zone is empty. In one embodiment, the occupants can program the group controller 1101 to bring the zone to different temperatures or privacy levels depending on the time of day, the time of year, the type of room (e.g. bedroom, kitchen, etc.), and/or whether the room is occupied or empty. In one embodiment, a group of zones are combined into a composite zone (e.g., a group of zones such as an entire house, an entire floor, an entire wing, etc.) and the central system 601 , 810 , 910 changes the temperature setpoints of the various zones according to whether the composite zone is empty or occupied.
[0105] FIG. 13 shows one embodiment of a central monitoring station console 1300 for accessing the functions represented by the blocks 601 , 710 , 810 , 910 in FIGS. 6 , 7 , 8 , 9 , respectively. The station 1300 includes a display 1301 and a keypad 1302 . The occupants can specify light level settings, privacy levels, etc using the central system 1300 and/or the group controllers. In one embodiment, the console 1300 is implemented as a hardware device. In one embodiment, the console 1300 is implemented in software as a computer display, such as, for example, on a personal computer. In one embodiment, the zone control functions of the blocks 710 , 810 , 910 are provided by a computer program running on a control system processor, and the control system processor interfaces with personal computer to provide the console 1300 on the personal computer. In one embodiment, the zone control functions of the blocks 710 , 810 , 910 are provided by a computer program running on a control system processor provided to a hardware console 1300 . In one embodiment, the occupants can use the Internet, telephone, cellular telephone, pager, etc. to remotely access the central system to control the temperature, priority, etc. of one or more zones.
[0106] FIG. 14 is a flowchart showing one embodiment of an instruction loop process 1400 for a motorized shade or group controller. The process 1400 begins at a power-up block 1401 . After power up, the process proceeds to an initialization block 1402 . After initialization, the process advances to a “listen” block 1403 wherein the motorized shade or group controller listens for one or more instructions. If a decision block 1404 determines that an instruction has been received, then the process advances to a “perform instruction” block 1405 , otherwise the process returns to the listen block 1403 .
[0107] For a motorized shade, the instructions can include: open window, close window, open window to a specified partially-open position, report sensor data (e.g., light level, shade position, etc.), report status (e.g., battery status, window position, etc.), and the like. For a group controller, the instructions can include: report light sensor data, report status, etc. In systems where the central system communicates with the motorized shades through a group controller, the instructions can also include: report number of motorized shades, report motorized shade data (e.g., status, position, light, etc.), report motorized shade window position, change motorized shade window position, etc.
[0108] In one embodiment, the listen block 1403 consumes relatively little power, thereby, allowing the motorized shade or group controller to stay in the loop corresponding to the listen block 1403 and conditional branch 1404 for extended periods of time.
[0109] Although the listen block 1403 can be implemented to use relatively little power, a sleep block can be implemented to use even less power. FIG. 15 is a flowchart showing one embodiment of an instruction and sensor data loop process 1500 for a motorized shade or group controller. The process 1500 begins at a power-up block 1501 . After power up, the process proceeds to an initialization block 1502 . After initialization, the process advances to a “sleep” block 1503 wherein the motorized shade or group controller sleeps for a specified period of time. When the sleep period expires, the process advances to a wakeup block 1504 and then to a decision 1505 . In the decision block 1505 , if a fault is detected, then a transmit fault block 1506 is executed. The process then advances to a sensor block 1507 where sensor readings are taken. After taking sensor readings, the process advances to a listen-for-instructions block 1508 . If an instruction has been received, then the process advances to a “perform instruction” block 1510 ; otherwise, the process returns to the sleep block 1503 .
[0110] FIG. 16 is a flowchart showing one embodiment of an instruction and sensor data reporting loop process 1600 for a motorized shade or group controller. The process 1600 begins at a power-up block 1601 . After power up, the process proceeds to an initialization block 1602 . After initialization, the process advances to a check fault block 1603 . If a fault is detected then a decision block 1604 advances the process to a transmit fault block 1605 ; otherwise, the process advances to a sensor block 1606 where sensor readings are taken. The data values from one or more sensors are evaluated, and if the sensor data is outside a specified range, or if a timeout period has occurred, then the process advances to a transmit data block 1608 ; otherwise, the process advances to a sleep block 1609 . After transmitting in the transmit fault block 1605 or the transmit sensor data block 1608 , the process advances to a listen block 1610 where the motorized shade or group controller listens for instructions. If an instruction is received, then a decision block advances the process to a perform instruction block 1612 ; otherwise, the process advances to the sleep block 1609 . After executing the perform instruction block 1612 , the process transmits an “instruction complete message” and returns to the listen block 1610 .
[0111] The process flows shown in FIGS. 14-16 show different levels of interaction between devices and different levels of power conservation in the motorized shade and/or group controller. One of ordinary skill in the art will recognize that the motorized shade and group controller are configured to receive sensor data and user inputs, report the sensor data and user inputs to other devices in the zone control system, and respond to instructions from other devices in the zone control system. Thus, the process flows shown in FIGS. 14-16 are provided for illustrative purposes and not by way of limitation. Other data reporting and instruction processing loops will be apparent to those of ordinary skill in the art by using the disclosure herein.
[0112] In one embodiment, the motorized shade and/or group controller “sleep,” between sensor readings. In one embodiment, the central system 601 sends out a “wake up” signal. When a motorized shade or group controller receives a wake up signal, it takes one or more sensor readings, encodes it into a digital signal, and transmits the sensor data along with an identification code.
[0113] In one embodiment, the motorized shade is bi-directional and configured to receive instructions from the central system. Thus, for example, the central system can instruct the motorized shade to: perform additional measurements; go to a standby mode; wake up; report battery status; change wake-up interval; run self-diagnostics and report results; etc.
[0114] In one embodiment, the motorized shade provides two wake-up modes, a first wake-up mode for taking measurements (and reporting such measurements if deemed necessary), and a second wake-up mode for listening for commands from the central system. The two wake-up modes, or combinations thereof, can occur at different intervals.
[0115] In one embodiment, the motorized shades use spread-spectrum techniques to communicate with the group controllers and/or the central system. In one embodiment, the motorized shades use frequency-hopping spread-spectrum. In one embodiment, each motorized shade has an Identification code (ID) and the motorized shades attaches its ID to outgoing communication packets. In one embodiment, when receiving wireless data, each motorized shade ignores data that is addressed to other motorized shades.
[0116] In one embodiment, the motorized shade provides bi-directional communication and is configured to receive data and/or instructions from the central system. Thus, for example, the central system can instruct the motorized shade to perform additional measurements, to go to a standby mode, to wake up, to report battery status, to change wake-up interval, to run self-diagnostics and report results, etc. In one embodiment, the motorized shade reports its general health and status on a regular basis (e.g., results of self-diagnostics, battery health, etc.)
[0117] In one embodiment, the motorized shade use spread-spectrum techniques to communicate with the central system. In one embodiment, the motorized shade uses frequency-hopping spread-spectrum. In one embodiment, the motorized shade has an address or identification (ID) code that distinguishes the motorized shade from the other motorized shades. The motorized shade attaches its ID to outgoing communication packets so that transmissions from the motorized shade can be identified by the central system. The central system attaches the ID of the motorized shade to data and/or instructions that are transmitted to the motorized shade. In one embodiment, the motorized shade ignores data and/or instructions that are addressed to other motorized shades.
[0118] In one embodiment, the motorized shades, group controllers, central system, etc., communicate on a 900 MHz frequency band. This band provides relatively good transmission through walls and other obstacles normally found in and around a building structure. In one embodiment, the motorized shades and group controllers communicate with the central system on bands above and/or below the 900 MHz band. In one embodiment, the motorized shades and group controllers listen to a radio frequency channel before transmitting on that channel or before beginning transmission. If the channel is in use, (e.g., by another device such as another central system, a cordless telephone, etc.) then the motorized shades and/or group controllers change to a different channel. In one embodiment, the sensor, central system coordinates frequency hopping by listening to radio frequency channels for interference and using an algorithm to select a next channel for transmission that avoids the interference. In one embodiment, the motorized shade and/or group controller transmits data until it receives an acknowledgement from the central system that the message has been received.
[0119] Frequency-hopping wireless systems offer the advantage of avoiding other interfering signals and collisions. Moreover, there are regulatory advantages given to systems that do not transmit continuously at one frequency. Channel-hopping transmitters change frequencies after a period of continuous transmission, or when interference is encountered. These systems may have higher transmit power and relaxed limitations on in-band spurs.
[0120] In one embodiment, the controller 301 reads the sensors at regular periodic intervals. In one embodiment, the controller 301 reads the sensors at random intervals. In one embodiment, the controller 301 reads the sensors in response to a wake-up signal from the central system. In one embodiment, the controller 301 sleeps between sensor readings.
[0121] In one embodiment, the motorized shade transmits sensor data until a handshaking-type acknowledgement is received. Thus, rather than sleep if no instructions or acknowledgements are received after transmission (e.g., after the instruction block 1510 , 1405 , 1612 and/or the transmit blocks 1605 , 1608 ) the motorized shade retransmits its data and waits for an acknowledgement. The motorized shade continues to transmit data and wait for an acknowledgement until an acknowledgement is received. In one embodiment, the motorized shade accepts an acknowledgement from a zone thermometer and it then becomes the responsibility of the zone thermometer to make sure that the data is forwarded to the central system. The two-way communication ability of the motorized shade and zone thermometer provides the capability for the central system to control the operation of the motorized shade and/or zone thermometer and also provides the capability for robust handshaking-type communication between the motorized shade, the zone thermometer, and the central system.
[0122] In one embodiment of the system 600 shown in FIG. 6 , the motorized shades 602 , 603 send window temperature data to the group controller 601 . The group controller 601 compares the window temperature to the room temperature and the setpoint temperature and makes a determination as to whether the motorized shades 602 , 603 should be open or closed. The group controller 601 then sends commands to the motorized shades 602 , 603 to open or close the windows. In one embodiment, the group controller 601 displays the window position on the visual display 1110 .
[0123] In one embodiment of the system 600 shown in FIG. 6 , the group controller 601 sends setpoint information and current room temperature information to the motorized shades 602 , 603 . The motorized shades 602 , 603 compare the window temperature to the room temperature and the setpoint temperature and makes a determination as to whether to open or close the windows. In one embodiment, the motorized shades 602 , 603 send information to the group controller 601 regarding the relative position of the windows (e.g., open, closed, partially open, etc.).
[0124] In the systems 700 , 750 , 800 , 900 (the centralized systems) the group controllers 707 , 708 send room temperature and setpoint temperature information to the central system. In one embodiment, the group controllers 707 , 708 also send temperature slope (e.g., temperature rate of rise or fall) information to the central system. In the systems where the thermostat 720 is provided to the central system or where the central system controls the HVAC system, the central system knows whether the HVAC system is providing heating or cooling; otherwise, the central system uses window temperature information provide by the motorized shades 702 - 705 to determine whether the HVAC system is heating or cooling. In one embodiment, motorized shades send window temperature information to the central system. In one embodiment, the central system queries the motorized shades by sending instructions to one or more of the motorized shades 702 - 705 instructing the motorized shade to transmit its window temperature.
[0125] The central system determines how much to open or close motorized shades 702 - 705 according to the available heating and cooling capacity of the HVAC system and according to the priority of the zones and the difference between the desired temperature and actual temperature of each zone. In one embodiment, the occupants use the group controller 707 to set the setpoint and priority of the zone 711 , the group controller 708 to set the setpoint and priority of the zone 712 , etc. In one embodiment, the occupants use the central system console 1300 to set the setpoint and priority of each zone, and the group controllers to override (either on a permanent or temporary basis) the central settings. In one embodiment, the central console 1300 displays the current temperature, setpoint temperature, temperature slope, and priority of each zone.
[0126] In one embodiment, the central system allocates HVAC light to each zone according to the priority of the zone and the temperature of the zone relative to the setpoint temperature of the zone. Thus, for example, in one embodiment, the central system provides relatively more HVAC light to relatively higher priority zones that are not at their temperature setpoint than to lower priority zones or zones that are at or relatively near their setpoint temperature. In one embodiment, the central system avoids closing or partially closing too many windows in order to avoid reducing light in the window below a desired minimum value.
[0127] In one embodiment, the central system monitors a temperature rate of rise (or fall) in each zone and sends commands to adjust the amount each motorized shade 702 - 705 is open to bring higher priority zones to a desired temperature without allowing lower-priority zones to stray too far form their respective setpoint temperature.
[0128] In one embodiment, the central system uses predictive modeling to calculate an amount of window opening for each of the motorized shades 702 - 705 to reduce the number of times the windows are opened and closed and thereby reduce power usage by the motors 409 . In one embodiment, the central system uses a neural network to calculate a desired window opening for each of the motorized shades 702 - 705 . In one embodiment, various operating parameters such as the capacity of the central HVAC system, the volume of the house, etc., are programmed into the central system for use in calculating window openings and closings. In one embodiment, the central system is adaptive and is configured to learn operating characteristics of the HVAC system and the ability of the HVAC system to control the temperature of the various zones as the motorized shades 702 - 705 are opened and closed. In an adaptive learning system, as the central system controls the motorized shades to achieve the desired temperature over a period of time, the central system learns which motorized shades need to be opened, and by how much, to achieve a desired level of heating and cooling for each zone. The use of such an adaptive central system is convenient because the installer is not required to program HVAC operating parameters into the central system. In one embodiment, the central system provides warnings when the HVAC system appears to be operating abnormally, such as, for example, when the temperature of one or more zones does not change as expected (e.g., because the HVAC system is not operating properly, a window or door is open, etc.).
[0129] In one embodiment, the adaptation and learning capability of the central system uses different adaptation results (e.g., different coefficients) based on light levels, whether the HVAC system is heating or cooling, the outside temperature, a change in the setpoint temperature or priority of the zones, etc. Thus, in one embodiment, the central system uses a first set of adaptation coefficients when the HVAC system is cooling, and a second set of adaptation coefficients when the HVAC system is heating. In one embodiment, the adaptation is based on a predictive model. In one embodiment, the adaptation is based on a neural network.
[0130] FIG. 17 is a block diagram of a control algorithm 1700 for controlling the motorized shades. For purposes of explanation, and not by way of limitation, the algorithm 1700 is described herein as running on the central system. However, one of ordinary skill in the art will recognize that the algorithm 1700 can be run by the central system, by the group controller, by the motorized shade, or the algorithm 1700 can be distributed among the central system, the group controller, and the motorized shade. In the algorithm 1700 , in a block 1701 of the algorithm 1700 , the setpoint light levels from one or more group controllers are provided to a calculation block 1702 . The calculation block 1702 calculates the motorized shade settings (e.g., how much to open or close each motorized shade) according to the desired light level, privacy level, etc. In one embodiment, the block 1702 uses a predictive model as described above. In one embodiment, the block 1702 calculates the motorized shade settings for each group independently (e.g., without regard to interactions between group). In one embodiment, the block 1702 calculates the motorized shade settings for each zone in a coupled-zone manner that includes interactions between groups. In one embodiment, the calculation block 1702 calculates new window openings by taking into account the current window openings and in a manner configured to minimize the power consumed by opening and closing the motorized shades.
[0131] Window shade settings from the block 1702 are provided to each of the motorized shade motors in a block 1703 , wherein the motorized shades are moved to new opening positions as desired (and, optionally, one or more of the fans 402 are turned on to pull additional light from desired windows). After setting the new window openings in the block 1703 , the process advances to a block 1704 where new measurement values (e.g., temperature, light, privacy, etc.) are obtained from the group controllers (the new zone temperatures and light levels being responsive to the new motorized shade settings made in block 1703 ). The new zone temperatures are provided to an adaptation input of the block 1702 to be used in adapting a predictive model used by the block 1702 . The new zone temperatures also provided to a temperature input of the block 1702 to be used in calculating new motorized shade settings.
[0132] As described above, in one embodiment, the algorithm used in the calculation block 1702 is configured to predict the motorized shade opening needed to bring each group to the desired setting based on the current temperature, the available heating and cooling, the amount of light available through each motorized shade, etc. The calculating block uses the prediction model to attempt to calculate the motorized shade openings needed for relatively long periods of time in order to reduce the power consumed in unnecessarily by opening and closing the motorized shades. In one embodiment, the motorized shades are battery powered, and thus reducing the movement of the motorized shades extends the life of the batteries. In one embodiment, the block 1702 uses a predictive model that learns the characteristics of the system and the various zones and thus, the model prediction tends to improve over time.
[0133] In one embodiment, the group controllers report zone temperatures and/or light levels to the central system and/or the motorized shades at regular intervals. In one embodiment, the group controllers report zone temperatures to the central system and/or the motorized shades after the zone temperature has changed by a specified amount specified by a threshold value. In one embodiment, the group controllers report zone temperatures to the central system and/or the motorized shades in response to a request instruction from the central system or motorized shade.
[0134] In one embodiment, the group controllers report setpoint temperatures and/or light levels, zone priority values, etc. to the central system or motorized shades whenever the occupants change the setpoint temperatures or zone priority values using the user controls 1102 . In one embodiment, the group controllers report setpoint temperatures and zone priority values to the central system or motorized shades in response to a request instruction from the central system or motorized shades.
[0135] In one embodiment, the occupants can choose the thermostat deadband value (e.g., the hysteresis value) used by the calculation block 1702 . A relatively larger deadband value reduces the movement of the motorized shade at the expense of larger temperature variations in the zone.
[0136] In one embodiment, the occupant sensor 1201 is used to change the privacy priority from relatively lower to relatively higher priority. Thus, for example, the system can be configured to provide relatively more privacy when a room or area is occupied than when the area is unoccupied. In one embodiment, a hysteresis-like value is used in connection with the occupancy sensor such that the privacy setting of an area changes relatively slowly so that the motorized shades do not run up and down repeatedly if a person walks in and out the area detected by the occupant sensor 1201 . In one embodiment, the system 601 uses the data from the occupant sensor 1201 to learn when an area is likely to be occupied or unoccupied for a period of time and vary the privacy setting accordingly.
[0137] In one embodiment, the motorized shades report sensor data (e.g., window temperature, light, power status, position, etc.) to the central system and/or the group controllers at regular intervals. In one embodiment, the motorized shades report sensor data to the central system and/or the group controllers whenever the sensor data fails a threshold test (e.g., exceeds a threshold value, falls below a threshold value, falls inside a threshold range, or falls outside a threshold range, etc.). In one embodiment, the motorized shades report sensor data to the central system and/or the group controllers in response to a request instruction from the central system or group controller.
[0138] In one embodiment, the central system is shown in FIGS. 7-9 is implemented in a distributed fashion in the group controllers 1100 and/or in the motorized shades. In the distributed system, the central system does not necessarily exists as a distinct device, rather, the functions of the central system can be are distributed in the group controllers 1100 and/or the motorized shades. Thus, in a distributed system, FIGS. 7-9 represent a conceptual/computational model of the system. For example, in a distributed system, each group controller 100 knows its zone priority, and the group controllers 1100 in the distributed system negotiate to allocate the available light, privacy, heating/cooling, etc. among the zones. In one embodiment of a distributed system, one of the group controller assumes the role of a master thermostat that collects data from the other group controllers and implements the calculation block 1902 . In one embodiment of a distributed system, the group controllers operate in a peer-to-peer fashion, and the calculation block 1902 is implemented in a distributed manner across a plurality of group controllers and/or motorized shades.
[0139] In one embodiment, the motorized shade reports its power status to the central system or group controller. In one embodiment the central system or group controller takes such power status into account when determining new motorized shade openings. Thus, for example, if there are first and second motorized shades serving one zone and the central system knows that the first motorized shade is low on power, the central system will use the second motorized shade to modulate the light into the zone. If the first motorized shade is able to use the fan 402 or other light-based generator to generate electrical power, the central system will instruct the second motorized shade to a relatively closed position in and direct relatively more light through the first motorized shade when directing light into the zone.
[0140] In one embodiment, the central system or group controller instructs the shades to open in response to a fire or smoke alarm signal. In one embodiment, the central system or group controller instructs the shades to open or close in response to a signal from a burglar alarm system. In one embodiment, the central system or group controller instructs the shades to open or close in response to a window open, window close, door open, and/or door close signal from a burglar alarm-type system. In one embodiment, the group controller is provided to a network connection (e.g., an Internet connection, cellular telephone connection, telephone connection etc.) to allow the homeowner to remotely open or close the blinds or to remotely change priority parameters in the control system (e.g., desired relative priority of privacy, temperature, and light, desired temperature, desired privacy level, desired light level, etc.). In one embodiment, the user can remotely control the network-connected group controller via telephone or cellular telephone.
[0141] FIG. 18 shows one embodiment of a motorized shade, with a tubular motor 303 , internal batteries as the power source 350 , and an electronics module 1801 . The electronics module includes for example, the controller 301 , the optional capacitor 306 , the RF transceiver 302 , and the optional RFID tag 309 .
[0142] FIG. 19 shows one embodiment of a motorized shade with a tubular motor 303 , the power source 350 , the electronics module 1801 , and a fascia 1901 .
[0143] FIG. 20 shows one embodiment of a window shade roller that includes a low-profile mounting system. In FIG. 20 , the power source 305 , the electronics module 1801 and the motor 303 are provided in the roller tube 202 . A first mounting member 2011 is provided to the motor 303 . A second mounting member 2010 is configured to be provided to a window casing. The first mounting member 2011 mates with the second mounting member 2010 to hold the window shade roller in place while preventing rotation of the first mounting member 2011 relative to the second mounting member 2010 . A third mounting member 2001 is provided to the tube 202 and a fourth mounting member 2004 is configured to be provided to a window casing. The third mounting member 2001 mates with the fourth mounting member 2004 to hold the window shade roller in place while allowing rotation of the tube 202 relative to the fourth mounting member 2004 . In one embodiment, a spring 2002 presses the third mounting member 2001 against the fourth mounting member 2004 . In an alternate embodiment, the third mounting member 2001 is held by a clamp, screw, or the like.
[0144] The motor turns the roller tube relative to the first mounting member 2011 . The motor can be mounted either such that the motor case is provided to the window shade roller and the motor shaft is provided to the first mounting member 2011 or such that the motor case is provided to the first mounting member 2011 and the motor shaft is provided to the window roller shade. In one embodiment, the motor (either the shaft or the motor case) is provided to the roller tube 202 via a sound-reducing mounting, such as, for example, a resilient mounting, to reduce noise.
[0145] The first power source is provided to the electronics module 1801 to provide power to the electronics module (and to the motor 303 ). In one embodiment, the first power source 305 includes one or more batteries. In one embodiment, the spring 2002 presses against a first terminal of the first power source 305 and provides electrical connection from the first terminal to the tube 202 . In one embodiment, an electrical connection from the spring 2002 to the tube 202 is provided by at least a portion of the third mounting member 2001 . The spring 2002 presses on the first power source 305 and thereby presses a second terminal of the first power source 305 against a connection terminal 2012 . A first electrical connection is provided from the connection terminal 2012 to the electronics module 1801 . A second electrical connection is provided from the tube 202 to the electronics module 1801 thereby completing an electrical circuit between the electronics module 1801 and the first and second terminals of the first power source 305 . In one embodiment, the connection terminal 2012 is held in place by a terminal mounting module 2022 . In one embodiment, the terminal mounting module 2022 is held in place in the tube 202 by a screw or other mechanical fastener.
[0146] The assembly shown in FIG. 20 provides a convenient way to adjust the width of the roller shade to allow the roller shade to fit windows of various widths. The tube 202 can be cut to a desired length without affecting the operation of the motor 303 , electronics module or mounting members 2010 , 2011 , 2001 , and 2004 . Thus, the tube 202 can conform to the width of the window. The mounting members 2010 , 2011 , 2001 , 2004 form a low-profile mounting that reduce the space between the window and the ends of the roller tube assembly thus allowing the roller shade material wound on the roller tube to be almost the same as the width of the window. Moreover, the mounting members 2010 , 2011 , 2001 , 2004 are substantially hidden by the roller tube 202 and thus aesthetically pleasing.
[0147] FIG. 21 shows one embodiment of a modular window shade roller that includes a low-profile mounting system. FIG. 22 is an exploded view of the modular window shade roller from FIG. 21 . In FIGS. 21 and 22 , the power source 305 , the spring 2002 and the third mounting member 2001 are provided to a tube 2102 . The motor 303 is provided to a second tube 2104 . The electronics module 1801 is provided to a cylindrical module 2101 . A first end of the cylindrical module 2101 is configured to mate with the first tube 2102 and a second end of the cylindrical module 2101 is configured to mate with the second tube 2104 . The first tube 2102 , the second tube 2104 , and the cylindrical module 2101 mate together to form a tube (similar in function to the tube 202 ) upon which the roller shade material can be rolled. The motor 303 is provided to the second tube 2104 . In an alternate embodiment, not shown, the cylindrical member 2101 and the second tube 2104 are constructed as a single assembly rather than two assemblies configured to mate together.
[0148] A first mounting member 2011 is provided to the motor 303 . A second mounting member 2010 is configured to be provided to a window casing. The first member 2011 mates with the second mounting member 2010 to hold the window shade roller in place while preventing rotation of the first mounting member 2011 relative to the second mounting member 2010 . A third mounting member 2001 is provided to the tube 2102 and a fourth mounting member 2004 is configured to be provided to a window casing. The third mounting member 2001 mates with the fourth mounting member 2004 to hold the window shade roller in place while allowing rotation of the tube 2102 (and cylindrical module 2101 and tube 2104 ) relative to the fourth mounting member 2004 . In one embodiment, the spring 2002 presses the third mounting member 2001 against the fourth mounting member 2004 . In an alternate embodiment, the third mounting member 2001 is held by a clamp, screw, or the like.
[0149] The motor turns the tube 2104 (and thus also the cylindrical module 2101 and tube 2102 ) relative to the first mounting member 2011 . The motor can be mounted either such that the motor case is provided to the tube 2104 and the motor shaft is provided to the first mounting member 2011 or such that the motor case is provided to the first mounting member 2011 and the motor shaft is provided to the tube 2101 . In one embodiment, the motor (either the shaft or the motor case) is provided to the roller tube 2104 via a sound-reducing mounting, such as, for example, a resilient mounting, to reduce noise.
[0150] The first power source is provided to the electronics module 1801 to provide power to the electronics module (and to the motor 303 ). In one embodiment, the first power source 305 includes one or more batteries. In one embodiment, the spring 2002 presses against a first terminal of the first power source 305 and provides electrical connection from the first terminal to the tube 2102 . In one embodiment, an electrical connection from the spring 2002 to the tube 2102 is provided by at least a portion of the third mounting member 2001 . The spring 2002 presses on the first power source 305 and thereby presses a second terminal of the first power source 305 against the connection terminal 2012 . The connection terminal 2012 is provided to the cylindrical module 2101 . A first electrical connection is provided from the connection terminal 2012 to the electronics module 1801 . A second electrical connection 2131 is provided from the tube 2102 to the electronics module 1801 thereby completing an electrical circuit between the electronics module 1801 and the first and second terminals of the first power source 305 . In one embodiment, the connection terminal 2012 is held in place by a terminal mounting module 2022 . The second electrical connection 2131 is provided to the cylindrical module 2101 in the region where the cylindrical module 2101 mates with the tube 2102 .
[0151] The assembly shown in FIGS. 21 and 22 provides a convenient way to adjust the width of the roller shade to allow the roller shade to fit windows of various widths. The length of the tube 2104 and the cylindrical assembly 2101 are fixed. The tube 2102 can be cut to a desired length and mated to the cylindrical module 2101 such that roller tube assembly formed by the combination of the first tube 2102 , the cylindrical module 2101 , and the second tube 2104 conform to the width of the window. The mounting members 2010 , 2011 , 2001 , 2004 form a low-profile mounting that reduce the space between the window and the ends of the roller tube assembly thus allowing the roller shade material wound on the roller tube to be almost the same as the width of the window. Moreover, the mounting members 2010 , 2011 , 2001 , 2004 are substantially hidden by the roller tube assembly and thus aesthetically pleasing.
[0152] FIG. 23 shows one embodiment of the first mounting member 2011 and the second mounting member 2010 . In FIG. 23 , the second mounting member 2010 includes one or more protrusions 2333 . The protrusions 2333 mate with corresponding intrusions on the first mounting member 2011 (as shown in FIG. 25 ) such that when the first mounting member 2011 is placed against the second mounting member 2010 , the first mounting member is held in place by the protrusions 2333 . In one embodiment the tube 202 or 2102 is made at least in part from conducting material.
[0153] FIG. 23 also shows one embodiment of a mount 2120 for mounting the motor 303 in the tube 202 or the tube 2104 . The mount 2120 adapts the outside of the motor casing to the inside diameter of the tube 202 or 2104 such that the motor shaft is held substantially centered in the tube. In one embodiment, one or more slots or grooves 2301 in the outer diameter of the mount 2120 mate with one or more ribs in the tube 202 or 2104 (as shown in FIG. 25 ) to prevent the mount 2120 from rotating in the tube. In one embodiment, the mount 2120 is constructed from a sound-dampening material. In one embodiment, the mount 2120 is constructed from a sound-dampening resilient material such as, for example, foam, rubber, plastic, felt, etc. In one embodiment, a plurality of mounts 2120 are used to hold the motor 303 in the tube 202 or 2104 .
[0154] FIG. 24 shows one embodiment of the third mounting member 2001 and the fourth mounting member 2004 . The fourth mounting member 2004 includes a cylindrical protrusion configured to mate with a corresponding hole or intrusion in the third mounting member 2001 such that when the third mounting member 2001 is mated to the fourth mounting member 2004 , the third mounting member 2001 is held in place but free to rotate with respect to the fourth mounting member 2004 . In one embodiment, the third mounting member 2001 includes an optional tab 2440 to facilitate retraction of the third mounting member 2001 during installation of the roller shade in the window.
[0155] FIG. 26 (consisting of FIGS. 26A-26C ) shows details of mounting a window shade using the low-profile mounting. The second mounting member 2010 and the fourth mounting member 2004 are mounted to the window casing, window frame, or other desired mounting location. The first mounting member 2011 is mated to the second mounting member 2010 . The third mounting member 2001 is retracted by pushing the third mounting member 2001 against the spring 2002 . The roller shade tube assembly (e.g., the tube 202 or the assembly using the tube 2102 ) is positioned to place the third mounting member 2001 over the fourth mounting member 2004 such that when the third mounting member 2001 is released, the third mounting member 2001 mates with the fourth mounting member 2004 (as shown in FIG. 26C ). The roller shade material can be attached to the roller tube either before or after the roller tube is mounted to the window.
[0156] In one embodiment, one or more mounting holes in the second mounting member 2010 and/or the fourth mounting member 2004 are slotted to allow the mounting member to be shifted up or down to level the roller shade
[0157] In one embodiment, a slot is provided in the roller tube 202 or 2102 to provide clearance for the optional tab 2440 to allow the third mounting member 2001 to be retracted into the tube 202 or 2102 during mounting.
[0158] FIG. 27 shows an alternate embodiment of the low profile mounting that further facilitates adapting the roller shade to different windows. In FIG. 27 , a mounting adapter 2727 is placed between the third mounting member 2001 and the tube 202 or 2102 . The mounting adapter 2727 mates with the tube 202 , 2102 and provides a slot for facilitating retraction of the third mounting member 2001 , thus removing the need for a slot in the tube 202 , 2102 . In one embodiment, the spring 2002 extends through the mounting adapter 2727 . In one embodiment, the spring 2002 presses against the base of the mounting adapter 2727 and a separate spring (not shown) is provided in the mounting adapter 2727 to press against the third mounting member 2001 .
[0159] In the disclosure above, the third mounting member 2001 is described with an optional tab 2440 to facilitate retracting the third mounting member 2001 by pushing the third mounting member towards the tube 202 , 2102 . In an alternate embodiment, the tab 2440 is omitted. In one embodiment, a slot for a screwdriver or other tool is provided in the third mounting member 2001 . The screwdriver or other tool is inserted in the slot to facilitate retracting the third mounting member 2001 .
[0160] It will be evident to those skilled in the art that the motorized shade is not limited to the details of the foregoing illustrated embodiments and that the present motorized shade may be embodied in other specific forms without departing from the spirit or essential attributed thereof, furthermore, various omissions, substitutions and changes may be made without departing from the spirit of the invention. For example, although specific embodiments are described in terms of the 900 MHz frequency band, one of ordinary skill in the art will recognize that frequency bands above and below 900 MHz can be used as well. The wireless system can be configured to operate on one or more frequency bands, such as, for example, the HF band, the VHF band, the UHF band, the Microwave band, the Millimeter wave band, etc. One of ordinary skill in the art will further recognize that techniques other than spread spectrum can also be used and/or can be used instead spread spectrum. The modulation used is not limited to any particular modulation method, such that modulation scheme used can be, for example, frequency modulation, phase modulation, amplitude modulation, combinations thereof, etc. The one or more of the wireless communication systems described above can be replaced by wired communication. The one or more of the wireless communication systems described above can be replaced by powerline networking communication. The foregoing description of the embodiments is, therefore, to be considered in all respects as illustrative and not restrictive, with the scope of the invention being delineated by the appended claims and their equivalents.
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An electronically-controlled roll-up window shade that can easily be installed by a homeowner or general handyman is disclosed. The motorized shade includes an internal power source, a motor, and a communication system to allow for remote control of the motorized shade. One or more motorized shades can be controlled singly or as a group. In one embodiment, the motorized shades are used in connection with a zoned or non-zoned HVAC system to reduce energy usage. In one embodiment, the motorized shade is configured to have a size and form-factor that conforms to a standard manually-controlled motorized shade. In one embodiment, a group controller is configured to provide thermostat information to the motorized shade. In one embodiment, the group controller communicates with a central monitoring system that coordinates operation of one or more motorized shades. In one embodiment, the internal power source of the motorized shade is recharged by a solar cell.
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FIELD OF THE INVENTION
This invention relates to thermochemical ice penetrators and, more particularly, to improved thermochemical ice penetrators having enhanced safe storage and handling characteristics.
BACKGROUND
To provide radio communications or signals from an undersea source, such as a submerged submarine, a radio antenna must be raised from that source to a position above the surface of the water to permit RF propagation into the overlying atmosphere. Communications buoys, carried in the submarine, serve in that function. As an example known to those skilled in this technology, a communication buoy may be released from a submerged submarine. The buoy conveniently floats to the surface carrying an antenna, and exposed the antenna to the atmosphere. Self contained RF equipment them transmits RF to a predesignated frequency carrying modulated with information to other radio stations listening on the transmitting frequency.
In Arctic regions, moreover, one is confronted with polar ice overlying the sea. The ice is a physical barrier to movement of any buoyant object from the under side and, like water, does not adequately propagate RF energy. For Arctic environments, thus, the communications buoy, more aptly referred to as the Arctic communications buoy, includes a penetrator for penetrating the ice and creating a passage through which an RF antenna may be raised from beneath the ice.
One type of ice penetrator that has gained acceptance in that application is of the thermochemical type. The ice penetrator uses heat generated by a thermochemical reaction between material of the penetrator and the ice to melt a hole through the ice. One reactant is water, which is at least partially supplied by the ice as it melts. The second reactant is the thermochemical material of the penetrator which reacts exothermally on contact with water. Such penetrator material is, typically, an alkali metal or an alloy containing a alkali metal, preferably lithium. The reaction products include lithium hydroxide, a solid that may dissolve in water, and hydrogen, a gas. The reaction products are pertinent to aspects of the present invention.
An excellent source of more detailed background of, structure to and applications for the present invention is found in the patent to Eninger, et. al., U.S. Pat. No. 4,651,834, granted Mar. 24, 1987, assigned to TRW Inc, the assignee of the improved ice penetrator herein described and this application. To avoid unnecessary repetition herein one should make reference to the Eninger, et. al. patent as that background information is incorporated by reference in this specification.
As may be noted in the Eninger Patent the geometry of the outer surface of the penetrator's front end therein illustrated possess somewhat flat or blunt shapes. Later designs for ice penetrators produced in accordance with the Eninger patent, however, are artillery shell shaped or, as alternatively viewed, bullet shaped in geometry, a shape which appears to enhance the penetrator's speed of penetration through ice without undue consumption of the penetrator's material.
Although successfully applied, it has been discovered that under certain circumstances the lithium penetrator has a serious drawback. If released from a depth of between 300 and 600 feet under the water surface, the penetrator produces an acoustic report, a somewhat loud explosion, on contact with the water. When used in military submarines such noise could alert enemy vessels to the submarine's presence with possible calamitous results. Importantly, should the explosion occur too close to the submarine damage to personnel and equipment could possibly result. The present invention eliminates that hazard. Moreover, should the compartment housing the penetrator, the buoy table, inadvertently become flooded with water while in a deeply submerged submarine, at the high pressure existing at such depths one conceives that a similar potential for damage could result. The present invention also eliminates that potential hazard.
The mechanics of the explosive reaction are not fully understood. It is believed, however, that at the high pressures existing at great ocean depths, the lithium penetrator generates more heat than it can safely dissipate in the water, eventually melting the lithium and/or causing the penetrator to break apart into many smaller pieces. As is known, lithium is more reactive in the molten state. A greater surface area of highly reactive lithium is thus exposed to the ocean water in a relatively short period of time, resulting in the very violent chemical reaction, an explosion. Should the penetrator include sodium, which is even more reactive in water than lithium alone, more intense reactions might occur.
An object of the present invention therefore is to prevent thermochemical ice penetrators from exploding when exposed to the ocean water at great depths;
An additional object of the invention is to provide an improved ice penetration apparatus that cannot cause acoustic reports;
A further object of the invention is to provide a safety mechanism for strong and handling lithium type ice penetrators or ice penetrators containing other more reactive metals, such as sodium, that are alloyed with lithium; and
An additional object is to prevent undue fragmentation or melting of the ice penetrator before and during deployment.
SUMMARY OF THE INVENTION
In accordance with the foregoing objects the improved ice penetrator apparatus includes protective apparatus for the thermochemical ice penetrator to prevent an undesired explosive sound producing chemical reaction between water and the material of said ice penetrator, particularly while the ice penetrator is resident in a buoy tube prior to release. The protective apparatus of least partially covers or sheaths the thermochemical ice penetrator and forms a unitary assembly therewith. The protective material has a characteristic that it is non-reactive to the ice penetrator material, typically lithium and/or a sodium lithium alloy, and to water. Any water that might flood or leak into the buoy tube, thus, cannot react violently with the stored ice penetrator, even though, as example, the water is at the high pressure occurring at depths below 300 feet. The safety or protective apparatus thus enhances the usefulness of thermochemical type ice penetrators.
In one particular embodiment of the invention, the protective apparatus is a diving bell structure having a metal body, suitably stainless steel, that present an open ended receptacle, in which to snugly receive the ice penetrator. Any water as might enter the diving bell creates, in an initial exothermic reaction with the penetrator, a gas that forces additional water out of the receptacle, thereby extinguishing the reaction; producing, hence, a self limiting reaction.
In a second form of the invention a clam shell like structure encases the ice penetrator in a snug fit chamber. The separate portions of the clam shell are formed of Nylon material. A spring located within the clam shell provides a bias force to force the two shell portions away from one another and against the buoy tube walls. Upon deployment, the spring serves to detach the clam shell, which may then fall away so that the penetrator may function in the ice. Prior to deployement such water as may enter within the clam shell in this arrangement, as at the seam between the facing shell portions, produces, in addition to the gas, earlier discussed, another liquid reaction product, that dissolves in the water. Such liquid reaction product is non-reactive and, as greater concentrations of that reaction product are formed within the water in the clamshell, the water to lithium reaction decreases to a very slow rate, resulting in a self limiting chemical reaction. The foregoing process avoids a fast acting violent reaction.
In a further embodiment the protective apparatus is a fluid tight container or wrap formed on the ice penetrator, suitably with plastic wrapping material and a wax overlayer, to form a unitary assembly that fits within the buoy tube of the ice penetrator apparatus. The wrap contains associated extending tabs that are fastened to the buoy tube. This apparatus is relatively easy to assemble and is formed of inexpensive components. The wrap prevents water from access to and, hence, precludes any reaction between water and the ice penetrator. The tabs serve to unwrap, essentially peel, the ice penetrator, like a banana, when the ice penetrator is forced out of the buoy tube while the tabs remain restrained by the buoy tube.
The foregoing and additional objects and advantages of the invention together with the structure characteristic thereof, which was only briefly summarized in the foregoing passages, becomes more apparent to those skilled in the art upon reading the detailed description of the preferred embodiments, which follows in this specification, taken together with the illustrations thereof presented in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Drawings:
FIG. 1 illustrates in section view a first diving bell embodiment of the invention;
FIG. 2 illustrates in section view a second clam shell embodiment of the invention;
FIG. 3 illustrates an additional clam shell embodiment of the invention in smaller scale in exploded view;
FIG. 4 illustrates a banana skin embodiment of the invention; and
FIG. 5 partially illustrates in reduced scale a buoy tube assembly containing an improved penetrator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention improves upon ice penetrator systems that use a thermochemical penetrator of pure lithium. It appears to be of even greater benefit in those improved ice penetrators that incorporate sodium, which is more reactive with water than lithium, as an alloy, and are generally described in U.S. Pat. No. 4,651,834, to Eninger et al.
Preliminary to study of this detailed description, reference is made initially to column 19 line 27 through column 30 line 40 of the specification and to FIGS. 19-30 of the drawings of patent U.S. Pat. No. 4,651,834, granted Mar. 24, 1987, to Eninger et al., hereafter some times referred to as the Eninger patent. The Eninger patent describes the physical construction of and alternative designs for ice penetrator apparatus containing flotation devices by which vertically upwardly directed ice penetration is achieved through the polar ice and in which antennas, rigid telescoping or reeled, are shown to be carried and/or pulled from a location in the water underlying an ice flow to a location above the ice flow so that the antenna is exposed to the atmosphere. Such illustrations and description are referred to and are incorporated herewithin as part of the detailed description of the present invention and may be used to provide additional basis to elements in the claims appended to this application. While the entirety of the cited patent is incorporated herewithin, the foregoing sections specifically identified are especially pertinent.
Referring now to FIG. 1, an ice penetrator 1, suitably of a bullet shape, containing a generally cylindrical portion and at its front end a cone shaped portion, is ensheathed or covered by a solid body or shell 3 also of bullet shape, sometimes referred to as a "diving bell", whose inner volume and geometry conforms to the outer geometry of penetrator 1 so as to snugly fit over the ice penetrator with slight clearance and, like a sheath, cover all but the penetrator's bottom end. The penetrator includes a base 2 for attachment to an antenna, not illustrated, as described in the Eninger Patent. Base member 2 is formed of a material that does not react with the lithium and/or lithium sodium alloys, suitably stainless steel, to provide a suitable anchor.
At most the spacing between the sides of the penetrator and the inner cylindrical surface of the shell 3 should be no more than 40 mils in clearance, a slight crack. As is apparent any such crack is exposed to the ambient in the area surrounding the bottom end of the shell as illustrated with some exaggeration in the figure.
The diving bell shell is formed of a material that does not react chemically with the material of the penetrator or with water; it is non-reactive in this context. With a lithium penetrator, one material of that desired characteristic is stainless steel. Aluminum, as example, should not be used for the shell in that instance, since aluminum reacts with lithium. The shell is formed by any suitable known technique, such as by molding and/or forging. The details of such forming processes, however, are known to those skilled in the art and need not be further described.
To assemble, ice penetrator 1 is inserted into the shell, which serves as a receptacle, at the latter's open end. That open end also allows the penetrator to easily be removed for deployment. External packaging, not illustrated, is used to retain the penetrator within the shell in inventory until such time as the penetrator is placed in a buoy tube for deployment.
The assembly is then placed within the cylindrical buoy tube 5, partially illustrated in this figure. As is apparent the protective cover essentially functions like a diving bell. If for any reason water leaks into or floods the buoy tube, the water chemically reacts with the lithium to form hydrogen gas. The hydrogen begins to fill the clearance space within the diving bell. As greater amounts of hydrogen gas is formed, the gas begins to force the water out of the clearance space due to hydrostatic pressure and, eventually, forces all water out of the space. With no water remaining the water and lithium reaction extinguishes. Effectively the protective covering causes the chemical reaction between water and lithium to be self limiting; the reaction starts initially, but soon stops before any explosion occurs.
When the improved thermal ice penetrator of this embodiment is inserted in the buoy tue for deployment, an end cap, 4, is provided at the front end and connected to the diving bell. For deployment, the end cap and diving bell connected to it, are expelled from the buoy tube propelled by compressed carbon dioxide released from an associated carbon dioxide cartridge, which is conventional in these systems and is not illustrated or further described. The penetrator assembly is now free to ascend through the water and into the ice by a force applied by an extendable mast, not shown.
The alternative embodiment of FIG. 2 illustrates in partial view a clam shell arrangement, formed of elements 7 and 9, which encloses ice penetrator 1. In this arrangement two shell portions 7 and 9 matingly fit together along an axially extending edge 8 to define a confining volume or region of a shape and size that corresponds to the outer geometry and size of ice penetrator 1 and, when closed as illustrated in the figure, completely covers all sides of the penetrator, excepting base member 2, with a snug fit to serve as protective housing. In a general sense, the clam shell halves in this embodiment may be obtained by cutting the diving bell embodiment of FIG. 1 along the axis in half and welding a half moon shaped disk of the same material to the bottom end of each half. However instead of the metal, a non-metal is preferred as described hereafter.
The internal clearance between clam shell and penetrator, preferably, is no greater than 20 mils. Moreover the fit between the clam shell halves need not be and is not air or fluid tight, the significance of which becomes more apparent from the discussion of operation, which follows hereinafter. Suitably the shell portions are formed of Nylon material, which is non-reactive to lithium and to like metals in the same column of the periodic table of elements. The nylon gives a lower drag coefficient on contact with the metal of cylindrical buoy tube 5 in which the protected unit is installed and stored pending deployment. A thin strip of spring steel 11, suitably stainless steel, is wrapped halfway around the penetrator and fits between the penetrator and the clamshell halves. As example in one practical embodiment the spring may be one half inch in width, 0.01 inches thick and six inches in length.
As is apparent the clam shell halves are not fastened together by any fastening device or latch to better ensure that the halves easily fall away from the penetrator on deployment. The unit is assembled by hand with the assembler depositing the spring and penetrator in one half and then placing the remaining half in position, manually pushing against the bias of the spring. While so compressing the clam shell halves together the assembler may insert the penetrator assembly within the buoy tube. Since the diameter of the buoy tube's inner cylindrical walls is not much greater than the outer diameter of the penetrator assembly, the buoy tube walls thereby prevent the shell halves from significant separation, awaiting deployment.
Spring 11 exerts a separating force on the two halves of the clam shell, pushing the two portions against the inside surface of the buoy tube. During deployment, the assembly is forced out of the buoy tube and into the water by a force applied to the bottom or rear end by an extendable mast, not illustrated. Upon exiting the buoy tube, the spring forces the clamshell halves to separate and free the ice penetrator, allowing the penetrator to move upwardly and make contact with the overlying ice. The spring will also fall away and sink in the water.
In the unlikely event that buoy tube 5 leaks prior to deployment and water enters the buoy tube prematurely, water would also leak through the mating edges or seam 8 between the clam shell halves and comes into contact with the lithium, with which the water chemically reacts. One of the products of the reaction is lithium hydroxide, LiOH, a solid that is soluable in water, which is in addition to the hydrogen gas discussed in connection with the previous embodiment. Since the two shell halves are fitted together tightly within the buoy tube, the formed lithium hydroxide cannot be easily flushed away and dissolves in the water. As the reaction continues the remaining water that leaked into the clamshell contains greater and greater concentrations of lithium hydroxide. As this occurs the reaction slows down naturally, a phenomenon referred to as Le Chatelier's Principle. Hence the reaction is effectively self limiting; the reaction does not effectively continue and any likelihood of an explosive rapid reaction is avoided. As in the prior embodiment safety is enhanced.
A more practical version of such clam shell arrangement is presented in FIG. 3 to which reference may be made. The exploded perspective view shows clam shell halves 7 and 9, spring 11, penetrator 1, which is partially cut away. Spring 11 is partially wrapped around the cylindrical periphery of penetrator 1. For convenience a groove or indentation 10 may be formed in the inner cylindrical wall of shell half 7 and a like groove or indentation formed in the inner wall of the other shell half to form a seat for spring 11 at a predetermined position along the axis of the cylindrcal portion of the formed clam shell. This assists the assembler in retaining the spring in position when assembling the two clam shell halves together. In this version the bottom end of the clam shell is open. Each clam shell half contains a radially inwardly directed lip or flange portion 12, only one portion being illustrated, that forms a circular rim at the bottom end of the assembly to hold penetrator 1 in position. Penetrator base 2 is attached to a disc 14 which holds the antenna wire 16, partially illustrated. Further a cylindrical antenna sheath 18, illustrated partially cut away, is mounted coaxial with the penetrator and abutts against flange portion 12. The disk and antenna sheath closes the end of the clam shell.
In another alternative form of the protective apparatus, illustrated in FIG. 4, the ice penetrator is completely encased in an air tight fluid tight wrapping. As shown in section penetrator 1 is covered initially by a plastic wrap 15, which is non-reactive with the lithium, and that covering is followed by a layer of wax 17, suitably conventional bee's wax available as yellow bee's wax U.S.P./NF CAS NO. 8012-89-3. Suitably the wrap is a clingable type such as the familiar Saran wrap marketed in grocery stores. Two pairs of elongate strips are included at opposite sides of the penetrator.
In forming the fluid tight assembly, the penetrator is wrapped with the plastic wrapping material from the bottom up, leaving the ends of the strips as extending tabs 19 and 21. Thereafter the assembly is repeatedly dipped into molten bee's wax to build up an overlaying wax layer to the desired thickness, much the same process used to form candles, leaving the tabs uncovered. Each time the assembly is dipped a coating of liquid wax is formed on the surfaces. When withdrawn the coating solidifies. The assembly is again dipped and withdrawn adding more coating. This dipping process is repeated until the desired thickness is reached. As example a coating of one-sixteenth inch in thickness may be built up onto a 0.005 inch thick plastic wrap.
As a consequence the casing is fluid tight and does not permit any water to contact the penetrator, thereby avoiding the possibility of a chemical reaction should the buoy tube be prematurely filled with water. It is appreciated that the components to this alternative embodiment are readily available and are very inexpensive.
As shown in FIG. 4, the tabs are fastened to opposite sides of the buoy tube by a tack weld to the side of the buoy housing, by bonding a ring or bulk head to the housing side and attaching tabs to such ring or bulk head. Upon deployment an expelling force from an extendable mast, not illustrated, is applied to the bottom of the assembly; hence, to the bottom of the penetrator, while the tab ends are restrained by the buoy tube. With sufficient force exerted by an extensible column, not illustrated, in the buoy, the penetrator is forced out of the protective package, and the tabs effectively peel back the wrapping, much akin to peeling a banana.
Although not necessary to an understanding of the invention, an illustration of a buoy tube assembly is provided in FIG. 5. In this view the outline of tube 5 is presented in invisible lines thereby revealing the arrangement of the affordescribed penetrators, particularly the penetrator of FIG. 3, in site. The assembly includes a floatation device 20, penetrator assembly 22, representing the outer view of clam shell halves 7 and 9, an estendable mast 24 and the bottomost electronics section 26. Tube 5 is conveniently sized to fit within a submarine's torpedo tube. As the foregoing are known elements they are not described further.
It is believed that the foregoing description of the preferred embodiments of the invention is sufficient in detail to enable one skilled in the art to make and use the invention. However, it is expressly understood that the details of the elements which are presented for the foregoing enabling purpose are not intended to limit the scope of the invention, in as much as equivalents to those elements and other modifications thereof, all of which come within the scope of the invention, become apparent to those skilled in the art upon reading this specification. Thus the invention is to be broadly construed within the full scope of the appended claims.
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Improved ice penetrator apparatus includes protective apparatus for the thermochemical ice penetrator to prevent an undesired explosive sound producing chemical reaction between water and the material of said ice penetrator, particularly while the penetrator is resident in a buoy tube prior to release. The protective apparatus at least partially covers the thermochemical ice penetrator and forms a unitary assembly therewith. The characteristic of the protective material is such that it is non-reactive to the ice penetrator material, typically lithium and/or a sodium lithium alloy, and to water. The protective apparatus may assume any of a diving bell, clam shell and banana skin structural form.
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FIELD OF THE INVENTION
The invention relates to a method, and to a circular knitting machine, for making tights and similar garments having a body and two tubular legs.
BACKGROUND TO THE INVENTION
A known circular knitting machine has a needle cylinder movable with alternating rotary motion, a system for controlling the needles, and a disc or plate coaxial with the cylinder and movable with it. Such a machine is not capable of producing a plurality of the garments simultaneously, each garment requiring no further process to complete it. It is an object of the invention to permit the making of a plurality of complete garments simultaneously and quickly without any operations additional to the forming of the garments on the machine.
SUMMARY OF THE INVENTION
The invention provides a circular knitting machine for making garments, such as pairs of tights, each garment constituted by a body having a front portion and a rear portion, and by two tubular legs, the machine having a needle cylinder capable of alternating rotational motion, a system for controlling the needles, and a plate coaxial with the cylinder and rotatable with it, characterised in that the needle cylinder has a number of needles, arranged in arcuate groups, at least equal to that which is necessary for making one of the two portions of the body of each of a plurality of the garments; a plate with the same number of needles running along radial channels and formed in the said arcs; said cylinder and said plate being movable with a synchronous alternating angular motion over an angle of arc at least equal to the arc occupied by the group of needles intended to form one half of said front or rear portions; and a plurality of stationary thread guides distributed around the cylinder to supply to the needles of the cylinder and of the plate two threads for each said garment, for forming the two legs and the body of the garment; in that the said control system comprises first axially stationarily positioned control means for the cylinder needles for forming the knitted garment and for the progressive insertion of different numbers of the cylinder needles in different strokes of the cylinder and plate, the first control means facing the needle arcs for each leg, and second axially stationarily positioned control means for the needles of the plate for forming the knitted garment and for the progressive insertion of corresponding different numbers of the plate needles in the said different strokes; the first control means being actuable to form the garment during each stroke in one direction with only the needles of the cylinder, and the second control means being actuable to form the garment during each stroke in the reverse direction with only the needles of the plate, progressively to form with each thread each of the legs and then to form with the two threads the corresponding areas of the front and rear portions of the body.
According to a further aspect, the invention provides a method of production of garments, such as pairs of tights, each garment having a body having a front portion and a rear portion, and two tubular legs, with a knitting machine employing alternating rotary motion of two members holding rows of needles, relative to stationary thread guides, characterised in that with respective threads from the thread guides the toes of a plurality of the garments are started simultaneously, forming rows of knitted loops which increase in length gradually with alternate strokes of the said needleholding members to form toes and contiguous tubular legs; in that pairs of successive rows are knitted by the said member to form right-hand and left-hand portions of the front and the rear of each body portion, using for each garment two threads, with which threads also the legs are formed; and in that the said pairs of successive rows are mutually engaged along a dividing line between the right-hand and left-hand portions.
The invention will be better understood from the following description and with reference to the accompanying schematic drawings, by way of example only, of an embodiment of the invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a garment which can be made according to the invention;
FIGS. 2 and 3 are diagrams of the manner in which the garment is made;
FIG. 4 shows the arcuate groups of needles for the simultaneous formation of four garments; and
FIG. 5 shows a partial vertical section of a machine according to the preferred embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The machine illustrated in FIG. 5 comprises a needle cylinder 1 mounted in traditional manner with bearings of which only the one referenced 3 is shown, to rotate with alternating motion relative to a fixed structure 5. This structure 5 by means of columns 7 and 9 supports an intermediate ring 10 and an upper ring 12, both surrounding the needle cylinder. 14 denotes the needles of the cylinder running in the longitudinal channels of the cylinder. The butts of the needles are controlled by cams and counter-cams, generally denoted by 16 and of known type, carried by the ring 10. 18 denotes oscillating selectors of known type, slidably taken up by the channels of cylinder 1 to control the raising of the needles. These selectors are able to co-operate with output cams 20 when they are not excluded from the action of one of said cams to be pushed back into the bottom of the channel; this selection arrangement is one of the traditionally known arrangements able to be used in the machine under consideration; 22 denotes the cams for lowering the selectors. For selection, selectors 18 have removable teeth upon which pushers or sliding bars 24 are able to act, controllable from time to time with substantially radial movement by a programme drum 26, of a known type, mounted for intermittent angular shifts about an axis parallel to that of cylinder 1; the programme drum 26 has perimetrically longitudinal blades 28 with teeth distributed according to specific programmes, effected by selective removal of teeth from the individual blades. This selection arrangement and the intermittent and timely manner of advance of a drum 26 are well known in the art. Several selection arrangements are disposed around the cylinder.
Coaxially and level with the upper end of the needle cylinder a disc or plate 30 is mounted carried by a shaft 32 to rotate synchronously with the needle cylinder; the shaft 32 is mounted by means of a bearing 34, on a structure 36 which can be moved for convenience of access to the top part of the needles and also for easy access to the disc or plate 30 for maintenance or replacements. In plate 30 there are radial grooves for the movement of needles 38 which can be controlled by cams 39 mounted on an annular structure 40 supported by the structure 36. In said radial channels of the plate there are also oscillating selectors 41 similar to those denoted 18 and actuable by means of cams 42 and pushers or sliding bars 43 (similar to those marked 24) on the controlling action of a programme created in a programme drum 44 mounted to rotate intermittently along a radial axis; said programme drum 44 is mounted on the structure 36 and controlled by intermittent advances in a manner similar to that of drum 26 and thus with systems of conventional type.
The needles 14 and the needles 38 are controlled to form--independently of one another--rows of loops of one and the same garment; needles 14 and needles 38 are designed to take up the thread from one and the same thread guide such as 50. Rows of loops formed by the needles 14 may be followed by rows of loops formed by the same needles or by the needles 38 and viceversa. A thread guide 50 may also be replaceable and selected from several thread guides side by side for changing at the required time the type of yarn during the making of the various areas of the same garment.
The needle cylinder 1 and the disc or plate 30 are simultaneously actuated with an alternating angular motion by means of devices typical of circular knitting machines, particularly those used for hosiery. Differently from hosiery circular machines, the machine under consideration has much greater diametral dimensions, being designed to produce several garments at the same time. In the arrangement diagrammatically represented in FIG. 4 it is provided that a machine of the type described should make four pairs of tights simultaneously, provision being made for an even angular distribution of the garments under formation along the annular zone of operation of needles 14 and 38. The individual garments are made at the peripheral annular zone of operation of the two circles of needles, the cylinder needles 14 and plate needles 38 operating to form rows at the front and rear portions respectively of the garments. In the example according to the diagram in FIG. 4, provision is made for eight arcuate groups of needles G1 . . . G8 both of the cylinder and of the plate. The needles of each arc G1 . . . G8, either of the cylinder or of the plate, are intended for the formation of a different leg of the four garments. The two needle arcs of a pair of contiguous arcs G are separated by a needle arc T1, T3, T5 and T7. The needle arcs G1, T1, G2; G3, T3, G4; G5, T5, G6; G7, T7, G8, form needle arcs, respectively M1, M3, M5, M7 both of the cylinder and of the disc, intended to form the body part of each of the four garments. Arcs M1, M3, M5, M7 are separated by arcs either without needles or with needles which are inoperative in the arrangement illustrated in FIG. 4, intended to form four garments. To feed the needles of each of the arcs G1, G2 . . . G8, provision is made for the relevant thread guide 50. Still facing each of said arcs G1, G2 . . . G8 at least one selection unit is provided, comprising a programme drum 26 and at least one selection unit with a programme drum 44. Again facing each arc G1, G2 . . . G8 cam profiles are provided for raising and lowering both the selectors 18 and 41 and the needles 14 and 38.
Both the needle cylinder 1 and the plate 30 can move in alternating angular motion over an angle limited to the sum of an arc G and of half of arc T (plus the width of the cams operating for lifting and lowering) for the functions indicated hereinunder.
Taking into consideration that a leg must be formed with 400 needles, each of the arcs G comprises a number of needles of the order of 200 in the cylinder and as many in the plate. The arcs T will comprise, e.g. about 40 needles in the cylinder, and as many in the plate; arcs of approximately the same dimensions as arcs T are provided between the needle arcs M1, M3, M5, M7. It follows from this that both the cylinder and the plate will each have about 2000 needles. The diameter of the cylinder and that of the plate will be related to said number of needles (or to the number of needles necessary for the number of garments to be produced simultaneously) and as a function also of the fineness of the needles selected and of the knitted fabrics of the garments to be produced.
An explanation will now be given of the modus operandi for the production of a garment, according especially to FIGS. 1 to 4.
The garment is started from the toes PP, continued to form the legs GG, then the so-called crotch area TT and finally the area of the body MM with the relevant final elastic edge EE.
Having imparted an alternating motion to the cylinder and at the same time to the plate, operations are begun to lift a limited number of needles 14 at the centre of each of the arcs G1 . . . G8 of the cylinder during the movement in one direction of the apparatus 1-30 of cylinder and plate; during the reverse movement the corresponding needles 38 of the plate are caused to project radially in a centrifugal direction, and therefore they "lift". The formation of the toes is continued during alternating strokes of said apparatus, before which strokes the progressive insertion is effected of further needles at the ends of the needle arc already operating, both of the cylinder and of the plate, in substantially symmetrical manner. There are then formed for each of the eight legs rows RC1 between the points A1,B1 with the cylinder needles and rows RC2 between the points B1,A1 with the needles of the plate, the rows being gradually increased as they are developed with successively greater arcs such as the one defined by points A1,B2, until the insertion of all the needles of the arcs G is reached to form rows RC3 between the points A3, B3 and RC4 between the points B3,A3 respectively, with the needles of the cylinder during movement in one direction and with the needles of the plate during movement in the reverse direction. Each leg is then formed starting from the toes PP, the front face formed by the rows produced by the needles 14 of the cylinder and the rear face formed by the rows produced by the needles 38 of the plate; the thread passes alternately from the partial front rows to the rear ones, being presented and fed at the same point by the respective thread guide, as the thread is seized from time to time by the raised needles.
The knitted fabric of the two contiguous legs GG, formed for example by the needle arcs G1 and G2 (the same applies to the arcs G3,G4; G5,G6; G7,G8), after said legs have been completed to the desired length, must be continued to form the body MM. After having formed the end rows RC5 and RC6 between the points A5,B5 and A7,B7, thus completing the length of the legs, the needle selection programme imposes the simultaneous or progressive insertion of the needles of arc T1 comprised between the arcs G1 and G2 both in the cylinder and in the plate; the progressive character of the insertion will take place between the ends of the arc T1 and the centre of said arc T1; RC7 and RC8 denote rows of loops of progressively increasing length formed in the crotch area TT, between points A9,B9 and A10,B10. Having reached the end of the crotch, i.e. point TE in FIG. 1, when all the needles of the arc T1 have been inserted, the formation of the body is begun with a number of needles equal to the sum of the needles of arcs G1, T1, G2 both of cylinder and plate.
For the formation of the body use is made of the two threads fed by two thread guides 50 belonging to the arcs G1 and G2. At each oscillation in the two directions of the cylinder and plate unit two rows of loops are formed, for the right-hand and the left-hand areas respectively of the body MM. With particular reference to FIGS. 2 and 4, starting for example from the extreme outer point E2 of the needle arc G2 there is formed with a thread, and in terms of arcs of fabric being considered as being knit in the direction opposite to the direction of needle cylinder and plate motion, during the swinging in one direction 01 a row of loops RM2 with the needles of the cylinder of the arc G2 between the point E2 and the centre point ME of arc G2,T1,G1; simultaneously there is formed with the other thread a row of loops RM1 with the thread belonging to the needle arc G1 between the point ME and the point E1, still with the needles of the cylinder. The swinging stroke in the direction of the arrow 01 having ended, reversing the movement of the cylinder and of the plate along the arrow 02, a second row RM4 is formed with the needles of the cylinder comprised between the point ME and the point E2, and simultaneously a row of loops RM3 is formed with the needles of the plate between the point E1 and the centre point ME. During a new swing in the direction of arrow 01 a row RM6 is formed with the needles of the plate and with the thread of the arc G2 between point E2 and point ME and simultaneously a row of loops RM5 is formed with the needles of the plate and with the thread of the arc G1 between point ME and point E1. A fourth swing along 02 determines the formation of a row of loops RM8 between the centre point ME and the end E2 with the needles of the plate and a row of loops RM7 between the end E1 and the point ME with the needles of the cylinder.
The alternating motion continues until all the body MM and the elastic edge EE have been formed.
It will be noted that to hook together at points ME the rows of loops RM2,RM4 on the one hand, RM1,RM7 on the other, and RM6,RM8 on the one hand, and RM3, RM5 on the other, respectively, formed by the needles of the cylinder and by the needles of the plate, along the socalled dividing line denoted by CV in FIG. 1 and therefore in the central area of the needle arcs T1, T3, T5 and T7, both of the cylinder and of the plate, at least one needle or a limited group of needles (of the cylinder and of the plate) are controlled to engage the two threads which are fed facing the needle arcs such as G1 and G2. This or these needles can form loops on every occasion, or also engage the thread and hold the loop to form loops only once with both threads.
The selections of the needles to obtain the insertions during the formation of the toes PP, the insertions during the formation of the area TT of the crotch and to determine the lifting and lowering at the proper time of the needles of one and the other front members to form the respective rows, are conveniently obtained through the two selection programmes supplied by drums 26 and 44 respectively. It is obvious that when the cylinder needles are operating along an arc, those of the plate cannot operate, and vice-versa. The spaces without needles between the arcs M1, M3, M5, M7 during the formation of the body, and the arcs with needles which are inoperative such as T1, T3, T5, T7 during the formation of the legs, ensure that the fabric of the various rows can be properly made, even though the amplitude of the alternating angular travel of the cylinder and plate assembly is greater than the amplitude of the row of loops to be made. Even when rows of contiguous loops are formed simultaneously with the needles of the same rotary member (i.e. the cylinder or plate) and with two contiguous thread guides, as in forming the body, the formation of the loops of the two rows always takes place instantaneously in different areas of the periphery of the machine.
It is possible to provide for the simultaneous formation of more or fewer than four garments on the same machine, and it is also possible to provide for the simultaneous insertion of two needles or of all the needles in arcs T1, T3, T5, T7. It is further possible to provide for the formation of the toes with extensions suitably established adjacent the toes PP, after first lifting all the needles of the arcs G.
The machine can also make garments other than tights.
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A circular knitting machine for simultaneously making several pairs of tights and the like, with two tubular legs and a body portion having a front and a back, comprises a movable unit carrying a cylinder with a circle of cylinder needles and a plate carrying an adjacent circle of plate needles. The movable unit moves with alternating rotary movement relative to several thread guides disposed around the circles of needles. In order to make several garments simultaneously, the circles are divided into as many arcuate groups of needles as there are garments. Each arcuate group is divided into two equal sub-groups separated by a middle group. The needles of each group are automatically brought into operation in a sequence to knit the toes and legs (on the sub-groups), then the crotch (using the middle group as well), then the body (still using two threads, one for the left-hand and one for the linked right-hand side).
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority from PCT application no. PCT/EP2005/000705, filed Jan. 25, 2005, which is based on German Application No. 102004005954.3, which was filed Feb. 2, 2004, of which the contents of both are hereby incorporated by reference.
FIELD OF APPLICATION AND PRIOR ART
The invention relates to an operating device for an electrical appliance, preferably a domestic appliance, as well as a method for evaluating or operating such an operating device.
BACKGROUND INFORMATION
It is known from the prior art of DE-A-19645678 or DE-A-19811372, to provide an operating panel for an electrical appliance or domestic appliance under which at a specific application forming a so-called operating field is provided a pressure-sensitive piezoelectric element. If a pressure is exerted on the cover, which can be made from thin high-grade steel or aluminium for example, said pressing action through the piezoelectric element can be evaluated as a desired operation. An associated evaluation or control gives a signal to the electrical appliance. It is considered disadvantageous that the use of piezoelectric elements give rise to certain disadvantages, particularly because they are in part mechanically fault-prone and cannot be easily installed in an appliance. It is also frequently necessary to use special manufactures or components for piezoelectric elements, which negatively influences expenditure, particularly costs and short-term availability. The use of other sensor elements, such as capacitive or optical sensor elements, suffers from the disadvantage that they can only be used behind metallic operating panels at present at a high cost or not at all or an optical transparency is vital for an optical system.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter relative to embodiments and the attached diagrammatic drawings, wherein show:
FIG. 1 illustrates a section through an operating device according to the invention, two different materials for the operating fields being shown;
FIG. 2 illustrates a graph of the signal voltage over time during an operating process;
FIG. 3 illustrates an oblique view of a hob, where an operating device according to FIG. 1 is integrated into the frame; and
FIG. 4 illustrates another embodiment.
DETAILED DESCRIPTION
The problem solved by the invention is to provide such an operating device and method similar to the aforementioned types in such a way as to avoid the disadvantages of the prior art and in particular to permit the use of an operating device which can be constructed from standard components, as much as possible, with limited manufacturing expenditure.
This problem is solved by an operating device and methods as disclosed and claimed herein. Advantageous and preferred developments of the invention form the subject matter of the further claims and are explained in greater detail hereinafter. By express reference the wording of the claims is incorporated into the description.
According to one embodiment of the invention, the pressure-sensitive sensor element is constituted by an electret microphone capsule, which is advantageously a standard component. The electret microphone is relatively limited in size and, in particular, has a relatively small thickness. This electret microphone capsule converts the movement of the operating field which is transmitted to the capsule into an electrical signal. This can be evaluated as an operation (e.g., on or off indication provided by user) and it is possible to provide certain signal thresholds, as will be explained in greater detail hereinafter.
This makes it possible to use a conventionally used component, particularly a standard component as the pressure-sensitive sensor element. Such microphone capsules have the advantage of a high sensitivity. Even a relatively limited operating movement on the diaphragm, which conventionally evaluates sound pressure or waves, is sufficient for a reliable detection or differentiation. In addition, such standard components are obtainable in a completely connected and wired manner, which simplifies use and assembly and/or connection.
It is possible for the operating field to be part of a cover or panel, which can extend over a larger (and in some embodiments, a particular much larger area) of the electrical appliance. The cover can be contained in a frame of a hob (e.g. cooktop, heating element or stove), for example. In one embodiment, the operating field, cover, or panel is advantageously closed and has no interruptions. In particular, it is smooth or planar on the outside. As a result of such a closed construction, it is possible to provide an attractive design and a resistance to water or the like.
It is advantageous if the operating field (e.g., the area of operation of the corresponding cover or panel) is elastic in nature, or thinner in an area over the sensor element than it is elsewhere. In the case of an otherwise relatively thick cover or panel intended to offer mechanical strength and to avoid sagging, the cover can be pressed upon by the user in the vicinity of the operating field or at the sensor elements. Such thinner constructions can be made by providing a localized recess, or thinning the cover on the inside or back.
One possibility for the construction of an operating field or a panel or cover is to make it electrically conductive and/or from thin metal. It is possible to use metal sheets, which in particular, due to their resistance to mechanical effects and ability to withstand dirt, can be used with advantage. A preferred material is high-grade steel or aluminium for example.
According to a further embodiment of the invention, the sensor element is connected to or coupled to the operating field or cover by means of an advantageously elastic coupling element. A direct, physically complete coupling can be provided using a coupling element and advantageously leads to the underside of the operating cover or rear surface. Elasticity can be provided as a protection for the sensor element or the entire operating device in such a way that with a standard, prescribed operating force the coupling element is not, or is scarcely, compressed, i.e. essentially retains its shape and, in particular, effective length. Only when the operating force rises to such an extent that it far exceeds the standard, prescribed force, for example by a factor of 2 to 4 or higher than normal, is it possible to press in, or shorten, the coupling element. This prevents the user from over-pressing and potentially damaging or destroying the sensor element.
Numerous elastic components can be used as the coupling element. Preferably an elastomer is used and can be directly connected to the electret microphone capsule diaphragm.
According to another embodiment of the invention, a support can be provided below the operating field and the electret microphone capsule is placed thereon and is advantageously supported with respect to the operating field in such a way that although an operating force acts on the microphone capsule it does not cause sagging or deformation of the support. The support is advantageously a printed circuit board. Electrical contacts or leads provided for the control or evaluation can be placed thereon. In the case of a circuit board, they are advantageously constituted by corresponding conducting tracks. The support or circuit board can have a control circuit, or the like, provided for the microphone capsule and, for example, the complete electrical appliance.
In another embodiment of the invention, several operating fields or areas on the cover are provided for different functions or separate functional units of the electrical appliance instead of a single operating field on the operating device. These operating fields are preferably arranged groupwise, or in juxtaposed manner in an operating area, which can be correspondingly designed for special marking or identification. In one preferred embodiment, a one-piece, continuous cover is provided in which the operating fields are located or which inter alia form the operating area. This offers the advantage that manufacturing costs are kept lower and it can in particular be ensured that the cover is water-proof, etc. It is also advantageously possible to construct such a cover as a part which is separate and easily removable from the microphone capsules. This means that one or more electret microphone capsules, together with the control and evaluation, can be built upon such a support. A cover can then be placed thereon. In other embodiments, variants of the cover can be differently designed, as a function of the design requirements of different manufacturers or the intended use. This is particularly advantageous with metal or similar covers.
It is alternatively possible to fix an electret microphone capsule to the actual cover or form a type of module therefrom. The side with the diaphragm on which the operating pressure is to act can then be provided on the side directed away from the cover. Thus, the microphone capsule is pressed against a support or the like during operation. However, the fitting of the microphone capsule to the cover generally gives rise to increased connection costs in manufacturing for the electret microphone capsules. Prefabrication with a finished connection to a control or evaluation is no longer possible, and is only possible if the control or evaluation is located on the cover.
Advantageous, exemplified dimensions ensure that the operating field is only pressed in or deflected by a small amount for operation or detection by the electret microphone capsule. The deflection can be a maximum of 100 μm, and advantageously 1 μm to 10 μm. The resulting signal initiated at the microphone capsule can be examined for a type of threshold or signal value. Only on reaching or exceeding this signal is the signal looked upon as a desired, prescribed operation, which then leads to a corresponding initiation of the operating process for the appliance. Such an operating path or deflection is virtually undetectable by a user, which can be a desired feature, because the operating behaviour is then the same as with optical or capacitive contact switches for example, but without it being necessary to accept the aforementioned disadvantages thereof. The prescribed or intended operating force can be a few Newtons for example, which can lead to the aforementioned deflection in the case of a correspondingly constructed cover or operating field.
In a prescribed method for the evaluation of the operating device by pressure action on the operating area resulting from the user pressing the operating field, the electret microphone capsule or its diaphragm is deflected, and is reset following release. This process initiates signals, or forms a signal pattern, characteristic of the fundamental pattern. These signals or the signal pattern are then evaluated as an operation (e.g., a user activating or deactivating the control) if the signal is within the prescribed limits. In a simple variation, it is possible to evaluate the signal as an activation after the signal has reached the maximum necessary value by pressing or deflecting the cover, so that the signal is above the threshold for a certain time, for example more than half or one second.
In another construction, which in particular gives a different operating behaviour and a more reliable operation, the resetting signal can be awaited. In particular, there must be a certain time interval between the signal caused by the user pressing the cover and the resetting signal. This should be less than 5 seconds, advantageously less than 2 seconds. This means that if a user presses on the operating field for a desired operation and instinctively, or in accordance with practice, immediately or shortly thereafter releases the same, this is evaluated as an operating process. However, if the user accidentally places a heavier object on the user operating area of a cooktop, such as a saucepan, where the object remains there for a longer time period thereon, this is detected and no operation is evaluated.
Advantageously, the operating device and method is used for an electrical domestic appliance such as a hob, e.g., cooktop or other similar appliances such as washing machines, dryers, rinsing machines and microwaves.
These and further features of the preferred developments of the invention can be gathered from the claims, description and drawings and the individual features, both singly or in the form of subcombinations, can be implemented in an embodiment of the invention and in other fields and can represent advantageous, independently protectable constructions for which protection is claimed here. The subdivision of the application into individual sections and the subheadings in no way restrict the general validity of the statements made thereunder.
Turning now to the figures, FIG. 1 shows in section an operating device 11 , which is intended for a cooktop having a flat cover for example. An operating field 13 is provided in a plate or cover, which is shown in the left-hand area as a glass ceramic plate 14 a . The right-hand area illustrates the extent to which it can also be a metal plate 14 b . Beneath the operating field 13 is formed a thinner area of the cover 15 , which essentially coincides with the extent of the operating field. Inscriptions or the like can be provided as markings on the top surface of the cover. In addition, the thinner area 15 on the top of the operating field 13 can face the user and consequently has a guidance function for the latter (e.g., where the user can place their finger for operating the appliance). It is shown how a finger 17 of a user is placed on the operating field 13 . If a certain operating pressure is exerted, as described hereinbefore, the cover 14 in the thinner area 15 or operating field 13 deflects. This is illustrated by a downwardly curved broken line.
An electret microphone capsule 21 is placed on a support 19 beneath plate 14 and the operating field 13 . The microphone capsule 21 comprises a housing 23 , which in the manner shown contains the diaphragm 25 . The microphone capsule 21 or diaphragm 25 is coupled to the underside of the thin area 15 by direct application by means of an elastomer part 27 , which can be cylindrical for example. Thus, a movement of the thinner area 15 is directly transmitted to the diaphragm 25 . Moreover, the microphone capsule 21 has an electrical connection or lead 29 to the outside. If the support 19 is constructed as a printed circuit board, the electrical connection or lead 29 can also be in the form of printed-on conducting paths.
Elastomer part 27 projects through an opening in the top of housing 23 . This opening can also provide a certain guidance for elastomer part 27 , but its mobility should not be restricted.
The thinner area 15 can advantageously be provided in cover 14 , but is not required. This is more particularly dependent on the choice of material for operating field 13 or cover 14 . If, as shown, the materials are relatively rigid or strong, such as metal 14 b or glass ceramic 14 a , it is advantageous, because this can bring about a certain deflection with the intended operating pressure.
FIG. 3 shows a cooktop 31 , using so-called glass ceramic hobs. In conventional manner it has an all-round hob frame 33 , which on the left-hand, lower side is constructed as a front surface directed towards a user. The frame 33 has various operating fields 13 , namely to the far left an ON-OFF switch and in the central area switches for the power adjustment of the individual hotplates 35 and which are diagrammatically illustrated in circular form. In each case, the associated function can be initiated by pressure on the operating fields 13 . From the construction standpoint, under the hob frame 33 is provided an operating device similar to that of FIG. 1 . The surface of the hob frame 33 or the latter can be formed from a metal coating, plate or foil corresponding to the cover 14 of FIG. 1 . Beneath the operating fields 13 , there is the microphone capsule according to FIG. 1 , and the remaining area of the hob frame 33 the metal can be solidly lined (e.g., of regular thickness).
Alternatively, the hob frame can be made from a possibly several mm thick flat material, which can be metallic or have some other construction. The matter may have its thickness reduced from below, in the vicinity of the operating fields 13 or an associated operating device, in such a way that in said thinned areas the microphone capsule 21 of FIG. 1 can be housed. As an alternative to a thinning out of a thicker metal layer from below, the thinning of the material can also take place from above. In this case, a resulting depression could be used as structuring for a precise application of a finger or the like.
Another embodiment is illustrated in FIG. 4 . In FIG. 4 , wherein a glass ceramic plate 114 a (or metal place 114 b ) is shown with an operating field 113 , which is contacted by a user's finger 117 . The operating device 111 comprises a circuit board 131 , a microphone capsule 121 comprising a housing 123 , two diaphragms 125 a , 125 b and wire lead 129 . In this embodiment, the printed circuit board 131 is positioned up against the plate 114 , and there is no elastomeric component as is shown in FIG. 1 . When the user's finger presses on the operating field 113 , a deflection 127 occurs.
Function
Through the application of the finger 17 to operating field 13 whilst exerting a certain pressure falling within the range indicated hereinbefore, the operating field 13 or thinner area 15 is deflected downwards. The deflection can be a few μm, for example 2 μm to 10 μm with an operating force of approximately 2 Newtons. The electret microphone capsule converts this small movement into an electrical signal, as is shown in exemplified manner in FIG. 2 .
In the present invention, the microphone capsule 21 is not used for producing an electrical signal as the result of transforming sound pressure into a movement. Instead a mechanical movement, which takes place by the coupling using elastomer part 27 to the underside of the operating field 13 , is directly converted into an electrical signal. Elastomer 27 serves to compensate mechanical tolerances in connection with the spacing between diaphragm 25 and the underside of operating field 13 . It can also provide a type of overpressure protection, as explained hereinbefore.
The graph of FIG. 2 shows how the signal voltage U of microphone capsule 21 changes over time during operation. At time t D the finger 17 is placed on the operating field 13 and presses the location, which leads to the portion 50 in the negative area. At time t L finger 17 is removed, so that the thinner area 15 or operating field 13 moves upwards again into the original position and in the same way diaphragm 25 can again move upwards. There is consequently a change of the signal curve to the positive area 51 and then it finally tilts over again so as to pass to the original, low voltage value.
The desired operation (e.g., activating the function or control by the user) can be concluded from this typical curve pattern for an operating process. As a function of the desired use or evaluating method for the operation, either the pressing action, or the release, can be looked upon as the desired operating indication. If a particularly rapid reaction to an operating process is desired, then upon pressing, i.e. during the drop of the signal curve, an operating process can be detected as such and a function initiated as from a specific value, which corresponds to a specific operating path. However, if certain undesired or faulty actuations, for example through the application of objects or an unintentional wiping over an operating field are to be excluded, then it is recommended that the release time be awaited. This must be in a given time window with respect to the pressing time, for example approximately 1 second. These different methods can be deposited or filed in an associated evaluation or control circuitry and performed in this way.
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An operating device for an electrical appliance, for example a cooking appliance, is provided with a deformable metallic control panel, underneath which an electret microphone cartridge is disposed. The membrane of the microphone cartridge can be coupled to the lower side of the control panel by means of an elastomer. When pressure is exerted on the control panel by a user pressing on the operating field and causing it to deflect, the membrane of the electret microphone is moved, which in turn causes movement in the microphone and causes a signal that can be evaluated as the operating input by a user.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 09/398,617 filed Sep. 17, 1999, U.S. Pat. No. 6,198,897
BACKGROUND OF THE INVENTION
In color printers a plurality of color planes are sequentially aligned and deposited onto a transfer media such as a transfer belt. The transfer belt is then used to transfer the accumulated color planes to a piece of paper or other media. A problem associated with this process is misregistration or misalignment of one or more of the color planes. Alignment of the color planes and optimization of the transfer is crucial in achieving a high quality image. Due to the fact that each individual color plane is transferred onto the belt or paper at different locations along the travel path of the transfer belt, variations of the transfer quality and positioning of the belt within the travel path must be compensated for with a high degree of precision.
There are many instances where position variations and transfer quality variations can develop and cause a concomitant degradation in the resulting image. Factors such as variations in the width of the belt, the belt tension, and the belt resistivity are examples of factors that lead to transfer quality and belt position variations. It would be desirable to have a method and apparatus that compensates for variations within a printer which is inexpensive to implement and does not add complexity to the printer.
BRIEF SUMMARY OF THE INVENTION
A method and apparatus for providing transfer quality optimization in printers is disclosed. A transfer belt subassembly includes a transfer belt and a storage device. The transfer belt also includes a home position indicator. The transfer belt subassembly is measured and characterized relative to the home position indicator before being installed in a printer. The measurement and calibration data for the transfer belt is then stored in the storage device that is part of the transfer belt subassembly. When the transfer belt subassembly is inserted into a printer, a controller within the printer is placed in communication with the storage device. A sensor is used to determine the home position of the transfer belt from the indicator, and a resulting signal indicating when the belt is at the home position is provided to the controller. The controller utilizes the measurement and calibration data from the storage device to provide correction with respect to each color station of the color printer, taking into account and compensating for variations in the transfer belt subassembly. In such a manner, the measurement and calibration data is predetermined before the transfer belt subassembly is inserted into the printer, thereby simplifying the printer composition. By use of the calibration and measurement data, precise alignment of the color planes with respect to one another is achieved, and the proper electrical transfer setting suited to that belt is obtained for improving transfer quality.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The invention will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a diagram illustrating the apparatus of the present invention wherein the image is accumulated on an intermediate transfer member (ITM).
FIG. 2 is a diagram illustrating the apparatus of the present invention wherein the image is accumulated on a print medium.
FIG. 3 shows a typical transfer operating characteristic curve that can be included in the ITM memory.
FIG. 4 is an example of a graphical representation of the transfer characteristics for 4 colors at the 1 st transfer stations.
FIG. 5 is an example of a graphical representation of the transfer characteristics for 2 media at the 2 nd transfer station.
FIG. 6 is a flow chart illustrating the method of the present invention.
FIG. 7 . is a diagram illustrating the apparatus of the present invention wherein the image is accumulated on a print medium using “plate-like” transfer members.
DETAILED DESCRIPTION OF THE INVENTION
Color printers typically utilize a transfer belt assembly to accumulate an image from a plurality of color planes. The color planes are placed onto the belt in succession as the transfer belt passes by the photoconductive (PC) drum associated with each color station. Once the belt has traversed all of the PC drums a resulting image, which will later be transferred to a print medium, is provided on the transfer belt. Alternatively, the transfer belt is used to transport a piece of print medium, such as paper, card stock, or transparencies, and the color planes are deposited directly onto the print medium as the medium passes by the PC drums of each color station.
Referring to FIG. 1, a preferred embodiment of an apparatus 10 for compensating for transfer belt positioning variations, transfer quality variations, belt resistivity and transfer roll resistivities, which may vary from subassembly to subassembly, is shown. While the preferred embodiment refers to a printer, it should be appreciated that the present invention relates to any image forming apparatus. The apparatus 10 includes a transfer belt subassembly 15 , a controller 90 and color stations 42 - 45 . Each color station pertains to a different color plane. In this embodiment color station 42 is utilized for providing a yellow (Y) color plane, color station 43 for providing a cyan (C) color plane, color station 44 for providing a magenta (M) color plane and color station 45 for providing a black (K) color plane. Other embodiments may have different numbers (one or more) of color stations.
Each of the color stations includes a print head 30 , a developer assembly 32 and a PC drum 34 . (This detail is shown only for color station 42 .) The print head 30 forms a latent image on the PC drum 34 . Toner (not shown) is supplied to the PC drum via developer assembly 32 to produce a developed toned image, also known as a color plane, from the latent image on the PC drum. Each color station may be realized through any one of a plurality of prior art configurations of these elements.
The transfer belt subassembly 15 contains a transfer belt 20 , one or more home position sensors ( 70 and 71 ), a memory device 80 and a plurality of rollers. As shown in FIGS. 1 and 2, the transfer belt is disposed about, or adjacent to, said rollers. The plurality of rollers include an end roller 41 (also referred to as a tension roller), a drive roller 40 , a first transfer roller 50 , a second transfer roller 51 , a third transfer roller 52 , and a fourth transfer roller 53 . (Note: A transfer roller is one category of a transfer member, discussed further hereafter.) The accumulated image is then transferred to a print medium (not shown) by transfer roller 55 , which is adjacent to said transfer belt. Depending upon the embodiment, other rollers may be useful or necessary. It should be appreciated that other embodiments not including transfer rollers may also be utilized. Referring to FIG. 2, a second embodiment of an apparatus 11 for providing transfer belt correction is shown. The apparatus 11 is similar to the apparatus disclosed in FIG. 1, except that the color planes are directly deposited onto a print medium disposed upon and transported by the transfer belt.
In the simplified embodiment of FIG. 2, the transfer belt 20 surrounds and traverses an ellipsoidal path defined by rollers 40 and 41 . The transfer belt 20 also includes a home position indicator 75 that is useful for accurately identifying a specific position of the transfer belt 20 with respect to the transfer belt subassembly 15 . The home position indicator 75 of the transfer belt 20 provides a reference point for the measurement and calibration data. The indicator 75 may be realized as a hole punched in the transfer belt 20 or as indicia printed or painted on the belt. The indicator 75 may also be realized as a magnetic or an electrostatic device. While the home position sensor 70 is shown as part of the subassembly 15 in this embodiment, the home position sensor 70 could also be located external to the subassembly 15 . The home position sensor 70 must be able to detect the presence of the home position indicator 75 . Thus, when the home position indicator 75 comprises a hole punched in the transfer belt 20 , an optical sensor may be used to detect the presence of the hole. When painted or printed indicia are used to indicate the home position a reader must be used to sense the presence of the indicia. Similarly, when a magnetic or electrostatic device is used as the home position indicator a sensor sensitive to the magnetic or electrostatic device is used to determine the presence of the home position indicator 75 .
Roller 40 is used as a drive roller and is in mechanical communication with a drive motor 60 . Roller 40 thus provides for movement of the transfer belt 20 through the belt path.
Alignment of the color planes on the transfer belt is crucial for providing a high quality resulting image. There are a number of factors that affect the alignment of the color planes on the transfer belt. For example, there may be variations in the thickness or width of the belt as well as variations in the tension of the belt along the belt path. In the second embodiment, the print medium may move with respect to the transfer belt. In addition, both the mechanical and the electrical parameters of belts may vary around the belt circumference and on average between subassemblies.
The object of this invention is to provide an intermediate transfer member (ITM) subassembly for a color EP printer that functions as a modular subassembly in which characterization data critical to function is measured at time of manufacture and stored in a memory device affixed to the ITM subassembly. Characterization data includes belt resistivity range for transfer current/voltage adjustment; transfer roll resistivity; surface velocity profile for drive velocity correction (primarily due to belt thickness variation); and belt tracking profile for correction of image position perpendicular to the direction of belt travel. The characterization data is accessible to the machine into which the ITM subassembly is installed, enabling the machine microcontroller to provide proper operating points for transfer quality, feed-forward velocity control for process direction registration of color planes, and imaging start of scan delays for scan direction registration of color planes. Additional information stored at time of manufacture may include: a) date of manufacture of component parts, b) source of component parts, c) diameters of drive and idler rolls, d) belt length, e) belt tension, f) drive motor initialization values, g) allowable lifetime in cycles, and h) EC level. A unique serial number or bit pattern is recorded in the memory either as received from the memory component supplier or at time of manufacture for identification and possible lockout of unauthorized subassemblies. The information stored at time of manufacture is write protected against later, unauthorized modification. Data is stored in a form readily accessible to the machine controller—in a tabular format.
Remaining memory is allocated for use while the ITM subassembly is installed in the color EP machine. The machine writes number of cycles of use into the memory so that overall usage of the subassembly can be tracked. The machine displays an end of life warning and may force an end-of-life lockout based upon this recorded cycle count. Life is recorded in the preferred embodiment by burning bits in a sequence of memory locations—in which each bit represents nominally 1000 cycles and total life is 255K cycles, thus consuming 255 bits of memory plus a lockout bit. Page count and job count may be similarly recorded as other ways of accessing subassembly life.
As described above, this invention serves multiple functions, as exemplified by the function of the Memory device affixed to ITM subassembly: (See 80 in FIG. 1.)
a) Stores serial number and bit pattern enabling the machine to recognize an authorized unit and to lock out an unauthorized unit.
b) Stores information about the ITM subassembly used by the machine for control.
i) OEM ID
ii) ITM subassembly EC Level
iii) Belt length in zones for velocity control
iv) Belt length in zones for start of imaging control
v) Belt cycle end-of-life limit
vi) Belt pages end-of-life limit
vii) Belt job count end-of-life limit
viii) Belt DC time between sensors vs. temperature relationship
ix) Time between sensors for 108.21 mm/sec at 30° C. with AC feed-forward
x) Time between sensors for 108.21 mm/sec at 30° C. without AC feed-forward
xi) Function enable: 1) cycle lockout, 2) page lockout, 3) job lock-out, 4) DC velocity correction enable, 5) AC velocity feed-forward enable, 6) start of scan delay feed-forward enable, 7) transfer offset enable.
c) Stores details of components which comprise the ITM subassembly. This is of an information nature; and not used by the machine for control purposes.
i) Date of manufacture of ITM subassembly
ii) Date of manufacture of component parts
iii) Source of component parts
iv) Diameters of drive and idler rolls
v) Belt length
vi) Belt tension
d) The preferred memory, the DS 1985, has a write protection feature to protect data written at time of manufacture against unauthorized modification.
e) Has memory allocated for use while the ITM subassembly is operated in the associated color EP machine to track life cycles, pages and jobs. Here, cycles can be recorded by burning one bit for every 1000 cycles, consuming 255 bits of memory to tally 255K cycles, with one bit remaining as a lockout bit. Pages and jobs are tallied in the same way.
f) Has an end-of-life lockout feature to prevent further operation once cycles, pages, or jobs, or a combination thereof, has exceeded an allowable criterion.
g) Stores transfer operating point data either as a modification to the setpoint (preferred) or as a complete setpoint table to provide best print quality when the ITM assembly is operated in the associated color EP machine.
h) Stores process direction velocity characterization data in a format that allows the machine microcontroller to correct velocity errors that affect color plane registration in the process direction.
i) Stores lateral or “scan direction” (perpendicular to process direction) belt tracking characterization data in a format that allows the machine microcontroller to correct for tracking errors that affect registration of color planes in the scan direction relative to black.
In order to compensate for variations in the belt the transfer belt subassembly 15 is measured and characterized in a special test fixture at the time the subassembly 15 is manufactured. The data that reflects the measured and characterized transfer belt subassembly 15 is stored in a storage device (also called an integrated circuit) 80 , which is part of the belt subassembly 15 . The storage device 80 may be a semiconductor memory such as a DS1985 non-volatile and one-time programmable 16K bit memory available from Dallas Semiconductor Corp. of Dallas, Tex. The stored data is also referred to as calibration data.
Other non-volatile memories that can be used include the Dallas Semiconductor DS1982, 1K bit Add-Only memory that can be used only if a subset of the disclosed functions are implemented and memory is conservatively managed. Larger memory devices and conventional EPROMS, EEPROM and NVRAM memories with read/write capabilities can be used with loss of write protection at time of manufacture and possible (unauthorized) resetting of the subassembly life-tracking bits.
In a first embodiment, the system includes four imaging stations. The system may also include a transfer station for transferring the image from the belt to a print medium. The term transfer station is used here to define both (1) the location where the black or color belts transfer images to the transfer belt (sometimes referred to hereafter as first transfer stations) and (2) the location where the image is transferred from the transfer belt to the print medium (sometimes referred to hereafter as the second transfer station). Each imaging station includes an image bearing member, which may be a photoconductive (PC) drum, an optical source such as a laser assembly operative to produce latent images on the image bearing member, a toner source, and a developing member operative to produce developed toned images from the latent image on the image bearing member. An electrically biased first transfer member is associated with each imaging station. The transfer members, which are disposed adjacent to each image bearing member, are operative in conjunction with the image bearing member upon application of the appropriate voltages to transfer toner from the image bearing member to a substrate passing through the nip between the image bearing member and the transfer member. Servo operations are used to set the operating voltages on each of the transfer members at first transfer. Variations in first transfer members include, but are not limited to, (1) transfer rolls and (2) “plate-like” transfer members that have rubbing contact rather than rolling contact at the first transfer stations. Transfer rolls typically comprise a supporting steel shaft 6 to 8 mm in diameter with a 3 to 6 mm thick layer of resistive urethane or EPDM foam that is molded or bonded with an electrically conductive path to the supporting shaft. Foam resistivity is typically 10 6 to 10 10 ohm-cm and foam durometer is typically 25 to 80 Shore 00. Other shaft materials and foam materials and thicknesses are also possible. Plate-like transfer members ( 150 , 151 , 152 , 153 of FIG. 7 ) that may be used in place of rollers at first transfer include resistive urethane blades and resistive fiber brushes which have a stiffness sufficient to press the transfer belt into contact with the photoconductor drum with a force in the range of 10 to 100 g/cm. Material resistivity is chosen to produce a voltage drop of 1 to 400 volts through the plate-like member when a current of 0.5 uA/cm is passed through the plate-like transfer member.
In operation, to transfer toner from the PC drum 34 to the transfer belt 20 at the first transfer assembly, the rotating PC drum surface is charged by a charging assembly. Portions of the drum surface are selectively discharged by the optical energy from a laser, LED array, or the like. Toner is transferred to the drum as determined by the pattern of charge on the drum and as developed by a developing assembly. The developed toner is then transferred to the transfer belt 20 at the nip between the PC drum 34 and the transfer roller 50 . To effect the movement of the toner to the ITM belt, a high voltage power supply 68 (not shown) is electrically connected to each transfer roller shaft to apply a voltage to the transfer roller opposite in polarity to the charge on the toner. Alternatively, the high voltage power supply can be in the form of (1) a plurality of power supplies, one being for each transfer roll or (2) a single high voltage power supply shared among the first transfer rolls. There may be an independent high voltage power supply for the second transfer roll, said power supply possibly having a larger voltage range to handle a wide variety of media. Another alternative could be the combining of the power supply for the second transfer roll with that of one or more of the first transfer rolls (e.g., the black color roll). Other combinations are also possible. Preferably, there is an independent power supply for the second transfer roll. To aid in the transfer of the toner, a velocity difference between the PC drum and the ITM belt is optionally utilized to agitate the toner and improve the transfer efficiency. The velocity difference is between −2.5% and +2.5%, but is nominally 0% in the preferred embodiment. Any suitable controller 90 controls all operations.
The transfer belt 20 is nominally neutral in charge as it enters the first color PC/transfer roller nip. However, it may have a tribo-electrically generated charge from the feed process or a slight residual charge remaining from a previous revolution. Charged areas on the PC drum are at nominally −1000 V and discharged (toner-covered) areas at nominally −340 V. The PC drum core is at −200 V.
When the leading edge of the PC image arrives at the nip between the PC drum 34 and the transfer roller 50 , the transfer “image” voltage is applied to the transfer roller shaft. Immediately prior to the end of the PC image exiting the nip, the transfer “inter-image” voltage is applied to the transfer roller shaft. This timing applies the transfer “image” voltage only to the image areas of the PC drum. Non-imaged areas see only the “inter-image” transfer voltage that is set to minimize toner transfer and to avoid excess current flow.
The transfer operating points are defined for each transfer of the image to and from the belt. The transfer operating points include the transfer voltage and current limits. The operating points may be changed to reflect differences in the belt resistivity in order to produce an optimal image. The printer includes a setting for low, normal, and high modes. The characterization data also includes a low, normal and high mode. The following table reflects the setting achieved by the mode selected in the printer in conjunction with the mode stored as part of the characterization data.
Transfer Setting
Memory device
Machine mode
01 = low
00 = normal
10 = high
Low
Low
Low
Normal
Normal
Low
Normal
High
High
Normal
High
High
Thus, if the machine is set to low mode, and the characterization data from memory device indicates a 01 for low, the operating points will be set to their low values. If the memory device indicated a 00 for a normal setting while the machine is in the low mode, the operating points would again be set low. However, if the machine was set to low mode and the memory device indicates a 10 for high, the operating points would be changed to their normal setting. Accordingly, the mode of the machine may be further adjusted by taking into account the appropriate characterization data pertaining to the transfer station.
As an alternative to storing a value that selects from among a plurality of transfer modes stored in the printer, the transfer operating characteristic for a particular transfer belt can optionally be stored in the memory device in a form that completely describes the transfer characteristic for that belt.
In another embodiment, which consumes substantially more memory in the ITM, a complete set of transfer tables are contained in the ITM memory and made available to the machine controller. In contrast to the first embodiment that stores a low, normal, or high selection value that is used to select operating modes or offsets from tables stored in machine memory, the second embodiment stores the actual transfer control tables in the ITM memory. This second embodiment provides for significant differences in ITM transfer performance that can arise from multiple causes, including 1) change in ITM belt materials or supplier, 2) change in first transfer roll material, or 3) replacement of the first transfer rollers with lower-cost plate-like transfer members. Transfer operating data can also be provided in the form of an algorithm.
The machine that associates with the ITM module and attached memory uses a transfer servo process to compensate for shifts in the electrical properties of transfer rolls at 1 st and 2 nd transfer, the ITM belt, and the photoconductor drum coatings. Changes in the electrical properties of these elements arise as a result of temperature and humidity changes, mechanical wear, and electrical fatigue. To maintain high transfer efficiencies and good print quality, the transfer roll operating voltage needs to be adjusted to compensate for these changes. The process of determining the operating voltages at 1 st and 2 nd transfer is termed a servo process. A servo voltage is determined for each transfer roll as that voltage on the transfer roll shaft which delivers a fixed current of nominally 8 μA to the ITM belt and supporting photoconductor (PC) drum at 1 st transfer or to the ITM belt and supporting backup roll at 2 nd transfer. Each PC drum is charged to a predetermined surface potential of nominally −500 volts during the transfer servo process with the PC core potential at −200 volts. The ITM backup roll surface is set to nominally −600 volts during the servo process. The operating voltage applied to the shaft of each transfer roll during the printing process is calculated via a corresponding pre-determined transfer characteristic from the servo voltage. The transfer characteristic is stored in table form in machine memory or in the ITM memory. When the tables are stored in ITM memory, they may be read into machine memory and stored for rapid access.
A slope and offset representation of the transfer characteristic at each of the four color 1st transfer stations and a slope and offset representation of the 2nd transfer characteristic by media type and print mode (e.g. simplex/duplex) are provided in this implementation. An additional set of table entries is required for each significantly different machine process speed. The table values for a single color could be used in place of table values for the four individual colors at 1st transfer if toner charge/mass and belt initial conditions were similar at each of the four stations.
In the preferred embodiment, one set of tables is provided for transfer at 108 mm/second process speed and a second set for transfer at 4 mm/second. A total of eight tables are thus provided at 1 st transfer for the four color stations at two process speeds. A total of 20 tables are provided at 2 nd transfer for ten media types and print modes at two process speeds.
An example of the parametric representation of a transfer characteristic is shown in FIG. 3 . Here, each transfer characteristic is represented using an offset and a slope value for each of 3 line segments. The horizontal axis represents the transfer servo voltage required to produce an 8 μA servo current as previously described. The vertical axis represents the voltage applied to the transfer roll shaft during printing. The transfer servo slope breakpoints on the horizontal axis corresponding to 02 and 03 in FIG. 3 are common to all four 1 st transfer tables and to 2 nd transfer. Each of the six numerical values representing the slope and offsets for the three line segments is stored in an 8-bit byte; the transfer roll operating offset voltage is represented in 25 volt increments and slope is represented in 64th's. Each transfer characteristic thus consumes 48 bits of ITM memory.
The table values corresponding to a 108 mm/second process speed at each of the four 1 st transfer color stations and at 2 nd transfer for standard 20 pound paper media and transparencies are given in Table 1. Offsets are given relative to the −200 volt photoconductor drum core at 1 st transfer and relative to the −600 volt ITM back up roll surface potential at 2 nd transfer.
TABLE 1
A) Offset Voltage and Multiplier Representation of
1st and 2nd Transfer Characteristics
Servo Range
0 to 500
500 to 1000
1000 to Max
volts
volts
output
Transfer Station
O1
S1
O2
S2
O3
S3
1st
Yellow
28
0.8
28
0.8
28
0.8
Transfer
1st
Cyan
100
0.8
100
0.8
100
0.8
Transfer
1st
Magenta
200
0.8
200
0.8
200
0.8
Transfer
1st
Black
300
0.8
300
0.8
300
0.8
Transfer
2nd
20#
−96
2.8
454
1.71
1148
1.02
Transfer
Paper
Simplex
2nd
Trans-
0
2.24
520
1.2
1092
0.63
Transfer
parency
B) 1-Byte per Entry Representation of
1st and 2nd Transfer Characteristics (decimal)
25 volts per bit Offset,
signed integer, −3200 to +3175 volts;
1/64th's per bit Slope,
unsigned integer, 0 to 3.98 multiplier
Servo Range
0 to 500
500 to 1000
1000 to Max
volts
volts
output
Transfer Station
O1
S1
O2
S2
O3
S3
1st
Yellow
1
51
1
51
1
51
Transfer
1st
Cyan
4
51
4
51
4
51
Transfer
1st
Magenta
8
51
8
51
8
51
Transfer
1st
Black
12
51
12
51
12
51
Transfer
2nd
20#
−4
179
18
109
46
65
Transfer
Paper
Simplex
2nd
Trans-
0
143
21
77
44
40
Transfer
parency
The tabular representation of the 1 st transfer characteristics from Table 1 A) is shown in graphical format in FIG. 4 . Because the slope values for all four color stations are constant across all servo ranges, no breakpoints are visible in FIG. 4 . The tabular representation of the 2nd transfer characteristics from Table 1 A) is shown in graphical format in FIG. 5 .
Table 1B) duplicates Table 1A) with values shown in the 1 byte per entry format in which they are stored in the semiconductor memory.
The machine transfer control algorithm may also be parametrically altered based upon the ITM cycle count tallied (by cycles or pages) during the life of the ITM.
A map of the memory contents for one embodiment is shown below:
TABLE 2
Page
Bits
Description
0
256
Reserved for Uniqueware component ID
1
256
OEM ID
Belt cycle end-of-life limit
Belt pages end-of-life limit
Belt job count end-of-life limit
Time between sensors for 108.12 mm/sec at 30° C.
with AC feed-forward
Time between sensors for 108.12 mm/sec at 30° C.
without AC feed-forward
Belt DC time between sensors vs. temperature
relationship (2 byte slope and offset)
Belt length in zones for velocity control
DC Velocity Count to set 108.12 mm/sec belt surface
velocity at 30° C.
AC Velocity Count, Initial Offset from DC count at
Home Location (2 bytes, signed)
AC Velocity Count, Number of steps (Ns) per table
increment (4 lsb's of byte)
Start of Scan, Initial Offset for K, M, C, & Y
(2 bytes each, unsigned)
Start of Scan, Number of slices (N) per table
increment for K, M, C, & Y (1 or 2), 2 bits each
Reserved for Future Use (Calibration Motor
Halls/Rev, FG's/Rev, Ref Clock)
Function enable (1 bit each): 1) cycle
lockout, 2) page lockout, 3) job lock-out,
4) DC velocity correction, 5) AC velocity feed-
forward, 6) Start of Scan Delay feed-forward,
7) transfer offset enable, 8) transfer table enable
Page locked at time of manufacture (if Dallas
2
256
Semiconductor i-Button)
ITM subassembly EC Level
Date of manufacture of ITM subassembly
Date of manufacture of component parts
Source of component parts
Diameters of drive and idler rolls
Belt tension, Belt length
Page locked at time of manufacture
3
256
ITM subassembly cycle tally @ 1000 cycles per bit =
255K cycles max + lockout bit
4
256
ITM subassembly page tally @ 1000 pages per bit =
255K pages max + lockout bit
5
256
ITM subassembly job tally @ 1000 jobs per bit = 255K
jobs max + lockout bit
6-8
512
Transfer operating point offsets or complete transter
tables, 1st transfer PC's to belt
Transfer Offset Table, 2 bits per Color, 00 or
10 = Normal, 01 = High, 11 = Low
Transfer table for each color at 1st transfer at
1 byte per constant:
[Slope breakpoints at full speed (2 bytes),
Slope breakpoints at ½ speed (2 bytes)]
[Offset 1, Slope 1, Offset 2, Slope 2, Offset 3, Slope 3]
4 Tables for 1st transfer (4 colors) at full
speed; 4 tables at ½ speed operation
Pages locked at time of manufacture.
8-11
1024
Transfer operating point offsets or complete
transfer tables, 2nd transfer belt to media
Transfer Offset Table, 2nd Transfer, 2 lsb's: 00 or
10 = Normal, 01 = High, 11 = Low
Transfer table for each media type at 1st transfer at
2nd transfer
[Slope breakpoints at full speed (2 bytes),
Slope breakpoints at ½ speed (2 bytes)]
[Offset 1, Slope 1, Offset 2, Slope 2, Offset 3, Slope 3]
10 Tables for 10 media types at full speed; 10 tables for
10 media types at ½ speed
Pages locked at time of manufacture.
12-
2656
Belt AC velocity correction, serial correction
21.375
with respect to home hole 2 bits/zone, up to 1328
zones; Ns speed change steps per encoded increment/
decrement
Correction Table: 00 or 10 - no change; 01 = +Ns steps;
11 = −Ns steps (˜0.01% per step)
Plan of Record: 1264 zones of ˜0.703 mm each,
pages locked at time of manufacture
21.375-
2656
Belt Black-Ref Delay to image serial correction
31.75
table 2 bits/zone, up to 1328 zones;
N slices per encoded increment/decrement (1 or 2 slices
where 1 slice = 1/7200 inches)
Correction Table: 00 or 10 = no change; 01 = +N slices;
11 = −N slices
Plan of Record: 1264 zones of 16.9 scans each at
600 dpi (889 mm); locked at mfg
31.75-
2656
Belt Magenta-Ref delay to image serial correction
42.125
table 2 bits/zone, up to 1328 zones;
N slices per encoded increment/decrement
(1 or 2 slices where 1 slice = 1/7200 inches)
Correction Table: 00 or 10 = no change; 01 = +N slices;
11 = −N slices
Plan of Record: 1264 zones of 16.9 scans each at
600 dpi (889 mm); locked at mfg
42.125-
2656
Belt Cyan-Ref delay to image serial correction table 2
52.5
1328 bits/zone, up to zones;
N slices per encoded increment/decrement (1 or 2 slices
where 1 slice = 1/7200 inches)
Correction Table: 00 or 10 = no change;
01 = +N slices; 11 = −N slices
Plan of Record: 1264 zones of 16.9 scans each at 600 dpi
(889 mm); locked at mfg
52.5-
2656
Belt Yellow-Ref delay to image serial correction table
62.875
2 bits/zone, up to 1328 zones;
N slices per encoded increment/decrement (1 or 2 slices
where 1 slice = 1/7200 inches)
Correction Table: 00 or 10 = no change;
01 = +N slices; 11 = −N slices
Plan of Record: 1264 zones of 16.9 scans each at 600 dpi
(889 mm); locked at mfg
The subassembly is a field replaceable unit. Thus a worn out subassembly can be easily replaced with another subassembly which also has its own stored calibration data. The printer can use the new subassembly, which has its own set of calibration data unique to the subassembly, to provide a high quality printed image.
Referring now to FIG. 6, a flowchart showing a method 100 for providing transfer quality optimization of color planes deposited on a transfer belt is provided.
At a first step 110 , an image transfer subassembly is provided. The subassembly includes a transfer belt and a memory device. The memory device is used to store characterization data particular to the subassembly.
The next step 120 establishes a set of Transfer Operating Points for each transfer station as part of the characterization of the subassembly. The Transfer Operating Points take into account differences in the belt and transfer roll resistivity and enable the machine microcontroller to adjust the power supply settings in accordance with variations in the belt and transfer roll resistivity.
At step 130 the characterization data is stored in the memory. Accordingly, the data remains with the subassembly such that when the subassembly is installed into a printer, the associated characterization data (which may be different for each subassembly) is also maintained with the subassembly.
Finally, at step 140 , the characterization data is applied from the memory to the controller to provide the proper adjusting of the power supplies to take into account variations in the resistivity of the belt that may differ from subassembly to subassembly.
By way of the above described apparatus and method, errors associated with variations of the transfer belt subassembly are removed or significantly reduced. By including the memory device as part of the transfer belt subassembly, the transfer belt subassembly can be removed and a replacement subassembly installed while still maintaining a high precision of color plane registration and transfer quality on the transfer belt.
Having described preferred embodiments of the present invention it should be apparent to those of ordinary skill in the art that other embodiments and variations of the presently disclosed embodiment incorporating these concepts may be implemented without departing from the inventive concepts herein disclosed. Accordingly, the invention should not be viewed as limited to the described embodiments but rather should be limited solely by the scope and spirit of the appended claims.
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A method and apparatus for providing transfer quality optimization in printers is disclosed. A transfer belt subassembly includes a transfer belt and a storage device. The transfer belt also includes a home position indicator. The transfer belt subassembly is measured and characterized relative to the home position indicator before being installed in a printer. The measurement and calibration data for the transfer belt is then stored in the storage device that is part of the transfer belt subassembly. When the transfer belt subassembly is inserted into a printer, a controller within the printer is placed in communication with the storage device. A sensor is used to determine the home position of the transfer belt from the indicator, and a resulting signal indicating when the belt is at the home position is provided to the controller. The controller utilizes the measurement and calibration data from the storage device to provide correction with respect to each color station of the color printer, taking into account and compensating for variations in the transfer belt subassembly. In such a manner, the measurement and calibration data is predetermined before the transfer belt subassembly is inserted into the printer, thereby simplifying the printer composition. By use of the calibration and measurement data, precise alignment of the color planes with respect to one another is achieved, and the proper electrical transfer setting suited to that belt is obtained for improved transfer quality.
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FIELD OF THE INVENTION
The present invention relates generally to reducing airflow problems in low profile processor-based devices, such as servers, and particularly to a system for holding cables out of a cooling airflow passing through the device.
BACKGROUND OF THE INVENTION
Many current processor-based devices, such as servers, have been designed with a smaller overall package size. One dimension that has been reduced in a variety of devices is the height. For example, some servers have been designed with a low profile, such as 1 U servers, that have a relatively short distance between the bottom and the top of the server chassis. The lower profiles and otherwise smaller packages have created difficulty in providing an uninterrupted airflow through the device for cooling of components.
Exemplary components that tend to be obstructive to airflow include cables, such as SCSI cables, often used to form connections between one or more PCI cards and the motherboard. Placement of the cables can be difficult to control and they can end up in a position inhibiting airflow through the chassis of the device.
It would be advantageous to have a technique for reducing the airflow interference caused by such cables.
SUMMARY OF THE INVENTION
According to one embodiment of the present invention, a system is provided for reducing interruption to airflow through the chassis of a processor-based device, such as a server. The system includes a generally flat tray disposed along a base or floor of the chassis. The tray is designed to receive a cable, such as an SCSI cable. Typically, clips are used to secure the cable to the tray.
According to another aspect of the invention, a system is provided for facilitating better airflow through a server. The system includes a server chassis having a chassis floor. A cable retention tray is deployed along the chassis floor. The cable retention tray is designed to secure a generally flat cable along the chassis floor to reduce or prevent interference with airflow through the chassis.
According to another aspect of the present invention, a method is provided for facilitating cooling of components in a processor-based device, such as a server. The method includes deploying a generally flat tray along an area of the chassis that reduces interference with airflow. The method further includes laying a low profile, signal carrying cable along the tray where it is retained at a position substantially out of the path of airflow.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
FIG. 1 is a perspective view of a rack with a plurality of processor-based devices, e.g. servers, mounted therein;
FIG. 2 is a front view of a low profile server;
FIG. 3 is a partially exploded perspective view of the server illustrated in FIG. 2;
FIG. 4 is a cross-sectional view taken generally along line 4 — 4 of FIG. 3;
FIG. 5 is a perspective view of a cable tray disposed within the chassis of an exemplary server;
FIG. 6 is a cross-sectional view taken generally along line 6 — 6 of FIG. 5;
FIG. 7 is a perspective view of a PCI card riser assembly designed for mounting in a low profile chassis of an exemplary server;
FIG. 8 is a cross-sectional view of the PCI card assembly taken generally along line 8 — 8 of FIG. 7;
FIG. 9 is a cross-sectional view similar to FIG. 8 but showing the PCI card assembly in an eject position;
FIG. 10 is a perspective view of the right end of the riser assembly illustrated in FIG. 7;
FIG. 10A is a perspective bottom view of the riser assembly illustrated in FIG. 7;
FIG. 11 is a partial front view of an exemplary server illustrating an indicator;
FIG. 12 is partial rear view of an exemplary server illustrating a rear indicator;
FIG. 13 is a circuit diagram for use with the indicators illustrated in FIGS. 11 and 12;
FIG. 13 a is a diagram representing the functionality of the circuit illustrated in FIG. 13;
FIG. 14 is a perspective view of a retractable LCD module in a retracted position within an exemplary server;
FIG. 15 is a perspective view of the retractable LCD unit illustrated in FIG. 14 but in an open or operable position;
FIG. 16 is a top view of the LCD unit in an open position;
FIG. 17 is a top view similar to FIG. 16 but with the LCD unit in a retracted position;
FIG. 18 is a top view of a cable management system deployed with an exemplary server that is retracted in a rack;
FIG. 19 is a top view of the cable management system illustrated in FIG. 18 with the exemplary server extended from the rack;
FIG. 20 is a perspective view of a portion of an exemplary rack and rail; and
FIG. 21 is an exploded view of an end of the rail illustrated in FIG. 20 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring generally to FIG. 1, an exemplary implementation of the present invention is illustrated. In this embodiment, a plurality of densely packaged, processor-based devices 30 are shown mounted in a rack system 32 . Rack system 32 is designed to slidably receive a plurality of the processor-based devices 30 . Typically, devices 30 are mounted on retractable rails that permit the device to be moved between a retracted position within rack 32 and an extended position in which the device is at least partially extended from rack system 32 . This extension allows removal or servicing of an individual device 30 , as illustrated in FIG. 1 .
Throughout this description, an exemplary processor-based device is described and referenced as server 30 , but other devices also can benefit from the unique features described herein. The exemplary server 30 is a low profile server, such as a 1 U server designed to occupy one unit of vertical space in rack system 32 .
Server 30 includes a chassis 34 having a front 35 designed with pair of drive bays 36 . Drive bays 36 are configured to receive a pair of hot pluggable drives 38 . The front of chassis 34 also may be designed to receive an ejectable CD drive assembly 40 and an ejectable floppy drive assembly 42 . In the particular design illustrated, CD drive assembly 40 and floppy drive assembly 42 are combined and removable or insertable as a single unit. The exemplary design also includes other features, such as a retractable liquid crystal display (LCD) 44 and an indicator panel 46 .
In server 30 , components are densely packaged, but adequate cooling of the components is maintained. As illustrated in FIG. 3, chassis 34 is divided into at least two general zones, including a high pressure, high airflow zone 48 and a relatively low pressure, low flow zone 50 . An airflow is created into high pressure zone 48 by a blower assembly 52 . Blower assembly 52 typically includes a fan 54 , such as a centrifugal fan, e.g. an exemplary blower unit is a 24 volt Gamma blower. Similarly, airflow through low pressure zone 50 is created by a blower 56 . In the embodiment illustrated, blower 56 comprises a fan integral with an internal power supply 58 oriented such that its fan discharges airflow into low pressure zone 50 .
Preferably, blower assembly 52 discharges airflow at a greater rate and pressure than blower 56 . Thus, the air pressure created in high pressure zone 48 is maintained at a higher level than the air pressure in low pressure zone 50 during operation of the fans. This ensures sufficient airflow across densely packed, heat producing components disposed within high pressure zone 48 of chassis 34 .
To ensure that minimal high pressure air from zone 48 flows into low pressure zone 50 , open areas between the zones have been blocked by an air baffle 60 . Air baffle 60 prevents the output of blower assembly 52 from disrupting the air flow created through low pressure zone 50 by blower 56 .
Exemplary components disposed in high pressure zone 48 include one or more, e.g. two, processors 62 , each coupled to a corresponding heat sink 64 . Each heat sink 64 includes a plurality of cooling fins 66 that decrease in height along an inwardly directed end to provide additional room for other components. For example, a plurality of memory modules 68 , e.g. DIMMs, may be mounted within high pressure zone 48 at an angle to facilitate the low profile design of chassis 34 . In this embodiment, memory modules 68 are disposed at an angle over at least one of the heat sinks 64 , but the decreasing height of the inwardly disposed cooling fins permit the memory modules to be so oriented without contacting the heat sink. Another exemplary component disposed in high pressure zone 48 is a PCI card 70 .
In operation, blower assembly 52 draws air in along drives 38 and discharges the airflow into high pressure zone 48 . The size and capacity of the fan is adjusted according to the size of chassis 34 and the layout of components disposed in high pressure zone 48 . However, the capacity should be sufficient to create enough pressure in high pressure zone 48 that the necessary quantity of cooling air passes across the components disposed in zone 48 , e.g. heat sinks 64 and memory modules 68 .
Preferably, the airflow is discharged towards the rear of chassis 34 . In the illustrated embodiment, chassis 34 includes a cutout region 72 for receiving an air outlet or vent through which air is discharged from high pressure zone 48 . For example, a vent region 74 may be disposed in a cover 76 designed to fit over chassis 34 and enclose high pressure zone 48 and low pressure zone 50 . Vent region 74 is disposed in a “scooped” region 78 of cover 76 . When cover 76 is disposed on chassis 34 , scooped region 78 extends inwardly into the interior of chassis 34 in high pressure zone 48 along cutout region 72 . As illustrated best in FIG. 5, vent region 74 includes a vent and preferably a plurality of vents 80 that permit the airflow to exit generally in a direction in line with the discharge from blower assembly 52 . Exemplary vents 80 are formed as a plurality of louvers along scooped region 78 .
Cover 76 also may include an air inlet 82 and an air outlet 84 for blower 56 , or alternatively, inlet 82 and outlet 84 can be formed through chassis 34 . As blower 56 is operated, air is drawn through inlet 82 along the combined CD/floppy drive and into the power supply assembly 58 . The air is discharged from blower 56 into low pressure zone 50 until it exits through outlet 84 . Low pressure zone 50 may include a variety of components that vary according to the design of chassis 34 and server 30 . In the exemplary embodiment, low pressure zone 50 includes a PCI card 86 , an inline EMI filter 88 and an internal array controller cable tray 90 .
Other features of server 30 include a dual PCI card and an ejectable riser assembly 92 to which PCI cards 70 and 86 are attached. Also, DIMM modules 68 and processors 62 preferably are attached to a motherboard 94 . Drives 38 are coupled to a removable SCSI back plane 96 . A raid on a chip (ROC) board 98 is disposed intermediate blower assembly 52 and power supply 58 . A power switch and LED PC board 100 is deployed within chassis 34 generally proximate indicator panel 46 for cooperation therewith. A back plane 102 for the combined CD and floppy assembly is deployed between floppy drive assembly 42 /CD assembly 40 and power supply 58 . Additionally, a pair of mounting rails 104 can be attached to the sides of chassis 34 to permit engagement with corresponding rails of rack system 32 , as described below. It should be noted that a variety of component arrangements can be utilized, however, the exemplary illustrated arrangement provides for a dense packaging of components separated into two cooling zones that are able to readily maintain the components at desirable operating temperatures. Several of the unique, inventive features that facilitate the above-described packaging are described below.
One of the unique features of server 30 is cable tray 90 . In low profile servers, such as the illustrated 1 U server, larger SCSI cables can interfere with the fit of internal components as well as being detrimental to thermal performance, e.g. heat removal. Cable tray 90 is designed to hold an SCSI cable 106 and to lie generally flat along a floor 108 of chassis 34 . The low profile tray holds cable 106 substantially out of the airflow through low pressure zone 50 . Thus, cable 106 can be used to form an electrical connection between a PCI card and motherboard 94 without interrupting airflow and thermal performance. Preferably, cable tray 90 includes a flat base 109 and a plurality of tabs 110 that extend over and retain cable 106 , as illustrated in FIGS. 5 and 6. Preferably, tabs 110 extend upwardly from flat base 109 and may be integrally formed with flat base 109 , as by plastic injection molding.
In the particular embodiment illustrated, SCSI cable 106 is connected to the board edge of motherboard 94 by an SCSI connector 112 . Electrically, a control signal is implemented on an internal SCSI connector for an adapter to electrically switch the signal paths from being driven by an onboard controller to being driven by the adapter controller. The signal path preferably is optimized so that when no adapters are plugged in, there will be negligible impact on the signal quality.
Another feature that facilitates the dense packaging of components within chassis 34 is riser assembly 92 , illustrated best in FIGS. 7 through 10A. The design of riser assembly 92 permits the mounting of at least two full length PCI cards, such as PCI cards 70 and 86 , as illustrated in FIGS. 8 through 10. Riser assembly 92 includes a framework 120 having a center frame portion 122 disposed between PCI cards 70 and 86 and a pair of frame ends 124 , 126 that are disposed generally perpendicular to center frame portion 122 . Frame ends 124 and 126 preferably are spaced apart to slidably receive PCI cards 70 and 86 . Typically, each frame end 124 and 126 includes appropriate supports 128 for supporting each PCI card.
Additionally, riser assembly 92 includes a PCI riser card 130 disposed along center frame portion 122 . A pair of oppositely facing connectors 132 are electrically coupled to PCI riser card 130 and extend in opposite directions therefrom for coupling with PCI card 70 and PCI card 86 . Connectors 132 are mounted to PCI riser card 130 in a vertically staggered arrangement. Additionally, a riser card connector 134 is mounted to riser card 130 and configured for connection with motherboard 94 at a connection location 136 (see FIG. 6) to permit communication with PCI cards 70 and 86 .
Additionally, riser assembly 92 includes a lever and preferably a pair of levers 138 connected by a handle 140 . Lever or levers 138 are pivotably mounted to riser assembly 92 , preferably at center frame portion 122 for pivotable motion about a pivot mount 142 . Each lever 138 also includes an engagement end 144 that has an engagement feature, such as a recess 146 designed to engage a rib 148 , typically mounted on chassis floor 108 (see also FIG. 6 ).
When riser assembly 92 is moved downwardly into chassis 34 (generally over cable tray 90 ), engagement end 144 and recess 146 engage rib 148 , as illustrated best in FIG. 9 . Handle 140 is then pressed to pivot lever 138 about pivot 142 , thereby driving riser card connector 134 into engagement with a corresponding connector, e.g. a connector on motherboard 94 , and riser assembly 92 into proper position. To remove riser assembly 92 , handle 140 simply is pulled upwardly which moves riser assembly 92 and riser card connector 134 laterally to permit lifting of the entire assembly from chassis 34 .
It should be noted that riser assembly 92 may be further secured in chassis 34 by a plurality of engagement features. For example, as illustrated in FIGS. 10 and 10A, a plurality of pins and receptor slots can be used to secure riser assembly 92 into chassis 34 when levers 138 are pivoted to an installed position. As illustrated in FIG. 10, frame end 126 may be designed with a pin 150 and a receiving slot 154 that are located for engagement with a corresponding receiving slot 152 and pin 156 , respectively, that are attached to chassis 34 (see FIGS. 4 and 5 ). In this embodiment, receiving slot 154 is formed in a tab 158 that extends upwardly from chassis floor 108 (see FIGS. 5 and 6 ), and pin 156 also is formed to extend generally upwardly from chassis floor 108 for sliding engagement with receiving slot 152 .
As illustrated best in FIGS. 10 and 10A, riser assembly 92 may also include one or more, e.g. two, pegs 160 that extend generally downwardly from the bottom of center frame portion 122 . Pegs 160 are located for engagement with corresponding slots 162 formed in a bracket 164 mounted to chassis floor 108 (see also FIG. 6 ). Bracket 164 and slots 162 are designed to engage and retain pegs 160 when levers 138 move riser assembly 92 into its installed position, as illustrated best in FIG. 8 .
Another unique feature of server 30 is an indicator system 162 illustrated in FIGS. 11 through 13. Indicator system 162 permits a technician to identify the appropriate server 30 , or other processor-based device, that requires attention and to disconnect the unit without risking disconnection of the wrong unit.
When multiple servers are mounted in a rack, particularly when the units have low profiles, such as 1 U servers, it can be difficult for a technician to ensure that he or she unplugs the proper unit at the rear when the unit was initially identified from the front. Thus, indicator system 162 can be activated to provide an indicator of the desired server from the front of the server and from the rear of the server. A variety of tags, logos, audible indicators etc. could be activated by an actuator to provide appropriate designation of the server requiring attention.
However, a preferred indicator system 162 provides a front switch 164 and a front light 166 , as illustrated in FIG. 11 . Similarly, exemplary indicator system 162 provides a rear switch 168 and a rear light 170 , as illustrated in FIG. 12 . When either front switch 164 or rear switch 168 is depressed while lights 166 and 170 are off, both lights 166 and 170 are illuminated. If either switch 164 or 168 is depressed while lights 166 and 170 are illuminated, both lights 166 and 170 turn off.
This allows an individual to identify a unit requiring attention from the front. Once identified, front switch 164 is depressed to illuminate front light 166 and rear light 170 . The individual may then walk around to the back of a rack containing multiple units, identify the unit having an illuminated rear light 170 , and unplug cables from the unit. The unit then can be removed from the front of the rack for service or replacement. This prevents the inadvertent disconnection of the wrong unit. Lights 166 and 170 preferably have a visually noticeable color, such as a blue color.
An exemplary circuit for use in indicator system 162 is illustrated in FIG. 13 and the functionality of the circuit is illustrated in FIG. 13 a . The exemplary circuit may be powered by an auxiliary power supply Vaux 172 . Power supply 172 may be separated from the main system power supply which allows the circuitry to be operated even when the main system power is off. Other components of the circuit include a NAND-gate 174 , a D-flipflop 176 and an inverter 178 .
In this exemplary embodiment, the D-flipflop 176 is illustrated after its reset condition, that is its output Q is low and Q/ is high. When either push button 164 or 168 is depressed, the signal line PUSH/ (labeled 172 a ) level changes from high to low. This signal transition causes the clock input signal, CLK 166 d , of D-flipflop 176 to change from low to high, via NAND-gate 174 . The clock signal latches the high state at the D input, therefore changing the Q output (labeled 166 c ) from low to high. Because the Q output signal is passed through the inverter 178 , the signal (LED-ON/ 166 a ) at the cathode pins of LEDs 166 and 170 is changed from high to low. This turns on or illuminates LEDs 166 and 170 . At this time, the D input of the flipflop 176 is low. When either push button 164 and or 168 is depressed again, the CLK input latches the low state from the D input, causing the Q output, STATUS 166 c , to change from high to low. This transition goes through the inverter 178 , effectively turning off both LED 166 and LED 170 .
In the embodiment illustrated, one of the NAND-gate 174 inputs also can be controlled by software designed to allow LEDs 166 and 170 to be turned on, turned off or blinked. Application software on the server or on a remote server can be utilized to control the state of the LEDs. The D-flipflop 176 output Q/, STATUS/ 166 b , also can be monitored by software. This would allow a technician from a remote site to control the state of LEDs 166 and 170 and to notify another technician in the server room as to which server requires service. Upon completion of the service work, the servicing technician would then push either button 164 or 168 . The remote technician is thereby able to monitor the LED status and to determine completion of the service work. It should be noted that the figure and functionality described are exemplary, and other circuits can be used to accomplish the device identification described above.
Another unique feature of the exemplary server 30 is the retractable LCD 44 , illustrated in FIGS. 14 through 17. The liquid crystal display module 44 can be moved between a retracted position, as illustrated in FIG. 14, and a display or open position, as illustrated in FIG. 15 . The LCD module includes a display 180 that can be used as a visual interface for various information related to the operation of server 30 . However, when LCD module 44 is not in use, it can be moved to the retracted position to permit access to CD drive assembly 40 and floppy drive assembly 42 .
LCD module 44 is pivotably mounted to a retraction assembly 182 by a module pivot 184 that allows LCD module 44 to be pivoted between the display position and a position generally perpendicular to the front of server 30 for retraction. Retraction assembly 182 includes an outer guide housing 186 disposed generally between floppy drive assembly 42 /CD drive assembly 40 and drive bays 36 . Outer guide housing 186 is designed to slidably receive LCD module 44 therein.
Retraction assembly 182 further includes a pivot mount bracket 188 to which module 44 is pivotably mounted via pivot 184 , as best illustrated in FIGS. 16 and 17. Generally opposite pivot 184 , bracket 188 includes one or more attachment features 190 to which one or more resilient members, such as a pair of springs 192 can be attached. Preferably, a pair of springs positioned above and below each other are used to balance the biasing force on pivot mount bracket 188 and LCD module 44 as LCD module 44 is drawn into an open interior 194 of outer guide housing 186 . Exemplary springs 192 include coil springs that are pulled to a stretched position when LCD module is moved to its open or display position. Thus, the coil springs bias LCD module 44 back into open interior 194 when module 44 is pivoted to a position generally in alignment with open interior 194 . An appropriate electric line or lines 195 may be routed to LCD module 44 through outer guide housing 186 , as best illustrated in FIGS. 16 and 17.
When units, such as servers, are stacked sequentially in rack system 32 , the various cables coupled to the various server ports can be difficult to manage. This is particularly true with low profile servers, such as 1 U servers, due to the relatively large number of closely spaced units. Accordingly, the densely stacked servers benefit from a cable management system 200 , such as that illustrated in FIGS. 18 and 19. The exemplary cable management system 200 includes a tray bracket 202 mounted to and extending rearwardly from each server 30 . At least one and preferably a pair of spools 204 serve as a cable support member and are mounted to tray bracket 202 in a position that permits the plurality of various cables 206 to be wrapped and held generally along the backside of server 30 . Spools 204 can be mounted in a variety of locations depending on the design of server 30 and rack system 32 , but the spools are preferably located in positions to provide strain relief for the cables and to bundle the cables for routing.
Cable management system 200 further includes a tension device 208 and a retainer member 210 . Tension device 208 and retainer 210 preferably are mounted towards the back of rack system 32 generally on a level with server 30 . Retainer 210 may be mounted or formed at a position on an opposite side of rack system 32 from tension device 208 , as illustrated in FIGS. 18 and 19. Retainer 210 also is positioned slightly rearward of tension device 208 .
In an exemplary embodiment, tension device 208 comprises a tension reel 212 , such as a torsion spring loaded reel, having an extensible member 214 , such as a cord or cable. Extensible member 214 is connected to cable bundle 206 at a location intermediate the cable connectors plugged into the rear of server 30 and retainer 210 . Specifically, extensible member 214 is connected to cable bundle 206 generally intermediate the position at which cable bundle 206 is in contact with retainer 210 and the position of the closest spool 204 . Thus, when a specific server 30 is slid to an extended position in rack system 32 , extension member 214 is pulled outwardly, as illustrated in FIG. 19 . However, when the server is returned to its retracted position within rack system 32 , extension member 214 is retracted into tension reel 212 , thereby pulling cable bundle 206 to a neatly folded position to the rear of server 30 , as illustrated in FIG. 18 .
When multiple thin profile devices, e.g. servers, are mounted in a rack system 32 , a rack rail must be positioned for engagement with the side mounting rails 104 attached to chassis 34 of each device 30 . With low profile devices, multiple rails must be deployed in rack system 32 to receive the multiple corresponding servers. To facilitate assembly of rack system 32 , and specifically the attachment of rack rails for supporting each device 30 , unique rails have been designed for easy insertion and removal.
As illustrated best in FIG. 20, a preferred rack system includes a front support member 220 and a back support member 222 on each side of rack system 32 . Front support member 220 includes a plurality of mounting openings 224 that inhabit a substantial portion of the member. Similarly, rear support member 222 includes a plurality of mounting openings 226 that extend upwardly for a substantial distance along the support member. The mounting openings are designed to receive a rail 228 that extends from the front to the rear of rack system 32 between front support member 220 and rear support member 222 . It should be noted that mounting openings 224 and 226 can be in a variety of configurations and can be changed to mounting tabs, brackets or other features able to engage the corresponding mounting ends of each rail 228 .
In the illustrated embodiment, each rail 228 includes a rear mounting end 230 and a front mounting 232 . Each mounting end 230 , 232 includes engagement features for engaging the mounting structures along front and rear support members 220 , 222 . In the exemplary, illustrated embodiment, rear mounting end 230 and front mounting end 232 each include a pair of tabs 234 sized and spaced for receipt in corresponding mounting openings 222 . Thus, rail 228 may be positioned at multiple different locations along support members 220 and 222 .
In the preferred embodiment, rear mounting end 230 is fixed and front mounting end 232 is resiliently movable. Alternatively, rear mounting end 230 can be made resiliently movable, or both mounting ends can be made resiliently movable. Regardless, an exemplary resiliently movable mechanism 236 is illustrated best in FIG. 21 .
In this embodiment, rail 228 includes a first rail portion 238 and a second rail portion 240 that may be slidably coupled to first rail portion 238 by a plurality of pins or fasteners 242 . As illustrated, second rail portion 240 is formed with a pair of slots through which pins 242 extend into contact with corresponding mounting brackets 244 disposed on the interior of first rail portion 238 . Heads 246 of pins 242 retain second rail portion 240 slidably trapped against first rail portion 238 . In this embodiment, front mounting end 232 is formed at the front of second rail portion 240 for selective, sliding movement into and out of engagement with mounting openings 224 of front support member 220 . Front mounting end 232 may include a bumper 248 to buffer the contact between first rail portion 238 and second rail portion 240 when sliding second rail portion 240 farther into first rail portion 238 .
To ensure that rear mounting end 230 and front mounting end 232 remain firmly connected to rear support member 222 and front support member 220 , respectively, second rail portion 240 is biased outwardly from first rail portion 238 by a biasing system 250 . An exemplary biasing system 250 includes a coil spring 252 disposed within a channel 254 located on the interior of first rail portion 238 . An abutment tab 256 is disposed at an interior end of channel 254 . A second abutment tab 258 extends inwardly from second rail portion 240 generally at an end of spring 252 longitudinally opposite of abutment tab 256 when second rail portion 240 is slidably mounted to first rail portion 238 .
Thus, spring 252 biases second rail portion 240 and mounting end 232 in an outward direction to firmly move rear mounting end 230 and front mounting end 232 into engagement with rear support member 222 and front support member 220 , respectively. However, rail 228 can quickly and easily be removed by overcoming the bias of spring 252 and forcing second rail portion 240 to slide inwardly into first rail portion 238 . This resilient, movable mechanism 236 permits quick installation and removal of rails 228 from rack system 32 to accommodate the mounting of multiple devices, such as servers without the use of screws or other types of fasteners.
The actual features of rails 228 by which each server 30 is slidably mounted thereto depends on the configuration of mounting rails 104 . However, a variety of available sliding rails 104 and corresponding mounting rails 228 can be utilized, as known to those of ordinary skill in the art.
It will be understood that the foregoing description is of preferred embodiments of this invention, and that the invention is not limited to the specific forms shown. For example, a variety of devices other than servers can benefit from the various features described herein; the configuration of the overall chassis and the location of components can be adjusted according to a specific application; the size and capacity of the blower assemblies can be adjusted according to each application; and a variety of materials can be utilized in the construction of various components described herein. These and other modifications may be made in the design and arrangement of the elements without departing from the scope of the invention as expressed in the appended claims.
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A system for facilitating airflow in a processor-based device, such as a server. The system is particularly amendable for use in low profile devices that inherently have reduced space for airflow. The system utilizes a tray deployed along a base wall or other wall of the device chassis. The tray is utilized to secure a cable or cables that would otherwise inhibit airflow.
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This application is a continuation of U.S. application Ser. No. 08/897,832 filed Jul. 21, 1997, now U.S. Pat. No. 6,027,582, which is a continuation-in-part of U.S. application Ser. No. 08/836,473 filed Aug. 25, 1997, abandoned.
FIELD OF THE INVENTION
The invention relates to products made from an aluminum alloy of the AlZnMgCu type (the 7000 series according to the Aluminum Association designation) with thicknesses greater than 60 mm. These products can be hot-rolled plates or sheets, forged blocks or extruded products. In cases where the product does not have a parallelepipedic shape, the term thickness refers to the smallest dimension of the product at the time of quenching (for example, the thickness of the thinnest wall for a section).
DESCRIPTION OF RELATED ART
Thick rolled, forged or extruded products made of aluminum alloys from the 7000 series are used to mass produce—by cutting, surfacing or machining—high strength pieces for the aeronautics industry, for example wing elements such as wing spars or fish plates, and fuselage elements such as frames, or mechanical engineering pieces like machine-tool components or molds for plastics.
These pieces must have a set of properties that are frequently antithetical to one another, requiring difficult compromises in the precise definition of the chemical composition and in the transformation range of the products used.
In effect, in the heat treated state, the products must simultaneously have:
high mechanical strength in order to limit the weight of metal used,
sufficient toughness to reduce the crack propagation rate,
good fatigue resistance due to their use in structures subject to vibrations or stresses which are not constant over time,
sufficient stress corrosion resistance.
Moreover, the alloy must be able to be cast and transformed under proper conditions so as to obtain acceptable metallurgical quality. The transformation which follows the casting of the plate or billet usually comprises a homogenization, a hot transformation by rolling, forging or extrusion, a natural aging, a quenching (for example by immersion in or spraying with a quenching liquid), a possible de-stressing by cold traction or compression, a natural aging and an artificial aging.
The cooling during the quenching can be more or less rapid. What is meant here by the quench rate is the average cooling speed (in ° C./s) of the product from 450° to 280° C. at quarter thickness. A product is said to be quench sensitive if its static mechanical properties, such as its yield strength, decrease when the quench rate decreases, which naturally has a greater chance of occurring in thick products.
In order to obtain high mechanical strength, as well as good toughness, a fibrous structure is generally sought, which is obtained by avoiding too great a recrystallization of the alloy. For this purpose, one or more elements called “antirecrystallants” such as Zr, Ti, Cr, Mn, V Hf, or Sc are added to the composition. Thus, the compositions registered with the Aluminum Association for the alloys 7010 and 7050 comprise an addition of Zr at contents from 0.10 to 0.16%, and from 0.08 to 0.15%, respectively.
This is clearly illustrated by the recent article by DORWARD et al., “Grain Structure and Quench-Rate Effects on Strength and Toughness of AA7050 AlZnMgCuZr Alloy Plate”, Metallurgical and Materials Transactions A, Vol. 26A, pp. 2481-2484, which indicates, for example for 7050, a Zr+Ti content of 0.14%, and shows the effect, for 14-mm thick plates produced in the laboratory and not de-stressed, of extreme variations in the recrystallization rate between 15 to 80% on the yield strength of plates in the T6 temper. It also shows the effect on the quench sensitivity of 7050 of a quench rate of less than 20° C./s, which corresponds to the quench rate of products with thicknesses greater than about 50 mm.
However, these laboratory experiences are different from industrial practice, since the final thickness of 14 mm is obtained by a tepid-rolling which results in a relatively refined microstructure that is quite different from the microstructures that normally characterize thick plates obtained by hot rolling.
According to the DORWARD article, the effect of the recrystallization rate on L-T toughness diminishes with the quench rate. By way of example, FIG. 6 in the article by DORWARD et al. shows that for a quench rate of 8° C./s (which corresponds to a half-thickness of about 100 mm, characteristic of a heavy plate for the application considered), the L-T toughness is the same for a recrystallization rate of 15% or 50%, and is reduced by about 10% when the recrystallization rate goes up to 90%.
The addition of antirecrystallant elements, which would make it possible to limit the recrystallization, has the distinct disadvantage of reducing the ability of the product to harden after quenching and annealing, especially when it is thicker, since it hardens less at the core than on the surface, resulting in significant differences in the mechanical properties.
Thus, the article by M. CONSERVA and P. FIORINI, “Interpretation of Quench Sensitivity in AlZuMgCu alloys”, Metallurgical Transactions, Vol. 4, March, 1973, pp. 857-862, mentions a loss of structural hardening capacity, measured in terms of the density of GP zones, for thin sheets of Al—Zn5.5—Mg2.5—Cu1.6 alloy with an addition of either 0.23% Cr or 0.22% Zr relative to the same alloy without these additions.
This article teaches What zirconium is more effective than chromium in limiting the loss of the hardening power of the alloy during annealing. But even in the presence of zirconium, when the quench rate is 4° C./s, that is the quench rate at the core of a product approximately 200 mm thick immersed in cold water, the loss of hardening power is considerable and the zirconium no longer makes it possible to limit the quench sensitivity. The article also shows that, for the composition tested, even in the absence of chromium or zirconium, a loss of hardening power is observed for a quench rate of the order of 4° C./s.
In order to reduce quench sensitivity, Russian metallurgists have proposed the alloy V93, or 1930 according to the Russian standard GOST 11069, which does not include any antirecrystallant elements, but which has a very different composition from that of the alloys 7010 and 7050, including in particular a high iron content (between 0.20 and 0.45%) which is unfavorable to toughness and fatigue resistance.
The article by H. A. HOLL, “Investigations into the possibility of reducing quench sensitivity in high-strength AlZnMgCu alloys”, Journal of the Institute of Metals, July 1969, pp. 200-205, makes the same observation as to the harmful effect of the elements Zr, Mn, Cr and V, that is the antirecrystallants, but also of Fe and Si at commercial purity levels, on the hardenability of thin sheets. This means that in order to reduce the quench sensitivity of these alloys, it is necessary to use compositions with low Fe and Si contents, which increases production costs with respect to alloys of commercial purity. However, the teaching of this article, which relates to thin sheets, cannot be transferred to heavy plates, due to the microstructural differences which result from the different production processes.
Finally, the Applicant performed a measurement of the yield strength R 0.2 in the L and TL directions on sheets of different thicknesses made from treated alloy 7050 in the T7451 temper intended for the aeronautics industry and observed a loss of about 0.5 MPa per mm of additional thickness. FIGS. 1 and 2 show the statistical distribution of these values for the L direction and the TL direction, respectively. These results match those in the above-mentioned article by DORWARD et al., which shows, in the T6 temper, a loss on the order of 40 MPa between quench rates of 25° C./s and 8° C./s, which approximately corresponds to the cooling speeds in cold water at the core of plates with respective thicknesses of 60 and 150 mm. Thus, the prior art does not indicate, for thick products made from alloys of the 7000 type, any means which make it possible to simultaneously control recrystallization using zirconium to obtain high strength and toughness, and to limit the quench sensitivity so as to obtain homogeneous mechanical properties between the surface and the core of the product and to avoid the loss of mechanical strength in proportion to the thickness of the product, especially when it is desirable to use alloys with Fe and Si of commercial purity.
Moreover, it is known that for alloys of the 7000 type which contain copper, stress corrosion resistance declines when the quench rate decreases, that is, when the thickness increases. Thick products made from alloys of the 7000 type with high copper contents are therefore not a possible solution when seeking good corrosion behavior.
SUMMARY OF THE INVENTION
The object of the invention is to find, for alloys of the 7000 type containing copper with additions of zirconium, a specific range of composition for thick products which renders them not very quench sensitive, in which recrystallization is kept to a low level while the commercial purity of the iron and silicon is retained, and which results in high mechanical strength and toughness as well as good fatigue behavior, without any harmful effect on stress corrosion resistance.
In accordance therewith, the invention is directed to a rolled, extruded or forged AlZnMgCu alloy product >60 mm thick, preferably >125 mm thick, with the following composition (% by weight):
5.7 < Zn < 8.7
1.7 < Mg < 2.5 (and preferably < 2.3)
1.2 < Cu < 2.2 (and preferably < 2.1)
Fe < 0.14
Si < 0.11
0.05 < Zr < 0.15
Mn < 0.02
Cr < 0.02
with Cu+Mg<4.1 (and preferably <4.05)
other elements <0.05 each and <0.10 in total, which product, after shaping, is treated by natural aging, quenching and possibly annealing, and in the T7451 (de-stressed by controlled traction) or T7452 (de-stressed by compression) temper has the following properties:
a) a conventional yield strength at 0.2% of elongation R 0.2 , measured at quarter-thickness in the L and TL directions >400 MPa,
b) toughness under plane strain in the S-L direction, measured at half-thickness,>26 MPa{square root over (m)} and in the L-T direction, measured at quarter-thickness, >74−0.08 e−0.07 R 0.2L MPa{square root over (m)} (e being the thickness of the product in mm), c) a stress corrosion threshold >240 MPa, and preferably >300 MPa.
Preferably, the products according to the invention have a volume fraction of recrystallized grains, measured in the part disposed between the quarter-thickness and the half-thickness ≦35%. The magnesium content is preferably kept higher than the copper content.
Another subject of the invention is a product made from an alloy with the more limited composition:
5.7<Zn<8.7
1.7<Mg<2.15
1.2<Cu<2.0
Fe<0.14 Si<0.11
0.05<Zr<0.15
Mn<0.02 Cr<0.02
with Mg+Cu<4.0
other elements <0.05 each and <0.10 in total, having the same properties as before, but in which the recrystallization rate has little influence on these properties.
The toughness under plane strain is preferably >28 MPa{square root over (m)} in the S-L direction and >74−0.08 e−0.07 R 0.2L MPa{square root over (m)}. The latter formula is commonly used in the aeronautics industry. Other objects of the invention are products with the same composition as before which, after an annealing for an equivalent time t(eq) between 600 and 1,000 hours, has the following properties:
a) R 0.2 at quarter-thickness in the L and TL directions >425 MPa,
b) toughness under plane strain in the S-L direction >25 (preferably 28) MPa{square root over (m)} and in the L-T direction >74 (preferably 75)−0.08 e−0.07 R 0.2(L) MPa{square root over (m)},
c) a stress corrosion threshold >240 MPa (preferably 300 MPa).
When the equivalent time is between 1,000 and 1,600 hours, the properties are the following:
a) R 0.2 in the L and TL directions >400 MPa,
b) toughness under plane strain in the S-L direction >28 MPa{square root over (m)} and in the L-T direction >76 (preferably 77)−0.08 e−0.07 R 0.2(L) MPa{square root over (m)}
c) a stress corrosion threshold >240 MPa.
The equivalent time t(eq) is defined by the formula:
t(eq)=(∫exp(−16,000/T)dt)/exp(−16,000/T ref )
where T is the instantaneous temperature in ° K during the annealing and T ref is a reference temperature selected at 120° C. (393° K). t(eq) is expressed in hours.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents the yield strength at 0.2% R 0.2 in the L direction, as a function of thickness, of a set of sheets made of alloy 7050 in the T7451 temper according to the prior art.
In the same way, FIG. 2 represents R 0.2 in the TL direction, as a function of thickness, of the same set of sheets.
FIG. 3 represents, in an Mg—Cu diagram, the composition range of the invention (in a broken line), as well as the preferred range (in a light solid line), and the limited range (in a bold solid line).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Contrary to all expectations, and to the teaching of the above-mentioned article by DORWARD et al. in particular, the inventors determined a composition range for alloys of the 7000 type containing copper and zirconium, with commercial contents of iron and silicon, which makes it possible to control recrystallization and which, beginning at a thickness of about 60 mm, results in a reduction of the quench sensitivity of the product when the thickness of the product increases, while retaining good toughness and good stress corrosion resistance, with a conventional industrial transformation range.
The magnesium content of the alloy is reduced relative to that of the alloys 7010 or 7050, since it is centered around 2% instead of 2.3%, but it is not possible to go below 1.7% and still retain sufficient mechanical properties. The copper is centered around 1.7%, which corresponds to an increase relative to 7010, but a decrease relative to 7050. It is important to maintain a certain equilibrium between Cu and Mg: if Cu+Mg>4.1, the toughness-yield strength compromise is adversely affected, rendering the product insignificant. It can be advantageous to keep the Mg content higher than the Cu content. The composition range according to the invention, as well as the preferred range, is represented in a Mg—Cu diagram in FIG. 3 .
Principally, zirconium is used as the antirecrystallant element, while manganese and chromium, which increase quench sensitivity, are avoided as much as possible. The Zr content must exceed 0.05% in order to affect the recrystallization but must remain below 0.15% in order to prevent quench sensitivity and to avoid problems during casting. The iron and silicon contents are equivalent to those in 7010 and 7050.
The process for producing the product according to the invention is similar to that for products made from alloys of the 7000 type, for example 7010 and 7050. It comprises the casting of a plate or a billet, a homogenization at a temperature between 450 and 485° C., a hot transformation in one or more stages by rolling, extrusion or forging at a temperature between 370 and 460° C. which is controlled so as to obtain the desired recrystallization rate, a quenching by immersion in or spraying with cold water or at a temperature lower than 95° C., a de-stressing by deformation at the ambient temperature (controlled traction or compression), at a rate of less than 5%, and possibly an aging treatment to obtain, for example, the tempers T6, T74, T76, T751, T7451 or T7651, particularly in the case of the utilization of these products for molds for plastics.
EXAMPLES
Example 1
Nine plates were cast, 3 of the standard alloy 7050, 3 with an alloy designated F according to the invention and 3 with an alloy X according to the invention, with the following composition (% by weight):
Zn
Mg
Cu
Si
Fe
Zr
alloy 7050
6.1
2.35
2.20
0.05
0.09
0.10
alloy F
6.1
2.25
1.68
0.05
0.09
0.10
alloy X
6.4
2.0
1.29
0.05
0.10
0.11
The nine plates were then scalped and homogenized to 475° C. (7050) and 465° C. (alloys F and X), respectively, and one plate of each alloy was rolled to a thickness of 130 mm, another to 150 mm, and the third to 200 mm. The inlet temperatures of the rolling were between 410 and 420° C. for the three alloys. The outlet temperatures of the rolling were between 425 and 440° C. All 9 plates were solution heat treated to 480° C., quenched by immersion in cold water and stretched with a deformation rate on the order of 2%. The plates were then subjected to a two-stage aging:
6 h at 120° C. and 17 h at 165° C. for the plates made of alloy 7050,
6 h at 115° C. and 10 h at 172° C. for the plates made of alloys F and X.
The conventional yield strength R 0.2 (in MPa) of each of these plates in the L and TL directions was measured at quarter thickness, as was the toughness K 1c (in MPa{square root over (m)}) in the L-T direction, in accordance with the ASTM E399 standard for CT test pieces. The results are indicated in Table 1, where the toughness is compared to the value (74−0.08 e−0.07 R 0.2(L) ) MPa{square root over (m)}, in which e designates the thickness of the plate in mm. This expression makes it possible, for thick products made from AlZnMgCu alloys with compositions similar to those of the known alloys 7010 and 7050 and from the alloys according to the invention, to compare products with different thicknesses and/or different static mechanical properties.
It is noted that plates made from the alloy according to the invention have a total absence of quench sensitivity when the thickness increases, which is not the case with the plates made from standard 7050, as will be seen in FIGS. 1 and 2. Thus, although the Mg and Cu contents are lower, an equal or greater level of mechanical strength is unexpectedly obtained for these thickness. Substantially better toughness is also observed.
TABLE 1
R 0.2(L)
R 0.2(TL)
K 1c(LT) at
74-0.08e-
Thickness
at 1/4 th.
at 1/4 th.
1/4 th.
0.07R 0.2(L)
[mm]
[MPa]
[MPa]
[MPa{square root over (m)}]
[MPa{square root over (m)}]
alloy
130
450
445
29.6
32.1
7050
150
443
442
28.4
31.0
200
415
410
24.0
29.0
alloy F
130
445
440
37.5
32.5
(inven-
150
443
442
35.8
31.0
tion)
200
448
438
32.6
26.6
alloy X
130
445
444
36.8
32.1
(inven-
150
443
440
36.1
31.0
tion)
200
441
436
33.0
27.1
Example 2
Two alloys were cast, the first of which had a composition according to the invention (alloy G), the second of which was a standard alloy 7050. The compositions of these alloys are shown in Table 2.
The cast plates were homogenized at around 470° C. and rolled in three passes to a thickness of 6 inches (152 mm), 7.5 inches (190 mm), or 8 inches (203 mm), as indicated in Table 3. The outlet temperatures of the rolling are also indicated in Table 3. The plates were solution heat treated at 480° C., quenched by immersion in cold water, and subjected to a controlled traction with a deformation rate of 2%. The plates were then subjected to a two-stage aging:
6 h at 115° C. and 10 h at 172° C. for the plates of alloy G (according to the invention),
6 h at 120° C. and 17 h at 165° C. for the plates of alloy 7050 (prior art).
For each alloy-thickness combination, the yield strength R 0.2 was measured at quarter-thickness in the L and TL directions, and the toughness K 1c was measured in the L-T direction (at quarter-thickness), the T-L direction (at quarter-thickness) and the S-L direction (at half-thickness), in accordance with the ASTM E399 standard. The recrystallization rate of each plate was also measured at quarter-thickness and at half-thickness. This measurement was performed on treated samples in the T351 temper, treated for 6 hours at 160° C., and then polished and attacked by a solution containing 84 parts chromium solution, 15 parts nitrogen solution, and 1 part fluoride solution at the ambient temperature for about ½ hour. The recrystallization rate was measured by image analysis on micrographs of these samples, in which the recrystallized grains appeared light against the dark non-recrystallized matrix. All of the results are indicated in Table 3.
It is noted that the plates according to the invention have a yield strength similar to or greater than that of 7050 with a higher toughness level, particularly in the L-T direction. In fact, the L-T toughness of the plate of alloy 7050 is less than 31.4 MPa{square root over (m)} for a thickness of 152 mm, or 28.1 for a thickness of 190 mm, that is, less than the values corresponding to 74−0.083−0.07 R 0.2L .
Moreover, in the plates according to the invention, tensile strength levels in the TC direction >300 MPa were measured after 30 days in a 3.5% NaCl solution, with immersion-emersion cycles of 10 and 50 min., in accordance with the ASTM G 44-75 standard relative to the measurement of stress corrosion resistance.
TABLE 2
Zn(%)
Mg(%)
Cu(%)
Fe(%)
Si(%)
Zr(%)
alloy G
6.01
2.26
1.62
0.09
0.04
0.11
(invention)
alloy 7050
6.01
2.28
2.22
TABLE 3
Recr.
74 -
R 0.2(L)
R 0.2(TL)
K 1c(LT)
K 1c(TL)
K 1c(SL)
rate
0.08e-
Outlet
at ¼
at ¼
at ¼
at ¼
at ½
at ¼
0.07
Alloy
Th.
temp.
th.
th.
th.
th.
th.
th.
R 0.2(L)
No.
mm
° C.
MPa
MPa
MPa{square root over (m)}
MPa{square root over (m)}
MPa{square root over (m)}
%
MPa{square root over (m)}
G
203
429
441
437
33.5
26.4
29.0
4
26.9
G
152
425
440
435
33.7
27.4
29.1
6
31.0
7050
152
427
435
431
28.4
24.8
27.1
42
31.4
7050
190
435
439
421
26.8
24.2
26.9
38
28.1
Example 3
Five types of alloys were cast, the compositions of which are shown in Table 4. The alloy A is a standard 7050, the alloy B is a 7050 optimized with a low MG content. The alloys C, D and E have compositions according to the invention. The cast plates were homogenized at around 470° C. and hot rolled to thicknesses of 8 inches (203 mm), or 8.5 inches (215 mm). The plates were then solution heat treated at 480° C., quenched by immersion in cold water, and subjected to a controlled traction with a deformation rate of 2%. The plates were then subjected to a standard two-stage aging with a first stage between 115° C. and 120° C., and a second stage around 170° C., this two-stage treatment being characterized by an equivalent time t(eq) between 950 hours and 1,580 hours, expressed by the equation: t ( eq ) = ∫ exp ( - 16 , 000 / T ) t exp ( - 16 , 000 / T ref )
in which T (in Kelvin) indicates the temperature of the heat treatment which continues for a time t (in hours), and T ref is a reference temperature, here set at 393 K or 120° C.
For each alloy-thickness combination, the yield strength R 0.2 in the L direction was measured at quarter-thickness and the toughness K 1c was measured at quarter-thickness in the L-T direction in accordance with the ASTM E399 standard. The recrystallization rate of each plate was also measured using the method described in Example 2. All of the results are shown in Table 4. The type A and B alloys correspond to the prior art, and the type C, D and E alloys correspond to the invention. For all of these alloys, the stress corrosion threshold was higher than 300 MPa.
TABLE 4
Recr.
74-
rate
R 0.2(L)
K 1c(LT)
0.08e-
Thick-
at 1/4
at 1/4
at 1/4
0.07
Mg
Zn
Cu
ness
th.
th.
th.
R 02(L)
Alloy
%
%
%
mm
%
MPa
MPa{square root over (m)}
MPa{square root over (m)}
A
2.42
6.0
2.29
215
<10
418
24.6
27.5
A
2.42
6.0
2.29
215
<10
420
23.4
27.4
A
2.42
6.0
2.29
215
<10
432
25.7
26.6
A
2.42
6.0
2.29
215
<10
430
25.7
26.7
B
2.07
6.4
2.15
203
20
417
27.2
28.6
C
2.22
6.0
1.84
215
444
29.9
25.7
C
2.22
6.0
1.84
215
440
29.3
26.0
C
2.22
6.0
1.84
215
<10
441
31.6
25.9
C′
2.21
6.0
1.83
215
<10
432
30.3
26.6
C
2.22
6.0
1.84
215
<10
419
30.3
27.5
D
2.25
6.0
1.60
203
<10
444
30.9
26.7
D
2.25
6.0
1.60
203
<10
432
32.8
27.5
D′
2.32
6.1
1.68
215
<10
416
32.9
27.7
E
2.08
6.4
1.69
215
<10
465
35.6
24.3
It is noted that or the alloys A and B, the value Of K 1c(LT) measured at quarter-thickness is always lower than the reference value 74−0.08 e−0.07 R 0.2(L) , whereas for the alloys according to the invention, it is always significantly higher. This indicates that the compromise between static mechanical properties and toughness is better.
Example 4
Three type E alloys were cast, whose compositions are shown in Table 5. The alloys were transformed according to the process in Example 3, and subjected to the same types of tests. The results are shown in Table 5.
TABLE 5
Recry.
74 -
rate
R 0.2(L)
K 1c(LT)
0.08e -
Thick-
at 1/4
at 1/4
at 1/4
0.07
Mg
Zn
Cu
ness
th.
th.
th.
R 0.2(L)
Alloy
%
%
%
mm
%
MPa
MPa{square root over (m)}
MPa{square root over (m)}
E
2.08
6.4
1.69
215
<10
465
35.6
24.3
E′
2.01
6.4
1.62
215
25
460
32.0
24.6
E″
1.99
6.4
1.66
215
70
442
29.0
25.9
It is noted that for the limited composition range chosen, the recrystallization rate had only a limited influence on the toughness—yield strength compromise, insofar as the value of K 1c(LT) measured at quarter thickness is always sharply higher than the reference value 74−0.08 e−0.07 R 0.2(L) .
Example 5
Four types of alloys were cast, the compositions of which are shown in Table 6. The type E alloys correspond to the invention, and the type B alloy corresponds to the prior art. All the alloys were transformed according to the process in Example 3. The thickness of the plates was 215 mm. However, the influence of the equivalent time of the second aging stage was examined. The plates were subjected to the same types of tests. The results are shown in Table 6.
TABLE 6
Recry.
74 -
Rate
R 0.2(L)
K 1c(LT)
0.08e-
at 1/4
at 1/4
at 1/4
0.07
Mg
Zn
Cu
th.
t(eq)
th.
th.
R 0.2(L)
Alloy
%
%
%
%
hours
MPa
MPa{square root over (m)}
MPa{square root over (m)}
E
1.99
6.4
1.66
60
989
442
29.0
25.9
E″
1.99
6.4
1.66
60
1186
431
28.7
26.6
E″
1.99
6.4
1.66
60
1383
408
30.2
28.2
E
2.08
6.4
1.69
<10
661
477
33.9
23.2
E
2.08
6.4
1.69
<10
858
465
35.6
24.2
E′
2.01
6.4
1.62
30
661
479
29.7
23.2
E′
2.01
6.4
1.62
30
858
459
32.0
24.6
E′
2.01
6.4
1.62
30
1055
448
32.5
25.4
B
2.13
6.0
2.10
15
1120
429
26.6
27.7
B
2.13
6.0
2.10
15
1383
417
27.2
28.6
B
2.13
6.0
2.10
15
1645
411
27.9
29.0
It is noted that for the products according to the invention, for the limited composition range chosen, the conditions of the aging have little influence on the compromise between toughness and yield strength, insofar as the value of K 1c(LT) measured at quarter-thickness is always sharply higher than the reference value 74−0.08 e−0.07 R 0.2(L) . On the other hand, the products according to the prior art are characterized by a K 1c(LT) value which is always sharply lower than the reference value.
Example 6
Two type D alloys were cast, the compositions of which are shown in Table 7 (the zinc content for both alloys was 6.0%). The alloys were transformed according to the process in Example 3. The plates were subjected to the same types of tests. The results are shown in Table 7.
TABLE 7
Recr
Recr
74 -
Rate
Rate
R 0.2(L)
R 0.2(TL)
K 1c(LT)
K 1c(SL)
0.08e -
at 1/4
at 1/2
at 1/4
at 1/4
at 1/4
at 1/2
0.07
Al-
Mg
Cu
Zr
th.
th.
th.
th.
th.
th.
th.
R 0.2(L)
loy
%
%
%
mm
%
%
MPa
MPa
MPa{square root over (m)}
MPa{square root over (m)}
MPa{square root over (m)}
D
2.25
1.60
0.12
203
5
17
431
431
32.8
29.5
27.5
D
2.25
1.60
0.12
153
4
8
433
431
33.8
29.7
31.5
D″
2.28
1.65
0.11
203
40
30
459
445
25.4
26.1
25.6
D″
2.28
1.65
0.11
152
44
35
447
441
28.5
25.0
30.5
It is noted that for the composition range chosen, recrystallization is critical in order to obtain an acceptable compromise between toughness and yield strength. More specifically, the value of the recrystallization rate must not exceed about 35% between quarter-thickness and half-thickness in order to ensure that: the value of K 1c(LT) measured at quarter-thickness is aways higher than the reference value 74−0.08 e−0.07 R 0.2(L) .
Example 7
Four ingots were cast, 2 in alloy Y according to the invention, and 2 in alloy Z, with a composition outside the range of the invention. The compositions (weight %) are given in the table below:
Mg
Zn
Cu
Fe
Si
Zr
alloy Y
2.15
8.46
1.55
0.07
0.04
0.1
alloy Z
2.32
8.68
1.9
0.07
0.04
0.11
The 4 ingots were scalped, homogenized at 470° C., and hot rolled to thicknesses of 100 or 150 mm (one plate at each thickness for each alloy). Rolling commenced at between 410 and 415° C. and finished at between 430 and 440° C. The 4 plates were solution heat treated at 475° C., quenched by immersion in cold water and stress-relieved using a stretch of around 2%. The plates were then given a two-step aging treatment (T7651 temper) of 24 hours at 120° C.+12 hours at 160° C.
For each plate, at the quarter-thickness position (¼t) the 0.2% offset yield strength R 0.2 was measured in the long (L) and transverse (LT) directions, and the plane strain fracture toughness K 1c was measured in the L-T direction, following the ASTM E399 standard using CT samples. The recrystallized volume fraction was also measured by image analysis at quarter-thickness. The results are shown in Table 8. The toughness (mPam) should be compared with the quantity 74−0.08 t−0.07 R 0.2 (MPam) where t is the plate thickness in mm (as in example 1). It can be seen that alloy Y (the invention) gives superior strength and toughness compared with alloy Z.
The stress-corrosion resistance of the alloy Y (invention) plates in the short transverse direction was measured following the ASTM G44-75 standard. No samples failed within 20 days exposure at stresses less than or equal to 240 MPa.
TABLE 8
Plate
R 0.2 (L)
R 0.2 (LT)
K 1c L-T
thickness t
Recrystallization
1/4t
1/4t
1/4t
74-0.08t-
(mm)
1/4t (vol %)
(MPa)
(MPa)
(mPam)
0.07R 0.2 (L)
alloy
100
18
525
522
30.2
29.3
Y
150
17
490
471
28.1
27.7
alloy
100
14
523
513
25.9
29.4
Z
150
10
477
458
26.3
28.6
|
A mold for plastics made of a rolled, extruded or forged AlZnMgCu aluminum alloy product >60 mm thick, and having a composition including, in weight %:
5.7 <
Zn < 8.7
1.7 <
Mg < 2.5
1.2 <
Cu < 2.2
Fe < 0.14
Si < 0.11
0.05 <
Zr < 0.15
Mn < 0.02
Cr < 0.02
with Cu+Mg<4.1 and Mg>Cu,
other elements<0.05 each and<0.10 in total,
the product being treated by solution heat treating, quenching and aging to a T6 temper.
| 2
|
FIELD OF THE INVENTION
The present subject matter relates generally to tower structures, and more specifically to methods and apparatus for assembling tower structures.
BACKGROUND OF THE INVENTION
Construction of towers for support of various items has been practiced for many years. Various towers of various materials, including wooden, steel, and, more recently, concrete, have been provided to support, for example, electrical transmission lines. In a like manner, wind driven apparatus including windmills and wind-driven power generators in various forms and designed for many purposes (including for example pumping of water from wells as well as, more recently, generation of electrical power) have also been developed.
Such towers are generally constructed of multiple pieces that are assembled at the location of the tower. The pieces are usually hoisted in place by a crane. Cranes can be very expensive to maintain and operate, and a substantial hourly cost is incurred for every hour the crane is on site.
For example, a large construction crane may require 16 truckloads to transport all of the component parts, substantial labor to assemble and inspect, and then substantial labor to disassemble. Accordingly, a method and apparatus for constructing a tower that minimizes or eliminates the need for a crane is desired.
SUMMARY OF THE INVENTION
The present invention broadly comprises a method and apparatus for constructing a tower. In one embodiment, the apparatus may include a structure including a foundation including a plurality of hydraulic cylinders; a truss tower located on the foundation and configured to support a tower built on the foundation; and a controller configured to control extension and retraction of the hydraulic cylinders.
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 illustrates a perspective view of an embodiment of the present invention;
FIG. 2 is a top view of the foundation of the embodiment shown in FIG. 1 ;
FIG. 3 illustrates a top view of the tower and a schematic of the cylinder control system;
FIG. 4 is a side view of all of the cylinders extended before the insertion of a new level;
FIG. 5 is a side view showing half of the cylinders retracted and half extended;
FIG. 6 is a side view of the first block that is fully inserted and the hydraulic cylinders below are extended to contact the block;
FIG. 7 is a side view of the insertion of the second block;
FIG. 8 is a side view of the completion of a level; and
FIG. 9 is a top view of an embodiment of the restraining truss shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is presently made in detail to exemplary embodiments of the present subject matter, one or more examples of which are illustrated in or represented by the drawings. Each example is provided by way of explanation of the present subject matter, not limitation of the present subject matter. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present subject matter without departing from the scope or spirit of the present subject matter. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present subject matter covers such modifications and variations as come within the scope of the disclosure and equivalents thereof.
FIG. 1 shows a perspective view of an exemplary embodiment of an apparatus 10 for constructing a tower 80 in accordance with the present invention. Tower 80 supports wind turbine 82 , but towers made according to the present invention may support other equipment, power lines, or other objects. Any such towers may be constructed according to the present invention.
Apparatus 10 includes a foundation 20 and a truss tower 40 located on the foundation 20 . Foundation 20 includes a plurality of hydraulic cylinders 22 , shown in FIGS. 3-8 . Truss tower includes vertical legs 42 , upper restraining truss 44 , and lower restraining truss 46 . As shown in FIG. 2 , the base 42 A of each vertical leg 42 of the truss tower 40 rests on foundation 20 .
FIG. 1 shows a truss tower including two restraining trusses, but more than two can be included and are within the scope of the present invention. The restraining trusses 44 and 46 provide horizontal force to support the tower 80 during construction of the tower. In particular, the restraining trusses 44 and 46 counteract uneven forces on the tower 80 during the method of construction described hereafter.
FIG. 9 shows a close up top view of a restraining truss, such as upper restraining truss 44 . Each restraining truss includes force bearing devices 48 to transfer force from the truss tower 40 to the tower 80 . Further, the force bearing devices 48 allow tower 80 to move past vertically as additional levels are added to tower 80 from below. In the embodiment shown in FIG. 9 , the force bearing device includes rollers 49 to exert horizontal force on tower 80 while still allowing tower 80 to move vertically. However, other devices known in the art may be used in this manner. Further, the force bearing devices may include hydraulic cylinders 50 to tighten the force bearing device up to the wall of tower 80 . The embodiment shown in FIG. 9 includes a hydraulic cylinder 50 for each force bearing device 48 . However, fewer may be used as long as the restraining truss can be sufficiently tightened around tower 80 .
In the embodiment shown in FIGS. 1-9 , tower 80 has an octagonal cross-section. However, other cross-section shapes are possible, such as square or circular cross-sections. All of these modifications are within the scope of the invention.
Tower 80 as shown in FIG. 1 includes a wind turbine 82 located on top of levels 84 . In one embodiment, levels 84 are first constructed with a crane, the truss tower 40 is constructed around the levels 84 , and then the crane lifts the wind turbine 82 to the top of levels 84 . The following procedure is then used to add additional levels to the tower using hydraulic cylinders 22 . However, if a heavy object like a wind turbine is not going to be located at the top of the tower, then the truss tower 40 can be constructed over foundation 20 and all levels can be constructed using the hydraulic cylinders 22 . This would allow the elimination of the need for a crane, as the addition of levels using the hydraulic cylinders 22 only needs a forklift, as discussed hereafter.
In an embodiment for a tower 80 with a wind turbine 82 , 10 2 m levels 82 may be constructed using a crane, and a height of wind turbine 82 may be 50 m. Thus, each leg 42 would be 20 m tall, upper restraining truss 44 would be at 20 m in height while lower restraining truss 46 may be at approximately 8 m from the bottom of truss legs 42 . Truss legs 42 may be square of 12 inches on a side, and may be 22 feet apart from each other.
In the embodiment shown in FIG. 1 , foundation 20 is constructed, and hydraulic cylinders 22 and block supports 24 are installed in the foundation 20 . Hydraulic cylinders 22 are arranged in pairs, with a block support 24 extending between each pair of cylinders. A plurality of levels 84 are constructed using a crane, the truss tower 40 is constructed around levels 82 and on foundation 20 , and the wind turbine 82 is added to the top of levels 84 . Additional levels are then added using hydraulic cylinders 22 and block supports 24 as shown in FIGS. 4-8 . In the embodiment shown in FIGS. 1-9 , hydraulic cylinders 22 and block supports 24 are then removed from foundation 20 after the desired number of additional levels are added.
In the embodiment shown in FIGS. 1-9 , there are 24 hydraulic cylinders 22 . In one embodiment, cylinders 22 are sized to lift a concrete tower with a final weight of 1800 tons. However, towers of any dimensions and material may be constructed using this method and apparatus. The size and number of cylinders may vary depending on the dimensions of the tower and the building material. All of these modifications are within the scope of the present invention.
In this regard, in the embodiment shown in FIGS. 1-9 , each level 84 and 86 is slightly wider than the level above, as shown in FIG. 3 . When the final level is added, the bottom of this final level will line up with the top of foundation 20 .
The first step of the process is shown in FIG. 4 , in which all of hydraulic cylinders 22 are extended to push up tower 80 by the height of one level. In the embodiment shown in FIGS. 1-9 , all of the levels 84 and 86 have approximately a same height. However, different heights could be used as long as the extension height of hydraulic cylinders 22 is greater than the tallest level. At this step, the tower must slide past the force bearing devices 48 on the restraining trusses, as noted above.
As shown in FIG. 5 , one half of hydraulic cylinders 22 are then retracted to allow block 86 A of new level 86 to be inserted. As noted above, in the embodiment shown in FIGS. 1-9 , new level 86 is made of two equal sized blocks 86 A and 86 B. However, embodiments where three or more blocks are used and/or each block is more or less than half of each level are possible and are within the scope of the present invention.
Block 86 A is inserted by the use of a forklift. Block 86 A is then connected to the level above. Block 86 A may be adhered to the block above, or may have grooves or projections that mate with the block above, or both. During this time, uneven forces are placed on the existing tower 80 . Accordingly, restraining trusses 44 and 46 exert horizontal forces on the tower 80 to prevent tower 80 from tipping over due to these uneven forces.
At this point, the other half of the hydraulic cylinders 22 are retracted, as shown in FIG. 6 . This allows block 86 B to be inserted using a forklift, as shown in FIG. 7 . Block 86 B is then connected to the level above in a similar manner as block 86 A, as shown in FIG. 8 . This should end the uneven forces on the tower, and reduce the load on the truss tower 40 .
Finally, the new level 86 is pushed up the height of a level by extending all of the hydraulic cylinders 22 , as shown in FIG. 4 . Half of the hydraulic cylinders are then retracted to allow the next level to be added, as described above. However, in the embodiment shown in FIGS. 1-9 , the seams between the two blocks are alternated from level to level. That is, the seam between two blocks is only located on a particular face for every other level, as shown in FIG. 1 . Thus, for example, a first level 86 is constructed by lowering a front half of hydraulic cylinders 22 , adding block 86 A to the front opening, lowering the back half of hydraulic cylinders 22 , and then adding back block 86 B. The following level would be constructed by lowering either the right (or left) half of hydraulic cylinders 22 , adding block 86 A to the right (or left) opening, lowering the left (or right) half of hydraulic cylinders 22 , adding block 86 B to the left (or right) opening. This is accomplished using the control computer 60 shown in FIG. 3 .
Control computer 60 receives position and pressure readings from each of the cylinders 22 through lines 60 A ( FIG. 3 does not show all of lines 60 A). Control computer 60 then sends signals to control pressurized fluid to each cylinder 22 through line 60 C to pressure manifold 62 . Based on the signals from the control computer 60 , pressure manifold 62 supplies pressurized fluid to each cylinder 22 through a respective valve 62 A. (Not all of valves 62 A are shown in FIG. 3 .) Control computer 60 also controls a return valve on each cylinder 22 through line 60 B. (Not all of lines 60 B are shown in FIG. 3 .) When the return valve is opened by control computer 60 , fluid runs through a respective return line 66 A to fluid reservoir 66 . (Only one of the 24 return lines 66 A is shown in FIG. 3 ). Fluid from fluid reservoir 66 is pressurized by electrical or diesel pump 64 before it is supplied to the pressure manifold 62 .
Control computer 60 has several programs to control multiple sets of the cylinders 22 . As discussed above, in the embodiment shown in FIGS. 4-8 , half of cylinders 22 are controlled to extend and retract together, and the halves are alternated for each level between (1) right and left half and (2) front and back half. Thus, control computer 60 at has programs to extend and retract (1) the right half of cylinders 22 , (2) the left half of cylinders 22 , (3) the front half of cylinders 22 , and (4) the back half of cylinders 22 . Additional commands such as all extend and all retract can also be programmed into control computer 60 . Further, if each level includes more than 2 blocks, additional commands will be needed to control smaller subsets of cylinders 22 .
Accordingly, a tower 80 may be constructed with less use of a crane, or without the use of a crane at all. As a forklift is much cheaper to operate than a crane, a substantial cost savings may be gained by using the present method and apparatus for constructing a tower.
The present written description uses examples to disclose the present subject matter, including the best mode, and also to enable any person skilled in the art to practice the present subject matter, including making and using any devices or systems and performing any incorporated and/or associated methods. 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.
|
A method and apparatus for constructing a tower, where the apparatus may include a structure including a foundation including a plurality of hydraulic cylinders; a truss tower located on the foundation and configured to support a tower built on the foundation; and a controller configured to control extension and retraction of the hydraulic cylinders.
| 4
|
BACKGROUND OF THE INVENTION
This invention relates to fine line patterning of semiconductor integrated circuits, and more particularly to a method of forming minute patterns in silicon by dry etching, such as by means of a chemical reactant in plasma form.
As the line geometry of semiconductor integrated circuit devices becomes smaller, there is a trend toward utilizing plasma dry etching processes instead of wet chemical etching processes. For more precise line width control the etching process should be anisotropic. In anisotropic etching of silicon, for example, the process of etching proceeds in depth only, in a vertical direction relative to the horizontal surface of the silicon wafer. In isotropic etching, in contrast, the silicon material etches both laterally and vertically, with the lateral component of etching producing an undercutting of the silicon surface beneath the masking material.
While anisotropic etching is preferred for obtaining more precise line width control, the sharp profile associated with the abrupt vertical etched wall which makes a 90° angle with the horizontal silicon surface gives rise to many severe manufacturing problems, such as those associated with step coverage, oxide overhang, residual ribbon formation, and photoresist bridging, to mention a few. These problems can be alleviated to a considerable extent by shaping the edge profile of the etched silicon so that it has a flat, inclined slope considerably less than 90° relative to the horizontal silicon surface.
SUMMARY OF THE INVENTION
In accordance with the invention, a method is provided for selectively etching a silicon surface of an integrated circuit component in a controlled manner by varying the degree of undercutting of the surface. A chemically reactive plasma environment is created from a gaseous medium containing two constituents. A first one of the constituents has the property of causing the silicon to etch anisotropically. The second constituent, when present with the first constituent, has the property of causing undercutting of the silicon, with the degree of undercutting increasing with increasing proportion of the second constituent. The silicon is subjected to the gaseous medium containing both constituents while the proportion of the second constituent is varied to control the etching of the silicon between a mode that is completely anisotropic and one that is completely isotropic.
By completely anisotropic is meant that the etching is predominantly in the vertical direction and there is little or no undercutting in the lateral direction. By completely isotropic is meant that the etching is uniform in all directions, and the undercutting in the lateral direction is equal to the vertical component of etching.
In accordance with a sepcific embodiment, the first constituent is carbon tetrachloride (CCl 4 ) and the second constituent is oxygen (O 2 ). When the etching process begins the carbon tetrachloride is present in the ratio of 150 parts to 80 parts oxygen, and the etching of silicon is completely isotropic. While the etching process continues, the proportion of oxygen is gradually reduced until there is no longer any oxygen present, at which time the etching process is completely anisotropic. The process is terminated at that point. As a result of gradually varying the proportion of the two gaseous constituents during the etching process, the edge profile of the etched silicon surface has a flat, uniform slope that is inclined considerably less than 90° relative to the horizontal silicon surface.
International Publication No. W081/02947, published Oct. 15, 1981, discloses a method of controlling undercutting during plasma etching of silicon by mixing gases. However, in that reference, a fluorine-containing compound is used as the single constituent in a plasma etching medium to achieve complete isotropic etching, rather than anisotropic etching. The amount of undercutting is reduced by mixing chlorine with the fluorine-containing compound, and complete anisotropic etching results when the plasma etching medium contains 100% chlorine. The reference does not disclose a process for shaping the profile of the etched silicon surface so that it has a flat incline considerably less than 90% relative to the horizontal silicon surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a chemically reactive plasma etching apparatus which can be used for carrying out the method according to the invention.
FIG. 2 is a graph showing the variation in undercutting of polysilicon with the proportion of oxygen added to carbon tetrachloride as a chemically reactive plasma.
FIGS. 3A through 3C are sectional views showing the effects of oxygen on the undercutting of polysilicon.
FIGS. 4A through 4C are sectional views showing some of the step coverage defects arising from anisotropic etching of polysilicon.
FIG. 4D is a sectional view showing the sloped edge profile of polysilicon etched in accordance with the invention.
FIGS. 5A through 5D are sectional views showing some of the effects of oxidation overhang resulting from anisotropic etching of polysilicon.
FIGS. 6A through 6D are sectional views showing how the defects of oxidation overhang shown in FIGS. 5A through 5D are avoided by sloping the edge profile of polysilicon according to the invention.
FIG. 7 is a sectional view showing the defect of residual ribbon formation resulting from anisotropic etching of polysilicon.
FIGS. 8A and 8B are sectional and plan views, respectively, showing the defect of photoresist bridging resulting from anisotropic etching of polysilicon.
FIGS. 9A and 9B are sectional and plan views, respectively, showing how the defects of photoresist bridging shown in FIGS. 8A and 8B are avoided by sloping the edge profile of polysilicon according to the invention.
FIG. 10 is a sectional view showing the edge profile of a double polysilicon layer structure resulting from controlled isotropic etching of the top layer followed by complete anisotropic etching of the bottom layer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is now made to FIG. 1 which shows a diagram of a reactive plasma etching apparatus for carrying out the method according to the invention. A main plasma chamber 10 is formed by a cylindrical wall 12 closed at both ends thereof by a top end plate 14 and a bottom end plate 16. The chamber 10 houses a lower electrode 18 and an upper electrode 20 spaced therefrom. A reactive plasma is produced between the electrodes 18 and 20 when a suitable gas is introduced within the chamber 10 and a source of radio frequency energy is applied across the electrodes 18 and 20.
The lower electrode 18 is electrically insulated from the bottom plate 16 by a spacer 22 of insulating material, such as Teflon. An exhaust gas outlet 24, communicating with the plasma chamber 10 through a central opening 25 passing through the bottom plate 16, the spacer 22, and the lower electrode 18, is connected to an exhaust pump system, not shown, for evacuating and maintaining the chamber 10 at the required low gas pressure. Gas for the plasma is furnished by a gas supply 26 through two conduits 28 entering the chamber 10 adjacent to the cylindrical wall 12. A gas distribution ring 30 surrounding the lower electrode 18 is used to deflect the gas stream emanating from the conduits 28 so that the gas flows laterally across the top surface of the lower electrode 18 where the semiconductor wafers 32 are positioned to receive the flow of gas. An outer dark space shield ring 34 surrounds the outer periphery of the lower electrode 18, and a smaller inner dark space shield ring 36 surrounds the inner surface of the lower electrode 18 facing the central opening 25.
Power to generate the plasma is supplied from an RF generator 38. Typically, the RF generator 38 provides 3 kilowatts of power output at 13.56 MHz. The power is switched optionally to the upper electrode 20 by a switching panel 40 coupling into an RF tuning network 42, or to the lower electrode 18 by the switching panel 40 coupling into an RF tuning network 43. The upper electrode 20 is adjustable vertically to vary its spacing from the lower electrode 18.
For reactive ion etching the RF power is supplied to the lower electrode 18 and the upper electrode 20 is grounded. For plasma etching power is supplied to the upper electrode 20 and the lower electrode 18 is grounded. In plasma etching, the etching process is accomplished by chemical reaction only. In reactive ion etching, the etching process is accomplished both by chemical reaction and by physically enhanced processes by way of ionic bombardment. Either plasma etching or reactive ion etching may be used to carry out the process of the invention. However, in the specific example for which graphical results are given the process used was that of reactive ion etching.
The gas or gas mixture required for the reactive plasma etching process is furnished by the gas supply 26. The gas supply 26 may include a source of carbon tetrachloride gas and a source of oxygen. The gas supply may also include other kinds of gases that may be necessary to etch other materials besides silicon during the manufacture of the integrated circuit devices.
Reference is now made to FIG. 2 which is a graph showing the variation in the amount of undercutting of N doped polysilicon as a function of the amount of oxygen added to a plasma environment of carbon tetrachloride. In this example, the flow rate of carbon tetrachloride was maintained constant at 150 SCCM, which stands for standard cubic centimeters per minute. Standard means that the gas flow was measured under the standard condition of one atmospheric pressure and 25° C. temperature. The polysilicon coated samples were etched at each of nine different flow rates of oxygen, also measured in SCCM. Samples were etched at 80, 70, 60, 50, 40, 30, 20 10, and 0 SCCM flow rates of oxygen. At each flow rate value measurements were made of the ratio of undercutting, or etching in the lateral direction, to the amount of etching in the vertical direction, and on the graph this ratio is expressed in percent of undercutting. Samples tested at 80 SCCM of oxygen showed 100% undercutting, which means that the etching was completely isotropic. Samples tested at 60 SCCM of oxygen showed about 80% undercutting. At 40 SCCM of oxygen the samples showed about 70% undercutting. At 20 SCCM of oxygen the samples showed about 45% undercutting. With no oxygen present the samples showed no lateral etching, which means the etching was completely anisotropic.
While the graph of FIG. 2 shows the experimental results of etching N doped polysilicon, it is expected that similar results will be obtained with N doped monosilicon and with P doped or undoped monosilicon and polysilicon. However, the N doped silicon materials will etch faster than the undoped or P doped silicon materials. For purposes of the invention, however, the term silicon is meant to encompass both monocrystalline and polycrystalline silicon, whether doped N type or P type, or whether it be intrinsic.
FIGS. 3A to 3C show the effects of etching a polysilicon layer with different proportions of oxygen added to carbon tetrachloride. In each of the FIGS. 3A through 3C, the polysilicon layer 44 is deposited on a silicon dioxide layer 46 overlying a silicon substrate 47 and is masked during etching by a photoresist layer 48. FIG. 3A shows the effect of etching polysilicon with no oxygen added to 150 SCCM of carbon tetrachloride. FIG. 3B shows the effect of etching polysilicon with 40 SCCM added to 150 SCCM of carbon tetrachloride. FIG. 3C shows the effects of etching polysilicon with 80 SCCM added to 150 SCCM of carbon tetrachloride. In FIG. 3A it will be seen that with pure carbon tetrachloride as the plasma etching gas, the etching is completely anisotropic because the surface of the polysilicon layer 44 is vertical and there is no undercutting or lateral etching. In FIG. 3B, with only 40 SCCM of oxygen added to the carbon tetrachloride, the etching of the polysilicon layer 44 is slightly isotropic, there being about a ratio of 1 to 2 of lateral etching verses vertical etching. In FIG. 3C, with 80 SCCM of oxygen added to the carbon tetrachloride the lateral etching of the polysilicon layer is approximately equal to the vertical etching, so the undercutting is 100%.
A few illustrations will now be described of some of the problems and defects arising from anisotropic etching, and how these problems can be alleviated by shaping the profile of the etched silicon surface so that it has a gradual slope rather than an abrupt vertical slope. In FIGS. 4A through 4D some of the problems associated with step coverage are shown. The same numerals are used to indicate the same parts, wherein 50 is a layer of silicon dioxide on a silicon substrate 47, 52 is a layer of polysilicon that has been deposited on the silicon dioxide layer 50 and etched anisotropically, and 54 is a layer of chemically vapor deposited silicon dioxide that has been deposited over the polysilicon layer 52 and silicon dioxide layer 50.
FIG. 4A shows the formation of crevices 56 at the lowermost corners where the polysilicon layer 52 meets the bottom silicon dioxide layer 50. Crevice formation is undesirable because it may cause discontinuity of the aluminum line deposited on top of it.
FIG. 4B shows a discontinuity in the layer 54 formed at 58. A discontinuity may result in incomplete passivation and may cause a short circuit.
FIG. 4C shows stress concentrations in the layer 54. There is a region 62 of compressive stress concentration at the top corner of the step in layer 54, and a region 64 of tensile stress at the lower corner of the step. Stress concentrations may give rise to fracturing of the layer 54.
The application of a flow glass with a high phosphorus pentoxide content is generally used over sharp polysilicon steps to provide a smooth topography on which to deposite a conducting layer of aluminum. However, the high temperature process involved, usually around 1000° C., will give rise to many undesirable effects. Furthermore, the high content of phosphorus pentoxide in the glass layer may react with water vapor to form an etching composition which attacks the aluminum. An excess amount of phosphorus pentoxide also tends to degrade the adhesion of aluminum to the glass.
The foregoing problems may be overcome by shaping the profile of the polysilicon layer 52 so that it has a gradual inclined slope as shown in FIG. 4D. This profile may be achieved by starting the etching process of the polysilicon layer 52 so that it is completely isotropic. For example, with 150 SCCM of carbon tetrachloride the oxygen content can start off with about 80 SCCM, as described in the test results of FIG. 2. Then the amount of oxygen can be decreased gradually during the etching process so as to decrease the amount of undercutting until there is no oxygen present. At this point, when the etching it completely anisotropic, the process is terminated.
FIGS. 5A through 5D show the adverse effects of oxidation overhang in a double polysilicon layer process caused by anisotropic etching of the first polysilicon layer. FIGS. 6A through 6D show how this defect is avoided by properly shaping the edge profile of the first polysilicon layer. In FIG. 5A, a first polysilicon layer 66 is deposited on a first silicon dioxide layer 68 overlying a silicon substrate 69 and then is anisotropically etched. In FIG. 5B a second silicon dioxide layer 70 is deposited over the first polysilicon layer 66. During this second oxide formation, a re-entrant region 71 forms where the two oxide layers 68 and 70 join together. In FIG. 5C a second polysilicon layer 72 is deposited over the second oxide layer 70, filling in the crevice 71. When the second polysilicon layer 72 is patterned and etched, a filament 73 of polysilicon remains where the re-entrant region 71 was filled in. The filament 73 may give rise to short circuits.
in FIGS. 6A through 6D the same steps in the double polysilicon process are shown for the case where the first polysilicon layer 66 is etched according to the invention by sloping the edge profile thereof. In FIG. 6B there is no re-entrant region formed between the two oxide layers 68 and 70, thereby avoiding the formation of a polysilicon filament, as shown in FIG. 6D.
FIG. 7 shows another defect known as residual ribbon formation, that is caused by anisotropic etching of a polysilicon layer 74 deposited on a silicon dioxide layer 76 overlying silicon substrate 75. A passivation oxide layer 77 is deposited over the polysilicon layer 74 and a conducting layer 78 is deposited on the oxide layer 77. The conducting layer 78 may consist of aluminum or polysilicon. The step height of the oxide layer 77 over the polysilicon layer 74 is denoted as T2 and the thickness of the conducting layer 78 is denoted as T1 in all regions except the regions next adjacent to the side edges where the conducting layer 78 is thicker and is denoted by the thickness T1+T2. When the conducting layer 78 is etched there will remain a ribbon 79 of conducting material, shown as the shaded areas, in the corners on each side of the oxide step 77. The ribbon 79 may be avoided by overetching the conducting layer but this will reduce the line width. Ribbon formation can be avoided without reducing the line width by properly sloping the edge profile of the polysilicon layer 74.
Another defect known as photoresist bridging is shown in FIGS. 8A and 8B. In the cross sectional view of FIG. 8A, the anisotropically etched polysilicon layer 80 is formed with a step and is covered with positive photoresist 82. Adjacent to the edge of the step in the polysilicon layer 80, in the region denoted by the numeral 84, the photoresist 82 is thickest. When the photoresist 82 is exposed through a mask, for example to delineate a line pattern of polysilicon, the light does not penetrate the thickest regions of the photoresist 82. As a result, when the exposed positive photoresist is removed, some of the photoresist in the thickest regions 84 is not removed and forms a bridge between adjacent lines, as shown in the top plan view of FIG. 8B. When the uncovered polysilicon is removed between the photoresist lines, the polysilicon remaining underneath the photoresist bridge will cause a short circuit between adjacent polysilicon lines.
The above defect can be avoided by providing a gradual step in the polysilicon layer 80, as shown in FIG. 9A. In this case the photoresist will be exposed throughout its depth along the inclined edge, and no bridging of photoresist will occur, as shown in FIG. 9B.
The shape of the edge profile of silicon can be varied by continuously varying the amount of oxygen mixed with the carbon tetrachloride. The profile can be a continuous slope, having an angle between 45° and 90°, as already shown and described.
In the case of sequential etching of a double polysilicon layer structure, shown in FIG. 10, the top polysilicon layer 86 may be slope etched for good step coverage, while the bottom polysilicon layer 88, which is separated from the top polysilicon layer 86 by an oxide layer 90, may be anisotropically etched for fine line width control. For example the bottom polysilicon layer 88 may be 2500 angstroms thick deposited on a gate oxide layer 92 of 500 angstroms thickness. The interpoly oxide layer 90 may be 1000 angstroms thick and the top polysilicon layer 86 may be 5000 angstroms thick. A photoresist layer 94 is shown over the top polysilicon layer 86 to mask the area where etching is not desired. The gate oxide layer 92 is shown deposited on a silicon substrate 96.
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The edge profile of a silicon layer is shaped to have a gradual incline considerably less than 90° by continuously reducing the amount of oxygen mixed with carbon tetrachloride in a reactive ion etching environment. The etching mode varies from complete isotropic etching when the amount of oxygen is maximum, to complete anisotropic etching when the oxygen content is zero.
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This application is a continuation of application Ser. No. 08/452,172 filed May 26, 1995 now abandoned.
BACKGROUND OF THE INVENTION
Poor material handling practices of arsenic containing compounds and some on-site disposal has resulted in contamination of soil and groundwater at various sites. Not only is the source of the arsenic in soil due to various industrial waste processes but also from the use of lead arsenic in pesticides which was used in this country from approximately the turn of the century to the 1950's. Arsenic in herbicide manufacturing also generates much arsenic waste and also contributed to much of the contamination.
The arsenic compounds contaminating sites around the U.S. include a number of both arsenate and arsenite salts. However, these contaminated sites also contain other heavy metals, volatile and semivolatile organic compounds, and organic pesticides, notably the organochlorine pesticides.
Arsenic is exceedingly toxic to mammals. Arsenic forms poisonous compounds which, if absorbed by mammals, such as humans, causes various types of cancer, exfoliation and pigmentation of skin, herpes, polyneuritis, hematopoiesis, and degeneration of both the liver and kidneys. Acute symptoms range from irritation of the GI tract which can progress into shock and death.
Remediation of these sites is now necessary given the new Environmental Protection Agency (EPA) laws due to this extreme toxicity. The EPA has developed criteria for classifying wastes or soils as hazardous due to leaching of heavy metals, such as arsenic, in the leaching from contaminated soil. The EPA standard for arsenic leachability and non-waste water matrices is 5 mg per liter (ppm) arsenic in the leachate as measured by the Toxicity Characteristic Leaching Procedure (TCLP) leachate. Ideally, a means to solidify or chemically stabilize the arsenic and other contaminants in the contaminated soil is preferred. Preferably, the method chosen would be suitable for in-situ treatment, and would result in a volume increase of less than 10 percent in the treated soil.
Arsenic exhibits relatively complex behavior due in part to its ability to assume a range of oxidation states (-III, O, III, V) and to form organic as well as inorganic compounds. Arsenic was usually disposed predominantly in the trivalent (III) and pentravalent (V) oxidation states, as arsenite and arsenate compounds. Arsenate forms relatively insoluble compounds with calcium, iron, aluminum and copper, and is strongly adsorbed into iron and aluminum oxides and hydroxides. Arsenite compounds are generally more soluble than arsenate compounds, making arsenite more mobile and having a greater leaching ability and contamination potential. In addition, arsenite is more toxic. It is also adsorbed onto iron and aluminum oxides and hydroxides, although to a lesser degree than arsenate. This is due in part to the markedly different pH-dependence of arsenite and arsenate adsorption. The maximum adsorption for arsenate occurs at pH 4-5, whereas that for arsenite occurs at pH 9. Due to the anionic nature of arsenate and arsenite ions (above pH 9) and the negative charge developed on oxide and hydroxide surfaces under alkaline conditions, adsorption decreases dramatically at higher pH due to electrostatic repulsions.
In the past, in order to eliminate or reduce arsenic contamination, cement stabilization was used. The problem with using cement for arsenic treatment is that it has little or no effect on arsenic stabilization and does not consistently render the soil nonhazardous for arsenic leaching. Cement and cement kiln dust do not stabilize arsenic against leaching by binding it in a cement matrix as once thought. In addition, cement causes an increase in pH wherein the arsenic becomes more soluble. In addition, cement solidifies the soil causing an increase in volume and therefore an increase in cost in disposing the contaminated material. Further, cement treated contaminated soil is difficult to work with due to the change in physical properties resulting from the treatment. For arsenic contaminated soils, cement alone is not effective at doses of even 25 and 50 percent. Tests indicate that cement or cement kiln dust in combination with various salts were not effective at reducing the leachability of arsenic to the desired levels. The samples treated with cement in combination with various salts show the same degree of leachability as those samples to which only pH control additives were applied.
As previously stated, the cement treatments also lead to an increase in volume. The increase in volume for the cement-treated samples is determined by measuring the weight of soil and final volume of the cement treated samples.
The 25 percent cement treatment resulted in a 54 percent increase in volume for the laboratory sample, while the 50 percent treatment resulted in an 82 percent volume increase.
One stabilization approach that can be used is the addition of ferric iron salts as demonstrated by McGaham U.S. Pat. No. 5,252,003 ('033 patent) in which ferric salt in combination with magnesium oxide is used to stabilize arsenate contaminated wastes or soils. However, one problem not addressed by the '033 patent is that the ferric iron may be reduced to ferrous iron in land disposal environments. Ferrous iron is not effective at stabilizing arsenic. The ferrous arsenate salts are much more soluble than the ferric salts. Arsenic may be released into ground water from the treated waste if such a reduction occurs.
Organic binders were also used to stabilize arsenic-contaminated material. Organic binders are also not preferred due to the fact that they also increase volume similar to that of cement and, therefore, increase the cost of eliminating the contaminated material.
SUMMARY OF THE INVENTION
This invention is a method for treatment of solid or semi-solid materials such as soils and sludges containing arsenic compounds in order to stabilize the contaminated material against leaching of arsenic. Specifically, this treatment utilizes aluminum compounds and an alkaline buffer in order to immobilize the arsenic via precipitation and adsorption. Preferably, this invention can be performed as an in situ treatment of arsenic contaminated soil utilizing aluminum sulfate and magnesium oxide.
The aforementioned problems of the prior art, that being the reduction of ferric compounds which result in release of arsenic back into the soil, are avoided using the present invention due to the fact that aluminum doesn't undergo oxidation-reduction reactions. Therefore, aluminum sulfate and a pH buffer combination results in a more effective and long term stable treatment of arsenic contaminated soil than the prior art ferric sulfate-magnesium oxide. In particular, the aluminum sulfate is best suited for applications under anoxic conditions (conditions which are void of oxygen). Conversely, ferric sulfate is better suited under oxic conditions (oxygenated). However, in soil, anoxic conditions are common. Therefore, if the iron treated soil becomes anoxic, the treatment process simply reverses, thereby releasing the arsenic back into the soil or environment. The ability to obtain effective treatment under anoxic conditions is extremely important regarding municipal landfills. In municipal landfills, the conditions are always anoxic and therefore, this invention has superior qualities over the prior art in municipal applications.
This invention is also especially effective against arsenate. However, if arsenite is found in a contaminated matter, it may be oxidized to form arsenate prior to treatment. An example of how to oxidize the soil is via hydrogen peroxide.
An example of a chemical reaction within the scope of this invention can be shown as follows:
Al.sub.2 (SO.sub.4).sub.3 +Na.sub.3 HAsO.sub.4 →2AlAsO.sub.4 +3Na.sub.2 SO.sub.4
The resulting arsenic stabilization is two-fold, utilizing both adsorption as well as precipitation. The aluminum arsenate product precipitates and therefore stabilizes the arsenic. The "alum" or aluminum sulfate also forms aluminum hydroxide which coprecipitates or adsorbs the arsenic, resulting in additional arsenic stabilization. Therefore, it is a combination of the AlAsO 4 plus arsenic adsorbing on the surface of aluminum hydroxide and getting trapped in a resulting matrix.
It is an object of the present invention to provide a method for treatment of materials such as soils or sludges containing arsenic compounds.
Further, an object of this invention is to render soil or waste that is hazardous for arsenic non-hazardous under TCLP tests.
Another object of the invention is to stabilize the material such as soil or sludges against leaching of arsenic in the natural environment.
Another object of the invention is to provide a convenient and inexpensive treatment. This is achieved primarily because the chemicals and equipment required to utilize the method of this invention are commercially available and relatively inexpensive and therefore make utilizing the method of this invention more convenient.
A further object of the invention is to result in minimal increase in the volume of the treated contaminated soil.
Still another object of this invention is to provide a method for treatment acceptable under the Synthetic Precipitation Leaching Procedure (SPLP) Test as well as the Multiple Extraction Procedure (MEP).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The form of arsenic contemplated within the scope of this invention can be organic or inorganic arsenicals. Examples of inorganic arsenicals may include, but is not limited to, arsenic acid and arsenic oxides. The organic arsenicals may include methane arsenicals such as mono-methyl sodium arsenate, Na(CH 3 )AsO 2 OH, cacadylic acid, dichlorophenylarsine and diethylarsine.
The contaminated soil or sludge to be treated will vary in consistency and composition. Also, the level of soil or sludge moisture may vary greatly. Sludge may consist of sedimentated or filtered waste product consisting of a thick viscous mass. Whether the treatment is for contaminated soil or contaminated sludge, the process of using this method is basically the same. The aluminum sulfate and the alkaline buffer is simply added to the soil (or sludge) and thoroughly mixed. It is especially beneficial if the soil has enough moisture to dissolve and subsequently form the products of the reaction, aluminum hydroxide and aluminum arsenate.
The preferred embodiment of this invention is the use of aluminum sulfate. However, other aluminum compounds may be utilized including aluminum chloride or any soluble aluminum salt or sodium aluminate.
The alkaline buffer used in this invention could be either magnesium oxide, magnesium hydroxide or a reactive form of calcium carbonate or calcium magnesium carbonate or any other suitable buffer that has the ability to buffer between pH 5 and 10. Since aluminum sulfate is an acid, the alkaline base is necessary to neutralize the acid and it is essential that this alkaline base therefore keep the pH in the appropriate range for forming the aluminum arsenate.
Soil Samples
All three soil samples tested were TCLP toxic for arsenic. The three soil samples (Sample Borings 1, 2 and 3 or "SB-1", "SB-2" and "SB-3") were supplied to the RMT Applied Chemistry Laboratory by S. S. Papadopulos and Associates. The samples were homogenized, and then subsamples were taken for the initial testing. Both TCLP (SW-846 Method 1311) and compositional analysis were performed on all three samples. On the basis of the results of the compositional and TCLP testing, the majority of the subsequent testing was on sample SB-1, since this sample had high compositional arsenic (24,000 mg/kg) and leached fairly high concentrations of arsenic in the TCLP test (150 mg/L). SB-2 had lower compositional arsenic, and so less work was done on that sample. SB-3 was used as a confirmation sample for the treatment process, since in terms of compositional arsenic, Sb-3 was similar to SB-1.
EXAMPLE 1
The testing performed on the samples was designed to determine what was in the samples and the leaching potential for those materials. The primary element of concern as arsenic. Leaching was evaluated in several ways. The Toxicity Characteristic Leaching Procedure TCLP test, Method 1311 in SW-846!, 55 Fed. Reg. 126, pgs. 26,986-998 (1990) is used by the USEPA for classifying wastes as hazardous. The test is designed to simulate the leaching potential of an actively degrading municipal landfill. As such, the TCLP test may not provide a realistic evaluation of the leaching potential of a waste disposed in an area other than a municipal landfill. An alternative test that can be used to ml leaching under less severe environments than a municipal landfill is the Synthetic Precipitation Leaching Procedure (SPLP, Method 1312, SW-846), which uses a simulated acid rain leaching solution. The leaching solution for the SPLP test is much less buffered than either of the two solutions used in the TCLP test; thus, it provides a less aggressive leaching medium. To model long-term leaching from a waste, the USEPA uses a serial elution leaching test, the Multiple Extraction Procedure (MEP). The original MEP was designed using the EP Toxicity test followed by nine elutions with a simulated acid rain. Since the time that the MEP was originally designed, the EPA has replaced the EP Toxicity test with the TCLP test, and has redesigned the simulated acid rain step to use the SPLP test. The MEP test procedure has not officially been updated, however.
Analytical laboratory procedures were done according to the USEPA protocols outlined in SW-846. However, a few analytical laboratory procedures were done using other protocol, most notably moisture content, which was done using ASTM Method D-2216-80. MEP tests were run using a standard TCLP test for the first elution, followed by nine successive elutions using the SPLP leaching solution.
For the treatability screening tests, a modified TCLP procedure was used to facilitate testing a large number of samples. The screening test uses one-tenth of the amounts of solid and liquid used in the standard test. The leaching solution used is chosen on the basis of knowledge of the waste and additives. If there is a question about which solution to use, either the TCLP pretest is run on the sample or both solutions are used. The samples are tumbled for 18 hours (±2 hours) on the standard TCLP tumbler, and are then filtered through a 0.45 μm filter. The filtrate is then analyzed directly without the normal digestion step. Arsenic was analyzed on graphite furnace AA.
The screening TCLP test uses one tenth of the prescribed sample weight and reagent volume, and a screening metals analysis in the laboratory, with no digestion or matrix spikes. The results are for screening purposes only. The procedure does not fulfill the requirements of the standard TCLP test.
Some screening SPLP tests were also conducted. The screening SPLP is similar to the screening TCLP test except that the SPLP leaching solution is used.
A number of treatment test additives can be used. For pH control, CaO (also contributes calcium ion) and MgO were added.
Aluminum addition was in the form of aluminum sulfate (alum) and CaO or MgO. Another additive may be copper sulfate.
With the exception of the solidified samples, the treatment additives were introduced into the bottle used for the screening TCLP test. The samples were mixed, but no extra water was added until the TCLP test solution was run. Normally, the screening TCLP test was run within a few minutes of mixing the treatment additive with the soil.
The solidified samples were prepared by mixing the soil with the additives. Water was added to form a cement-like slurry. The samples were cured for seven days. The samples were then pulverized to pass through the sieve used in the TCLP test. The screening TCLP test was performed on the pulverized material.
All additive weights are based on the wet weight of soil and the dry weight of additive, since the TCLP test is run on a wet weight basis. The weight of additive used is based on the weight of soil, not on the weight of the mixture (i.e., a 10 percent dose is the equivalent of 10 g additive per 100 g soil wet!).
Soil Characterization Prior To Stabilization
The results of the soil characterization are given in Tables 1 and 2. SB-1 and SB-3 contained 24,000 to 23,000 mg/kg of arsenic, respectively. Sample SB-2 had a lower arsenic concentration at 6,600 mg/kg (see Table 1).
TABLE 1______________________________________TREATABILITY STUDY SOILS COMPOSITIONAL METALS SB-1 SB-2 SB-3Parameter (mg/kg) (mg/kg) (mg/kg)______________________________________Arsenic 24,000 6,600 23,000______________________________________
All three samples leached arsenic above the hazardous waste criterion in the TCLP test. SB-1 leached 150 mg/L, SB-2 leached 240 mg/L, and SB-3 leached 550 mg/L in the TCLP tests (see Table 2).
TABLE 2______________________________________TREATABILITY STUDY SOILS TCLP METALS TCLP Criteria* SB-1 SB-2 SB-3Parameter (mg/L) (mg/L) (mg/L) (mg/L)______________________________________Arsenic 5.0 150 240 550______________________________________ *40 CRF 261.24 NS No Standard
The other metals were all below their respective hazardous waste criteria. Sample SB-3 contained higher levels of volatile compounds and organochlorine pesticides than did the other two soils.
In summary, all three soils were hazardous for arsenic.
Soil Characterization After Stabilization
In order to determine whether the arsenic in the soil samples was in the arsenate or arsenite form, several samples were oxidized with hydrogen peroxide, and then treated. If the arsenic were in the arsenate form initially, then the peroxide treatment should have little influence on the treatment test results. If a significant portion of the arsenic were in a reduced form (e.g., arsenite), then the peroxide oxidation should improve the treatment testing results. The results for both the unoxidized and oxidized samples are very similar, indicating that the arsenic is primarily in the arsenate form in the soil.
pH Control
Calcium oxide and magnesium oxide were added to samples SB-1 and SB-2 to determine the influence of pH on the leaching behavior of arsenic. Arsenic concentrations for both soils decrease as the pH increases; however, arsenic concentrations do not drop below 5 mg/L in the screening test until a lime dose of 20 percent is used and the pH is raised to 12.5. Under the conditions of the test, the solubility was not reduced sufficiently by the formation of relatively insoluble compounds (e.g., calcium arsenate) to render the soil nonhazardous.
Aluminum Addition
Aluminum can adsorb or precipitate arsenic, in a manner similar to ferric iron salts. The removal mechanism for arsenic is most likely adsorption onto aluminum hydroxide particles with coprecipitation of aluminum hydroxide and aluminum arsenate also occurring. Arsenic adsorption onto aluminum hydroxide decreases under very alkaline conditions due to electrostatic repulsion. Therefore, aluminum treatment is therefore most effective under mildly acidic to mildly basic conditions, namely pH from approximately 5 to 10. Several dosages of aluminum were tested on both soils SB-1 (see Table 3) and SB-2 (see Table 4). The results indicate that aluminum can reduce arsenic to around the 3 to 5 mg/L range. In order to confirm that the soil did not contain arsenite, the soil was oxidized with hydrogen peroxide prior to aluminum treatment. Treatment effectiveness was not improved by oxidizing the soil with peroxide, again indicating that there was no arsenite in the soil.
TABLE 3______________________________________SCREENING TEST RESULTS - ALUMINUM TREATMENT - SB-1SAMPLE pH.sub.1 Arsenic (mg/L)Soil SB-1______________________________________Untreated 5.0 150+ 2.5% Al.sub.2 (SO.sub.4).sub.3 4.91 5.6+ 5% Al.sub.2 (SO.sub.4).sub.3 4.79 3.2+ 2.5% MgO & 2.5% Al.sub.2 (SO.sub.4).sub.3 4.70 14+ 2.5% MgO & 5% Al.sub.2 (SO.sub.4).sub.3 4.58 8.7+ 5% MgO & 5% Al.sub.2 (SO.sub.4).sub.3 5.75 33+ 7.5% MgO & 5% Al.sub.2 (SO.sub.4).sub.3 8.57 4.8+ 7.5% MgO & 7.5% Al.sub.2 (SO.sub.4).sub.3 8.37 2.5+ 5% MgO & 10% Al.sub.2 (SO.sub.4).sub.3 5.03 3.8+ 7.5% MgO & 10% Al.sub.2 (SO.sub.4).sub.3 7.29 3.2+ 10% MgO & 10% Al.sub.2 (SO.sub.4).sub.3 8.40 4.9AFTER PEROXIDE TREATMENT+ 7.5% MgO & 5% Al.sub.2 (SO.sub.4).sub.3 8.57 6.5+ 7.5% MgO & 7.5% Al.sub.2 (SO.sub.4).sub.3 8.37 3.9______________________________________ pH.sub.1 = Final pH in screening test.
TABLE 4______________________________________SCREENING TEST RESULTS - ALUMINUM TREATMENT - SB-2SAMPLE pH.sub.1 Arsenic (mg/L)Soil SB-2______________________________________Untreated+ 2.5% Al.sub.2 (SO.sub.4).sub.3 4.94 14+ 5% Al.sub.2 (SO.sub.4).sub.3 4.77 8.3+ 2.5% MgO & 2.5% Al.sub.2 (SO.sub.4).sub.3 4.59 17+ 2.5% MgO & 5% Al.sub.2 (SO.sub.4).sub.3 4.58 9.0+ 5% MgO & 5% Al.sub.2 (SO.sub.4).sub.3 6.80 4.4______________________________________ pH.sub.1 = Final pH in screening test.
Other Stabilizing Agents
Copper sulfate may be incorporated as a treatment additive. Copper arsenate is highly insoluble (less soluble than ferric arsenate), and the copper sulfate may effectively reduce arsenic leaching.
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A method of treating arsenic-contaminated matter using an aluminum compound in conjunction with an alkaline buffer, thereby stabilizing the arsenic contained in the contaminated matter and decreasing leaching ability. Preferably, the aluminum compound is a soluble aluminum salt such as aluminum sulfate and the alkaline buffer is magnesium oxide.
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BACKGROUND OF THE INVENTION
This invention relates to method for mounting silhouette wall images such as art work and signs. In particular this invention relates to solid sheet materials in the form of single or multi piece artwork, signs, and the like, directly mounted to drywall or other structure without any visible form of suspension for any given piece of the image.
DESCRIPTION OF THE DRAWINGS
FIG. 1 a is unexploded side view in cross section illustrating the method of the present invention; and
FIG. 1 b is a plan view of a mounting aperture shown in cross section in FIG. 1 a.
BRIEF SUMMARY OF THE INVENTION
The invention provides a method for invisibly mounting art work and the like which includes the following steps:
attaching a fastener means and a finish piece to a mounting metal template having at least one keyhole for receiving at least one flat-headed mounting nail;
wherein the at least one keyhole aligns with at least one relief aperture in the fastener means;
positioning a locator template at a desired mounting location and marking the location of at least one mounting hole through the locator template onto a wall surface;
creating at least one hole in the wall surface marked by the locator template and inserting a mounting clip into the at least one hole;
wherein the at least one clip is easily removable without wall surface damage;
inserting said at least one flat-headed nail into said keyhole; and
aligning said at least one flat-headed mounting nail with the corresponding mounting clip and inserting the device at least one flat-headed mounting nail into the metal mounting template to mount said device for hiding any visible means of support.
And an apparatus comprising; a metal template having at least one keyhole formed therein; a fastener means attached one side to the metal template, wherein the fastener means has a relief aperture; the relief aperture being aligned with the at least one keyhole;
a finished piece attached to the opposite side of the fastener means thus forming a sandwich of the metal template, the fastener means, and the finished piece;
a locator template which corresponds to each keyhole location and also aligns to the relief aperture;
wherein at least one hole is formed in a wall surface;
at least one mounting clip for insertion into the at least one hole in a wall surface;
wherein the at least one clip is easily removable without wall surface damage;
at least one flat-headed mounting nail which inserts in the wall surface into the at least one keyhole, leaving a portion of the flat-headed mounting nail exposed;
wherein the exposed portion of the at least one flat-headed mounting nail is aligned with the at least one mounting clip and the sandwich is pressed into each mounting clip so that the finished piece is supported hiding any means of support.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawing, mounting template 16 is mounted on drywall 10 via nails 14 which are inserted into clips 12 placed in selected apertures 11 in drywall 10 . The shaft 14 ′ of flat heads of nail 14 key into aperture 22 and seat in narrow portion 22 ′ of mounting template 16 ( FIG. 1 b ). Double-sided mounting tape 18 is adhered to mounting template 16 and artwork or sign 20 .
Typically, steel forms mounting template 16 and can have a thickness of from a 32nd of an inch to an eighth of an inch with keyholes cut into it such that the shaft 14 ′ of nail 14 can seat itself in so that any assembled part can hang on the drywall surface. Mounting template 16 can be cut from any sheet material that can be cut to an exact shape using any known of plotting machine such as, for example, laser, waterjet, plasma and like plotters.
Tape 18 can be any known double sided adhesive tape, or gel-to-solid adhesive material, that will allow enough space between mounting template 16 and artwork 20 so as to accommodate the head 14 ′ of nail 14 via a relief aperture 17 .
Artwork or sign 20 can be any properly shaped sheet cut material that would be from the outermost finish of a given image. This material can also be cut to shape from any sort of sheet material ranging in thickness from forty thousandths of an inch and upwards. Artwork 20 can be cut from any sheet material that can be cut to an exact shape using any known plotting machine such as, for example, laser, waterjet, plasma, and like plotters.
Clip 12 can be any suitable Molly-type drywall insert, sized to accommodate nail 14 and hold it firmly in place.
The invention can use any vectored file of any drawing, artwork, logo, or symbol done in digital form which can be broken down as a collection of lines that can be positive (ie., white) on one side and negative (ie., black) on the other. Each should be closed in as objects such that they are, or can be made to be, individual pieces. The color differences describe the visual polarity that makes an image appear as it does when a sign is made on a blank wall.
Artwork 20 can be any drawing, logo, or symbol, as a collection of lines and parts, visually conveying a certain item, action, verbage, and/or perspective.
A locator template 13 for positioning clip holes can be a printed rendition of the entire image, in its actual size and dimensions. What material it's made from, or printed upon, is only limited by its compaction and storability properties, its strength, and how easy it will be to print on. Most locator templates are made from paper because they will only be used a few times.
If an image is only two colors, two exact colors, such as black and white, or even green and blue, it is preferably described visually in those colors in a positive/negative format. Thus one color, for example the negative, would be the background, ie, the drywall. The other color would be the image comprised for mounting template 16 , tape 18 and artwork 20 . In positive/negative format, shading (such as the color gray would be in a black and white image) is not possible.
Beginning with a vectored drawing of any sort of artwork, company logo, or symbol (that is completed in black and white, or positive and negative form) two renditions of the same image are made. One copy of this image is a true and exact printout of the lines making up the image using whatever size printer may be required to match the actual size of the image on paper. The general size of both images will be limited only by the size of the machines that can print, and cut them.
Along with the lines making up the image, this printed drawing forms the locator template which has numerous printed keyholes 22 , 22 ′ placed in such a manner as to allow for ample area for tape 18 to have an abundant surface area to effectively hold mounting template 16 and artwork 20 together. The placement of these keyholes will be unique to every part of a given image and allow for variables in drywall frame construction to not be in the way of whatever keyhole the installer chooses to use. Keyholes 22 , 22 ′ are laterally abundant, or even redundant, as framework studs run vertically. The keyhole arrangement on the locator template is custom engineered according to the support required for every different piece of every different image that is produced. Keyholes 22 , 22 ′ are identical both on the paper template and in the cut sheet material mounting template 16 .
The invention can be used to mount cut sheet materials directly to drywall of any known dimension. In the process of mounting, an installer first places the paper locator template 13 on a wall using masking tape. Once centered, and leveled, on the wall, the installer then searches to avoid framework studs behind drywall 10 that will prevent clips 12 from spreading on the backside of the drywall.
Once the installer locates, on the paper locator template 13 , the appropriate number of keyholes as prescribed by the installation requirements of the given image, the installer will punch a small indentation, through the paper and into the wall in the exact location of 22 ′, the center of the uppermost aperture of the keyhole printed on the paper template. The installer uses a pointy felt tip pen to place a small, colored, mark where the indentation was made in the drywall. This will enable the installer to easily see the indentations once the paper template has been taken down.
Once all the required holes 1 have been marked, the installer removes the paper locator template 13 and makes holes in the drywall where every corresponding indentation has been made. The installer inserts a clip 12 in every drilled hole 11 . The wall is now ready for installation of the image.
Another copy of the same file is then engineered such that it can be cut from the top finish product ( artwork, etc., 20 ) and assembled. There are three layers of material making up the pieces of any given image. The artwork 20 is the finish material, be it metal, carbon fiber, plastic, wood, etc., and can have a thickness ranging from thousandths of an inch up to ⅜ of an inch depending on its weight per square inch. The finish pieces are then attached to mounting template 16 via tape 18 which can be a double sided automotive trim tape such as made and sold by 3M Company. Mounting template 16 and artwork 20 are bonded together in such a way that all of their edges match and there is no overhang unless the design of the image calls for it.
While artwork 20 can be made of multiple pieces, mounting template 16 can come from the material cutter in one piece with the keyholes engineered into it. Mounting template 16 may be in more than one piece of layer without overlapping. The backside of mounting template 16 can be painted so as to prevent rusting and the front can be treated with alcohol to promote bonding with tape 18 . Artwork 20 is placed onto tape 18 leaving clearance around keyhole 22 , 22 ′. After tape 18 has been laid onto mounting template 16 the front side of the template can be painted. A removable cover sheet on tape 18 can be left in place until one is ready to attach artwork 20 .
Once assembled, each part of the whole image has three layers (mounting template 16 , tape 18 , and artwork 20 ) with numerous keyholes that an installer can use any one of. To install nails 14 , the installer inserts the nail head through the larger end of the keyhole and moves it up so as to seat shaft 14 ′ in portion 22 ′ of the keyhole. All keyholes 22 are engineered with the smaller ends up and the larger ends down.
The installer now places a small piece of tape over the larger, bottom end 22 of the keyhole so as to keep the nail in place during object placement on the wall. Once all the nails to be used are in place, the installer holds the image piece to the wall and pushes it into the corresponding clips that have been placed into the drywall. As the nails go into the drywall, the clips spread and clamp themselves onto the nails, and the assembled piece stays attached to the wall. When all pieces have been installed into the wall, the image is complete.
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A method of construction, assembly, and suspension that allows for the mounting of properly cut, placed and independently hanging pieces of sheet material to form a complete image of any size, on drywall or other substrate, without any visible means of support and minimal wall damage. Applicable to any image that best describes itself in only two colors, such as black and white, or simply, positive and negative.
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BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for improving processor performance by reducing processing delays associated with branch instructions. In particular, the present invention provides an instruction cache for a super-scalar processor wherein branch-prediction information is provided within the instruction cache.
The time taken by a computing system to perform a particular application is determined by three basic factors, namely, the processor cycle time, the number of processor instructions required to perform the application, and the average number of processor cycles required to execute an instruction. Overall system performance can be improved by reducing one or more of these factors. For example, the average number of cycles required to perform an application can be significantly reduced by employing a multi-processor architecture, i.e., providing more than one processor to execute separate instructions concurrently.
There are disadvantages, however, associated with the implementation of a multi-processor architecture. In order to be effective, multi-processing requires an application that can be easily segmented into independent tasks to be performed concurrently by the different processors. The requirement for a readily segmented task limits the effective applicability of multi-processing. Further, the increase in processing performance attained via multi-processing in many circumstances may not offset the additional expense incurred by requiring multiple processors.
Single-processor hardware architectures that avoid the disadvantages associated with multi-processing have been proposed. These so called "super-scalar" processors permit a sustained execution rate of more than one instruction per processor cycle, as opposed to conventional scalar processors which--while capable of handling multiple instructions in different pipeline stages in one cycle--are limited to a maximum pipeline capacity of one instruction per cycle. In contrast, a super-scalar pipeline architecture achieves concurrency between instructions both in different pipeline stages and within the same pipeline stage.
A super-scalar processor that executes more than one instruction per cycle, however, can only be effective when instructions can be supplied at a sufficient rate. It is readily apparent that instruction fetching can be a limiting factor in overall system performance if the average rate of instruction fetching is less than the average rate of instruction execution. Providing the necessary instruction bandwidth for sequential instructions is relatively easy, as the instruction fetcher can simply fetch several instructions per cycle. It is much more difficult, however, to provide sufficient instruction bandwidth in the presence of non-sequential fetches caused by branches, as the branches make the instruction fetching dependent on the results of instruction execution. Thus, the instruction fetcher can either stall or fetch incorrect instructions when the outcome of a branch is not known.
For example, FIG. 1 illustrates two instruction runs consisting of a number of instructions occupying four instruction-cache blocks (assuming a four-word cache block) in an instruction cache memory. The first instruction run consists of instructions S1-S5 that contain a branch to a second instruction run T1-T4. FIG. 2 illustrates how these instruction runs are sequenced through a four-instruction decoder and a two-instruction decoder, assuming for purposes of illustration that two cycles are required to determine the outcome of a branch. As would be expected, the four-instruction decoder provides a higher instruction bandwidth than the two-instruction decoder, but neither provides sufficient instruction bandwidth for a super-scalar processor. As illustrated in FIG. 3, the instruction bandwidth improves dramatically if the branch delays are reduced to zero.
The dependency between the instruction fetcher and the execution unit caused by branches can be reduced by predicting the outcome of the branch during an instruction fetch without waiting for the execution unit to indicate whether or not the branch should be taken. Branch prediction relies heavily on the fact that the outcome of a branch does not change frequently over a given period of time. The instruction fetcher can predict future branch executions using information collected on the outcome of the previous branch executions performed by the execution unit.
A conventional method for hardware-branch prediction uses a branch target buffer to collect information about the most-recently executed branches. See, for example, "Branch Prediction Strategies and Branch Target Buffer Design", by J.K.F. Lee and A.J. Smith, IEEE Computer, Vol. 17, pp. 6-22, January, 1984. Typically, the branch target buffer is accessed using an instruction address, and indicates whether or not the instruction at that address is a branch instruction. If the instruction is a branch instruction, the branch target buffer indicates the predicted outcome and the target address.
The hit ratio of a branch target buffer, i.e., the probability that a branch is found in the branch target buffer at the time it is fetched, increases as the size of the branch target buffer increases. FIG. 4 is a graph of the hit ratio for a target branch buffer for selected sample benchmark programs, and illustrates the necessity of a relatively large branch target buffer in order to obtain an acceptable prediction accuracy. Accordingly, it would be desirable to provide an improved hardware branch prediction architecture that would require less hardware support as compared with a conventional branch target buffer.
SUMMARY OF THE INVENTION
The present invention provides a super-scalar processor wherein branch-prediction information is provided within an instruction cache memory. Each instruction cache block stored in the instruction cache memory includes branch-prediction information fields in addition to instruction fields, which indicate the address of the instruction block's successor and information indicating the location of a branch instruction within the instruction block. Thus, the next cache block can be easily fetched without waiting on a decoder or execution unit to indicate the proper fetch action to be taken for correctly predicted branching.
More specifically, branch predication is accomplished in accordance with the present invention by loading a plurality of instruction blocks into the instruction cache memory, wherein each of the instruction blocks includes a plurality of instructions and instruction fetch information. The instruction fetch information includes an address tag, a branch block index and a successor index that includes a successor valid bit. A fetch program counter is used to generate and supply a fetch program counter value to the instruction cache memory in order to prefetch one of the plurality of instruction blocks stored in the instruction cache memory. The processor determines whether the successor valid bit of the prefetched instruction block is set to a predetermined condition which indicates that a branch instruction within the prefetched instruction block is predicted as taken. If the successor valid bit is not set to the predetermined condition, the fetch program counter value is incremented and supplied to the instruction cache memory to prefetch a succeeding instruction block. If the successor valid bit is set to the predetermined condition, a predicted target branch address is generated by the instruction cache memory based on information contained in the instruction fetch information field associated with the instruction block. The predicted target branch address and the branch location of the branch instruction within the instruction cache memory is then stored in a branch prediction memory. The branch instruction is subsequently executed with a branch execution unit which generates an actual branch location address and a target branch address for the executed branch instruction. The actual branch location and the target branch address are then respectively compared with the branch location and predicted target branch address stored in the branch prediction memory. A misprediction signal is generated if the compared values are not equal, and the successor valid bit and instruction fetch information are updated for the instruction block in response to misprediction signal.
The utilization of the instruction cache and branch prediction memory as described above, provides branch prediction accuracy substantially identical to that of a target branch buffer without requiring as much hardware support.
BRIEF DESCRIPTION OF THE DRAWINGS
With the above as background, reference should now be made to the following detailed description of the preferred embodiments in conjunction with the drawings, in which:
FIG. 1 shows a sequence of two instruction runs to illustrate decoder behavior;
FIG. 2 illustrates the sequencing of the instruction runs shown in FIG. 1 through a two-instruction and four-instruction decoder;
FIG. 3 illustrates the improvements in instruction bandwidth for the instruction runs illustrated in FIG. 2 if branch delays are avoided;
FIG. 4 is a graph of the hit ratio of a target branch buffer;
FIG. 5 illustrates a preferred layout for an instruction-cache entry in accordance with the present invention;
FIG. 6 an example of instruction-cache entries for the code sequence illustrated in FIG. 3;
FIG. 7 is a block diagram of a super-scalar processor according to the present invention;
FIG. 8 is a block diagram of an instruction cache employed in the super-scalar processor illustrated in FIG. 7;
FIG. 9 is a block diagram of a branch prediction FIFO employed in the super-scalar processor illustrated in FIG. 7; and
FIG. 10 block diagram of a branch execution unit employed in the super-scalar processor illustrated in FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The basic operation of an instruction cache for a super-scalar processor in accordance with the present invention will be discussed with reference to FIG. 5, which illustrates a preferred layout for an instruction-cache entry required by the super-scalar processor. In the example illustrated, the cache entry holds four instructions and instruction fetch information which is shown in expanded form to include a conventional address tag field and two additional fields: a successor index field which indicates both the next entry predicted to be fetched and the first instruction within the next entry predicted to be executed, and a branch block index field which indicates the location of a branch point within the instruction block. The successor index field does not specify a full instruction address, but is of sufficient size to select any instruction address within the instruction cache. The successor index field includes a successor valid bit that indicates a branch is predicted to be taken when set, and that a branch is not predicted to be taken when cleared.
FIG. 6 illustrates instruction-cache entries for the code sequence shown in FIG. 3, assuming a 64 Kbyte direct-mapped cache and the indicated instruction address. When a cache entry is first loaded, the address tag is set and the successor valid bit is cleared. The default for a newly-loaded entry, therefore, is to predict that a branch is not taken and the next sequential instruction block is to be fetched. FIG. 6 also illustrates that a branch target program counter can be constructed at branch points by concatenating the successor index field of the instruction block where the branch occurs to the address tag of the successor instruction block.
The validity of instructions at the beginning of a current instruction block are preferably determined by the low-order bits of the successor index field in the preceding instruction block. The successor index of the preceding instruction block may point to any instruction within the current instruction block, and instructions up to this point in the current instruction block are not executed by the processor. The validity of instructions at the end of the block are determined by the branch block index, which indicates the point where a branch is predicted to be taken The branch block index is required by an instruction decoder to determine valid instructions, while cache entries are retrieved based on the successor index fields alone.
To check branch predictions, the processor keeps a list of predicted branches, stored in the order in which the branches are predicted, in a branch prediction FIFO associated with the instruction cache. Each entry on the list indicates the location of the branch in the instruction cache, which is identified by concatenating the successor index of the entry preceding the branching entry with the branch location index field. Each entry also contains a complete program-counter value for the target of the branch.
The processor executes all branches in their original program sequence with a branch execution unit, and compares information resulting from the execution of the branches with information at the head of the list of predicted branches. The following conditions must hold for a successful branch prediction. First, if the branch is taken, its location in the instruction cache must match the location of the next branch on the list contained in the branch prediction FIFO. This condition is required to detect a taken branch that was predicted to be not taken. Secondly, the predicted target address of the branch at the head of the list must match the next instruction address determined by executing the branch.
The second comparison is relevant only if the locations match, and is required primarily to detect a branch which was not taken that was predicted to be taken. However, as the predicted target address is based on the address tag of the successor block, this comparison also detects that cache replacement during execution has removed the original target entry. In addition, comparing program-counter values checks that indirect branches were properly predicted.
The branch is mispredicted if either or both of the above-described conditions does not hold. When a misprediction occurs, the appropriate cache entry must be fetched using the location of the branch determined by the execution unit. The successor valid bit and instruction fetch information for the incorrect instruction block must also be updated based on the misprediction to reflect the actual result of the execution of the branch. For example, the successor valid bit is cleared if a branch had been predicted as taken but was not taken, so that on the next fetch of the instruction block the branch will be predicted as not taken. Thus, the successor valid bit and instruction fetch information alway reflect the actual result of the previous execution of the branch instruction.
With the above as background, reference should now be made to FIG. 7 for a detailed description of a preferred embodiment of the invention. FIG. 7 illustrates a block diagram of a super-scalar processor that includes a bus interface unit (BIU) 10, an instruction cache 12, a branch prediction FIFO 14, an instruction decoder 16, a register file 18, a reorder buffer 20, a branch execution unit 22, an arithmetic logic unit (ALU) 24, a shifter unit 30, a load unit 32 a store unit 33, and a data cache 34.
The reorder buffer 20 is managed as a FIFO. When an instruction is decoded by the instruction decoder 16, a corresponding entry is allocated in the reorder buffer 20. The result value of the decoded instruction is written into the allocated entry when the execution of the instruction is completed. The result value is then written into the register file 18 if there are no exceptions associated with the instruction. If the instruction is not complete when its associated entry reaches the head of the reorder buffer 20, the advancement of the reorder buffer 20 is halted until the instruction is completed, additional entries, however, can continue to be allocated. If there is an exception or branch misprediction, the entire contents of the reorder buffer 20 are discarded.
As illustrated in FIG. 8, the instruction cache 12 includes an instruction store array 36 which is a direct mapped instruction cache organized as 512 instruction blocks of four words each, a tag array 38 having 512 entries composed of a 19 bit tag and a single valid bit for the entire block, a dual ported successor array 40 having 512 entries composed of an 11 bit successor index and a successor valid bit which indicates when set that the successor index stored in the successor array . .340.!. .Iadd.40 .Iaddend.should be used to access the instruction store array 36, and indicates when cleared that no branch is predicted within the instruction block, a dual ported block status array 42 that contains a branch block indicator for each instruction block in the instruction cache 12 which indicates the last instruction predicted to be executed within a block, a fetch program counter (PC) 44 (including a PC latch 46, a MUX unit 48 and an incrementer (INC) 50) that generates a PC value that is used for prefetching the instruction stream from the instruction cache 12, an instruction fetch control unit 52 that controls the fetching of instructions from the instruction cache 12, the replacement of cache blocks on misses, and the reformatting of the successor array 40 and branch block array 42 on branches that are mispredicted, and an instruction register latch 54 which is loaded with the instructions to be provided to the instruction decoder 16.
The branch prediction FIFO 14 is used to maintain information related to every predicted branch within an instruction block. Specifically, the location in the cache where the branch is predicted to occur (i.e. the branch location) as well as the predicted branch target PC of the branch are stored within the branch prediction FIFO 14. As illustrated in FIG. 9, the branch prediction FIFO 14 is preferably implemented as a fixed array with a target PC FIFO and a branch location FIFO, incrementing read/write pointers 56 and 58, and also includes a target PC comparator 60 and a branch location comparator 62 which are respectively coupled to a branch location data bus (CPC) and a target PC data bus (TPC). The output signals generated by the target PC comparator 60 and the branch location PC comparator 62 are provided to a branch FIFO control circuit 63. The FIFO 14 could alternatively be implemented as a shiftable array or a circular FIFO.
The branch execution unit 22 contains the hardware that actually executes the branch instructions and writes the branch results back to the reorder buffer 18 As shown in FIG. 10, the branch execution unit 22 includes a branch reservation station 62, a branch computation unit 64 and a result bus interface 66. The reservation station 62 is a FIFO array which receives decoded instructions from the instruction decoder 16 and operand information from the register file 18 and reorder buffer 20 and holds this information until the decoded instruction is free from dependencies and the branch computation unit 64 is free to execute the instruction. The result bus interface 66 couples the branch execution unit 22 to the CPC bus and TPC bus, which in turn are coupled to the branch location comparator 62 and the target PC comparator 60 of the branch predication FIFO 14 as illustrated in FIG. 9.
In operation, the instruction cache 12 is loaded with instructions from an instruction memory via the BIU 10. The fetch PC 44 supplies a predicted fetch PC value to the instruction cache 12 in order to prefetch an instruction stream. As previously stated, the successor valid bit for each instruction block is cleared when the instruction block is first loaded into the instruction cache 12. Thus, when a given instruction block is first fetched from the instruction cache 12, any branch in the block is predicted as not taken. The prefetched instruction block is supplied to the instruction decoder 16 via the instruction decode latch 54. The predicted fetch PC is then incremented via the incrementer 50 and loaded back into the fetch PC latch 46 via the MUX unit 48. The resulting fetch PC is then supplied to the instruction cache 12 in order to fetch the next sequential instruction block in the instruction store.
The branch execution unit 22 processes any branch instruction contained in the first prefetched instruction block, and generates an actual PC value and target PC value for the executed branch instruction. Note, that if the branch is not taken on execution, the target PC value generated by the branch execution unit 22 will be the next sequential value after the actual PC value, i.e., the term "target PC" in this sense does not necessarily mean the target of an executed branch, but instead indicates the address of the next instruction block to be executed regardless of the branch results. The actual PC value and the target PC value are respectively supplied to the CPC bus and the TPC bus and loaded into the branch location comparator and the target PC comparator in the branch prediction FIFO.
Where a branch was predicted .Iadd.as .Iaddend.not taken but was taken on execution, the comparison of the actual PC value supplied by the branch instruction unit 22 with the branch location value supplied from the branch location FIFO of the branch prediction FIFO 14 will fail. The branch prediction FIFO 14 resets and generates a branch misprediction signal which is supplied to the instruction fetch control unit of the instruction cache 12. The target PC from the branch execution unit 22 is then loaded into the fetch PC latch 46 via the MUX unit 48 and the successor array is updated to set the successor valid bit under control of the instruction fetch control circuit 52. Thus, the branch will be predicted as taken on subsequent fetches of the instruction block.
When the successor valid bit is set indicating a branch is predicted as taken, the value of the fetch PC latch is loaded into the next available entry in the branch prediction FIFO. A reconstructed predicted fetch PC formed from the successor index and the tag field read out of the tag array is loaded via the MUX 48 into the fetch PC latch 46. This reconstructed fetch PC is supplied to the instruction store array 36 to fetch the next instruction and to the branch prediction FIFO. Thus, the branch prediction FIFO entry contains the branch location of the branch as well as the predicted target of the branch.
The branch execution unit 22 subsequently executes the branch instruction and generates an actual PC value and a target PC value which are supplied to the branch location comparator and the target PC comparator in the branch prediction FIFO. If the branch was predicted to be taken, the PC value generated by the branch execution unit 22 will always match the branch location loaded from the branch location FIFO. Three possible conditions, however, will result in the target PC value generated by the branch execution unit 22 not matching the target PC stored in the branch prediction FIFO 14: the branch was predicted as taken but was not taken in which case the successor valid bit must be cleared, the branch executed a subroutine return to an address which did not match the predicted address thereby requiring the successor index be updated, or cache replacement occurred prior to the execution of the branch instruction requiring the reloading of the instruction cache.
The principal hardware cost of the above-described branch prediction scheme is the increase in the cache size caused by the successor index and branch block index fields associated with each entry in the instruction cache. This increase is minimal when compared with other hardware prediction schemes, however, as the present invention saves storage space by predicting only one taken branch per cache block, and predicting non-taken branches by not storing any branch information associated with the instruction block into the successor index. For an 8 Kbyte direct mapped cache, the additional fields add about 8% to the cache storage required. The increase in overall system performance due to branch prediction, however, justifies the increased size requirement for the instruction cache.
The requirement for updating the cache entry when a branch is mispredicted does conflict with the requirement to fetch the correct branch target, i.e., unless it is possible to read and write the fetch information for two different entries simultaneously, the updating of the fetch information on a mispredicted branch takes a cycle away from instruction fetching. The requirement for an additional cycle causes only a small degradation in performance, however, as mispredicted branches occur infrequently and the increase in performance associated with branch prediction easily outweigh any degradation in performance due to the additional cycles required mispredicted branches.
The invention has been described with particular reference to certain preferred embodiments thereof. The invention is not limited to these disclosed embodiments and modifications and variations may be made within the scope of the appended claims.
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A super-scaler processor is disclosed wherein branch-prediction information is provided within an instruction cache memory. Each instruction cache block stored in the instruction cache memory includes branch-prediction information fields in addition to instruction fields, which indicate the address of the instruction block's successor and information indicating the location of a branch instruction within the instruction block. Thus, the next cache block can be easily fetched without waiting on a decoder or execution unit to indicate the proper fetch action to be taken for correctly predicted branching.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 11/906,324, filed Oct. 1, 2007; which claims the benefit of U.S. Provisional Application Ser. No. 60/849,150, filed Oct. 2, 2006.
FIELD OF THE INVENTION
The present invention relates to wireless communication, and more particularly to transmission in a Universal Mobile Telecommunications System (UMTS) Terrestrial Radio Access Network (UTRAN) or long term evolutions of UTRAN.
BACKGROUND OF THE INVENTION
LTE, or Long Term Evolution, is a name for research and development involving the Third Generation Partnership Project (3GPP), to identify technologies and capabilities that can improve systems such as the UMTS. The present invention involves the long term evolution (LTE) of 3GPP Implementations of wireless communication systems, such as UMTS (Universal Mobile Telecommunication System), may include a radio access network (RAN). In UMTS, the RAN is called UTRAN (UMTS Terrestrial RAN). Of interest to the present invention is an aspect of LTE referred to as “evolved UMTS Terrestrial Radio Access Network,” or E-UTRAN.
In general, in E-UTRAN resources are assigned more or less temporarily by the network to one or more user equipment terminals (UE) by use of allocation tables, or more generally by use of a downlink resource assignment channel. Users are generally scheduled on a shared channel every transmission time interval (TTI) by a Node B or an evolved Node B (e-Node B). A current working assumption for LTE is that users are explicitly scheduled on a shared channel every transmission time interval (TTI) by an eNodeB. An eNodeB is an evolved Node B and is the UMTS LTE counterpart to the term “base station” in the Global System for Mobile Communication (GSM). In order to facilitate the scheduling on the shared channel, the e-Node B transmits an allocation in a downlink control channel to the UE. The allocation information may be related to both uplink and downlink channels. The allocation information may include information about which resource blocks in the frequency domain are allocated to the scheduled user(s), which modulation and coding schemes to use, what the transport block size is, and the like.
An example of the E-UTRAN architecture is illustrated in FIG. 1 . This example of E-UTRAN consists of eNodeBs, providing the E-UTRA user plane (RLC/MAC/PHY) and control plane (RRC) protocol terminations towards the UE. The eNodeBs are interconnected with each other by means of the X2 interface. The eNodeBs are also connected by means of the S1 interface to the EPC (evolved packet core) more specifically to the MME (mobility management entity) and the UPE (user plane entity). The S1 interface supports a many-to-many relation between MMEs/UPEs and eNodeBs. The S1 interface supports a functional split between the MME and the UPE. The MMU/UPE in the example of FIG. 1 is one option for the access gateway (aGW).
In the example of FIG. 1 , there exists an X2 interface between the eNodeBs that need to communicate with each other. For exceptional cases (e.g. inter-PLMN handover), LTE_ACTIVE inter-eNodeB mobility is supported by means of MME/UPE relocation via the S1 interface.
The eNodeB may host functions such as radio resource management (radio bearer control, radio admission control, connection mobility control, dynamic allocation of resources to UEs in both uplink and downlink), selection of a mobility management entity (MME) at UE attachment, routing of user plane data towards the user plane entity (UPE), scheduling and transmission of paging messages (originated from the MME), scheduling and transmission of broadcast information (originated from the MME or O&M), and measurement and measurement reporting configuration for mobility and scheduling. The MME/UPE may host functions such as the following: distribution of paging messages to the eNodeBs, security control, IP header compression and encryption of user data streams; termination of U-plane packets for paging reasons; switching of U-plane for support of UE mobility, idle state mobility control, SAE bearer control, and ciphering and integrity protection of NAS signaling. The invention is related to LTE, although the solution of the present invention may also be applicable to present and future systems other than LTE.
In general, E-UTRAN may use orthogonal frequency division multiplexing (OFDM) as the multiplexing technique for a downlink connection between the eNode B and the UE terminal, in which different system bandwidths from 1.25 MHz to 20 MHz are applied. Using OFDM may allow for link adaptation and user multiplexing in the frequency domain. However, to utilize the potential of multiplexing in the frequency domain the Node B or eNode B needs to have information related to the instantaneous channel quality. In order for the Node B or eNode B to be informed of the channel quality, the user equipment terminal provides channel quality indicator (CQI) reports to the eNode B. The user equipment terminal may periodically or in response to a particular event send CQI reports to the respective serving e-Node B, which indicate the recommended transmission format for the next transmission time interval (TTI). The report may be constructed in such a way that it indicates the expected supported transport block size under certain assumptions, which may include, the recommended number of physical resource blocks (PRB), the supported modulation and coding scheme, the recommended multiple input multiple output (MIMO) configuration, as well as a possible power offset.
In general, the interface between a user equipment (UE) and the UTRAN or E-UTRAN has been realized through a radio interface protocol established in accordance with radio access network specifications describing a physical layer (L1), a data link layer (L2) and a network layer (L3). For example, the physical layer (PHY) provides information transfer service to a higher layer and is linked via transport channels to a medium access control (MAC) layer of the second layer (L2). Data travels between the MAC layer at L2 and the physical layer at L1, via a transport channel. The transport channel is divided into a dedicated transport channel and a common transport channel depending on whether a channel is shared. Also, data transmission is performed through a physical channel between different physical layers, namely, between physical layers of a sending side (transmitter) and a receiving side (receiver).
Typically, the second layer (L2) may include the MAC layer, a radio link control (RLC) layer, a broadcast/multicast control (BMC) layer, and a packet data convergence protocol (PDCP) layer. The MAC layer maps various logical channels to various transport channels. The MAC layer also multiplexes logical channels by mapping several logical channels to one transport channel. The MAC layer is connected to an upper RLC layer via the logical channel. The logical channel can be divided into a control channel for transmitting control plane information, such as control signaling, and a traffic channel for transmitting user plane information, such as data information.
Due to the different capabilities of the eNodeB and UE, the downlink (DL) and uplink (UL) physical layers for LTE may be different. Physical channels convey information from higher layers in the LTE stack, and physical signals may be used exclusively for use in the physical layer. Physical channels map to transport channels, which are service access points (SAPs) for the L2/L3 layers. The downlink physical channels are Physical Downlink Shared Channel (PDSCH), which is used for data and multimedia transport, Physical Downlink Control Channel (PDCCH), which conveys UE-specific control information, and Common Control Physical Channel (CCPCH), which is used to carry cell-wide control information. There are two types of physical signals, reference signals used to determine the channel impluse response (CIR), and synchronization signals which convey network timing information. The downlink transport channels are Broadcast Channel (BCH), Downlink Shared Channel (DL-SCH), Paging Channel (PCH), and Multicast Channel (MCH).
In the uplink, the physical channels are Physical Uplink Shared Channel (PUSCH) and Physical Uplink Control Channel (PUCCH), which carry control information such as channel quality indication (CQI), ACK/NACK, HARQ and uplink scheduling requests. The uplink physical signals are uplink reference signal and random access preamble. The uplink transport channels are Uplink Shared Channel (UL SCH) and Randon Access Channel (RACH).
In order to facilitate the scheduling on the shared channel, the eNodeB transmits an allocation in a downlink shared control channel to the user equipment (UE). The allocation information will often be related to both uplink and downlink. In LTE for example, if the UE is scheduled for both uplink and downlink transmission the UE may receive two allocation grants, one for the uplink and one for the downlink. The functionality of the allocation is in principle similar to the high speed shared control channel (HS-SCCH), which is used for high speed downlink packet access (HSDPA).
The allocation is used to signal which user(s) are going to be scheduled in each TTI. The current default assumption in 3GPP is that the allocation includes information about which resource blocks in the frequency domain are allocated to scheduled user(s), which modulation scheme to use, what the transport block size is, and the like. The allocation also often includes various information related to hybrid automatic repeat requests (HARQ).
The current working assumption of an evolved UTRAN is that LTE will be using Orthogonal Frequency Division Multiplexing Access (OFDMA) as the multiplexing technique in the downlink direction, where multiple users can be frequency multiplexed in the downlink direction with a single TTI (which will have the duration of two sub-frames, i.e., 1 ms). One of the key elements for efficient link operation is the utilization of HARQ, such that for each transmitted packet, physical resources will be allocated in the uplink, so that each allocated UE can transmit HARQ acknowledgement or negative acknowledgement (ACK/NACK) based on its reception. The assumption for the downlink is that HARQ is asynchronous, but it is expected that the UE's transmission of ACK and NACK will be time-wise tied to the received transmission. In cases where UE does not have data to transmit in the uplink at the time of ACK/NACK, a dedicated physical control channel is assumed to carry the ACK/NACK bit. Otherwise, the ACK/NACK could also be piggy-backed to the data transmission. Both the allocation in uplink and downlink is decided and controlled by the eNodeB.
The number of users multiplexed in downlink may change significantly from sub-frame to sub-frame. Some of the factors contributing to such variations include changes in traffic (burstiness) which means that varying number of users have different and fast varying amounts of data to transmit, or properties of radio-aware scheduling that have changes in number of users allocated per sub-frame.
Given that the traffic is asymmetrical (or time-alternating as in the case of VoIP (Voice over Internet Protocol), it will often happen that ACK/NACK need be sent in uplink as data-non-associated transmission, or transmission on a separate physical channel tied to the downlink allocation, for example. Such resources need be reserved and provided if no adaptive mechanism is available, and we need to allocate the resources according to the worst-case multiplexing amount. This causes a loss in system capacity. Therefore, there is a need to overcome the problems discussed above.
SUMMARY OF THE INVENTION
The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is intended to neither identify key or critical elements of the invention nor delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
The present invention is related to a framework for mapping the dedicated uplink control channels directly to single physical resource blocks (PRBs). The framework is able to efficiently shift physical resources to and from the uplink control channel for ACK/NACK reports, in a data-non-associated control signaling scheme and on a per subframe basis. The present invention is also concerned with scheduler, for example an eNodeB scheduler, which uses its scheduling history and knowledge of user equipment (UE) capabilities to increase utilization of uplink resources.
When an eNodeB is used to schedule users on a shared channel in a transmission time interval, it allocates the uplink physical resources for ACK/NACK at least partly based on the current amount of the physical resources for downlink transmission, or the allocation history of the downlink transmission. The amount of physical resources for downlink transmission is determined at least partly based on the number of users and/or the number of packets multiplexed within a downlink subframe in a physical resource block. The eNodeB is also adapted to allocate uplink physical resources for data transmission based on amount of physical resources allocated for transmission of ACK/NACK reports.
For delayed uplink allocation, the amount of allocated physical resources for ACK/NACK reports is also estimated based whether some of the ACK/NACK reports can be piggy-backed to uplink data transmission.
In accordance with a first aspect of the invention, a method is provided that includes determining an amount of physical resources for downlink transmission, and allocating uplink physical resources for transmission of data-non-associated control signaling based at least on the amount of physical resources for downlink transmission. The amount of physical resources for downlink transmission may include an amount of downlink control signaling.
In accordance with the first aspect of the invention, determining the amount of physical resources for downlink transmission is at least partly based on number of user equipment terminals multiplexed within a downlink subframe in a physical resource block.
In accordance with the first aspect of the invention, determining the amount of physical resources for downlink transmission is at least partly based on a number of packets multiplexed within a downlink subframe in a physical resource block.
In accordance with the first aspect of the invention, the method may further include allocating uplink physical resources for data transmission based at least on the amount of uplink physical resources allocated for transmission of data-non-associated control signaling.
In accordance with the first aspect of the invention, determining the amount of physical resources for downlink transmission is based on whether the data-non-associated control signaling is at least partly incorporated into uplink data transmission.
In accordance with the first aspect of the invention, the amount of physical resources for downlink transmission comprises physical resources allocated for current transmission.
In accordance with the first aspect of the invention, the amount of physical resources for downlink transmission comprises physical resources allocated for past transmission.
In accordance with the first aspect of the invention, the user equipment terminals include user equipment terminals in semi-static locations.
In accordance with the first aspect of the invention, uplink control channel boundaries for each of the user equipment terminals are allocated within boundaries of a single physical resource block.
In accordance with a second aspect of the invention, an apparatus is provided that may include a determiner for determining an amount of physical resources for downlink transmission, and an allocation unit for allocating uplink physical resources for transmission of data-non-associated control signaling based at least on the amount of physical resources for downlink transmission. The amount of physical resources for downlink transmission may include an amount of downlink control signaling.
In accordance with the second aspect of the invention, the apparatus may also include a recorder for recording a number of user equipment terminals multiplexed within a downlink subframe in a physical resource block, and the determiner is responsive to the number of multiplexed user equipment terminals for determining the amount of physical resources for downlink transmission.
In accordance with the second aspect of the invention, the apparatus may also include a recorder for recording a number of packets multiplexed within a downlink subframe in a physical resource block, and the determiner is responsive to the number of multiplexed packets for determining the amount of physical resources for downlink transmission.
In accordance with the second aspect of the invention, the allocation unit is configured to allocate uplink physical resources for data transmission based at least on the amount of uplink physical resources allocated for transmission of data-non-associated control signaling.
In accordance with the second aspect of the invention, the determiner is configured to determine the amount of physical resources for downlink transmission based on whether the data-non-associated control signaling is at least partly incorporated into uplink data transmission.
In accordance with the second aspect of the invention, the amount of physical resources for downlink transmission includes physical resources allocated for current transmission.
In accordance with the second aspect of the invention, the amount of physical resources for downlink transmission includes physical resources allocated for past transmission.
In accordance with the second aspect of the invention, the user equipment terminals include user equipment terminals in semi-static locations.
In accordance with the second aspect of the invention, uplink control channel boundaries for each of the user equipment terminals are allocated within boundaries of a single physical resource block.
In accordance with the second aspect of the invention, the apparatus may be included in or is a network element.
In accordance with the second aspect of the invention, the apparatus may further include a scheduler for scheduling downlink packets, and a prediction module for predicting a number of expected reports based at least on the amount of physical resources for downlink transmission.
In accordance with a third aspect of the invention, an apparatus is provided that includes means for determining an amount of physical resources for downlink transmission, and means for allocating uplink physical resources for transmission of data-non-associated control signaling based at least on the amount of physical resources for downlink transmission. The amount of physical resources for downlink transmission comprises an amount of downlink control signaling.
In accordance with the third aspect of the invention, the apparatus may further include means for scheduling downlink packets, and means for predicting a number of expected reports based at least on the amount of physical resources for downlink transmission.
In accordance with a fourth aspect of the invention, a system is provided that includes a determiner for determining an amount of physical resources for downlink transmission, an allocation unit for allocating uplink physical resources for transmission of data-non-associated control signaling based at least on the amount of physical resources for downlink transmission, and at least one user equipment terminal responsive to the allocation of uplink physical resources for transmission of data non-associated control signaling for providing control signaling according to the allocation. The amount of physical resources for downlink transmission comprises an amount of downlink control signaling.
In accordance with the fourth aspect of the invention, the system may further include a network element that includes the determiner and the allocation unit.
In accordance with a fifth aspect of the invention, a computer program product is provided that includes a computer readable storage structure embodying computer program code thereon for execution by a computer processor, wherein said computer program code comprises instructions for performing a method including the steps of determining an amount of physical resources for downlink transmission, and allocating uplink physical resources for transmission of data-non-associated control signaling based at least on the amount of physical resources for downlink transmission.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the invention will become apparent from a consideration of the subsequent detailed description presented in connection with accompanying drawings, in which:
FIG. 1 illustrates an exemplary E-UTRAN architecture.
FIG. 2 illustrates an exemplary mapping scheme between dedicated uplink control channels and the physical resource block (PRB) structure, with 12 sub-carriers per PRB.
FIG. 3 illustrates similar exemplification of mapping of ACK/NACK control channel to PRB using a distributed method when several PRBs are reserved for control.
FIG. 4 illustrates an example of the relation between downlink allocation and required uplink ACK/NACK resources, with data-non-associated transmission in the uplink.
FIG. 5 illustrates an exemplary method according to an embodiment of the present invention.
FIG. 6 illustrates another exemplary method according to an embodiment of the present invention.
FIG. 7 illustrates a block diagram for an apparatus that is configured to carry out the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Based on the physical resources that may be needed for sending an acknowledgement/negative acknowledgement (ACK/NACK) report, a network element, for example an evolved NodeB (eNode B), may reserve a significant signaling space for each transmission (tied to downlink packet transmission). For example, in WCDMA/HSDPA, it is possible to use a factor-10 repetition of the ACK/NACK bit as well as efficient frequency diversity by spreading. This means that the fading margin is rather small for the WCDMA case except when the signaling is in flat channel conditions.
Depending on the design of the control channels in LTE, it may be possible to have less frequency diversity. For example, in sending an ACK/NACK report in UTRAN LTE, it may be possible to use distributed transmission of the 10 repetitions. However, this may impact many physical resource blocks that could be used for data transmission, and there may be a need to reduce overhead. For example, using an added fading margin of 3 dB, about 4 sub-carriers (0.5 ms) per ACK/NACK report may be needed in order to obtain the same uplink coverage as is obtained in WCDMA/HSDPA. Therefore, according to an exemplary embodiment of the present invention, a physical resource block (PRB) defined as having 12 sub-carriers, it is possible to fit three ACK/NACK reports into the space corresponding to a single PRB.
For example, if there is a mixture of VoIP (Voice over Internet Protocol) and HTTP (Hypertext Transfer Protocol) transmissions occurring within a cell, it may be necessary to multiplex between a few to quite many packets every subframe, for example between 2-10 when using an opportunistic scheduler. Therefore, in the worst-case, space corresponding to four PRBs should be allocated, but on average less space may be allocated. Moreover, it may be possible to limit the scheduling flexibility in order to fix the number of multiplexed packets every transmission time interval (TTI). The same consideration may also be taken when dealing with RRC, SID TCP ACK, and TCP KAM messages.
According to an exemplary embodiment of the present invention uplink control signalling, for example ACK/NACK), may be setup as follows. Uplink control channel boundaries for every user are contained within a single PRB. Therefore, when uplink control is not needed (e.g. three instances), the PRB can be immediately used for scheduled transmission in the uplink. For scheduled transmissions, the allocated physical resource for ACK/NACK in the uplink is hard-coded to the allocation in downlink (e.g. allocation specific). In this exemplary embodiment the eNodeB may be able to plan ahead in physical resource allocation.
The approach is exemplified in FIG. 2 . In the example as shown in FIG. 1 , two PRBs are allocated to control signalling, and a total of 6 ACK/NACK reports can fit within the allocated area. When a user, i.e. UE, is allocated in downlink, the user knows which of the 6 dedicated control resources it must use based on its order in the allocation table. For persistent or non-scheduled allocations, the mapping between downlink packet and associated uplink resource may be given by higher layer (or alternative L1/L2) signaling. Here L1 and L2 are air interface Layers 1 and 2. Layer 1 is known as the physical layer and Layer 2 a data link layer which comprises two sublayers: a media access control (MAC) and a logic link control (LLC) sublayers. This L1/L2 signaling is referred to as some control signaling means, which are located below the RRC layer. With this L1/L2 signaling, it is possible to have control messages transmitted by the MAC, which would then be in control of the control signaling resource for persistent allocations.
The scheme illustrated in FIG. 2 is useful in reducing the fading margin. If needed, a user equipment terminal (UE) can detect from the allocation table (uplink allocation transmitted in downlink) if the control channel PRBs are scheduled and then “ACK/NACK control channels” may be defined according to preset or predetermined rules. For example, if a second control PRB as shown in FIG. 3 is suddenly allocated for data transmission, the UE would know there are now just 3 available control channels for the ACK/NACK report, and that distributed transmission would not be possible. As also shown in FIG. 3 , when the second PRB is not allocated, then there are 6 ACK/NACK “spaces” distributed over the two PRBs.
A method according to this exemplary embodiment is shown in FIG. 6 . The method may include a step S 20 of setting uplink control channel boundaries within a physical resource block (PRB). For example, FIG. 2 shows dedicated control channels within the PRB for ACK/NACK reports. The method may also include a step S 21 of deciding whether uplink control is needed. If uplink control is needed, then the method includes a step S 23 of using control signalling space for uplink control. However, if it is determined that uplink control is not needed, i.e. there is available control signalling space, then the method may include a step S 22 of allocating scheduled data transmission to the physical resource blocks. In that case, the method may further include a step S 24 of hard coding the allocated physical resources for ACK/NACK reports in the uplink to allocation in the downlink.
In an exemplary embodiment of the invention, the eNodeB may allocate uplink resources for ACK/NACK reports according to the worst-case multiplexing requirements, and may also consider the probability of data-non-associated ACK/NACK, i.e. ACK/NACK reports that are not piggy-backed to data transmissions. For example, if the eNodeB assumes a multiplexing limit per subframe of 6 (including both semi-static and scheduled transmission), it needs to allocate two PRBs for signaling.
According to an exemplary embodiment of the present invention, the eNodeB can dynamically use parts of the space allocated for uplink ACK/NACK control (or other needed control on dedicated channel) for scheduling user data in the uplink when the eNodeB knows that this control signaling space will not be used by any user, i.e. any user equipment terminals (UEs), in a cell served by the eNodeB. For example, if only 1-3 users are multiplexed in a certain downlink subframe, the eNodeB can schedule data transmissions in the second PRB, which has been allocated for control signalling as shown in FIG. 2 , for the uplink subframe where the ACK/NACK reports would normally be sent.
For example, FIG. 4 shows the allocation in downlink, taking into consideration how many users and/or packets are multiplexed within each subframe. FIG. 4 also shows the processing time of the UE and when the ACK/NACK report associated with a certain subframe need be transmitted from each of the receiving UE. In the example as shown in FIG. 4 , maximally 8 packets are multiplexed within a subframe and this requires 3 control PRBs for a maximum PRB allocation. FIG. 4 shows the actual need of PRBs for control information below the uplink allocation boxes. In the mapping of semi-static users to the control PRBs, the users should be grouped such that they do not prevent freeing of control PRBs. For example, it may not be efficient to allocate persistent users to different control PRBs. It is understood that semi-static users are users that are allocated resources in a semi-static manner, i.e. they are allocated resources once, and then this allocation is valid for a certain period of time, or until the resource is taken away again. For example, one persistent allocation pattern would be to have a user allocated a resource every 10 th TTI. Accordingly, both the UE and the eNodeB know when the resource is allocated for the user, and there is no need to use resource allocation overhead for this user. However, as these users are not known by other scheduled users, these semi-static allocated users may be treated differently.
FIG. 5 shows an exemplary method according to an embodiment of the present invention. The method shown in FIG. 5 may be carried out in a eNodeB. In the method, the eNodeB may conduct downlink packet scheduling for a sub-frame, for example sub-frame ‘n,’ in step S 10 . The eNodeB may then record the number of users and/or packets multiplexed within the downlink sub-frame ‘n,’ including semi-static allocations in step S 11 . The eNodeB may then predict how many ACK/NACK reports are expected from the users/user equipment terminals (UEs) in step S 12 . For delayed uplink allocation, the eNodeB may then calculate how much dedicated resource space is needed for the ACK/NACK reports in step S 13 . In calculating the amount of dedicated resource space required, the eNodeB may take into consideration when the ACK/NACK reports will be transmitted, and whether some of the ACK/NACK reports can be piggy-backed to uplink data transmission for some of the users/UEs in a data-associated control signaling scheme.
For example, if there are k1 scheduled downlink users and k2 persistently scheduled downlink users, there would be k=k1+k2 scheduled users for sub-frame ‘n’, who would need the control signaling of the ACK/NACK reports in the uplink. If persistent scheduling is not implemented in downlink, then k2 is ‘0’. Since uplink and downlink allocations are disconnected/uncorrelated, there would be m=m1+m2 allocations in the uplink, if there is piggy-backed ACK/NACK signaling. Here m1 denotes scheduled users and m2 denotes persistently scheduled users. If m3 uplink users, with m3 being a subset of the m, are able to carry their own uplink control signaling, then m4 users (m4=m−m3) will have to transmit their ACK/NACK signaling using data-non-associated transmission. Knowing the number of data-non-associated users within one PRB, it is possible to calculate how many uplink resources need be reserved for the control signaling. Accordingly, the method shown in FIG. 5 may also include a step S 14 of allocating users in the uplink in unused ‘control signaling reserved’ PRBs based on how many uplink resources are needed to be reserved for the control signalling.
Depending on how the mapping scheme is devised, it is possible to adjust the probabilities of freeing ACK/NACK resources also considering the data-associated ACK/NACKs.
When an eNodeB is used to schedule users on a shared channel in a transmission time interval (TTI), the eNodeB allocates the uplink physical resources for data-non-associated control signaling based on the current amount of the physical resources for downlink transmission, or the allocation history of the downlink transmission. The amount of physical resources for downlink transmission is determined at least partly based on the number of users, i.e. user equipment terminals, and/or the number of packets multiplexed within a downlink subframe in a physical resource block (PRB). The eNodeB is also adapted to allocate uplink physical resources for data transmission based on amount of physical resources allocated for transmission of data-non-associated control signaling.
For delayed uplink allocation, the amount of allocated physical resources for data-non-associated control signaling is also estimated based on whether the data-non-associated control signaling can be piggy-backed to uplink data transmission. The users for which the amount of uplink physical resources for data-non-associated control signaling is allocated include users in semi-static locations.
FIG. 7 shows some components of an apparatus 11 that may be included in a network element, such the eNode B discussed in relation to exemplary embodiments of the present invention. The apparatus may include a processor 22 for controlling operation of the device, including all input and output. The processor 22 , whose speed/timing is regulated by a clock 22 a , may include a BIOS (basic input/output system) or may include device handlers for controlling user audio and video input and output as well as user input from a keyboard. The BIOS/device handlers may also allow for input from and output to a network interface card. The BIOS and/or device handlers also provide for control of input and output to a transceiver (TRX) 26 via a TRX interface 25 including possibly one or more digital signal processors (DSPs), application specific integrated circuits (ASICs), and/or field programmable gate arrays (FPGAs). The TRX enables communication over the air with another similarly equipped communication terminal. The apparatus 11 may also include volatile memory, i.e. so-called executable memory 23 , and also non-volatile memory 24 , i.e. storage memory. The processor 22 may copy applications (e.g. a calendar application or a game) stored in the non-volatile memory into the executable memory for execution. The processor functions according to an operating system, and to do so, the processor may load at least a portion of the operating system from the storage memory to the executable memory in order to activate a corresponding portion of the operating system. Other parts of the operating system, and in particular often at least a portion of the BIOS, may exist in the communication terminal as firmware, and are then not copied into executable memory in order to be executed. The booting up instructions are such a portion of the operating system.
Still referring to FIG. 7 , the apparatus 11 may also include a scheduler 15 for scheduling downlink packets in a sub-frame. The apparatus 11 may further include a recorder 13 for recording the number of users and/or packets multiplexed within the sub-frame. The apparatus 11 may also include a prediction module 14 that may be responsive to the recorded number of multiplexed users and/or packets for predicting a number of expected ACK/NACK reports. The apparatus 11 may also include a determiner 12 that can be responsive to the predicted number of expected ACK/NACK reports for determining how much dedicated resource space is required for the expected ACK/NACK reports. The apparatus 11 may further include an allocation unit for allocating users/UEs to the unused physical resources, i.e. unused PRBs.
The functionality described above (for both the radio access network and the UE) can be implemented as software modules stored in a non-volatile memory, and executed as needed by a processor, after copying all or part of the software into executable RAM (random access memory). Alternatively, the logic provided by such software can also be provided by an ASIC (application specific integrated circuit). In case of a software implementation, the invention can be provided as a computer program product including a computer readable storage structure embodying computer program code—i.e. the software—thereon for execution by a computer processor.
It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the scope of the present invention.
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The present invention is related to methods, apparatuses, systems and computer software for determining an amount of physical resources for downlink transmission, and allocating uplink physical resources for transmission of data-non-associated control signaling based at least on the amount of physical resources for downlink transmission. The amount of physical resources for downlink transmission comprises an amount of downlink control signaling. The present invention further relates to a framework for mapping the dedicated uplink control channels directly to single physical resource blocks. The framework is able to efficiently shift physical resources to and from the uplink control channel for ACK/NACK reports, in a data-non-associated control signaling scheme and on a per subframe basis. The present invention is also concerned with scheduler, for example an eNodeB scheduler, which uses its scheduling history and knowledge of user equipment capabilities to increase utilization of uplink resources.
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FIELD OF THE INVENTION
This invention relates to novel polycarbonate compositions comprising blends which contain thermoplastic olefin copolymers. The thermoplastic olefin copolymer blends are prepared from precursor functionalized olefin polymers and functionalized polymers under reactive conditions. The resulting polycarbonate compositions unexpectedly display improved physical properties.
BACKGROUND OF THE INVENTION
Plastics are conventionally divided into two distinct and important groups: thermoplastics and thermosetting materials. Thermoplastics are those which melt to become viscous liquids when heated and solids when cooled. They are characterized by their flexibility as well as their ability to be repeatedly softened and hardened. Examples of common thermoplastics include acrylic, nylon, polyesters, polyvinyl chloride and polystyrene. Conversely, thermosetting materials are those which can only be heated and shaped once and, thus, they are not reworkable. Further, thermosetting materials are often hard, rigid, insoluble and infusable. Illustrative examples of such materials include phenolics, epoxies and unsaturated polyesters.
It is of increasing interest to prepare polycarbonate blends that comprise toughened thermoplastics since they are often employed in many commercial applications. Commercial methods for toughening thermoplastics usually involve blending into the plastic an elastomer having a low glass transition temperature. Often, however, the immiscibility and incompatibility of the elastomer with the thermoplastic produce poor physical properties in the blend. A compatibilization strategy is then required to improve physical properties. Said strategy typically involves incorporating copolymers prepared from the thermoplastic and the elastomer in the blend. The copolymer serves to improve rubber phase dispersion and adhesion, and thereby improves compatibility and physical properties of the blend.
An example of such polycarbonate blends is one which comprises acrylonitrile-butadiene-styrene (ABS) terpolymers. However, due to the presence of unsaturated polybutadiene rubber, these blends are susceptible to thermal and photochemical degradation. As a result of this, ABS has limited uses in outdoor applications.
Accordingly, the instant invention is directed to novel polycarbonate compositions comprising blends which contain thermoplastic olefin copolymers. Said thermoplastic olefin copolymers are prepared from reactions of ortho compound functionalized olefin polymers and acid, acid anhydride or thiol functionalized polymers. Additionally, in the instant invention, ortho compound is defined as orthoesters and orthocarbonates.
DESCRIPTION OF THE PRIOR ART
Graft copolymers derived from addition polymers and elastomers have traditionally been prepared by polymerizing an olefinic monomer in the presence of a rubber substrate and a free radical initiator. The graft reaction can be achieved in emulsion, suspension, solution or bulk processes. While such processes are widely used, they are not desirable since they disadvantageously require handling and disposing of monomers, solvent and reaction by-products.
Other investigators have focused on the preparation of addition polymer-rubber copolymers by melt processing amine functionalized addition polymers with functionalized elastomers since amines are known to react with a variety of electrophilic moieties including anhydrides, epoxides and alkyl halides. However, this method is not favored since amine-functionalized addition polymers are not available in bulk quantities for copolymer formation.
Finally, in commonly assigned U.S. application Ser. No. 08/160,133, thermoplastic olefin copolymers and blends comprising them are disclosed and in U.S. Pat. No. 5,153,290, polymers of ethylenically unsaturated cyclic orthoesters are disclosed, wherein said unsaturated cyclic orthoesters are prepared by reacting a hydroxy substituted cyclic orthoester with acryloyl chloride.
The instant invention is patentably distinguishable from the above-described since, among other reasons, it is directed to novel polycarbonate compositions comprising blends which contain thermoplastic olefin copolymers that are prepared by melt or solution reactions of ortho compound functionalized olefin polymers and acid, acid anhydride or thiol functionalized polymers, wherein said thermoplastic olefin copolymers comprise ester or sulfide olefin polymer to addition polymer linkages. Further, the novel polycarbonate compositions comprising blends which contain the above-described copolymers unexpectedly display desirable reduced gloss properties, improved tensile strengths, favorable heat deflection temperatures (HDT), improved melt flow indices, improved elongation values and notched Izod values of at least about 450 joules/M and preferably at least about 550 joules/M.
SUMMARY OF THE INVENTION
The instant invention pertains to novel compositions comprising a polycarbonate and blends which contain thermoplastic olefin copolymers wherein the copolymers comprise ester or sulfide olefin polymer to polymer linkages. The thermoplastic olefin copolymers are prepared by the reaction of ortho compound functionalized olefin polymers comprising structural units of the formula ##STR1## and a polymer having acid, acid anhydride or thiol functionality. Illustrative examples of the functionalized polymers include polyphenylene ether, polyphenylene sulfide and functionalized polymers of vinyl monomers such as polystyrene and acrylics.
Each R 1 is independently a hydrogen, lower alkyl (C 1 -C 5 hydrocarbon), substituted or unsubstituted aromatic radical or a halogen and R 2 is --CH 2 -- or a substituted or unsubstituted divalent aromatic radical and m is greater than or equal to 1.
X is a substantially inert linking group and preferably is represented by groups of the formulae ##STR2##
Y is selected from the group consisting of cyclic orthocarbonates and cyclic orthoester moieties having the formula ##STR3##
R 3 is a C 1 -C 10 primary or secondary alkyl or aralkyl or a C 6 -C 10 aromatic radical or an alkylene radical forming a second 4 to 8 membered ring with C* thus producing a bicyclo compound. R 4 is a C 1 -C 10 primary or secondary alkyl or aralkyl or a C 6 -C 10 aromatic radical. Further, R 3 and R 4 together with atoms connecting them can form a 4 to 8 membered ring thus producing a spirobicyclo compound. R 5 is a hydrogen, alkyl or aryl. l is 0 or 1 and n is an integer from 0 to 2. p is 0 or 1 and t is 0 when R 3 and C* form a bicyclo compound and is otherwise 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polycarbonate compositions of the instant invention may comprise structural units of the formulae ##STR4## wherein A 1 is a divalent substituted or unsubstituted aliphatic, alicyclic or aromatic radical, preferably --A 2 --Y--A 3 -- wherein A 2 and A 3 are each independently a monocyclic divalent aromatic radical. Y is a bridging radical in which 1 to 4 atoms separate A 2 from A 3 and VII is a preferred subgenus of VI.
The A 2 and A 3 values may be unsubstituted phenylene or substituted derivatives thereof, illustrative substituents (one or more) being alkyl, alkenyl, alkoxy and the like. Unsubstituted phenylene radicals are preferred. Both A 2 and A 3 are preferably p-phenylene, although both may be o- or m-phenylene or one o- or m-phenylene and the other p-phenylene.
The bridging radical, Y, is one in which one or two atoms, preferably one, separate A 2 from A 3 . It is most often a hydrocarbon radical and particularly a saturated radical such as methylene, cyclohexylmethylene, 2-[2.2.1]-bicycloheptylmethylene, ethylene, isopropylidene, neopentylidene, cyclohexylidene, cyclopentadecylidene, cyclododecylidene or adamantylidene, especially a gem-alkylene (alkylidene) radical. Also included, however, are unsaturated radicals and radicals which contain atoms other than carbon and hydrogen; for example, 2,2-dichloroethylidene, carbonyl, phthalidylidene, oxy, thio, sulfoxy and sulfone. For reasons of availability and particular suitability for the purposes of this invention, the preferred units of formula VII are 2,2-bis(4-phenylene)propane carbonate units, which are derived from bisphenol A and in which Y is isopropylidene and A 2 and A 3 are each p-phenylene.
The material represented by formula VIII
HO--A.sup.1 --OH (VIII)
is the source of structural units of formula VI above; A 1 is as previously defined.
Illustrative non-limiting examples of VIII include:
2,2-bis(4-hydroxyphenyl)-propane (bisphenol A);
2,2-bis(3,5-dibromo-4-hydroxyphenyl)propane;
2,2-bis( 3,5-dimethyl-4-hydroxyphenyl)propane;
1,1-bis(4-hydroxyphenyl)cyclohexane;
1,1-bis( 3,5-dimethyl-4-hydroxyphenyl)cyclohexane;
1,1-bis(4-hydroxyphenyl)decane;
1,4-bis(4-hydroxyphenyl)propane;
1,1-bis(4-hydroxyphenyl)cyclododecane;
1,1-bis(3,5-dimethyl-4-hydroxyphenyl)cyclododecane;
4,4-dihydroxydiphenyl ether;
4,4-thiodiphenol;
4,4-dihydroxy-3,3-dichlorodiphenyl ether;
4,4-dihydroxy-3,3-dihydroxydiphenyl ether;
1,3 benzenediol; and
1,4-benzenediol.
Other useful dihydroxyaromatic compounds which are also suitable for use in the preparation of the above copolycarbonates are disclosed in U.S. Pat. Nos. 2,999,835; 3,028,365; 3,334,154 and 4,131,575, all of which are incorporated herein by reference. The preferred bisphenol is 2,2-bis(4-hydroxyphenyl)propane (bisphenol A).
The polycarbonates of the instant invention may be prepared by reacting bisphenols with a carbonate source such as phosgene or dimethyl carbonate using conventional techniques. These include melt polymerization, interfacial polymerization and interfacial conversion with bischloroformate followed by polymerization. Chain termination agents such as phenol may also be employed.
Preparation of functionalization monomers (ethylenically unsaturated cyclic ortho compounds) which are grafted to produce the functionalized olefin polymers employed in the invention is achieved by reactions between hydroxy-substituted orthoester and α,β-unsaturated acid chlorides to form unsaturated esters such as the methacrylate or acrylate type. The preparation is further illustrated by the following examples. Molecular structures of all products in Examples 1-3 were confirmed by proton and carbon-13 nuclear magnetic resonance spectroscopy.
EXAMPLE 1
A 5-liter 3-necked flask fitted with a mechanical stirrer, pressure equalizing addition funnel and nitrogen inlet was charged with 301 grams (2.03 moles) of 4-hydroxymethyl-2-methoxy-2-methyl-1,3-dioxolane, 514 grams (5.08 moles) of triethylamine and 2 liters of methylene chloride. The flask was immersed in an ice-water bath and 193.1 grams (2.13 moles) of acryloyl chloride was added over 50 minutes under nitrogen, with stirring. The mixture was stirred at room temperature overnight, filtered and the filtrate was washed twice with 2-liter portions of water, dried over magnesium sulfate, filtered and vacuum stripped. A free radical inhibitor, 3-t-butyl-4-hydroxy-5-methylphenyl sulfide, was added in the amount of 200 ppm. to the residue which was then distilled under vacuum. The desired 4-acryloyloxymethyl-2-methoxy-2-methyl-1,3-dioxolane distilled at 80°-85° C./0.5-1.0 torr.
EXAMPLE 2
The procedure of Example 1 was repeated, employing 281 grams (1.9 moles) of 4-hydroxymethyl-2-methoxy-2-methyl-1,3-dioxolane, 481 grams (4.76 moles) of triethylamine and 199 grams (1.9 moles) of methacryloyl chloride. The product, 4-methacryloyloxymethyl-2-methoxy-2-methyl-1,3-dioxolane, was collected at 80° C./0.4 torr.
EXAMPLE 3
The procedure of Example 1 was repeated, employing 21 grams (100 mmol.) of 4-hydroxymethyl-2-methoxy-2-phenyl-1,3-dioxolane, 25.3 grams (250 mmol.) of triethylamine, 9.5 grams (105 mmol.) of acryloyl chloride and 150 ml. of methylene chloride. The crude product was purified by column chromatography over basic alumina, using 15% (by volume) ethyl acetate in hexane as an eluant, to yield the desired 4-acryloyloxymethyl-2-methoxy-2-phenyl-1,3-dioxolane.
The functionalized olefin polymers employed in the instant invention may be prepared via co-extrusion of a large variety of graftable compounds and polyolefin. The extrusion techniques as well as the graftable compounds include those described in commonly assigned U.S. Pat. No. 5,153,290, the disclosure of which is incorporated herein by reference.
The polymers employed in this invention comprising acid or acid anhydride functionality are prepared by standard free radical polymerization techniques known to those skilled in the art. The functionalized vinyl monomer (such as functionalized polystyrene and acrylics), and optionally one or more conventional vinyl monomers are polymerized via bulk, suspension, emulsion or solution polymerization methods in the presence of a free radical initiator, such as azobisisobutyronitrile (AIBN) or benzoyl peroxide. Broadly, the functionalized vinyl monomer may comprise from about 0.1 to 100 mole percent of the total monomer feedstream; however, the operable concentration may depend upon the specific functionalized monomer. The polymers comprising thiol functionality are typically prepared by polymerization of vinyl mercaptan precursors as well as by the methods described in Adv. Polym. Sci., Vol. 15, 1974, pp. 61-90.
The concentration of free radical initiator generally ranges from about 0.001 to about 1.0 weight percent based on total weight of monomers. A variety of organic solvents is suitable for the solution polymerization method and halohydrocarbons, such as methylene chloride; ketones such as methyl ethyl ketone and acetone; and aromatic hydrocarbons, such as toluene and ethylbenzene, are often preferred. The temperature of the free radical polymerization generally ranges from 40° C. to about 150° C. The resulting polymers employed in this invention possess a weight average molecular weight (as determined by gel permeation chromatography) typically ranging from about 40,000 to about 250,000.
The functionalized polymers employed in this invention are capable of reacting with the above-described functionalized olefin polymers to form thermoplastic olefin copolymers. The olefin polymers that are functionalized in accordance with the instant invention and suitable for forming such copolymers include elastomers that possess a glass transition temperature, Tg, less than about 0° C. and preferably less than about -20° C. Illustrative examples of suitable polyolefins include ethylene propylene diene comonomer (EPDM) rubbers, ethylene alkene rubbers such as poly(ethylene-copropylene), polydiene rubbers such as poly(butadiene). Additionally, functionalized polyacrylates such as poly(butylacrylate) may also be employed.
In a preferred example, a functionalized polymer in accordance with the instant invention designated styrene acrylonitrile-A (SAN-A), prepared by the copolymerization of styrene, acrylonitrile and an acid, acid anhydride or masked thiol functionalized vinyl monomer, is melt extruded with an EPDM rubber functionalized with a cyclic orthoester or carbonate as depicted by formula I to afford a novel EPDM-SAN copolymer. A typical example includes reacting SAN-A with an EPDM rubber functionalized with cyclic 2-methoxy-2-methyl-1,3 dioxolane to form a EPDM-SAN copolymer.
The reactions between functionalized polymer and the functionalized olefin polymers is conventionally conducted in the melt or in solution. The process of preparing the thermoplastic olefin copolymers of this invention, for instance by the melt, comprises mixing olefin polymers functionalized with cyclic orthoesters or orthocarbonates with the acid, acid anhydride or thiol functionalized polymer employed in this invention and melt reacting the mixture at a temperature ranging from about 170° C. to about 350° C. Preferably, the temperature ranges from about 200° C. to about 260 C. Typical melt processing techniques include continuous extrusion through a single screw or twin screw extrusion device, such as a Welding Engineers 20-mm. twin screw extruder, and melt reaction in a Helicone reactor or Brabender melt mixer. One skilled in the art will recognize that if extrusion is employed, the screw design, screw speed, and feed rate may vary.
The copolymer containing blends employed in the instant invention typically range from about 20 to about 90 weight percent, preferably from about 40 to about 80 weight percent, functionalized olefin polymer, and typically from about 80 to about 10 weight percent, preferably from about 60 to about 20 weight percent, functionalized polymer. Optionally, an unfunctionalized polymer such as SAN, may be added to the functionalized polymer and functionalized olefin. The concentration of unfunctionalized addition polymer typically comprises from about 0 to about 50 weight percent, preferably from about 0 to about 25 weight percent, based on the weight of the functionalized polymer. More preferably, no unfunctionalized polymer is employed.
The following additional examples are to further illustrate and facilitate the understanding of the invention. All products obtained may be confirmed by conventional techniques such as proton and carbon 13 nuclear magnetic resonance spectroscopy as well as infrared spectroscopy.
EXAMPLE 4
The synthesis of a styrene acrylonitrile addition polymer comprising 1.0 mole percent acrylic acid functionality was achieved by charging a 5L, 3-neck round bottomed flask equipped with a stirrer and thermometer with 800 mL (6.98 mol) styrene, 300 mL (4.56 mol) acrylonitrile, 8.29 g (115 mmol, 1 mole percent) acrylic acid, 3.83 g (23.3 mmol) AIBN and 1.5 L methyl ethyl ketone to produce a mixture. The mixture was then purged with nitrogen for 5 minutes and then stirred at 70° C. for 24 hours. The resulting viscous solution was cooled to room temperature and precipitated into methanol using a commercial blender. Polymer was isolated by filtration, washed with methanol and dried in a vacuum oven at 60° C. for 48 hours to afford 731 (73% isolated yield) of white powder, SAN-A. FTIR spectroscopy confirmed the incorporation of the acid monomer by the presence of the carbonyl absorbtion at 1730 cm -1 . Qualitative analysis of the FTIR spectra revealed an acrylonitrile concentration of 27 weight percent.
EXAMPLE 5
SAN comprising 1 mole percent acrylic acid as prepared in Example 4 was tumble mixed with orthoester functionalized EPDM and extruded in a twin screw extruder at 450° F. to produce an extrudate (EPDM, SAN and copolymer). The extrudate was cooled in a water bath, pelletized and dried for 4 hours at 80° C. Copolymer analysis was obtained from acetone extractions which dissolve away any unreacted SAN and leave behind unreacted EPDM and EPDM-SAN copolymer as insolubles. The analysis revealed high degrees of grafting and thus copolymer formation.
It is expected that isolated copolymers prepared by extrusion or solution polymerization may be mixed with additional unfunctionalized or functionalized SAN and EPDM and extruded under conditions similar to those described above in order to produce poly(acrylonitrile-EPDM-styrene) (AES) blends.
The instant blends may be prepared in situ in an extruder. Also, in the alternative, substantially pure copolymers may be prepared and isolated. Subsequent blends may be prepared by mixing the isolated copolymers with additional resins followed by extruding in a manner similar to the one described in Example 5.
The method for producing the polycarbonate compositions of the instant invention is not particularly limited, and the conventional methods are satisfactorily employed. Generally, however, melt blending methods are desirable. The time and temperature required for melt blending are not particularly limited, and they can properly be determined according to the composition of the material.
The temperature varies somewhat with the blending ratio of polycarbonate to blends which contain thermoplastic olefin copolymers, but it is generally within a range of 200° to 500° C.
Any of the melt blending methods may be used, if it can handle a molten viscous mass. The method may be applied in either a batchwise form or a continuous form. Specifically, extruders, Banbury mixers, rollers, kneaders and the like may be employed.
EXAMPLE 6
An extrudate was prepared by charging a twin screw extruder set at 400 rpm at a throughput of 12 lbs/hr and temperatures in the ranges of 90° to 260° C. with 64 parts bisphenol A polycarbonate (Mn 50,000), 20 parts SAN (Mn 35,000), 16 parts AES-2 (prepared from a two-step extrusion process employing 1 part SAN-A functionalized with 1 mole % acrylic acid and 4 parts EPDM functionalized with 1 mole % cyclic orthoester (as prepared in Example 1) to yield a 1:4 copolymer blend which was diluted with additional acid functionalized SAN to produce a 1:1 copolymer blend), 0.1 part bis(2,4-di-t-butyl)pentaerythritol diphosphite, 0.1 part 1,3,5-tris(3,5-di-t-butyl-4-hydroxybenzyl)isocyanurate and 0.5 part pentaerythritol tetrastearate. The extrudate was cooled in a water bath, pelletized and dried for 4 hours at 80° C. yielding a polycarbonate composition (A).
EXAMPLES 7-8
Polycarbonate compositions (B) and (C) were prepared in the manner described in Example 6 except that 16 parts AES-1 (prepared from a single step extrusion of 1 part SAN-A functionalized with 1 mole % acrylic acid and 1 part EPDM functionalized with 1 mole % cyclic orthoester to produce a 1:1 copolymer blend) was employed in lieu of AES-2 in the former and 16 parts acrylonitrile-butadiene-styrene (ABS) (50 parts butadiene/50 parts SAN with 60% grafted to rubber) was employed in lieu of AES-2 in the latter.
The polycarbonate compositions in the table which follows correspond to the compositions described in Examples 6-8. The data confirms polycarbonate composition formation as well as the new and unexpected results obtained in the instant invention.
__________________________________________________________________________ Melt Tensile Flow MaximumPolycarbonate Gloss Strength (psi) Index Elongation %Composition (60°) at break HDT (°C.) (g/10 min.) at break__________________________________________________________________________A 58 7662 104 3.29 178B 53 7454 106 3.19 126C (control) 98 7309 110 1.88 109__________________________________________________________________________
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Novel polycarbonate compositions comprising blends which contain thermoplastic olefin copolymers are prepared from precursor orthoester and orthocarbonate functionalized olefin polymers and functionalized polymers and the novel polycarbonate compositions display improved physical properties.
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This is a division, of application Ser. No. 871,163, filed Jan. 20, 1978, now U.S. Pat. No. 4,243,509 issued Jan. 6, 1981, which is a continuation of application Ser. No. 689,002, filed May 24, 1976 and since abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of coal conversion to form hydrocarbon gases and liquid suitable for conversion to fuels.
More particularly, this invention relates to apparatus for reacting carbonaceous material such as pulverized coal with heated hydrogen to form hydrocarbon liquids suitable for conversion to fuels or for use as a chemical feedstock.
2. Description of the Prior Art
The problem is to react coal directly with hydrogen in such a way as to maximize the yield of liquid products. A number of researchers have shown that at the beginning of coal pyrolysis a transient period exists for a few tenths of a second where the coal is highly reactive toward hydrogen. If excess hydrogen is not available during this period, some of the free-radical pyrolytic fragments will strip molecular hydrogen from the aromatic groups while other fragments will polymerize to form unreactive char. The overall effect is a limited yield of liquid and gaseous hydrocarbons, and a large yield of char. If instead, excess hydrogen is present during the critical transient period, many more hydrogenated fragments that are amenable to still further hydrogenation are produced. The overall effect of pyrolysis in hydrogen is a much larger yield of liquids and gases, and a lower char yield.
It is generally well known the conversion of coal to liquid or gaseous fuels is achieved by the addition of hydrogen. This may be accomplished by the direct contact of coal with hydrogen as in the Bureau of Mines Hydrane process to produce methane; by a catalyzed liquid-phase reaction with hydrogen to produce liquid products as in the Synthoil process; or indirectly by reacting coal with steam. Many different processes have been proposed and are under development. These schemes vary in the method of contacting coal and hydrogen or steam, and in the type of coal feed utilized. A solid such as coal can be contacted with a gas in three basically different ways. In the first, gas is forced through a fixed or slowly moving bed of solid. Another method of contact is by use of a fluidized bed. With sufficiently small solid particles and a sufficiently high gas velocity in vertical upward flow the air dynamic drag forces on the individual particles begin to approach the gravitational forces and the particles themselves begin to move about. The bulk properties of the gas solid mixture then become those of a fluid. Because of the improved heat and mass transfer characteristics in a fluidized bed as opposed to a fixed bed, most coal gasification processes now are the fluidized bed variety. Yet another basic category of gas solid contacting is entrained flow as in the Bigas process. In this regime gas velocities are high enough and particle sizes low enough that the solid particles are carried along with the gas stream. An advantage of the entrained flow processes is the ability to utilize any grade or class of coal. Caking coals will agglomerate causing difficult problems when fed to fluidized or fixed bed systems. Further advantages of entrained flow with respect to gas production include operation at high temperatures so that tar production is kept to a minimum, adaptability to slagging conditions and high energy production per unit volume. The present invention utilizes this type of entrained flow coal conversion process. Heretofore no large scale attempt to use this approach for direct hydrogenation of coal has been made.
A patent issued to W. C. Schroeder, U.S. Pat. No. 3,030,297, describes a process which comprises heating dry particles of coal entrained in a heated stream of hydrogen at total pressure of about 500-6000 psig from a temperature below about 300° C. to a reaction temperature in the range of from about 600° C. to about 1000° C. Two minutes are required to heat the coal particles to about 600° C. and then two to twenty seconds time at temperature for hydrogenation. The slow heat-up results from the main hydrogen stream being utilized to carry the coal into the reactor. The products of reaction are then cooled below reaction temperature to provide a product comprised of light oil, predominantly aromatic in nature, and hydrocarbon gases, primarily methane and ethane, and carbon monoxide.
This process is disadvantaged in that the coal particles entrained in the hydrogen are preheated prior to introduction into a heating chamber thus the reaction process is started upstream of the reaction chamber which will cause agglomeration and plugging within the conduit carrying the entrained coal. The present invention overcomes this agglomeration problem by providing two sources of gas, one source of gas such as hydrogen brings entrained coal into an injector at ambient temperature, and a separate source provides heated hydrogen to an injector which contacts the entrained dense phase coal downstream of an injector within a reaction zone thereby starting the hydrogenation process within the reaction chamber and not upstream of the chamber.
Schroeder is further disadvantaged in that he attempts to heat the entrained coal particles through a tube wall. At the mass throughputs specified in the example, it is doubtful that enough heat could be transferred through the tube wall in a reasonable length to sufficiently heat the coal and, at the same time, use the tube wall to contain the system pressure. This type of reactor does not scale to the necessary larger diameters for commercial coal conversion reasonably because the heat transfer surface-to-volume ratio decreases rapidly with an increase in size.
Schroeder is still further disadvantaged in that the mixing and the heating takes place in minutes and seconds whereas the present invention accomplishes the hydrogenation of the entrained coal in milliseconds and if a uniform flow pattern can be maintained (to avoid back mixing which will cause longer residence time and gas production instead of liquids) and if the coal can be dispersed uniformly even on a microscopic scale (to minimize gas diffusion limitations), and if rapid and efficient quenching can be achieved (Schroeder carries the hydrogenated products through a conduit towards a separate quenching chamber whereas the present invention quenches the reaction products immediately upon exiting the end of the reaction chamber), then it should be possible to hydrogenate a substantial fraction of the coal to liquid products. The utilization of rocket engine type injector principles in a coal liquefaction plant as described in the present invention is believed to be unique and is one of the principal objects of the invention.
Another patent issued to Schroeder et al, U.S. Pat. No. 3,152,063, teaches a process which comprises dispersing pulverized and catalyzed coal, in the absence of a pasting oil, in hydrogen under a pressure of about 500 to 4000 psig, reacting the mixture of coal and hydrogen at a temperature in the range of about 450° to 600° C., for a gas residence time of less than about 200 seconds, cooling the reaction products and recovering liquid and gas hydrocarbon products therefrom.
Schroeder teaches passing of catalyzed coal and hydrogen into a two-stage reactor that consists of a multiplicity of parallel tubes axially extending within the reactor. The tubes are heated by a source of hot gas to start the reaction within the tubes. Vaporized oil and gas products are drawn off as well as unused hydrogen to a cooling device. The residual heavier oil and tar products are collected in the bottom of the reactor and a source of hydrogen may then be brought in to further hydrogenate these heavier products.
This invention is disadvantaged in that the pulverized coal must be passed through a catalyzing process, sent through a dryer and grinder and finally separated into minute particles by passing the coal through a screening process. The present invention utilizes finely-divided pulverized coal directly without the foregoing pre-treatment process.
Schroeder's invention is further disadvantaged in that it also utilizes the carrier hydrogen in the coal passages as the main source of hydrogen. The heat-up process then takes considerable time as compared to the present invention in that the carrier gas cannot be pre-heated prior to entering into a reaction chamber.
Additionally, the invention is disadvantaged in that the coal particles are heated through a tube or a series of tubes thereby seriously affecting the ability to scale-up the process to commercial production proportions. A commercial unit would necessarily have to process in the neighborhood of 1000 tons/hour. The Schroeder patents teach a mass throughput of approximately 145 lbs/hr ft. 2 , a very low process rate. For example, in a commercial reactor using the Schroeder process, each reactor being 15 feet in diameter, 82 reactors would be needed to process 1000 tons/hr of coal. In addition, because of the small surface-to-volume ratio the reactors would have to be on the order of one hundred feet long to transfer sufficient heat through the wall transporting the entrained coal particles. One of the most important advantages of the high throughput of dense phase coal particles through the reactor of the present invention (33,000 lbs/hr ft. 2 ) is that it is scaleable to a commercial size. Two reactors utilizing the principles set forth in the following specifications, 6-feet in diameter would process 1000 tons/hr of coal. The heat is supplied directly in the hydrogen so that vessel surface-to-volume ratio is not a limiting factor.
Although the chemistry of coal pyrolysis and hydrogenation has been apparent for some time, no well-developed reactor exists which efficiently utilizes the rapid-reaction regime. Some of the basic reasons for this appear to be a lack of adequate gas/solid injection and mixing technology, difficulty in meeting chemistry and residence time requirements, and agglomeration and plugging of the reactor. Hydrogenation of raw bituminous coal usually results in agglomeration, so that typical fluidized bed or moving bed reactors cannot be used as heretofore described. In addition, the requirement of short residence time (less than 1 sec) necessarily restricts the reactor to an entrained flow type. By maintaining rapid mixing, heat-up, and reaction of the coal near the point of injection and hot reactor walls, the agglomeration problem can be avoided. The uniform and precise mixing of extremely large feed streams in time of a few milliseconds is the special accomplishment of large rocket engine injectors and one of the principal objects of the present invention.
SUMMARY OF THE INVENTION
It is an object of this invention to convert coal particles entrained in a gas in a dense phase to hydrocarbon liquids and gases by hydrogenating the coal particles.
More particularly, it is an object of this invention to provide an apparatus which utilizes rocket engine injection and mixing techniques in an entrained flow reactor to rapidly mix and react a separate stream of heated hydrogen with a dense phase stream of pulverized coal at ambient temperature to produce liquid and gaseous hydrocarbons.
It is yet another object of this invention to build and operate a high-temperature, coal liquefaction reactor which minimizes secondary oil and tar decomposition reactions by optimum control of gas-phase residence time, and prevents reactor plugging from coal agglomeration by very rapid dispersion and reaction of the coal while maintaining the internal reactor wall at high temperature.
A coal liquefaction apparatus is provided which will produce hydrocarbon liquids and gases by hydrogenating pulverized coal with hydrogen by flowing pulverized coal particles entrained in a gas such as hydrogen in a dense phase in a coal flow conduit at ambient temperature toward an injector adjacent to a reaction chamber and including a heating means for heating a separate source of hydrogen. The dense phase pulverized coal is injected through the injector into the reaction chamber followed by injecting the heated separate source of hydrogen gas through the injector into the reaction chamber and means to separate the ambient temperature dense phase coal particles and the heated hydrogen prior to injection of the dense phase coal and the heated hydrogen into the reaction chamber to prevent premature hydrogenation of the pulverized coal. A quenching means is provided adjacent the reaction chamber to rapidly arrest the hydrogenation process at a predetermined time period when the reaction products exit the reaction chamber, and a collecting means is provided for collecting the reaction products.
The coal is fed to the reactor at nearly its bulk density so that the quantity of entrained gas is minimized, and the heated hydrogen brought in separately provides the heat source needed to raise the coal rapidly to reaction temperatures.
An entrained flow reactor using rocket engine injection and mixing techniques to react a stream of hot hydrogen with a stream of pulverized coal was designed, built, and operated. As an example only, typical reactor operating conditions were 1000 psig, 1100° F., ≈150 milliseconds residence time, and 0.36 lb H 2 /lb coal. Approximately 19% of the coal carbon was converted to a synthetic crude oil having a boiling range of 200°-350° C. and a heating value of 15,800 BTU/lb, 9% to gas containing methane, ethane, and carbon oxides, and 3% to organic compounds in the quench water. The coal throughput rate was approximately 33,000 lbs/hr ft 2 reactor cross section or 11,000 lbs/hr ft 3 reactor volume. The products of reaction were rapidly quenched to 220° F. in a distance of 1 ft using large flowrates of water through spray nozzles.
Thus, an advantage over the prior art is the use of rocket engine injection and mixing techniques to rapidly mix and react a stream of entrained coal with hot hydrogen to produce liquid and gaseous hydrocarbons.
Another advantage of the present invention over the prior art is the minimization of secondary oil and tar decomposition reaction by optimum control of gas-phase residence time by very rapid coal particle dispersion and reaction of the coal while maintaining the internal reactor wall at high temperature.
Yet another advantage over the prior art is the prevention of coal agglomeration upstream of the reaction chamber by transporting the entrained dense phase coal in a gas at ambient temperature.
Still another advantage over the prior art is the ability to use a carrier gas other than hydrogen for transporting the coal particles in a dense phase to the injector thus minimizing explosion hazards in the coal feed system due to hydrogen leakage to the atmosphere from moving mechanical parts such as valves, buildup of explosive mixtures of hydrogen and air in the coal containing vessels, and loss of hydrogen through venting when lock hoppers are used.
A still further advantage over the prior art is the immediate quenching of the hydrogenated coal particles as they exit the end of the reaction chamber thereby maximizing the product yield of liquid and gaseous hydrocarbons.
Another advantage over the prior art is the direct hydrogenation of coal particles in a reaction chamber as opposed to heating the exterior wall of a tube surrounding the hydrogen and coal particles contained within the tube.
The above-noted objects and advantages of the present invention will be more fully understood upon the study of the following description in conjunction with the detailed drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a flowsheet schematic of the coal liquefaction apparatus;
FIG. 2 is a detailed cross-section of the principal elements of the invention;
FIG. 3 is an enlarged partially cross-sectioned view of the hot hydrogen and the coal flow coupling upstream of the injector;
FIG. 4 is an enlarged cross-section of the concentric injector;
FIG. 5 is a view of the heater coil element and electrical coupling adjacent the reaction chamber and coal flow tubes;
FIG. 6 is an alternative view of the reaction chamber illustrating diverging walls from the injector face to the exit plane of the reactor tube;
FIG. 7 is an alternative view of an injector illustrating a four-on-one injection pattern; and
FIG. 8 is a view taken along lines 8--8 of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a coal liquefaction unit generally designated as 10 consists of a nitrogen supply system generally designated as 12 that serves as a purge supply source as well as a pressurizing source for a quench water tank system generally designated as 14.
A high pressure coal feeder generally designated as 16 comprises a cylindrical vessel 18 suspended from a load cell 20. The coal feeder 16 is charged by flowing coal from a low pressure conical tank 22 through a tube 24. To charge the high pressure coal feeder 16, the conical tank 22 is pressurized to about 55 psig with nitrogen from supply system 12, a ball valve 26 at the conical tank bottom is quickly opened wide, and the coal flows in a dense phase through the tube 24 to the coal feeder 16. The excess nitrogen vents out of the coal feeder through a dust filter 28. After the coal feeder 16 is charged, the tube 24 is disconnected and capped as shown at 27, and the dust filter 28 is disconnected and the pressure relief line 32 connected in its place, as shown in FIG. 1. A hopper hydrogen feed line 30 from a hydrogen source 48 or inert gas from an inert gas source 50 is opened for subsequent operation. Load cell 20 readings before and after charging indicate the quantity of coal in the feeder. The bottom 19 of the coal feeder 16 is conically shaped with a 30° included angle to provide smooth discharging of coal. Coal is fed to the reactor assembly by opening a ball valve 34 and flowing in a dense phase through a feed line 36. The hydrogen or inert gas pressure in the coal feeder is maintained, for example, about 60 to 70 psi higher than in the reactor assembly generally designated as 38 so as to provide the driving force for feeding the coal to the reactor assembly 38. The weight of hydrogen carried in the coal as a percent of the coal flowrate is about 0.5% when the reaction chamber pressure is 1000 psig. In the case of inert transport gas, the weight percent transport gas will vary according to gas density. The flowrate of coal is about 0.15 pound per second and the flowrate of hydrogen is about 0.0075 pound per second where hydrogen is used as the carrier gas. Load cell readings are printed during a test so that the coal feed rate can be continuously monitored (not shown). When the feeder ball valve 34 is in a closed position, nitrogen from nitrogen supply system 12 flowing through a line 40 is purged through the feed line 36 to keep it clear and to prevent the coal side of the injector (FIG. 4) from overheating. The portion of the coal feed line passing through a top flange 37 and making up part of an injector assembly 92 (FIG. 3) is typically fabricated from stainless steel. Details of the injector assembly 92 are shown in FIGS. 3 and 4.
Pressurized water for a quench system generally designated as 42 is supplied by, for example, a 150 gallon pressurized quench water tank system 14. The flow of water can be accurately measured continuously during tests and is varied by changing the pressure on the water tank from nitrogen supply system 12. Accurate flow control is possible because the pressure drop across spray nozzles 106 (FIG. 2) is normally about 180 psi. In addition, there is about another 130 psi in pressure drop ahead of the spray nozzles.
It would be obvious to use fluid other than water to quench the hydrogenated products as they exit the reaction chamber such as steam, oil or cold gas (hydrogen).
There are three gas supply systems, one for nitrogen, one for hydrogen and one for an inert gas. The nitrogen supply system 12 supplies the nitrogen bleed to a preheater assembly 39 through a conduit 31 and reactor pressure shells 53, and for purging the coal feed line through line 40. The flows are controlled by using sonic nozzles (not shown) and varying the pressure upstream of the nozzles to obtain various flowrates. The hydrogen source 48 supplies the high pressure coal feeder 16 and the preheater assembly 39. The hydrogen flow to the coal feeder 16 is on demand and is only measured with an orifice (not shown). The gas supplied to the coal feeder 16 need not be hydrogen from hydrogen source 48 but may be an inert gas such as nitrogen, carbon dioxide or mixture thereof from inert gas source 50. The hydrogen flow to the preheater assembly 39 is controlled by a sonic nozzle and upstream pressure regulator (not shown). The hydrogen system may be set up so that nitrogen can be used in place of hydrogen for purging and leak checks (not shown).
Product gas from a spherical catch tank 52 flows through a conduit 54 to a liquid separator tank 56 and then through a back pressure regulator system. After the product gas is let down in pressure, the flowrate is measured using an orifice and then the gas goes to a burnstack 58 through a tube 60. A gas sample bottle system generally designated as 62 is connected to the high pressure side through a line 64 of the gas sample bottle system 62 and is vented back into the system through a line 66 to burnstack 58. The sample bottle valves 68 are automated to open in sequence about every 30 to 60 seconds during a test.
The liquid product letdown is controlled by a tank liquid level control system generally designated as 70 that actuates an on-off valve 72. The flow out of catch tank 52 is regulated by a linear plug valve 74. The linear plug valve 74 is basically a variable orifice that is used to prevent the liquid from surging out of catch tank 52 so fast that pressure control in the reactor assembly 38 is upset. A header of three valves 76 is used to select which of drums 78 is to receive the liquid product.
A more detailed drawing of the hydrogen preheater assembly generally designated as 39 is presented in FIGS. 2 and 5 and of the reactor assembly generally designated as 38 is presented in FIG. 2. The hydrogen preheater assembly is contained within a pressure shell 41 and the preheater coil 43 is a stainless steel tube through which an electric current is passed as hydrogen passes through it. The preheater coil 43 is thin walled and small in diameter at end 45 and heavy walled and larger in diameter at end 47. As the hydrogen enters end 45 it is relatively cool and as it progresses down through helical-shaped preheater coil 43 it heats up and expands. The variable I.D. and wall thickness of the coil compensates for this expansion of hydrogen. Seven motor-generator sets (not shown) supply about 600-800 amps to copper stud conductors 77 and 79 connected to plate 80 through the wall 49 with a power input up to 150 Kw. The heat transfer from the resistively-heated wall 49 to the pressurized hydrogen entering end 45 of preheater coil 43 through hydrogen feed line 30 is excellent and has demonstrated efficiencies of about 99%. Since the tube wall strength is very low at the heater operating temperatures (the wall is about 200° F. hotter than the hydrogen at the exit 47 of the tube 43), the preheater coil 43 is contained in a pressure shell 41 made from, for example, carbon-steel pipe and 600 lb flanges 82 and 84. The void space 86 in the pressure shell 41 is stuffed with, for example, a very low thermal conductivity insulation 87 such as Fibrefrax, a product of Carborundum Corporation, Refractories and Insulation Division, Fibrefrax Branch, Niagra Falls, New York, and is purged continuously with about 5 SCFM of nitrogen at about 1000 psig. The copper stud conductors 77 and 79, plate 80, and inlet end 45 of the preheater coil 43 are electrically isolated from the pressure shell 41 and serve as the positive connection to the motor generator sets. The ground connection is made to another end 51 of the pressure shell 41 through the blind stainless steel flange 88 that is sandwiched between the two carbon steel, weld-neck flanges 84 and 85. A thermocouple 90 is immersed in the gas exiting the preheater assembly 39, and a pressure transducer (not shown) is connected to a similar port in the flange.
In a similar fashion, referring to FIG. 2, the reactor tube 98 and injector assembly generally designated as 92 are enclosed in a pressure shell 53 so that the hot reactor tube walls 94 experience very little stress while at high temperature. The reactor 98 is supported by the insulation 87 and slip fits through a hole in the insulation support plate 96 so that thermal elongation of the reactor tube 98 is allowed. The preheater assembly 39 is connected to the injector assembly 92 via a stainless steel coiled tube 100. This tube is coiled so that it can thermally elongate without applying a force against the injector assembly 92, possibly bowing the reactor tube 98. The reactor tube 98 and injector assembly 92 can easily be removed from the pressure shell 53 by removing the top flange 37 and a small amount of insulation 87. Several bosses 102 along the side of the pressure shell 53 permit thermocouple measurements along the reactor outside wall, and one directly inside the bottom of the reactor tube 98 near exit plane 99.
The quench zone 104 consists, for example, of 3 rows of 4 full-cone spray nozzles 106 that screw into the quench zone pipe wall 108 from the outside. As the reaction products exit the reactor tube 98, they are quenched immediately with water sprays supplying water at about 3 to 6 gpm. Enough spray water is used to reduce the product temperature to about 200° F. The liquid, gas, and solids are forced down into spherical catch tank 52 (FIG. 1) where the gas separates and exits. The liquid level control system 70 (FIG. 1) is used to maintain a liquid level in the spherical catch tank 52 and to let down the slurry product into drums 78 (FIG. 1). Vent line 71 connects to the liquid level control system 70.
FIGS. 3 and 4 illustrate in more detail the injector assembly 92 and reactor tube 98 combination wherein a stream of hot (1500°-2000° F.) hydrogen is reacted with a stream of pulverized coal. The injector assembly generally designated as 92, for example, consists of a housing body 110 that is separable from a coal feed line assembly 112 and the reactor tube 98 by a pair of, for example, AN type nuts 114 and 116. The coal feed line assembly 112 consists of 3 tubes, an outer shell tube 130, an insulation tube 118, and a post tube 120. The post tube 120 is 3/8 inch O.D. (Dimension "D" FIG. 4)×0.083 inch wall 321, stainless steel. A 0.55 inch length of end 121 of the post tube 120 is machined to form end 121 to 0.254 inch O.D. (Dimension "I" FIG. 4)×0.020 inch wall. The entire injector assembly 92 is contained within the pressure shell 53 (FIG. 2). The post tube 120 extends through top flange 37 via a packing gland fitting such as a 3/8 inch Conax fitting 105 made by Conax Corporation of Buffalo, New York, and is coupled with coal feed line 36 outside of the pressure shell 53. End 121 of the post tube 120 extends concentrically within a separate cone 122 that is connected to housing body 110 by AN nut 116. An annulus 124 (FIG. 4) is defined between inner wall 123 of cone 122 and outer surface 125 of end 121 of post tube 120. Annulus 124 is 0.350 inch O.D. with a gap of 0.048 inches (Dimension "G" FIG. 4) to the outer surface 125 of end 121 of the post tube 120. End 121 is recessed 0.212 inch (Dimension "F"). Three wire spacers 117 are brazed to end 121 to center the post tube 120 and end 121 in the annulus 124. The post tube 120 is supported as it passes through a plate 115 by a 3/8 inch Conax fitting 135 that is screwed into plate 115. The insulation tube 118 is 1 inch O.D.×0.049 inch wall, 321 stainless steel and terminates at end 119 in a cone that diverges toward but is not affixed to the outer wall of the post tube 120 near end 121. End 113 of tube 118 is affixed to plate 115. An annulus 126 is defined by an outer surface 127 of tube 120 and an inner surface 128 of tube 118. The annulus 126 is filled with insulation material 87. The outer shell tube 130 is a structural member that houses concentric tubes 118 and 120 and connects at a first end 132 to plate 115 and at the other end 134 to housing body 110 by nut 114. Tube 130 is 1.5 inch O.D.×0.049 inch wall, 321 stainless steel. An annulus 136 is defined by an outer surface 138 of tube 118 and an inner surface 140 of housing body 110. The annulus 136 serves to direct a hot hydrogen exterior port 111 toward annulus 124 and out injector assembly 92 (FIG. 4). An annulus 131 is defined by outer surface 138 of tube 118 and inner surface 129 of tube 130 and is filled with insulation 87 that is kept from falling in annulus 136 by a sleeve 133. The reactor tube 98 (FIG. 3) is 1.5 inch O.D.×0.049 inch wall (Dimension "B", 321 stainless steel tube, is 3 feet long (Dimension "A"), and is connected to the housing body 110 by nut 116. The overall injector assembly 92 is about 1 ft long (Dimension "C").
In operation, the coal liquefaction plant functions in the following manner: A pulverized bituminous coal such as Kentucky hvAb may be utilized. Other types of pulverized coal such as lignite and sub-bituminous may also be used. The coal is typically 70% less than 74 microns in size (200 mesh coal) and is fed into high pressure coal feeder 16. The average coal particle size is 40 to 50 microns. A quarter inch line approximately 20 feet long directs dense phase coal from valve 34 into post tube 120 outside of top flange 37 towards the injector assembly 92. The pressure shells 41 and 53 are pressurized with nitrogen to approximately 1000 psig from nitrogen supply system 12. Typically, a 70 psi differential between coal feeder 16 and the pressure shells 41 and 53 is maintained to encourage coal flow in a dense phase through feed line 36 into the injector assembly 92. In other words, the pressure within the coal feeder is approximately 1070 psig during operation. In this specific example hydrogen from hydrogen source 48 is directed towards the coal feeder 16 through hydrogen feed line 30 and the ratio of hydrogen to coal is about 0.005 lbs of hydrogen per pound of coal. Obviously, an inert gas may be utilized in place of the hydrogen with the pulverized coal from inert gas source 50 to the coal feeder 16. Hydrogen is additionally fed from hydrogen source 48 through a conduit 29 into the hydrogen preheater assembly 39. The hydrogen is directed into a 321 stainless steel preheater coil 43 at end 45. The coil 43 at end 45 is 1/4 inch O.D.×0.035 inch wall and as the helix progresses down the coil 43 it transitions into a 5/16 inch O.D.×0.049 inch wall coil and from there into a 3/8 inch O.D.×0.083 inch wall coil. The hydrogen exits coil 43 at end 47 towards coiled tube 100 which directs hot hydrogen into the injector assembly 92. The hydrogen flowrate is 10 to 50 percent of the flowrate of dense phase coal. The coil is about 260 inches long in this example. The hydrogen is typically fed into coil 43 at the rate of 0.025 lbs per second. At startup the dense phase coal is flowed through feed line 36 into the post tube 120 outside top flange 37 and into the injector assembly 92 followed by introduction of hot hydrogen through the preheater coil 43. The hydrogen exits the heated coil in a temperature range between 1500° and 2000° F. (a typical temperature is 1650° F.) adjacent the injector assembly 92. Typically, in the foregoing example the reaction temperature within the chamber by reactor tube 98 is found to be about 1100° F. with a residence time of the pulverized coal within the reactor tube 98 of about 150 milliseconds when the hot hydrogen flowrate is 0.36 lbs of hydrogen per pound of coal. The reaction time in reactor tube 98 may be between 10 and 500 milliseconds for the hydrogenation process. As can be seen from the above, with a typical reaction temperature of about 1100° F. and a hydrogen temperature range of 1500°-2000° F., the hydrogen temperature is from 400° to 900° F. in excess of the typical reaction temperature.
It is desirable to promote better mixing to assure that hot hydrogen moves past the coal particles within the reactor tube 98. For example, the hot hydrogen velocity exiting the injector assembly 92 is approximately 1000 ft/second while the velocity of the dense phase entrained coal exiting the injector is about 7 ft/second. Within these parameters approximately 19 to 20% of the coal carbon is converted into a synthetic crude oil having a boiling range of about 200°-350° C. and a heating value of 15,800 BTU per lb, 9% to gas containing methane, ethane, and carbon oxides, and about 3% to organic compounds in the quench water. The coal throughput rate is approximately 33,000 lbs per hour ft 2 reactor cross-section or 11,000 lbs per hour ft 3 reactor volume. The products of reaction are rapidly quenched to about 225° F. downstream of exit plane 99 of reaction tube 98 in a distance of about 1 ft, the reaction products passing by water spray nozzles 106 in the quench zone below the reaction chamber defined by reactor tube 98. The water flowrate through the multiplicity of water spray nozzles is from 2 to 6 gallons per minute. The products are then moved into the catch tank 52 and from there to the various drums 78 where the solids are collected, the gas and by-products being directed into separator tank 56 and the by-products being directed through burnstack 58.
It would be obvious to use other means to heat the hydrogen being separately directed to the injector assembly 92 other than use of high electrical current to heat up a coil which is transporting the hydrogen. For example, a conventional fuel fired furance or heater could be utilized to heat up a coil tube containing hot hydrogen. Many other methods to heat hot hydrogen are within the state of the art.
Turning now to FIG. 6 an alternative reactor tube 141 is illustrated wherein one end of the reaction chamber connected to the injector assembly 92 at end 142 begins a diverging wall section which diverges towards end 144 adjacent plate 146. The diverging walls defining a reaction chamber 150 tend to discourage sticking of the partially hydrogenated products passing through the reactor tube 141, thus minimizing any tendency to plug.
FIGS. 7 and 8 disclose a different type of injector commonly known in the rocket engine field as a four-on-one injector. The injector consists of a center post 154 which transports dense phase coal particles and which is supported within an upper plate 156 and a bottom injector plate 160. The inner face 157 of plate 156 and the inner face 158 of injector plate 160 define an annular chamber 162 which directs hot hydrogen entering a conduit 164 from the preheater assembly into the chamber. A thermal insulator 159 is provided around the center post 154 so that coal particles transported within center post 154 are not prematurely heated. The injector plate 160 has drilled therein a series of four orifices 166 equidistantly spaced around the injector (FIG. 8) each of the orifices having an impingement angle with respect to the center line of the center post 154 of approximately 30° which facilitates greater mixing of the minute coal particles exiting center post 154 with the impingeing hot hydrogen downstream of the injector face. FIG. 8 better depicts the relationship of the orifices with respect to the center post 154.
It would be obvious to configure any number of gas streams on the central coal stream with different impingement angles, all of which are well within the state-of-the-art particularly in the rocket engine field.
It will, of course, be realized that various modifications can be made in the design and operation of the present invention without departing from the spirit thereof. Thus, while the principle, preferred construction and mode of operation of the invention have been explained and what is now considered to represent its best embodiment has been illustrated and described, it should be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically illustrated and described.
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An apparatus for reacting carbonaceous material such as pulverized coal with heated hydrogen to form hydrocarbon gases and liquids suitable for conversion to fuels wherein the reaction involves injection of pulverized coal entrained in a minimum amount of gas and mixing the entrained coal at ambient temperature with a separate source of heated hydrogen. The heated hydrogen and entrained coal are injected through a rocket engine type injector device. The coal particles are reacted with hydrogen in a reaction chamber downstream of the injector. The products of reaction are rapidly quenched as they exit the reacting chamber and are subsequently collected.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a non-provisional that claims priority under 35 USC 119(e) to provisional application No. 60/809,458 filed on May 31, 2006, and to provisional application No. 60/816,251 filed on Jun. 23, 2006.
BACKGROUND
[0002] Explosive Detection Systems (EDS) are used for detecting explosives and other contraband. They are used commonly in the airline industry and their prevalence and importance has increased after 9/11.
[0003] It is critically important that the technology used in EDS be sufficiently advanced so as not to miss the detection of explosives. Balanced with that, the technology should be sufficiently advanced so as to minimize false alarms and maximize throughput.
[0004] EDSs commonly use X-rays to penetrate an object of interest, such as a bag or container, which is placed on a conveyer belt and moved through the system. X-rays are emitted from an X-ray source and are directed at the object. Transmitted and/or reflected or refracted X-rays are detected by detectors. An image of the object is reconstructed from the detected X-rays and a threat detection is made, either manually by an operator who views the image, or automatically by a threat detection algorithm implemented in software.
[0005] The use of computed tomography (CT) scanners are known in the industry as a sensitive and accurate EDS, but typically have a lesser throughput. Advancements in CT EDS technology have improved throughput. A CT scanner is helpful in that it can determine the density of an object being observed. Determining the density can enable the system to decipher most explosives. There are, however, innocuous materials that are close in density to explosives, causing a high false alarm rate when basing the determination solely on density. Similarly, density alone is not sufficient information to decipher all explosives.
[0006] Dual energy CT scanners are known in the industry and enable the determination of Z effective of an object of interest, which enables the determination of the material from which the object is made, in order to decipher explosives. In other words, determining the Z effective of an object will enable one to discriminate it from objects of similar density, when density alone would not enable such discrimination.
[0007] Several approaches exist for the use of dual energy CT scanning. One such approach is employed in the L-3 Communications Examiner® EDS. The Examiner employs a dual energy X-ray source. A high-voltage power supply switches between a higher voltage (e.g., 160 Kv) and a lower voltage (e.g., 80 Kv). The power supply switches from the high voltage to the low voltage at a certain frequency which in turn causes the X-ray source to emit high energy X-rays and low energy X-rays at this frequency.
[0008] One drawback associated with this approach is the significant limitation on the frequency with which the power supply can switch from high to low and low to high. When switching from high to low, a sufficient amount of time must pass in order to enable the dissipation of the energy built up during the high-energy phase. Similarly, when switching from low to high, a sufficient amount of time must pass in order to build up the energy needed to obtain the high voltage required. Thus, present systems employing this approach have frequency limitations. One such system, the Multiview Tomography (MTV) system of L-3 Communications, can switch up to 240 times per second, well below the desired frequency of a few kHz for next generation CT scanners.
[0009] Another approach at dual energy CT scanning employs the use of two sets of detectors, each detector set sensitive to a different energy level. This approach uses one single energy X-ray source. As it is, CT scanners use multiple detectors. This approach would double the number of detectors, which results in several drawbacks: size, manufacturability, and cost, among them.
SUMMARY
[0010] Applicants herein have invented a dual-energy X-ray source that employs a single output DC (direct current) high-voltage power supply and a single tube. There are two electron guns included in the single tube, each gun having its own grid but both sharing a single anode.
[0011] In an embodiment, each of the guns is driven by the single, high-voltage power supply, one at a higher voltage and one at a lower voltage. One gun, through the use of its own grid, strikes the anode at a first angle. The second gun, through use of its own grid, strikes the anode at a different and second angle.
[0012] Such an approach enables a dual-energy X-ray source without the need for high voltage switching and provides for very fast switching, likely on the order of a frequency of greater than 10K Hz.
BRIEF DESCRIPTION OF DRAWINGS
[0013] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:
[0014] FIG. 1 is a block diagram of a dual-energy X-ray source system; and
[0015] FIG. 2 illustrates in further detail portions of the system of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention is directed at a high-frequency dual-energy X-ray source employable in a CT-based EDS or for other medical or non-medical applications where dual-energy X-ray screening is employed. The switching (from high energy to low energy and visa versa) frequency obtainable likely is on the order of 10K Hz or greater. The system employs a single output DC high-voltage power supply, and a single X-ray tube. The X-ray tube itself includes two electron guns, each having its own grid, and a single anode shared by both guns. One gun is driven at a high voltage and emits electrons through its grid at a first angle to the anode and the second gun is driven at a low voltage and emits electrons through its grid at a second angle to the anode.
[0017] As discussed in the Background section, it is advantageous to use dual energy in a CT scanning EDS to enable the determination of the Z effective of a material, in addition to the density of the material, in order to locate and discriminate explosives from surrounding objects. The conventional dual-energy X-ray source approach suffered from frequency limitations. The multiple detector approach suffered from cost, equipment manufacturability and clumsiness limitations, as well as size constraints.
[0018] Another approach, involving the use of two power supplies, each feeding its own X-ray tube, was contemplated. Such an approach can switch with sufficient frequency, which overcomes the speed limitation of the dual energy power supply approach. Such an approach, however, suffers from an inability to sufficiently filter out scatter radiation from the object. A scatter filter is needed for such purpose and must be tuned to one of the tubes, each of which is spatially different.
[0019] The present approach, described herein, discovered by Applicant, overcomes the drawbacks of the prior art. For example, it does not suffer from the scatter radiation problem above as only a single tube is used, for which a scatter radiation filter can be tuned.
[0020] FIG. 1 illustrates a dual-energy X-ray source approach according to the present invention. As shown, the system includes a DC high-voltage power supply 10 , which generates both high and low voltages, the high voltage being provided along line 22 and the low voltage being provided along line 24 . In one embodiment, the high-energy output voltage is 160 KV and the low-energy output voltage is 80 KV, but the invention is not so limited.
[0021] The system also includes a single tube 20 . Within the single tube 20 is included a first electron gun 16 and a second electron gun 18 . Also included is a single anode 12 . Each gun has a filament and its own grid. First gun 16 , which receives the high-voltage output from the power supply, has its own grid 26 . Second gun 18 , which receives the low-voltage output from the power supply, has its own grid 28 . Gun 16 shoots electrons through its grid to anode 12 at a first angle to emit X-ray radiation at a high energy. Second gun 18 shoots electrons through its grid 28 to anode 12 at a second angle to emit X-ray radiation at a lower energy. The angles are different, preferably symmetrical along a vertical axis of symmetry. The electrons impinge on the anode preferably at the same location. The target emits X-ray radiation from this location, thus forming a focal spot. The anode produces a core beam of X-ray radiation and a collimator may be used to channel the X-ray radiation. The two guns should be spatially separated by a clearance sufficient to withstand a significant voltage difference without a discharge.
[0022] The following equation represents the system of the invention: V=3×10 6 L 0.8 , where V is voltage difference between the guns in volts, and L is the distance between the two guns in a vacuum in meters. For a particular case when one gun is at 80 kV, another gun is at 160 kV, the distance L should be approximately 25 mm or more. One should appreciate, however, that it is possible to have the anode at +80 kV, one gun at −80 kV, and the other gun at 0 kV. This will not change the voltage difference between the two guns from 80 kV, nor will this change the energy of the produced X-rays. Other voltage settings are envisioned to suit a particular application.
[0023] FIG. 2 illustrates the portions of the system of the invention during use. As shown, the system includes first electron gun 16 and second electron gun 18 , each of which receives power from the power supply (not shown). First electron gun 16 shoots electrons at a high energy (shown as electron beam 34 ) to a focal spot 40 on anode 12 . Electron gun 18 similarly shoots electrons at a low energy (shown as electron beam 32 ) to focal spot 40 on anode 12 . Anode 12 , from focal spot 40 , in turn, produces fan beam 30 through a collimator (not shown).
[0024] This approach enables very fast switching, on the order of up to a frequency of 10K Hz or higher as the need for energy dissipation or additional energy is eliminated. Because only a single tube, with one focal spot, is used, a scatter filter can be tuned to the single tube, which addresses the scatter issue associated with the previously contemplated approach, discussed above. Finally, multiple detectors are not used in this approach, which addresses the cost and manufacturability issue associated with the prior art approach discussed.
[0025] Advantages obtained by this approach include the reduced cost, size and weight of the system. In addition, manufacturability and maintainability of the system both improve because of the need for fewer components. Further, with a reduced size and weight, such systems put less stress on a CT gantry in a CT-based EDS. Additionally, radiation shielding is simplified due to the more compact design.
[0026] It should be appreciated that this invention is not limited to the EDS application, but has other such applications, such as in the medical field, as well.
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A dual energy X-ray source for use in an explosive detection system includes only a single power supply and only a single X-ray tube. The X-ray tube includes only two electron guns and only a single anode. Each electron gun has its own grid and cathode. The X-ray source switches between producing a higher energy X-ray and producing a lower energy X-ray at a frequency of at least 4000 Hz.
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