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FIELD OF THE INVENTION
[0001] This invention relates to refrigeration systems for enclosed spaces and in particular but not only to a eutectic system that continues to provide temperature control over an enclosed space during periods when external power is not necessarily available.
BACKGROUND TO THE INVENTION
[0002] Many refrigeration systems are required to provide cooling without necessarily having access to a continuous supply of electricity. In some cases electrical power is not available for large parts of the day in remote areas or for mobile systems. In others, the systems are required to avoid consumption of power during peak periods. Conventional eutectic systems have been developed to operate under these circumstances, but do not provide adequate temperature control for many purposes. Solar power systems with storage batteries have been developed but are relatively expensive and cannot guarantee that electricity will be available.
SUMMARY OF THE INVENTION
[0003] It is an object of the invention to provide a refrigeration system using a eutectic subsystem with temperature control that can operate without external power for useful periods of time, or at least to provide an alternative to existing systems.
[0004] In one aspect the invention is a refrigeration system for an enclosure, including: a first cooling subsystem that is powered by an external source, a second cooling subsystem that is not necessarily powered by an external source, a first thermal pathway by which the first cooling subsystem, when powered, cools the second cooling subsystem, a second thermal pathway by which the second cooling subsystem cools the enclosure, and a controller in the second thermal pathway that operates to maintain the enclosure at a predetermined temperature.
[0005] Preferably the second thermal pathway is a refrigerant loop that conveys heat from the enclosure to the second cooling subsystem by convection. Refrigerant in the loop circulates by evaporation from a relatively low location to a relatively high location in the enclosure, followed by condensation and descent under gravity within the second subsystem. Preferably the controller includes a valve that regulates the flow of refrigerant around the loop without need of power from an external source.
[0006] Preferably the first cooling subsystem includes a compressor/condenser arrangement that is powered by mains electricity and the second cooling subsystem includes an insulated eutectic tank. In one embodiment the first thermal pathway includes a refrigerant loop between the first cooling subsystem and the second cooling subsystem, separate from the second thermal pathway. In another embodiment the first and second pathways are combined, so that the first cooling subsystem, when powered, cools both the second cooling subsystem and the enclosure.
[0007] In another aspect the invention is a method of cooling an enclosure, including: operating a powered cooling system to extract heat from a non-powered cooling system, and cooling the enclosure by convective transfer of heat from the enclosure to the non-powered cooling system.
[0008] Preferably the method further includes ceasing operation of the powered cooling system during periods when power is not available, and continuing to cool the enclosure during such periods by convective transfer of heat from the enclosure to the non-powered cooling system. Transfer of heat from the enclosure to the non-powered system is controlled to maintain the enclosure at a predetermined temperature
[0009] The enclosure may be a merchandiser, a cold storage room, a cabinet for medical supplies, a transportable container or an air conditioned room, for example.
LIST OF FIGURES
[0010] Preferred embodiments of the invention will be described with respect to the accompanying drawings, of which:
[0011] FIGS. 1A and 2B schematically show alternative refrigeration systems,
[0012] FIGS. 2A and 2B schematically show the alternative systems in more detail,
[0013] FIG. 3 shows a solenoid device that may be used as a valve in either system,
[0014] FIG. 4 shows a heat exchanger that may be used in either system, and
[0015] FIGS. 5 a, 5 b, 5 c are views of a merchandiser with a refrigeration system.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0016] Referring to the drawings it will be appreciated that the invention may be implemented in a range of different ways for a range of different purposes. The systems described here are given by way of example only. It will also be appreciated that many components of these systems are of a conventional nature and need not be described in detail.
[0017] FIGS. 1A and 1B show alternative refrigeration systems, each arranged to cool an enclosure 10 . Each system includes a first cooling subsystem 11 , typically compressor/condenser equipment that is electrically powered from an external source 16 such as mains electricity, and a second cooling subsystem 12 , typically a eutectic device that is generally without an external power supply. A first thermal pathway 13 , typically a refrigerant loop, links the first and second cooling subsystems, while a second thermal pathway 14 , also typically a refrigerant loop, links the second cooling subsystem with the enclosure. A temperature detector 17 in the second cooling system determines when operation of the first cooling system is required, while a temperature detector 18 in the enclosure determines when operation of the second cooling system is required.
[0018] In FIG. 1A the thermal pathways are separate and the first cooling subsystem 11 acts to cool the second cooling subsystem 12 which in turn cools the enclosure. In FIG. 1B the pathways are partially combined so that the first cooling subsystem cools both the second subsystem and the enclosure. In both cases, movement of refrigerant along the first pathway is generally driven by electrical power supplied to the first cooling system, while movement of refrigerant along the second pathway is generally driven by gravity and/or convection without need of external electrical power. A controller 15 such as a solenoid valve is provided in the second thermal pathway to control movement of the refrigerant in response to the detector 18 and thereby control the temperature of the enclosure. Various alternative arrangements of the subsystems and pathways are possible.
[0019] FIG. 2A shows the refrigeration system of FIG. 1A in more detail. The first cooling system 11 includes a compressor 20 , a condenser 21 , a float 22 , a heat exchanger 23 and a capillary brake 24 . The second cooling system 12 includes an insulated tank 28 containing a eutectic solution or other material, such as brine or ethylene glycol. The enclosure 10 is a refrigeration cabinet in this example. A refrigerant loop including an accumulator 25 forms the first thermal pathway 13 between the cooling systems, and might be considered as part of the first cooling system. A refrigerant loop forms the second thermal pathway 14 between the second cooling system and the enclosure, and includes one or more evaporators 26 and 27 in the enclosure. The second loop might be considered as part of the second cooling system.
[0020] The compressor system 11 in FIG. 2A is able to cool the system 12 when power is available from source 16 . Refrigerant in the loop 13 enters the compressor 20 as a relatively cool low pressure gas and is delivered to the condenser 21 as a relatively warm high pressure gas. The condenser dissipates heat from the gas into the atmosphere and produces a warm liquid within the loop. The float 22 and brake 24 are control devices that regulate the flow of liquid along loop 13 from the condenser to the eutectic tank, particularly when the system is started and the tank is relatively warm. The liquid is cooled by expansion through these devices. Once in the tank 28 the liquid refrigerant in loop 13 absorbs heat from the eutectic material by evaporating and then returning to the compressor through the heat exchanger as a gas. The accumulator 25 is a trap that prevents any unevaporated liquid refrigerant from reaching the compressor.
[0021] The eutectic system 12 in FIG. 2A cools the enclosure 10 without necessarily using power from an external source or being in direct contact with the enclosure. Refrigerant loop 14 is arranged so that the refrigerant circulates in response to the effects of gravity and convection with the overall rate of flow determined by the controller 15 . Refrigerant cools and descends within tank 28 and passes as a liquid from the tank into the enclosure. The refrigerant enters at a relatively low point in the enclosure and depending on the temperature of the enclosure, is either pushed up toward the roof evaporator 27 or begins to evaporate initially in the base evaporator 26 . The liquid thereby absorbs heat from the enclosure and returns to the tank 28 as a gas from a relatively high point in the enclosure.
[0022] FIG. 2B shows a refrigeration system in which the thermal pathways are combined, as an alternative to the system in FIG. 2A . The compressor subsystem 11 cools either the eutectic subsystem 12 alone, or both the eutectic subsystem and the enclosure, depending on the status of controller 15 . The system of FIG. 2B cools the enclosure more quickly under a heavy load but the combined pathways require a common refrigerant and are more difficult to repair in the event of a leak. On the other hand, the system of FIG. 2B allows use of different refrigerants that may be selected for performance of the particular loop.
[0023] FIG. 3 shows a solenoid valve 15 in more detail. The valve is operated by a microprocessor (not shown) that monitors the temperature detectors 17 and 18 and draws power from a battery (not shown). A pair of coils 30 are pulsed to open and close the seat 31 of the valve when required by the microprocessor. The valve is normally held in a closed position by a spring 32 and requires no power in that position. Similarly the valve may be held open by a magnet 33 without additional power. An appropriate coil is pulsed to change the open or closed status of the seat requiring minimal power for a short period of time. Other valve systems that operate from temperature differentials and do not require battery power might also be used.
[0024] FIG. 4 shows a heat exchanger 23 of FIGS. 2A and 2B in more detail. Warm liquid refrigerant passing from the condenser 21 through the high side float 22 reaches the heat exchanger as a cool liquid with some vapour. Relatively cold vapour from the eutectic tank also passes through the heat exchanger when moving back to the compressor 20 . The cold vapour from the tank sub-cools the liquid and vapour from the float to form a cool liquid without vapour moving towards the capillary brake 24 . The level of heat exchange between the inflowing and outflowing liquids and vapours is determined to enhance the efficiency of the compressor.
[0025] FIGS. 5 a, 5 b and 5 c are sectional views of a merchandiser that incorporates a refrigeration system as shown in FIG. 2A or 2 B. The merchandiser includes a cabinet 50 with front doors 51 , shelves 52 for products such as food or drink, and may be mounted on wheels 53 . Refrigerant from a eutectic tank 12 located in the rear of the cabinet flows through the base evaporator 26 upwards to the roof evaporator 27 , as indicated, and then returns to the tank. Valve 15 between the eutectic tank and the roof evaporator controls the flow of refrigerant. An optional fan 54 in the roof of the cabinet drives air flow downwards through the roof evaporator to the base evaporator, as indicated. The fan is powered by mains electricity and is generally not operated when power is not available.
[0026] As shown in FIG. 5 c, the compressor 20 is located in an upper part of the rear of the cabinet in this example. The condenser 21 is located on one side at the rear of the cabinet and may have a fan 55 to assist dispersal of heat when power is available. A relatively small compressor can be used because the effect of sudden or heavy loads in the cabinet, such as opening of the front doors and stocking of the shelves, is buffered by heat absorption in the eutectic tank. Operation of the compressor can also be optimised for predetermined time periods with a reduced number of start events.
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A refrigeration system for merchandisers, drug cabinets and similar enclosures ( 10 ) that continues to provide temperature control during periods when external power is not necessarily available. The system typically has a compressor/condenser subsystem ( 11 ) that is powered by mains electricity ( 16 ) and a second subsystem ( 12 ) that includes an insulated eutectic tank. The compressor/condensor ( 11 ) cools the tank ( 12 ) using external electrical power, when available, while the tank cools the enclosure ( 10 ) without requiring external power. A refrigerant loop ( 14 ) between the second subsystem ( 12 ) and the enclosure ( 10 ) operates by way of convection and/or gravity and a simple controller ( 15 ).
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BACKGROUND OF THE INVENTION
Field of the Invention
Seat belt retractors are known which incorporate an electric switch to activate a signal, either audible and/or visible, to alert the driver and occupants when a seat belt is not being used. This is also true of dual spool retractors which include separate spools contained within a common housing. A common arrangement has been to provide a sensor to activate the switch. Such a sensor slidably contacts the roll of webbing on a spool as the webbing is withdrawn, and mechanically operates the switch when the diameter of the roll has been reduced by a predetermined amount. Reference is made to U.S. Pat. No. 4,163,880 to Stephenson et al. for a switch of this type.
It has been suggested in U.S. patent application Ser. No. 089,648, filed Oct. 29, 1979 of Ocker et al., to provide a dual spool seat belt retractor with a comfort mechanism; such retractor may accommodate the above-referenced switch.
It would be desirable to provide an improved and simplified switch assembly for seat belt retractors and particularly dual spool seat belt retractors having a comfort mechanism.
SUMMARY OF THE INVENTION
In accordance with this invention there is provided in a dual spool seat belt retractor including a housing, a lap belt retractor mounted in the housing and adapted to store a lap belt thereon, a shoulder belt retractor mounted in the housing and adapted to store a shoulder belt thereon, the retractors being rotatable in rewind and extraction directions, rewind means associated with the retractors and normally exerting a rewind force urging the retractors towards the rewind direction, tension relieving means operatively associated with said shoulder belt retractor and effective in an operable position to relieve the rewind force associated with the shoulder belt retractor while being ineffective in an inoperable position to relieve such force, release means operable to position the tension relieving means in its inoperable position, the improvement comprising:
electric switch means for the control of an electrically activated signal device, the switch means being mounted on the housing and actuated by motion of the release means, whereby the switch is moved to a first electrical position when the tension relieving means is in its inoperable position, and is moved to a second electrical position when the tension relieving means is in its operable position.
Preferably, the release means is actuable to position the switch in its conducting condition in response to a predetermined number of revolutions of the lap belt retractor in the rewind direction and is also actuable to position the switch in its non-conducting condition in response to a predetermined number of revolutions of the lap belt retractor in the extraction direction. The release means preferably includes a step reduction gear mechanism to control actuation of the electric switch as well as the tension relieving means.
Also in accordance with this invention, there is provided a seat belt retractor comprising;
a housing;
at least one spool of seat belt webbing mounted in the housing for rotation in rewind and extraction directions;
rewind means connected to the spool to urge the spool towards the rewind direction;
lever means pivotably mounted on the housing for movement in a direction axially towards and away from the spool; and
switch means actuatable in response to the pivotable motion of the lever means to control an electrically activated signal device, the lever means being pivotably movable to a first position axially of the spool in response to a predetermined amount of rotation of the spool in the extraction direction, whereby the switch means is actuated, thereby deactivating the signal device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a dual seat belt retractor including the electrical switch of this invention.
FIG. 2 is a side view of the retractor of FIG. 1.
FIG. 3 is a cross-sectional view of a portion of the retractor taken along lines 3--3 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings, there is shown a dual spool retractor 10 including a U-shaped base having upstanding side flanges 14 and 15. A shoulder belt retractor 16 including a shaft 18 is journaled in bushing 20 for rotation in flanges 14 and 15 and a spool 22 mounted on shaft 18 is adapted to receive seat belt webbing (not shown). A locking gear 24 is mounted on shaft 18 interior of flange 14 and is adapted to be engaged by a locking pawl 26 pivotably mounted in openings 28 in flanges 14 and 15 in response to actuation by a pendulum 30 mounted in a carrier 32 on the exterior of flange 14 when the vehicle in which the retractor is mounted is subject to a deceleration force. A plastic extension 34 serves to transfer motion of the pendulum cap to pawl 26. Mounted below shoulder belt retractor 16 in flanges 14 and 15 is a lap belt retractor 35 including a shaft 36 journaled for rotation in bushing 38 in flange 14. A spool 40 is mounted on shaft 36 and is likewise adapted to receive seat belt webbing (not shown). Shaft 36 also carries a locking gear (not shown) which is likewise adapted to be engaged by locking pawl 26. Rewind springs (not shown) are mounted exteriorly of flange 15 and are coupled respectively to shafts 18 and 36 to bias the shafts in a rewind direction. A dual spool retractor of this type is described in U.S. Pat. No. 4,135,683 to Stephenson et al.
A plastic scroll plate 42 is mounted on a keyed extension 44 of shoulder belt retractor shaft 18 which extends exteriorly of flange 14. Screw 46 fixes scroll plate 42 for rotation with shaft 18. A plurality of tracks 48 and locking recesses (hooks) 50 are provided on the exterior surface of scroll plate 42. End 52 of spring follower 54 is adapted to be received in tracks 48 and hooks 50 in a manner disclosed, for example, in U.S. Pat. No. 4,002,311 to Fisher et al. to provide a tension elimination comfort mechanism to block scroll plate 42 and hence shaft 18 from rewind rotation due to the bias of the shoulder belt retractor rewind spring. Spring follower 54 has a looped end 56 which is received in channels 58 of a plastic spring rocker 60, with end 52 being biased towards the center of scroll plate 42.
A dual seat belt retractor of the type described above is more fully described in the aforementioned patent application Ser. No. 089,648 the disclosure of which is expressly incorporated herein by reference.
A spur gear 62 is mounted on the end of lap belt retractor shaft 36 and extends through an opening 64 in a housing 66 which is mounted via screws 68 to the exterior of flange 14. A larger driven gear 74 having external teeth is retained in housing 66. Gear 74 rotates on post 72 provided centrally in housing 66 and its teeth mesh with the teeth of spur gear 62. The exterior surface of gear 74 has an outwardly extending cam protrusion 76 which extends almost circumferentially but terminates in inclined portions 78 and 79 which extend to a recessed or valley portion 80 on the exterior surface of driven gear 74.
An extension 84 of housing 66 includes recesses 86 which receives a lateral post 88 of spring rocker 60. Spring rocker 60 is thus pivotably mounted for movement for limited rocking motion towards and away from flange 14. A spring 90 extends between a post 92 on flange 14 and post 94 on spring rocker 60 to bias the upper portion of spring rocker 60 away from the flange 14. Boss 96 on interiorly facing surface 98 of the lower end of spring rocker 60 is adapted to be in sliding contact with cam portion 76 of driven gear 74 when seat belt webbing is extracted away from lap belt retractor 35 and with valley portion 80 when seat belt webbing is fully or nearly fully stored on spool 40 of lap belt retractor 35.
An arm 70 also extends from the interiorly facing surface 98 of the lower end of spring rocker 60 and is positioned directly over the free end of an upwardly biased strip of electrically conductive resilient material 106 (preferably spring metal) extending substantially parallel to flange 14 from an electrically insulating support 100 to which its other end is fixed. Support 100 is attached to flange 14 and serves to support biased strip conductor 106 as well as to electrically insulate it from flange 14. The free end of the biased strip conductor 106 together with a contact point 104 of flange 14 comprises an electric switch. This switch is in a first closed conducting position when boss 96 of spring rocker 60 is in contact with the valley portion 80 of the cam surface of driven gear 74 and spring 90 has urged the spring rocker 60 away from the scroll plate 42 causing arm 70 of the spring rocker 60 to depress strip conductor 106 against its bias, into electrical contact with contact 104 on flange 14. The electric switch is in its second open non-conductive position when boss 96 of spring rocker 60 is in contact with the raised portion 76 of the cam surface of driven gear 74, and arm 70 has been raised to permit strip conductor 106 to separate from contact point 104. Contact point 104 may be the point of contact on the surface of flange 14, or a raised point on the surface such as the head of a rivet extending into or through flange 14.
The fixed end of strip conductor 106 is attached to a conductor 102 connected to an electrically operated signal device such as a light or buzzer not shown, which is in a circuit with a source of electrical energy, such as the service battery of the vehicle. In the first closed conducting position of the switch, the circuit is completed when the strip conductor 106 contacts point 104 which commonly is grounded to the frame of the vehicle, as is the service battery.
In operation of the above-described embodiment, when the lap and shoulder belts are in their normally stowed positions, boss 96 of spring rocker 60 is in contact with valley 80 on the exterior surface of driven gear 74 so that the upper portion of spring rocker 60 is pivoted away from scroll plate 42 due to the bias of its spring 90. End 52 of spring follower 54 is thus held away from scroll plate 42 and the rewind spring associated with the shoulder belt retractor 16 is biasing the shoulder belt in the rewind direction. Extending arm 70 urges strip conductor 106 into electrical contact with contact 104, thereby closing a circuit including a signal device. The relation between spur gear 62 and driven gear 74 is chosen so that as the lap belt (and shoulder belt) is extended from its retractor due to the occupant moving the tongue portion of a buckle assembly which is interfitted between the lap and shoulder belts portions towards the buckle, shaft 36 of lap belt retractor 35 rotates in an extraction direction which causes rotation of driven gear 74 in the opposite direction due to its meshing with spur gear 62 at the end of shaft 36. Due to the gear ratios, driven gear 74 rotates only a small portion of a revolution for each complete revolution of spur gear 62. Boss 96 is riding within valley 80 when the lap belt retractor is initially extended. As additional webbing is extended from lap belt retractor 35 so that shaft 36 further rotates in the extraction direction and causes additional rotation of driven gear 74, boss 96 rides up ramp 79 and onto cam portion 76 (FIG. 3). For example, the gear ratios may be selected such that when about two wraps of lap belt webbing are removed from the lap belt retractor, driven gear 74 has rotated about 1/3 of a revolution to position the cam portion such that the boss rides up ramp 79. At this point, spring rocker 60 is pivoted on its post 88 against the bias of its spring 90 with the result that end 52 of spring follower 54 becomes engaged with scroll plate 42 at the radially inward portion of one of its tracks and is thus in its operable position. At the same time extending arm 70 of the lower portion of the spring rocker 60 is moved outwardly away from strip conductor 106 as shown in FIG. 3, allowing the strip conductor to separate itself from contact point 104 on flange 14 because of its upward bias, thus breaking electrical contact and interrupting the circuit which includes the signal device.
Further extension of the shoulder belt webbing causes rotation of shaft 18 and hence scroll plate 42, with end 52 of spring follower 54 moving spirally outward along the track. Further protraction and slight retraction motion results in end 52 being positioned in one of the hooks 50 in a manner described in the aforementioned patent application and U.S. Pat. No. 4,002,311. At this point, the rewind force of the shoulder belt retractor rewind spring is blocked out and as a result the tension of the shoulder belt retractor against the occupant's torso is eliminated. The rewind force of a shoulder belt retractor rewind spring may be reestablished by extending the belts such that end 52 of spring follower 54 is moved to the end of the corresponding track, whereby spring action of the follower 54 moves end 52 again to the center of scroll plate 42, as described in the Fisher et al. patent.
In accordance with this invention, when the shoulder and lap belts are released such as occurs by release of the tongue plate from a seat belt buckle assembly by the occupant preparatory to leaving the vehicle, if the tension eliminator for the shoulder belt retractor 16 has not been engaged then both the lap and shoulder belts are wound up by their respective rewind springs in a normal fashion. However, should the tension eliminator be engaged, only lap belt retractor 35 will initially be rotated in the rewind direction due to the force of its rewind spring and lap belt webbing will initially be wound up. When lap belt retractor shaft 36 has rotated sufficiently in the rewind direction so that the lap belt is almost in a fully stowed position on spool 40, driven gear 74 has been rotated by spur gear 62 to a circumferential position at which boss 96 of spring rocker 60 rides down ramp 79 from cam portion 76 to valley 80 on the face of driven gear 74. As a result, spring rocker 60 is pivoted on its post 88 with the upper portion of spring rocker 60 being moved away from scroll plate 42 due to the bias of spring 90, whereby end 52 of spring follower 54 is moved and held away from scroll plate 42. The tension elimination mechanism is thus deactivated and the shoulder belt is rewound onto spool 22 due to the force of the shoulder belt retractor rewind spring. At the same time, projecting arm 70 urges strip conductor 106 into electrical contact with contact point 104, thus closing the circuit and activating the signaling device. Thus, energy is stored in spring 90, which is compressed as a result of rotation of the lap belt retractor in the extraction direction. The comfort mechanism is moved to its inoperable position due to release of the stored energy as spring 90 expands after the lap belt retractor has been rotated sufficiently in the rewind direction. The switch mechanism is moved to its contact position as a result of the same motion.
It can be seen that the present invention provides a dual spool seat belt retractor of the type including a comfort mechanism feature, which includes a simple electric switch for activating a signal device which is in an active state when the vehicle is in use and the seat belt is not in use, and in a passive state when the vehicle is in use and the seat belt has been employed. The present invention also provides a simple reduction gear consisting of only two gears, thus eliminating the need for an idler gear. Although the spring rocker 60 and the electric switch mechanism has been described as applied to a dual spool seat belt retractor with comfort feature, it would also apply to dual spool seat belt retractors without the comfort feature, as well as to single spool seat belt retractors. In addition, it should be noted that the switch may be designed so as to be normally opened and to be moved to a closed position upon extraction of the lap belt retractor webbing as described above.
It is to be understood that variations and modifications of the present invention may be made without departing from the scope thereof. It is also to be understood that the present invention is not to be limited by the specific embodiments disclosed herein but only in accordance with the appended claims when read in light of the foregoing specification.
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A dual spool seat belt retractor including a housing and lap and shoulder belt retractors mounted therein. An electric switch is provided for controlling an electric signal device, preferably used in conjunction with tension relieving means. The switch is preferably placed in its electrically conductive position in response to a predetermined number of revolutions of the lap belt retractor in the rewind direction.
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BACKGROUND OF THE INVENTION
This invention involves a filtering device for use on computer apparatus to essentially prevent the accumulation of dust and dirt inside the housing.
In the smallest of computer systems, no fan is required to cool the electronic components. However, for most personal computers, in particular the IBM XT, IBM AT, the various clones as well as the larger Mackintosh computers, an internal fan is included inside the computer cabinet, referred to as the housing. The power systems, internal disk drives, and particularly the hard disk drives, generate a substantial amount of heat. High temperatures will destroy or at least substantially reduce the life of the computer components so that a fan system is typically included in most of these personal computers. The fan is inside the housing drawing a draft into the housing through an air intake opening through the housing wall. This opening is typically a grate molded directly into the plastic housing of the computer.
At one time, essentially all computers were main frame types and were kept in clean rooms under highly controlled conditions. With the advent of the powerful personal computers which can now perform almost as well as the main frame computers did a few years ago, these small computers find their way into use under all sorts of conditions. Many small offices, for example, are not maintained in a most clean condition. In any case, there is little attempt in most offices to maintain a "dust-free" environment. After only a few months of use, a substantial amount of dust and dirt is drawn in through the air intake grids of the personal computer. Most of that dust settles on or is drawn by statistic electricity to the various components inside the cabinet. It is recognized that these components are sensitive to the accumulation of dirt, dust and even smoke entering and adhering to the vital internal components. Dust covers have been provided but these are inconvenient and seldom used. Furthermore, and most importantly, these covers offer no protection during computer operation. It is further recognized that a major portion of computer equipment failure is directly related to the accumulation of this dirt, dust and smoke particles inside the housing adhering to key components. Despite this recognition, little beyond the recommendation of dust covers and periodic cleaning by a skilled technition has been offered to alleviate the problem. The various devices and methods available in the prior art have not satisfied this problem nor attain the objects described hereinbelow.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a device to essentially prevent the dirt, dust and smoke particles present in the typical office environment from entering the computer cabinet.
It is a specific object of the present invention to provide a filtering device which does not require opening of the cabinet to install internal components.
It is a specific object of the present invention to provide a filtering device which can be attached on the exterior of the computer housing so that it is in full view and can be continuously visually monitored as to its performance as to the accumulation of dust, dirt and smoke particles, in order to determine when it should be replaced.
It is a specific object of the present invention to provide a filtering system which will diminish the air born contaminants from entering the cabinet, but provide a negliable reduction in the rate and volume of air flow entering into the computer cabinet so as to not significantly reduce the cooling effect of the fan system provided by the manufacturer.
It is a particular object of the present invention to provide a filtering device that reduces or essentially eliminates the coating of the chips and boards in the computer cabinet with dust and dirt particles which lead to excess heat build up and contact corrosion.
It is a further object of the present invention to provide a disposable filtering device that may be easily removed and discarded when the dust and dirt accumulated into the filter begins to reduce the air flow through the filter into the cabinet.
A specific object of the present invention is to provide a filtering device that requires no tools or special handling to install the device on the computer housing or to remove it for replacement.
It is an additional object of present invention to provide a filter device which will interfit over the disk slot opening of a disk drive and not be interfered with by the handle extending outwardly from the opening on the disk drive.
It is a specific object of the present invention to provide a filter device which attaches to and covers a disk slot in a disk drive and pivots away from the opening to insert and remove disks, but automatically recovers to seal off the opening from unwanted dust and dirt entering the disk slot.
It is preferred that the filter device further include a frame around a frame opening, the frame being abuttable with a front surface of the computer housing surrounding the air intake opening, and that the form filtration panel has an inside surface and an outside surface, the panel being of a size and shape sufficient to entirely cover the frame opening. It is further preferred that the adhesive means on the foam panel removably adhere the foam panel to the frame, and that the frame and foam panel cover the air intake opening sufficiently to require essentially all air flow into the intake opening to pass through the foam panel. It is further preferred that the frame include a front surface, side walls extending away from the front surface forming a space behind the front surface, and rear edges of the side walls abuttable with the front surface of the computer housing surrounding the air intake opening. It is further preferred that the size and shape of the panel, frame and the space allow the foam panel to adhesively adhere to the outside surface of the frame or in the alternative to the frame in the space behind the frame. It is further preferred that the filter device further include a hinge means hingeably attaching the frame to the housing allowing the frame to be swung away from the housing to expose the air intake opening. It is further preferred that the hinge means further include a spring means to springably urge the rear edges of the side walls against the front surface of the housing.
The invention is also a filter device for use on a computer apparatus that includes a heat generating electronic mechanism in a housing with an air intake opening through the housing, the opening having a length and positioned to draw air into the housing by a draft from a fan means in the housing. The filter device includes a frame around a frame opening with a front surface, side walls extending away from the front surface forming a space behind the front surface, and rear edges of the side walls abuttable with a front surface of the computer housing surrounding the air intake opening. The device further includes a foam filtration panel, having an inside surface and an outside surface, the panel being of a size and shape sufficient to entirely cover the frame opening, wherein the foam panel is porous and permeable reticulated flexible polymeric foam having three dimensional skeletal strands, and an adhesive means on the inside surface of the foam panel of sufficient adhesively adhere the foam panel to the outside surface of the frame or in the alternative to the frame in the space behind the frame. The frame and foam panel cover the air intake opening sufficiently to require essentially all air flow into the intake opening to pass through the foam panel.
The invention is a filter device for use on a computer apparatus that includes a heat generating electronic mechanism in a housing with an air intake opening through the housing, the opening having a length and positioned to draw air into the housing by a draft from a fan means in the housing. The filter device includes a foam filtration panel, having an inside surface and an outer surface; the panel being of a size and shape sufficient to entirely cover the intake opening. The device further includes an adhesive means on the inside surface of the foam panel of sufficient length to allow the inside surface of the foam panel to be adhesively adhered to an outside surface of the computer housing and positioned to cover the air intake opening sufficiently to require essentially all air flow into the intake opening to pass through the foam panel. The foam panel is porous and permeable reticulated flexible polymeric foam having three-dimensional skeletal strands, has a pore size in the range of about 40 to about 90 pores per lineal inch, and has a thickness in the range of about 3/16 inch to about 5/16 inch.
It is preferred that the polymeric foam include polyester urethane polymer, and that the contact adhesive strips be along the entire lengthwise edges of the foam panel. It is also preferred that the pore size be 55 to 65 pores per lineal inch, and that the thickness of the foam panel be 1/4 inch.
It is preferred that the adhesive means be a two sided adhesive film with one side permanently bonded to the foam and the other side a removable adhesive detechable from the machine. It is also specifically preferred that the foam be anti-static which is useful in retarding the accumulation of dust and dirt particles, but also avoids or even reduces the tendency of static electricity to accumulate which might endanger or damage the computer components, specifically the disks or disk drives. It is preferred that the foam be white in color to aid in the visual determination of dirt accumulation on and in the filter and to make an estimate as to the time the filter has been in place exposed to light.
The invention is also a method of maintaining internal cleanliness in a computer apparatus that includes a heat generating electronic mechanism in a housing with an air intake opening through the housing, the opening having a length and positioned to draw air into the housing by a draft from a fan means in the housing. The method includes providing a foam filtration panel including an inside surface and an outer surface, the panel being of a size and shape sufficient to entirely cover the intake opening, and a pair of adhesive surface strips on the inside surface along lengthwise edges of the foam panel. The foam panel has the same elements as above. The method also includes adhesively adhering the foam panel to an outside surface of the computer housing and positioning the panel to cover the air intake opening sufficiently to require essentially all air flow into the intake opening to pass through the foam panel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a filter device of the present invention shown in an exploded view illustrating how it is attached over the air intake grids of a computer housing.
FIG. 2 is a perspective view of the back side of the filter device illustrated in FIG. 1.
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2.
FIG. 4 is a perspective view of a second filter device of the present invention shown in an exploded view illustrating attachment over the disk insertion slot of an external disk drive.
FIG. 5 is an exploded perspective view of the filter device illustrated in FIG. 4.
FIG. 6 is a cross-sectional view taken along lines 6--6 of FIG. 4.
DESCRIPTION OF PREFERRED EMBODIMENTS
The foam panel is a polyester urethane polymeric foam that is porous and permeable with the three dimensional structure being reticulated skeletal strands. Satisfactory polymers include polyester, polyester-urethane, ester type of polyurethane, and other like polymers. The polyester polymeric foam is preferred. Typical filter foam material useful in this invention is SCOTT® filter foam, SIF® supplied by ScotFoam Corporation, a subsidiary of GFI, 1500 East Second Street, Eddystone, Pa. This polymeric foam filtering material is provided in nominal porosity grades from 10 to 100 as described in the technical data sheets Form No. TS-3644, TS-1023, FS-1001. This foam material is further described in U.S. Pat. No. 3,171,820 to R. A. Volz which issued Mar. 2, 1965 which describes reticulated foams and the process for their production. The technical data sheets and the United States patent are incorporated by reference thereto. A particular pore size of 55 to 65 pores per lineal inch with a foam panel thickness of one-quarter inch is most effect to provide excellent protection from the infiltration of dust, dirt and smoke particles but without unduly restricting the air flow volume and velocity into the air intake opening so as to avoid reducing the effectiveness of the cooling fan provided by the manufacturer. The presence of the filter over a period of time reduces the heat accumulation of the components in that the chips and boards inside the cabinet do not receive a coating of dust and dirt so there is less heat build up due to the insulation effect of that coating. As the pore size of the foam panel is increased to about 40 pores per lineal inch, there is a marked reduction in the effectiveness of filtration allowing the smaller particle size contaminates, such as smoke particles to enter into the cabinet more freely. As the pore size as is reduced to about 80 pores per lineal inch, the air flow is unsatisfactorily reduced into the housing cabinet, particularly with substantial accumulation in the foam of dust and dirt over a period of time. The specific foam used to construct filter device 10 illustrated in FIGS. 1 through 3 is Scot SIF® industrial foam in porosity grade 60, reported to have a minimum of 55 pores per lineal inch and a maximum of 65 pores per lineal inch. The two closest grades, 45 and 80, are barely satisfactory and grades further removed are not satisfactory. Anti-static properties are incorporated into the foam to reduce the tendency of the dust and dirt to be attracted into the computer housing and to avoid interference with the memory retention. The foam panel is provided in a white or natural color which allows the user to readily identify the accumulation of dust and dirt and to replace the filter by mere visual evaluation.
In FIG. 1, filter device 10 is shown exploded away from attachment over grid vent opening 16 through front panel 14 of computer housing 12. In FIG. 2, filter device 10 is viewed from the rear of foam panel 18 showing inside surface 22 with outside surface 20 hidden in this view. Two sided adhesive tape strips 24 and 26 extend along the lengthwise edges of panel 18 on surface 22. Adhesive tape 24 and 26 is a double-coated polyester film with a permanent rubber base adhesive on one side that permanently adheres to the foam panel and a removable acrylic adhesive on the other side which is adhesively attached to front panel 14. Paper strips 28 and 30 protect the exposed adhesive surface until it is attached to the computer housing. FIG. 3 shows the relative shape and dimensions of foam panel 18. In FIG. 4, disk drive 42 is provided as an external piece of hardware with the cooling fan drawing air in through the opening 46 which receives the disks engaged with handle 48. The housing of disk drive 42 includes front wall panel 44 and top 49. While air is drawn through opening 46, it is also necessary to have that opening excessible to receive the disks. It is therefore necessary that any filter device covering opening 46 be openable. Filter device 40 includes frame 50 surrounding opening 52. As with most disk drives, handle 48 extends outwardly past the surface of front face 44. Thus, if a foam panel were attached flush to face 44, handle 48 would be in the way. Filter device 40 includes frame 50 from which it extends vertical extension panel 59 at the top of which is hingeably attached horizontal hinge panel 62 connected at "V" cut hinge 60 cut all along the adjacent edges of panels 59 and 62. The entire frame device with the hinge is a single integral molding of a polymeric plastic. Doubled sided adhesive tape 66 is attached on the underside of horizontal panel 62 and is adhered on the bottom side of the adhesive to top 49. Foam panel 68 is attached on the front face of frame 50. In the exploded view of FIG. 5, it is shown how foam panel 68 which is of a similar composition to foam panel 18, is adhered by adhesive strips 72 on the top lengthwise edge and on the bottom lengthwise edge, mostly hidden in this view. Adhesive strips 72 attach permanently to foam 68 but provide a removable adhesive attachment on front face 70 of frame 50 which includes side walls 54 and top wall 58. Frame 50 surrounds frame opening 52 which is essentially a rectangular opening of a smaller size than foam panel 68. Extending upwardly from the rear of top wall 58 is vertical extension 58 which terminates at "V" cut hinge 60 to which is connected horizontal hinge panel 62. On the underside of horizontal hinge panel 62 is double sided adhesive tape 66 which permanently adheres panel 62 to top 49 of disk drive 42. Molded in spring member 64 aids in urging vertical panel 59 and thus frame 50 rearwardly to urge the rear edges of frame 50 against front face 44 of disk drive 42. If handle 48 extends outwardly past front face 44, foam panel 68 is adhered to front surface 70 of frame 50 as illustrated. However, as illustrated in the shadow view, should handle 48 be set inside and to the rear of front face 44, foam panel 68' may be attached in space 56 formed behind frame 50 and behind front surface 70 formed by side walls 54 and top wall 50 again adhesively attached by adhesive strips 72', this time with the foam panel facing in the opposite direction. The cross-section of 56 shows the positioning of foam panel 68 on the outside on in its alternative position at 68'.
While this invention has been described with reference to the specific embodiments disclosed herein, it is not confined to the details set forth and the patent is intended to include modifications and changes which may come within and extend from the following claims.
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A filter panel is provided to be adhesively attached to the outside of computer and disk drive housings to cover the air intake grids used to draw air into the housing by a draft from a cooling fan in the housing, with the filter device of a porous permeable reticulated flexible polyester polymeric foam about 1/4 inch thick with permanently adhered adhesive strips on the back side to removably attach the foam over the air intake opening, with a frame hinged to fit over disk drive slot spring to seal over opening.
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BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to an electrochemical gas sensor and a method for adjusting an electrochemical gas sensor. Electrochemical gas sensors are used to measure concentrations of a predetermined gas component in a gas. In the case of internal combustion engines in motor vehicles for instance, the concentration of oxygen in the exhaust gas is measured. This measurement is used to determine whether the air/fuel ratio of the internal combustion engine has the desired value.
DE 10 2005 033 263 A1 proposes a gas concentration measuring device, with which the impedance of the gas sensor element is measured with the aid of a computation circuit for controlling activation and diagnosing the gas sensor element. To measure gas concentration the current flowing through the gas sensor or the voltage present across the gas sensor must be regulated. This serves to put the gas sensor in a state in which the concentration can be measured.
It has proven that gas sensors are subject to major production variations, so that their electrical properties, such as impedance, differ by up to 20% for instance from gas sensor to gas sensor. To ensure that the control circuit does not become unstable even when there are major deviations, the controller must be designed so that it responds relatively slowly. This means that the air/fuel ratio is not stable all the time, resulting in the unnecessary consumption of a large quantity of fuel.
BRIEF SUMMARY OF THE INVENTION
The object of the invention is therefore to provide an electrochemical gas sensor that can be controlled more quickly.
It is also the object of the invention to provide a method for adjusting such an electrochemical gas sensor.
These objects are achieved by the subject matter of the independent claim. Further advantageous embodiments will emerge from the subclaims.
The invention relates to a control circuit for an electrochemical gas sensor for a motor vehicle, with which a digital controller is provided, featuring a feedback input and an output. The digital controller receives a value for the voltage present across a gas sensor cell by way of the feedback input. At the output the digital controller supplies a control value for a current flowing into the gas sensor cell.
A detection circuit is provided for detecting the properties of the gas sensor cell. It is also provided for adjusting the dynamic control properties of the digital controller according to the properties of the gas sensor cell.
The dynamic control properties of the digital controller are characterized for example by a z-transformed
F
z
(
z
)
=
a
1
z
+
a
2
z
2
+
b
1
z
+
b
2
.
During adjustment the parameters a 1 , a 2 , b 1 and b 2 are changed. The dynamic properties of the digital controller characterize how quickly and in some instances the overshoots with which the digital controller responds to deviations in the setpoint value.
The electrochemical gas sensor has the advantage that the digital controller can be adjusted according to the properties of the gas sensor cells. It is thus possible to tailor the controller property in each instance to the installed gas sensor cell, with the result that the digital control circuit is adjusted so that it responds quickly when there are deviations, without endangering the stability of the control loop.
The control parameters can also be tailored to the operating state of the gas sensor and temperature. It is also possible to use sensors of different types, for instance from different manufacturers, as the digital controller with the detection circuit can be tailored automatically.
In one embodiment the detection circuit is provided at least partially in a microcontroller. The microcontroller can manage a plurality of data, which is compared with the detected properties of the gas sensor cell.
The detection circuit is preferably configured so that it detects the properties of the gas sensor cell based on the voltage occurring across the gas sensor cell, when a current step is present at the output of the digital controller. Step responses are characteristic of the dynamic behavior of control elements and thus allow ready conclusions to be drawn about the control properties of the measured gas sensor cell.
In a further embodiment the detection circuit is also configured to detect the temperature of the gas sensor cell. Temperature is also a major influence on the behavior of the gas sensor cell. It is therefore helpful to consider the properties of the gas sensor cell at the measured temperature, to draw a conclusion about the sensor type for instance.
In a further embodiment the property of the gas sensor cell is calculated based on the impedance of the gas sensor cell, in order to characterize the gas sensor cell as accurately as possible.
In a preferred embodiment the detection circuit features an analog/digital converter for converting the voltage present across the gas sensor cell. Conversion to a digital value allows the digital calculation of gas sensor properties, which simplifies the comparison with already known gas sensors.
It is particularly appropriate to employ the described electrochemical gas sensor, if the gas sensor cell contains a Nernst cell, since such a cell is produced by a plurality of manufacturers, in each instance with major production variations.
The invention also relates to the use of an inventive electrochemical gas sensor in a motor vehicle to control the air/fuel mixture of an engine of the motor vehicle. The inventive provision of the detection circuit allows more precise adjustment of the control circuit for the gas sensor. This allows the electrochemical gas sensor to be controlled more dynamically, making it faster, which ultimately reduces fuel consumption.
The invention also relates to a method for adjusting an electrochemical gas sensor, with an inventive control circuit first being provided for an electrochemical gas sensor. The output of the digital controller is controlled so that the current at the output generates a step of maximum gradient. The properties of the gas sensor cell are then detected based on the voltage at the feedback input of the digital controller. This method can be used to characterize the gas sensor cell, in order to adjust the properties of the digital controller as a function of the properties of the gas sensor cell.
In one preferred embodiment the method is used to check the exhaust gas flow of an engine and the steps of activating the output and detecting the properties of the gas sensor cell are performed at least when the engine is started up. It is thus checked every time the engine is started up, whether the properties of the gas sensor cell have changed, for example due to aging, or whether a new gas sensor cell has been fitted during a repair. The digital controller is then tailored to the changed properties of the gas sensor cell.
In a further embodiment the control properties are adjusted a number of times during the trip, to tailor them to any temperature changes.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 shows an inventive control circuit for a gas concentration sensor.
FIG. 2 shows the frequency behavior of an inventive gas compensation sensor.
DESCRIPTION OF THE INVENTION
FIG. 1 shows an inventive control circuit for electrochemical gas concentration sensors. The assembly 1 consisting of a control circuit 100 and a Nernst cell 9 contains a Nernst cell 9 , as well as a digital controller 2 and a setpoint value generator 30 . The digital controller 2 controls a current source 20 , which determines the current Ip flowing into the Nernst cell 9 . The digital controller receives a setpoint value for controlling the current regulator 20 at its first input 3 . All the elements in FIG. 1 , which are not part of the Nernst cell 9 , are part of the control circuit 100 .
The Nernst cell 9 contains a first resistor 11 , which represents the resistance across the supply lines to the Nernst cell, and a second resistor 12 , which represents the internal resistance of the Nernst cell 12 . A voltage 10 drops across the Nernst cell 9 , being identified by the circle. The first resistor 11 , the second resistor 12 and the voltage 10 are connected to one another in series. The first connection of the voltage 10 is connected to ground 36 here, while its second connection is connected to a first connection of the second resistor 12 .
The second connection of the second resistor 12 is connected to the first connection of the first resistor 11 , the second output of which is connected to the output of the current source 20 . The first input of the sampling element 16 is connected to ground 36 and its second input is connected to the second connection of the second resistor 12 . The voltage Vs is generated between these two inputs of the sampling element 16 and then converted to a digital value in said sampling element. This digital value is fed to the input 5 of the digital controller 2 by way of the feedback path 160 .
The proposed gas sensor is a lambda control oxygen sensor. It ensures that the engine is operated with a constant air/fuel mixture. The voltage Vs is adjusted to a constant value. The digital controller 2 controls the current source 20 at its output 7 so that the current Ip brings about a voltage Vs, which is equal to the voltage in the setpoint value generator 30 . The size of the current Ip is a measure of the lambda value.
The voltage Vs is also measured by the limiter 17 . This limiter 17 measures whether the voltage Vs exceeds a specified threshold value. If so, the limiter 17 outputs a signal value to the digital controller 2 , which receives this value at its input 6 . If the voltage Vs exceeds the previously specified threshold value, the current Ip is reduced.
The current Ip is measured using a measurement circuit identified with the reference character 38 in the figure. The measured value Imess is a measure of the lambda value to be set in the engine controller and is output to the microcontroller of the engine controller.
The microprocessor 14 contains a detection circuit for identifying the properties of the Nernst cell 9 . When the engine starts up, the digital controller 2 controls the current source 20 so that it performs a current step from 0 mA for example to 5 mA. The driver of the current source 20 is dimensioned so that the rise is as steep as possible. The profile of the voltage Vs responds correspondingly to this current step. As described above, the voltage Vs is sampled by the sampling element 16 and converted to digital values using the AD converter 18 present in the sampling element. The sequence of digital values is output to the detection circuit 14 . The detection circuit 14 identifies properties of the Nernst cell 9 from the voltage profile Vs.
Nernst cells 9 from different manufacturers and different production batches differ in their transmission behavior. The measured step response characterizes the transmission behavior of the Nernst cell 9 and is used as the basis for control evaluation. The frequency profiles of different types of Nernst cells are stored in the storage unit 21 . The detection circuit 14 compares the voltage profiles received from the sampler 16 with the voltage profiles stored in the storage unit 21 .
Once the detection circuit 14 has identified the correct sensor type, it adjusts the properties of the digital controller 2 . To this end it changes the transmission characteristic of the digital controller 2 . The digital transmission characteristic of the digital controller 2 is characterized by amount and phase by a Bode diagram for example. The characteristics are adjusted by means of an amount/phase calibration according to the properties of the Nernst cell.
Sensors are generally manufactured with significant production variations. Deviations of up to 20% in transmission behavior are not uncommon. The detection circuit 14 can be used to detect whether such deviations from a normal value are present. If so, the digital controller 2 is also adjusted so that the control behavior of the system as a whole is optimized.
The use of the digital control structure in particular allows the necessary adaptations of the control parameters to be extracted directly from the step response of the sensor by means of software. The changed control parameters can be programmed directly into the digital controller 2 . The filter structure has the advantage that the control characteristic can be tailored easily to different states of the connected linear lambda probe. If a different type of probe is connected, it is only necessary to change the data in the detection circuit 14 , which is much easier and quicker than a hardware change.
If the detection circuit 14 is programmed so that it can also evaluate parameters such as trim resistance, heating resistances and the step response of the probe, it is also possible to tailor the control characteristic in a fully automatic manner to different predefined sensor types or even to tailor the controller characteristic individually in a fully automatic manner to the attached sensor.
The fully automatic calibration of the controller characteristic allows intelligent differentiation between different types of linear lambda sensors and automatic adaptation of the control circuit.
The controller characteristic is tailored individually to the respective connected linear lambda sensor in order to tailor control behavior taking into account the frequency characteristic of the sensor due to production variance, aging and temperature fluctuations for instance.
FIG. 2 shows a Bode diagram of the control characteristic of an open control circuit of a gas sensor according to FIG. 1 . A plurality of simulations have been carried out, in which the properties of the digital controller 2 and the gas sensor 9 were varied according to their production deviations. It has proven that the amplitude and frequency profiles of the open control circuit are very dependent on the parameters of the digital controller 2 and the gas sensor 9 .
The phase reserve at amplification 0 dB is read off to assess the stability of the control circuit. The phase reserve varies between 60 and 100° in the simulations shown in FIG. 2 . In order to be able to increase the phase reserve, the properties of the digital controller 2 are made dependent on the properties of the gas sensor 9 . This reduces the variation in the amplitude and frequency profiles of the Bode diagram. This allows a higher value to be achieved for the phase reserve.
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An electrochemical gas sensor is provided for a motor vehicle. The gas sensor contains a digital controller and a detection circuit. The digital controller captures, by a feedback input, a value of the voltage applied to the inside of the gas sensor cell. The output of the digital controller provides a control value for the current flowing in the gas sensor cell. The detection circuit is used to detect the properties of the gas sensor cell and to adjust the dynamic control properties of the digital controller corresponding to the properties of the gas sensor cell.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 14/095,298, entitled Elongate Pipe-Base Structure For Supporting Heavy Loads, and filed Dec. 3, 2013 by the same inventors. That application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates, generally, to temporary structures for supporting heavy loads over bodies of water or wetlands. More particularly, it relates to a modular heavy load-supporting structure having cylindrical sections that are laid end to end quickly to save time and materials.
2. Description of the Prior Art
It was a common practice before wetlands conservation was a concern to dredge out large sections of wetlands as needed when building roadways or bridges over such wetlands. Such dredging enabled barges to carry heavy equipment to the jobsite as the job site progressed across the landscape.
Over time, it became apparent that dredged wetlands were not recovering as expected, and laws now ban such dredging.
Stone causeways built in wetlands areas avoid such dredging, but they too are environmentally unacceptable.
The industry has adopted the practice of building a temporary bridge into the wetlands for the purpose of enabling heavy equipment to reach the job site. Although such bridges require pile driving, the small footprint of a pile causes no permanent damage to the wetlands, i.e., the wetlands recover quickly when the temporary piles are removed.
The primary drawback to the temporary bridge solution to the wetlands conservation problem is that such temporary bridges, since they must carry very heavy loads, can be quite expensive and time-consuming to build even though they are temporary structures that are removed when the main roadway or bridge is completed.
Thus there is a need for a temporary bridge structure that is assembled quickly from low cost materials but which can support extremely heavy loads.
There is also a need for a temporary bridge structure that is quickly disassembled as well when no longer needed.
However, in view of the art considered as a whole at the time of making the present invention, it was not obvious to those of ordinary skill in the art how the needed structure could be provided.
SUMMARY OF THE INVENTION
The long-standing but heretofore unfulfilled need for an improved structure for a temporary structure that supports heavy loads is met by a new, useful, and non-obvious invention.
The inventive structure includes at least one hollow cylinder having a longitudinal axis of symmetry and an elongate extent. In a preferred embodiment, a hollow cylinder has a thirty six inch outside diameter and a wall thickness of three-eighths of an inch. Such dimensions are preferred but are not critical because pipes of many different outside diameter and wall thicknesses can be used when building temporary bridges as disclosed herein.
A plurality of stress-distributing strengthening members is circumferentially positioned about and secured to the hollow cylinder in parallel relation to the longitudinal axis of symmetry.
The strengthening members have an extent substantially equal to the elongate extent of the elongate hollow cylinder and in the preferred embodiment each strengthening member has a generally “L” shape where the legs of the “L” are disposed in angular relation to one another. Another embodiment saves materials by providing one leg per strengthening member.
A first flat plate of rigid construction is disposed in a horizontal plane in overlying and secured relation to the hollow cylinder. A second flat plate of rigid construction is disposed in a horizontal plane in underlying and secured relation to the hollow cylinder in parallel and diametrically opposed relation to the first flat plate. The width of each flat plate may exceed but is substantially equal to the diameter of the hollow cylinder to which it is secured and the length of each flat plate is substantially equal to the length of its hollow cylinder.
In the preferred embodiment, a first pair of two-leg strengthening members is secured to a hollow cylinder on opposite sides of a vertical plane that bisects the hollow cylinder and above a horizontal plane that bisects the hollow cylinder. A second pair of two-leg strengthening members is secured to the hollow cylinder on opposite sides of the vertical plane and below the horizontal plane.
Each leg of each strengthening member of the first pair has a free end disposed in abutting and secured relation to the first rigid flat plate along the elongate extent of the first rigid flat plate. Each leg of each strengthening member of the second pair has a free end disposed in abutting and secured relation to the second rigid flat plate along the elongate extent of the second rigid flat plate.
As in the parent disclosure, an imperforate circular disc is positioned within the lumen of the hollow cylinder in perpendicular relation to the longitudinal axis of symmetry of the hollow cylinder and in longitudinally spaced relation to a preselected end of the hollow cylinder.
A first circular disc has a central opening formed therein is secured to a first end of the hollow cylinder. A second circular disc having a central opening formed therein is secured to a second, opposite end of the hollow cylinder. The central opening of the second circular disc having said central opening forms a socket that mates with a key when first and second hollow cylinder members are disposed in end-to-end abutting relation to one another along a common longitudinal axis of symmetry.
A first end of a truncate cylindrical member is secured to the imperforate cylindrical disc in concentric relation thereto and a second end protrudes through the central opening formed in the first circular disc having a central opening. The protrusion forms the key.
In a second embodiment of the invention, longitudinally disposed timbers form a timber mat.
At least one pedestrian walkway is provided in a third embodiment.
A fourth embodiment enables a non-linear connection between elongate hollow cylinders so that a temporary bridge may include at least two straight sections that are disposed at a predetermined angle relative to one another.
A fifth embodiment discloses strengthening members having only one leg.
An important object of the invention is to provide a temporary bridge structure capable of supporting extremely heavy equipment.
Another important object is to provide such a structure that can be made of any length.
Another object is to provide a structure that assembles quickly, without tight tolerances, and which is made from readily available materials.
Still further objects are to disclose a better method for building timber mats, pedestrian walkways, paths of travel having at least one angular turn, and strengthening members that save materials.
These and other important objects, advantages, and features of the invention will become clear as this disclosure proceeds.
The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts exemplified in the disclosure set forth hereinafter and the claims indicate the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed disclosure, taken in connection with the accompanying drawings, in which:
FIG. 1 is an end view of a hollow cylinder, strengthening members, and rigid flat plates used in the novel structure;
FIG. 2 is a top plan view depicting two hollow cylinders in transversely disposed relation to one another;
FIG. 3 is a top plan view of the FIG. 2 embodiment after longitudinally and transversely disposed timbers have been added thereto;
FIG. 4A is an end view of a first variation of a third embodiment;
FIG. 4B is an end view of a second variation of the third embodiment;
FIG. 5 is a top plan view of a fourth embodiment including a predetermined angle between two straight sections of a bridge;
FIG. 6A is a top plan view of a truncate hollow cylinder that creates a predetermined angle between end-to-end elongate hollow cylinders;
FIG. 6B is a first side elevation view of said truncate hollow cylinder, taken along line 6 B- 6 B in FIG. 6A ;
FIG. 6C is a second side elevation view of said truncate hollow cylinder, taken along line 6 C- 6 C in FIG. 6A ;
FIG. 6D is an end elevation view of said truncate hollow cylinder, taken along line 6 D- 6 D in FIG. 6A ; and
FIG. 7 is an end elevation view of a fifth embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts an illustrative embodiment of a novel structural flexural element which is denoted as a whole by the reference numeral 10 .
Novel structure 10 includes elongate hollow pipe or cylinder 12 having a longitudinal axis of symmetry. Four (4) elongate, generally L-shaped stress-distributing strengthening members, denoted 14 a , 14 a , 14 b , and 14 b are circumferentially positioned about elongate hollow cylinder 12 in parallel relation to said longitudinal axis of symmetry and are secured to said elongate hollow cylinder by suitable means such as welding. The legs of each L-shaped strengthening member are disposed in angular relation to one another.
A first flat plate 16 of rectangular configuration and rigid construction overlies cylinder member 12 and the first or upper pair 14 a , 14 a of the strengthening members is positioned to orient said first flat plate 16 in a horizontal plane. More particularly, the free end of each leg of strengthening members 14 a , 14 a is welded or otherwise secured to an underside of said first flat plate. Strengthening members 14 a , 14 a are secured to said hollow cylinder on opposite sides of a vertical plane that longitudinally bisects hollow cylinder 12 .
A second flat plate 18 of rectangular configuration and rigid construction underlies cylinder member 12 and the second or lower pair 14 b , 14 b of stress-distributing strengthening members 14 b , 14 b is positioned to orient said second flat plate 18 in a horizontal plane. More particularly, the free end of each leg of strengthening members 14 b , 14 b is welded or otherwise secured to a top side of said second flat plate. Strengthening members 14 b , 14 b are secured to hollow cylinder 12 on opposite sides of the vertical plane. Upper strengthening members 14 a , 14 a and lower strengthening members 14 b , 14 b are positioned on opposite sides of a horizontal plane that bisects hollow cylinder 12 .
First and second flat plates 16 and 18 are parallel to one another in their respective horizontal planes.
Defining the end view of hollow cylinder 12 as the face of an analog clock where twelve o'clock is the highest point of said hollow cylinder as drawn in FIG. 1 , upper strengthening members 14 a , 14 a are positioned roughly at the one and eleven o'clock positions and lower strengthening members 14 b , 14 b are positioned roughly at the five and seven o'clock positions.
FIG. 2 depicts a pair of said hollow cylinders 12 disposed in transversely spaced apart, parallel relation to one another. Said cylinders are interconnected to one another along their respective extents by a plurality of transversely disposed, longitudinally spaced apart diaphragm members, collectively denoted 19 .
As in the parent application, an imperforate circular disc 20 is positioned within the lumen of each hollow cylinder 12 in perpendicular relation to the longitudinal axis of symmetry of said hollow cylinder. A first circular disc 22 having a central opening 23 formed therein is secured to a first end of hollow cylinder 12 . A second circular disc 22 a having a central opening 23 a that forms a key-receiving socket is secured to a second, opposite end of hollow cylinder 12 in closing relation thereto. No reference numeral is provided for central openings 23 and 23 a in FIG. 2 to avoid cluttering of the drawings.
Truncate hollow cylinder member 24 has a first end 24 a secured to imperforate circular disc 20 in concentric relation thereto, i.e., truncate cylindrical member 24 has the same longitudinal axis of symmetry as does elongate hollow cylinder 12 . Second end 24 b of truncate cylindrical member 24 extends through the central opening formed in first circular disc 22 . The protrusion of second end 24 b forms a key or pin that mates with the key-receiving socket formed in second cylindrical disc 22 a when two (2) cylindrical members 12 are disposed in end-to-end abutting relation to one another along a common longitudinal axis of symmetry.
Thus a first or leading end of each elongate hollow cylinder 12 is provided with key or pin 24 b as depicted in FIG. 2 and the second or trailing end of each elongate hollow cylinder is provided with a key-receiving socket in the form of said central opening formed in second circular disc 22 a . The first and second centrally apertured circular discs 22 and 22 a , respectively, have the same structure. The difference in reference numerals merely points out their difference in positions at opposite ends of each elongate hollow cylinder.
FIG. 3 depicts a plurality of longitudinally-disposed timbers, collectively denoted 26 , supported by said transversely disposed diaphragms 19 . Timbers 26 collectively form a timber mat that provides a roadway for heavy equipment. As mentioned above, all prior art timber mats are formed by a plurality of transversely disposed timbers which are supported by longitudinally disposed diaphragms which are in turn supported by transversely disposed diaphragms. The novel arrangement of FIG. 3 thus eliminates the longitudinally disposed diaphragms of the prior art.
As best understood in connection with FIGS. 4A and 4B , each diaphragm 19 is connected at its opposite ends to a flat brace 21 that is welded to its associated hollow cylinder 12 in a vertical plane. The cylinder-abutting side of each brace 21 is arcuate to conform to the surface of its associated hollow cylinder. A plurality of openings, collectively denoted 28 , is formed in each brace 21 along its outboard edges and each diaphragm 19 has a plurality of openings formed in each of its ends which can be aligned with preselected openings 28 . Suitable nuts and bolts are used to secure the opposite ends of each diaphragm 19 to its associated brace 21 .
Such structure allows height adjustment of each diaphragm 19 along the vertical extent of its associated brace 21 and thus height adjustment of the timber mat supported by said diaphragms. The timber mat in FIG. 4B is elevated with respect to the timber mat depicted in FIG. 4A . The FIG. 4B timber mat is a prior art timber mat having transversely disposed timbers.
In the embodiment of FIGS. 3 and 4A , a pedestrian walkway is supported by a plurality of transversely disposed, longitudinally spaced apart boards, collectively denoted 30 , that are mounted atop and secured to rigid flat top plate 16 in cantilever relation thereto and which extend in an outboard direction relative to each hollow cylinder 12 . Elongate strips of plywood 32 or other suitable material overlie boards 30 and provide support for a pedestrian. As depicted in said FIGS. 3 and 4A , such a pedestrian walkway is provided on the outboard side of each hollow cylinder. An upstanding safety hand rail 34 is provided on the outboard side of each walkway and a longitudinally disposed timber 26 a that is smaller than a timber mat timber 26 may be used to provide a guiding curb for the equipment as depicted in said FIG. 4A . Still smaller timbers 26 b are used to support plywood 32 .
FIGS. 3 and 4A also disclose transversely disposed shorter boards 30 a directly overlying upper rigid flat plate 16 of their associated hollow cylinder 12 and filling in the spaces between the longer, cantilevered boards 30 .
As indicated in FIG. 4A , the transverse spacing of piles 13 that support hollow cylinders 12 may be selected to directly support treads 11 of a crane 15 or other item of heavy equipment.
A pedestrian walkway may also be provided as disclosed in FIG. 4B . In this embodiment, transversely disposed, cantilevered boards 30 and the shorter boards 30 a therebetween are not used. A plurality of transversely disposed, longitudinally spaced apart elongate timber mats 27 , only one of which is depicted in the end view of FIG. 4B , is mounted and secured to the rigid flat mounting plate 16 that surmounts each hollow cylinder 12 . Each of said timber mats 27 has a transverse extent that exceeds the distance between the transversely spaced apart hollow cylinders 12 . The distance by which each transverse timber mat 27 extends outboard of the hollow cylinders defines the width of each pedestrian walkway. Although not depicted in FIG. 4B , a longitudinally extending strip of plywood 32 fills in the gap between timbers 27 to provide a pedestrian walkway and a suitable safety handrail may be provided as well.
The structure that enables the novel temporary bridge to turn relative to a straight line is depicted in FIGS. 5 and FIGS. 6A-D .
FIG. 5 depicts novel turn-creating member 40 and its position between two end-to-end elongate hollow cylinders 12 . Note that no such turn or curve-creating member 40 is provided between the transversely spaced associated elongate hollow cylinders 12 that are disposed end-to-end because such elongate hollow cylinders follow the interior curvature of the turn or curve and thus are not as widely spaced apart as are the elongate hollow cylinders on the outboard side of the curve.
Turn-creating member 40 is hereinafter referred to as the first or outer truncate hollow cylinder. It has a diameter equal to the diameter of each elongate hollow cylinder 12 and a structure that is much the same as the structure as each elongate hollow cylinder.
FIGS. 6A-D respectively provide top plan, first side, second side, and end views of turn or curve-creating outer truncate hollow cylinder 40 .
FIG. 5 may be interpreted as depicting a turn to the left in the novel temporary bridge structure. Accordingly, the upwardly inclined (as drawn) second or inner truncate hollow cylinder 24 depicted in the top plan view of FIG. 5 and in enlarged view in FIG. 6A indicates such left turn. Similarly, first centrally-apertured circular disc 22 is disposed at an obtuse angle in FIG. 6A relative to a horizontal plane, and the left side 40 a of member 40 has a shorter extent than right side 40 b thereof. Moreover, said left and right sides 40 a , 40 b are inclined upwardly from a horizontal plane as depicted in said FIG. 6A . A member 40 for creating a right turn would include a downwardly tilted inner truncate hollow cylinder 24 in FIG. 6A and the respective lengths and inclinations of sides 40 a and 40 b would be reversed.
The rate of curvature is increased by employing more than one member 40 at the desired turn location. This cumulative structure is possible because each member 40 has a socket opening 23 a formed in each centrally-apertured circular disc 22 and 22 a and a key 24 b that protrudes through the central opening formed in each first centrally-apertured circular disc 22 .
More particularly, first or outer truncate hollow cylinder 40 is truncate relative to said elongate hollow cylinders 12 , and said first truncate hollow cylinder 40 has a diameter substantially equal to a diameter of each elongate hollow cylinder 12 .
A second or inner truncate hollow cylinder 24 is disposed concentrically within said first truncate hollow cylinder 40 and has a longitudinal axis of symmetry disposed at a predetermined angle relative to a longitudinal axis of symmetry of said first truncate hollow cylinder 40 . Said second truncate hollow cylinder 24 therefore has a leading end disposed in oblique relation to a trailing end of said second truncate hollow cylinder.
First truncate hollow cylinder 40 is positioned between two elongate hollow cylinders 12 disposed in end-to-end relation to one another, one of which is a leading elongate hollow cylinder and one of which is a trailing elongate hollow cylinder.
As best understood in connection with FIG. 5 , the trailing elongate hollow cylinder is in axial alignment with a trailing end of said first or outer truncate hollow cylinder 40 and said leading elongate hollow cylinder is in axial alignment with a leading end of said second or inner truncate hollow cylinder 24 .
The predetermined angle of said second truncate hollow cylinder 24 enables construction of a temporary bridge having at least two straight sections that form an angle with one another equal to the predetermined angle of said second truncate hollow cylinder 24 with respect to the longitudinal axis of symmetry of said first truncate hollow cylinder 40 .
In all other respects the structure of first or outer truncate hollow cylinder 40 is the same as each elongate hollow cylinder 12 . An imperforate circular disc 20 is positioned within a lumen of first truncate hollow cylinder 40 in parallel relation to a trailing end of said first truncate hollow cylinder and in spaced apart relation to the leading end of said first truncate hollow cylinder.
A first circular disc 22 having a central opening formed therein is secured to the leading end of first truncate hollow cylinder 40 and a second circular disc 22 a having a central opening that forms a key-receiving socket is secured to the trailing end of said first truncate hollow cylinder 40 in closing relation thereto.
Second or inner truncate hollow cylinder member 24 has a trailing end secured to said imperforate circular disc 20 in concentric relation thereto and a leading end protruding through the central opening formed in first centrally-apertured circular disc 22 . The leading forms a key that engages said key-receiving socket.
FIG. 7 depicts an elongate hollow cylinder 12 having flat top plate 16 secured thereto in a horizontal plane and flat bottom plate 18 secured thereto in a horizontal plane. Top flat plate 16 makes tangential contact as at 16 a with hollow cylinder 12 at the twelve o'clock position of the circle defined by said hollow cylinder 12 in end view and bottom flat plate 18 makes tangential contact as at 18 a with hollow cylinder 12 at the six o'clock position of the circle.
Upper strengthening members 14 a , 14 a are formed integrally with or welded to flat top plate 16 and depend therefrom in normal relation thereto. Lower strengthening members 14 b , 14 b are formed integrally with or welded to flat bottom plate 18 and project upwardly therefrom in normal relation thereto.
Upper strengthening members 14 a , 14 a are positioned on opposite sides of the twelve o'clock point of tangential contact 16 a in equidistantly spaced relation to said twelve o'clock point of tangential contact. Lower strengthening members 14 b , 14 b are positioned on opposite sides of the sic o'clock point of tangential contact 18 a in equidistantly spaced relation to said six o'clock point of tangential contact.
This embodiment has the advantage of providing substantially as much strengthening as the above-disclosed embodiments with less materials in that each strengthening member has one leg instead of two. It has the disadvantage of requiring a more precise placement of legs 14 a , 14 a , 14 b , 14 b relative to the placement of the two leg embodiments because there are only four points of strengthening contact instead of eight.
It will thus be seen that the objects set forth above, and those made apparent from the foregoing disclosure, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing disclosure or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention that, as a matter of language, might be said to fall therebetween.
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A temporary bridge for supporting heavy loads includes elongate hollow cylinders. A first rigid flat plate is horizontally disposed in overlying relation to each hollow cylinder and a second rigid flat plate is horizontally disposed in underlying relation to each hollow cylinder. Stress-distributing strengthening members formed by a pair of legs that are angularly disposed with respect to one another are circumferentially positioned about each hollow cylinder and the respective free ends of the legs are secured to their associated rigid flat plates. A key extends from a first end of each hollow cylinder and a mating socket is formed in a second end of each hollow cylinder to facilitate end-to-end interconnection of a plurality of hollow cylinders. Further embodiments include longitudinally-disposed timber mats, pedestrian walkways and curvature-creating members so that the bridge may follow a non-linear path of travel.
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FIELD OF THE INVENTION
The present invention relates to a detecting apparatus, and more particularly, to a detecting apparatus capable of precisely detecting and calibrating the geometric information of a sample.
BACKGROUND OF THE RELATED ART
The critical dimension of semiconductor device is continuously decreased, such that the damage induced by any defect on a chip is continuously increased. Hence, high resolution examination (both review and inspection) is required to properly find and check the defect. For example, scanning electron microscope (SEM), as a more advanced examination system, is popularly used for examining chips. In general, a sample (wafer or photomask or semiconductor substrate) is located under a charged particle beam during the examination process. Clearly, whether the sample is correctly located is a key factor of the examining result. In general, one detector is located under the sample and on a base (such as the Z-stage of SEM). The detector will project or emit a light to the sample and analyze a reflected light from the sample. According to the analyzing result, the detector could acquire the geometric information (such as position, direction and angle) of the sample.
There are some drawbacks in the conventional design of the examination system. First, the detector is fixed on the base. Hence, once the base is improperly located (such as the top surface of the base is not parallel to the bottom surface of the sample located on a predetermined position), the detector usually can not properly detect the sample (such as the light is not properly projected from the detector onto the sample, such that the quality of the reflected light is degraded.) Second, only one detector is used to detect the geometric information of the sample. Hence, once the sample has a displacement around the light (or around an axis parallel to the light), the detector usually can not find the displacement.
Therefore, it is desired to develop some new designs of examination system to improve the above drawbacks.
SUMMARY OF THE INVENTION
An apparatus for detecting the geometric information of a sample in an examination system. The apparatus includes an elastic supporting assembly and an optical-electronic assembly. The optical-electronic assembly could project a light beam to the sample, receive a reflected light beam from the sample, and analyze the received reflected light beam to acquire messages about the geometric information (such as position, direction, and tilt angle) of the sample. The elastic supporting assembly could fix the optical-electronic assembly on a base (such as the Z-stage) and adjust the geometric condition of the optical-electronic assembly (such as moving along X-axis, moving along Y-axis, rotating on X-Y plane, tilting on X-Z plane and tilting on Y-Z plane.)
An application of the proposed detecting apparatus is exemplified herein. By adjusting the elastic supporting assembly, the geometric condition of the optical-electronic assembly could be adjusted, for example, the distance between optical-electronic assembly and sample and/or the direction of the light projected by the optical-electronic assembly. Thus, after the geometric condition of the optical-electronic assembly is adjusted to achieve an optimal reflected light from the sample, the elastic supporting assembly could be locked to fix geometric condition of the optical-electronic assembly corresponding to the base. After that, whenever a new sample is appeared to be detected, by comparing the difference(s) between the new reflected light and the optimal reflected light, it is easy to adjust the geometric condition of the new sample, until the new reflected light also is optimized. Moreover, when the examination system (such as SEM) is maintained, the apparatus also could be used to calibrate the relative geometric relation (such as relative distance, relative angle and relative direction) between the base (such as Z-stage) and the sample to be tested. For example, when the location of the sample is not changed but the location of the base might be changed during the maintain process, the apparatus could be used to calibrate the location of the maintained base by comparing the difference(s) between the new reflected light and the optimal reflected light.
Another application of the proposed detecting apparatus is exemplified herein. Because the proposed apparatus usually only projects a light to the sample along only one direction (such as Z-axis), the proposed apparatus only can detect the displacement (or motion) that has a non-zero displacement (or motion) along the direction but can not detect displacement (or motion) totally on a plane vertical to the direction (such as X-Y plane). Therefore, to effectively detect the displacement (or motion) of the sample, it is worth to use two apparatuses that separately projects lights to the sample along two different directions (such as one along X-axis and another along Y-axis).
Some optional improvements of the proposed apparatus are exemplified herein. The elastic supporting assembly could comprise a planar structure and cubic structure. The planar structure may make a restricted linear motion and/or restricted pivot motion relative to a base where the proposed apparatus is located. The cubic structure may make a restricted deformation. Hence, the optical-electronic assembly on the elastic supporting apparatus could be linear moved, pivot moved or tilted.
Some optional improvements of the proposed apparatus are exemplified herein. The optical-electronic assembly could comprise a light source module and an analyzing module. The optical-electronic assembly also could have other improvements, such as beam-splitting module, automatic gain control circuit, background eliminating circuit, and so on. Hence, not only the receive light could be effectively analyzed, but also the generation of light and elimination of noise could be effectively adjusted.
These and other aspects, features and advantages of the present invention can be further understood from the accompanying drawings and description of embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side-view diagram illustrating a system for detecting the geometric information of a sample in accordance with one embodiment of the present invention.
FIG. 2 is a schematic side-view diagram illustrating an elastic supporting assembly in accordance with one embodiment of the present invention.
FIG. 3A is a schematic diagram illustrating the relative motion freedom(s) of the planar structure and the base by linear motion in accordance with one embodiment of the present invention.
FIG. 3B is a schematic diagram illustrating the relative motion freedom(s) of the planar structure and the base by rotation in accordance with one embodiment of the present invention.
FIG. 4A is a schematic side-view diagram illustrating a cubic structure in accordance with one embodiment of the present invention. FIG. 4B is a top view of the exemplary cubic structure in FIG. 4A .
FIG. 4C is a first side view of the exemplary cubic structure in FIG. 4A .
FIG. 4D is a second side view of the exemplary cubic structure in FIG. 4A .
FIG. 4E is a third side view of the exemplary cubic structure in FIG. 4A .
FIG. 4F is a fourth side view of the exemplary cubic structure in FIG. 4A .
FIG. 4G , FIG. 4H , FIG. 4I , FIG. 4J , and FIG. 4K are top, a first side, a second side, a third side, and a fourth side views respectively of FIG. 4A when in operation in accordance with one embodiment of the present invention.
FIG. 5 is a schematic diagram illustrating an exemplary optical-electronic assembly in accordance with the present invention.
FIG. 6 is a schematic diagram illustrating an exemplary optical-electronic assembly in accordance with the present invention.
FIG. 7 is a schematic diagram illustrating an exemplary optical-electronic assembly in accordance with the present invention.
FIG. 8 is a schematic diagram illustrating an exemplary optical-electronic assembly in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic side-view diagram illustrating a system for detecting the geometric information of a sample in accordance with one embodiment of the present invention. The exemplary system 10 comprises a holding apparatus 101 and at least one detecting apparatus 103 . The holding apparatus 101 is configured for holding a sample 23 . The detecting apparatus 103 separated from the sample 23 is for detecting the geometric information of the sample 23 . The detecting apparatus 103 comprises an elastic supporting assembly 20 and an optical-electronic assembly 21 . The optical-electronic assembly 21 projects a light beam 103 a on the sample 23 , and then receives a reflected light beam 103 a from the sample 23 and analyzes the reflected light beam 103 a . The elastic supporting assembly 20 supports the optical-electronic assembly 21 , fixes the optical-electronic assembly 21 to a base 201 (such as fixing on the top surface of the Z-stage) and adjusts a relative geometric relation (such as relative distance, relative angle and relative direction) between the optical-electronic assembly 21 and the sample 23 . Therefore, by using the elastic supporting assembly 20 to adjust the geometric condition of the optical-electronic assembly 21 , the light path of the light beam 103 a can be adjusted to optimize the quality of the received reflected light beam 103 a.
As an example, the exemplary system 10 is equipped with a first detecting apparatus 103 for detecting the displacement/motion of the sample 23 on an X-Y plane. A second detecting apparatus 105 may be set such that a second light beam 105 a is projected on another surface (such as the side of the sample 23 ) allowing the second detecting apparatus 105 to detect the position variation of the sample 23 on an X-Z plane or a Y-Z plane. In other words, because the sample 23 is a 3-dimensional object having a first edge, a second edge, and a third edge crossing a specific vertex of the sample 23 , at least two detecting apparatus 103 / 105 may be used to separately detect different displacements/motions of the sample 23 . For example, one detecting apparatus 103 which projects a light beam is used for detecting the displacement/motion on one plane defined by the first edge and the second edge, and another detecting apparatus 105 which projects another light beam is used for detecting the displacement/motion on another plane defined by the first edge and the third edge. Of course, the shape of the sample 23 is not restricted. Therefore, the first edge and the second edge could be the same edge if the shape of the surface defined by the first edge and the second edge is chosen from a group consisting of the following: circle, ellipse, oval, and combination thereof.
FIG. 2 is a schematic side-view diagram illustrating an elastic supporting assembly in accordance with one embodiment of the present invention. The elastic supporting assembly 20 comprises a planar structure 202 and a cubic structure 203 . The optical-electronic assembly (not shown in the figure) may be loaded and fixed on the elastic supporting assembly 20 . In one option, the planar structure 202 is positioned between the base and the cubic structure 203 . Herein, the area between the planar structure 202 and the base is larger than the area between the cubic structure 203 and the planar structure 202 , such that the cubic structure 203 is fixed on the base through the planar structure 202 . Alternatively, the cubic structure 203 may be positioned between the base and the planar structure 202 . Herein, the area between the cubic structure 203 and the base is larger than the area between the planar structure 202 and the cubic structure 203 , such that the planar structure 202 is fixed on the base 201 through the cubic structure 203 . Clearly, the key is how to use both the planar structure 202 and the cubic structure 203 to provide the required motion freedom, how to combine the planar structure 202 and the cubic structure 203 is not a key of the invention. As an example, the planar structure 202 could be mounted with the cubic structure 203 by a way selected from a group consisting of the following: screw, glue, nail, tack, electric welding, and combination therefore.
Continuing the above description, the planar structure 202 is equipped with a plurality of fasteners 202 b positioned within a plurality of holes 202 a respectively. It is noted that all of the holes 202 a usually are not designed on only one side of the planar structure 202 . For example, the holes 202 a may be separately located but not limited to on the two opposite edges of the planar structure 202 . Alternatively, the holes 202 a may all be located but not limited to on the same edge of the planar structure 202 . Moreover, the size of a hole 202 a is larger than the size of a body of a fastener 202 b passing through the hole 202 a and is smaller than the size of an end of the fastener 202 b . Clearly, when the fastener 202 is located in the hole 202 a but not locked, it is allowed to move in the hole 202 a (for the body of fastener 202 is narrower than the hole 202 a ) to provide at least one motion freedom. Of course, when the fastener 202 is located in the hole 202 a and locked (because the end of the fastener 202 b is wider than the hole 202 a ), there is no motion freedom. As an example, the shape, the size and the geometric relation of the holes 202 a and the fasteners 202 b are adjusted to allow the optical-electronic assembly (not shown in the figure) loaded on the elastic supporting assembly to have at least one motion freedom before all of the fasteners 202 b are locked. Herein, FIG. 3A and FIG. 3B shows an embodiment with two possible motion freedoms. Herein, the two motion freedoms may be chosen from a group consisting of the following: rotation/pivot on the locked fastener 202 b (the dotted arc line with an arrow), rotation/pivot on a point between the fastener 202 b and the planar structure 202 , linear motion along a direction parallel to a line crossing both of the holes 202 a , linear motion along a direction vertical to a line crossing both of holes 202 a (the dotted straight line with an arrow), and combination thereof. Thus, the planar structure 202 may be crossed with or offset from the base as shown in FIG. 3A and FIG. 3B , respectively. As an example, to provide the planar structure 202 with a significant motion freedom along the first direction ‘X’, the body of the fastener 202 can be made to be significantly smaller than the hole 202 a along a first direction ‘X’ and slightly narrower than the hole 202 a along a second direction ‘Y.” Furthermore, as an example, the shape of each hole 202 a could be chosen from a group consisting of the following: quadrangle, oblong, circle, square, and the combination thereof, and each of the fasteners 202 b may be chosen from a group consisting of the following: screw with nut, nail, tack and the combination thereof.
FIG. 4A is a schematic side-view diagram illustrating a cubic structure in accordance with one embodiment of the present invention. FIG. 4B is a top view, FIG. 4C is a first side view, FIG. 4D is a second side view, FIG. 4E is a third side view, and FIG. 4F is a fourth side view of the exemplary cubic structure in FIG. 4A . The cubic structure 203 is equipped with a first cavity 203 a , a second cavity 203 b , a first adjusting device 203 c and a second adjusting device 203 d . The first cavity 203 a is positioned between a top plate 205 b and a bottom plate 205 a . The second cavity 203 b is positioned between a top plate 205 c and a bottom plate 205 b . The corresponding adjusting device, for example, the first adjusting device 203 c comprises a first fastener (not shown in the figure) capable of passing through the top plate 205 b to a top surface of the second plate (plate 205 a ) and a second adjusting device 203 d comprises a second fastener (not shown in the figure) capable of passing through the top plate 205 c and the second plate 205 b to reach into a hole being terminated inside the bottom plate 205 a . Each of the adjusting devices ( 203 c and 203 d ) could be chosen from a group consisting of the following: screw with nut, nail, tack and the combination thereof. The first fastener increases the angular magnitude of a corresponding opening when the first fastener is locked (the end of the first fastener contacts with the second plate, such that the second plate is pushed away when the first fastener is locked into the first plate), and the second fastener is capable of decreasing decreases the angular magnitude of the corresponding opening when the second fastener is locked (the end of the first fastener could be embedded into the second plate, such that the distance between the first plate and the second plate is decreased when the fastener is locked into the first plate). Further, the first portion of the cubic structure 203 forming the wall 203 e of the first cavity 203 a is partially overlapped with a second portion of the cubic structure forming the wall 203 f of the second cavity 203 b . Herein, the first cavity 203 a is with a first opening oriented towards a first direction and a second cavity 203 b is with a second opening oriented towards a second direction that is different from the first direction, so that the deformation induced from the first cavity and the deformation induced from the second cavity is distributed over two different planes (or together forming a 3-dimension deformation).
Referring to FIG. 4B , FIG. 4C , FIG. 4D , FIG. 4E , and FIG. 4F , the first adjusting device 203 c adjusts an angular magnitude of a first angle θ 1 of the first opening and the second adjusting device 203 d adjusts an angular magnitude of a second angle θ 2 of the second opening. The first cavity 203 a and the second cavity 203 b are arranged along a specific direction (for example “Z”) to interact with the planar structure (not shown in the figure). Therefore, the deformation of the cubic structure 203 is not totally parallel to the top surface of the planar structure (i.e., the motion freedom(s) induced by the deformation is not totally parallel to the top surface of the planar structure). Herein, the angular magnitudes are in-measured along the specific direction.
FIG. 4G , FIG. 4H , FIG. 4I , FIG. 4J , and FIG. 4K are a top view, a first side, a second side, a third side, and a fourth side views respectively of FIG. 4A when the cubic structure is in operation in accordance with one embodiment of the present invention. In the case of compressing the angular magnitude of the second angle θ 2 , the first cavity 203 a is compressed along the Y-Z plane. Similarly, in the case of stressing the angular magnitude of the first angle θ 1 , the second cavity 203 b is de-compressed on the X-Z plane. According to the foregoing description in reference to FIGS. 4A to 4K , the exemplary elastic supporting assembly may provide more freedoms for the adjustment of the optical-electronic assembly to enhance the qualities and precision of the alignment for the optical-electronic assembly.
Furthermore, the cubic structure 203 could be made of elastic material or could be formed to become an elastomer or an elastic structure. According to the configuration of the cubic structure 203 aforementioned, the shape, the size and the geometric relation of the cavities ( 203 a and 203 b ) cooperated with the adjusting devices ( 203 c and 203 d ) are adjusted to allow the optical-electronic assembly (not shown in the figure) loaded on the elastic supporting assembly 20 in FIG. 2 to have at least one motion freedom before the adjusting devices ( 203 c and 203 d ) are locked. The motion freedom is chosen from a group consisting of the following: tilting by varying the first angle θ 1 of the first opening, tilting by varying the second angle θ 2 of the second opening, and the combination thereof.
Accordingly, the adjustment of the relative geometric relation (such as relative position and relative angle) between the optical-electronic assembly 21 and the sample 23 may be achieved by cooperating the cubic structure 203 and the planar structure 202 .
FIG. 5 is a schematic diagram illustrating an exemplary optical-electronic assembly in accordance with the present invention. The optical-electronic assembly 21 comprises a light source module 211 capable of emitting a light beam 214 to the sample 23 , and an analyzing module 212 capable of analyzing a reflected light beam 215 from the sample 23 .
FIG. 6 is a schematic diagram illustrating an exemplary optical-electronic assembly 21 in accordance with the present invention. In the example, the light source module 211 comprises an electrostatic discharge device 211 a electrically coupled with at least one external signal line that receives at least one external signal from an external environment, such that the noise (or the damages induced by electrostatic discharge) from the external environment through the external signal line is effectively blocked. Furthermore, as an example, the light source module 211 comprises a laser diode 211 b driven and controlled by a laser diode driver. The laser diode 211 b is configured for emitting a laser beam as the light beam 214 .
Further, the optical-electronic assembly 21 optionally comprises a beam splitting module 216 capable of splitting the light beam 214 and the reflected light beam 215 . The beam splitting module 216 could be positioned between the sample 23 and the light source module 211 , and/or between the sample 23 and the analyzing module 212 . As one example, as shown in FIG. 7 , the beam splitting module 216 comprises a first beam splitter 216 a which reflects the first portion 214 a of the light beam 214 and reflects the first portion 215 a of the reflected light beam 215 , and allows the second portion 214 b of the light beam 214 to pass through for projecting on the sample 23 and forms the reflected light beam 215 . As another example, as shown in FIG. 8 , the beam splitting module 216 may comprise a second beam splitter 216 b and a third beam splitter 216 c located separately and in sequence between the light source module 211 and the sample 23 . The second portion 214 c of the light beam 214 is reflected by the second beam splitter 216 b . The third portion 214 d of the light beam 214 passes through the second beam splitter 216 b and the third beam splitter 216 c and projects on the sample 23 to form the reflected light beam 215 . Then the first portion 215 c of the reflected light beam 215 is reflected by the third beam splitter 216 c , the second portion 215 d of the reflected light beam 215 passes through the third beam splitter 216 c and the third portion 215 e of the reflected light beam 215 is reflected by the second beam splitter 216 b . Different light splitting modules 216 correspond to different designs of the optical-electronic assembly 21 , especially correspond to different designs of the analyzing module 212 .
Next, as an example, the analyzing module 212 comprises a position sensor device 212 a and an automatic gain control (AGC) circuit 212 b coupled with the position sensor device 212 a as shown in FIG. 6 or coupled with a first detector 212 d capable of receiving the third portion 215 e of the reflected light beam 215 as shown in FIG. 8 . The position sensor device 212 a the first portion 215 a of the reflected light beam 215 and outputs a processed detected signal 218 which is a function of both the incident angle of the second portion 214 b of the light beam 214 on the sample 23 and a projected position of the second portion 214 b of the light beam 214 on the sample 23 . Herein, by using proper position sensor device 212 , such as a commercial position sensor device 212 having four detectors for providing quadrantal detection independently, it is easy to decide whether the second portion 214 b of the light beam 214 is properly projected on the sample 23 and whether the sample 23 is properly located on the predetermined position with predetermined angle. The automatic gain control circuit 212 b outputs an adjusting signal 219 to the light source module 211 according to a light intensity of the first portion 215 a of the reflected light beam 215 or the third portion 215 e of the reflected light beam 215 . Then, by referring to the output of the automatic gain control circuit 212 b , the light source module 211 decreases the light intensity of the light beam 214 when the light intensity of the light beam 214 is larger than a higher threshold. Similarly, the light source module 211 increases the light intensity of the light beam 214 when the light intensity of the light beam 214 is smaller higher than a lower threshold. Thus, the light source module 211 adjusts the light intensity of the light beam 214 according to the adjusting signal 219 , such that the light intensity of the first portion 215 a of the reflected light beam 215 could be optimal for proper operation of the analyzing module 212 .
Furthermore, as an example, the analyzing module 212 may further comprise a background eliminating circuit 212 c electrically coupled with the position sensor device 212 a . The background eliminating circuit 212 c eliminates the effect of a background light which is received with the first portion 215 a of the reflected light beam 215 by the position sensor device 212 a simultaneously. There are different approaches to achieve the object of the background eliminating circuit 212 c , based on the fact that the light source module 211 usually use laser as the light source. According to a first example, the background eliminating circuit 212 c filters to obtain the required first portion 215 a of the reflected light beam 215 by only allowing a portion of the received light within specific frequencies (corresponding to the frequencies of the light source module 211 ) to pass and blocking the other portion of the received light. According to a second example, background eliminating circuit 212 c divides the received light into a continuous portion which spans over continuous frequencies (corresponding to the backlight) and a discrete portion which discretely distributes only within some specific frequencies (corresponding to the reflected light). Then, the background eliminating circuit 212 c also produces a simulated light which is essentially out-phase with the continuous portion over all frequencies, such that the continuous portion is cancelled by the simulated light and only the discrete portion is passed.
Furthermore, as an example shown in FIG. 7 , for properly adjusting the light intensity of the light beam 214 with reference to the reflected portion of the light beam 214 and the operation of the light source module 211 , the optical-electronic assembly 21 may further comprise a photo receiver 220 capable of receiving the first portion 214 a of the light beam 214 and producing a corresponding output signal 220 a . A focus lens 222 may be optionally set for focusing the first portion 214 a of the light beam 214 on the photo receiver 222 . Optionally, the a power limitation circuit 221 produces a power limitation signal 221 a according the output signal 220 a (which is detected) and a reflection-transmission ratio of the first beam splitter 216 a (which is known when a specific beam splitter is used to form the first beam splitter 216 a ). The power limitation signal 221 a is proportional to the actual intensity of the light beam 214 . according to which the light source module 211 adjusts the light intensity of the light beam 214 . For example, to avoid the risk that only a very small portion of the second portion 214 b of the light beam 214 is reflected (the sample 23 might have a very low reflection coefficient) and then the automatic gain control (AGC) circuit 212 b generates the adjusting signal 219 driving the light source module 211 to overly increase the light intensity of the light beam 214 , the power limitation signal 221 a could be used to restrict the adjusted light intensity of the light beam 214 to be smaller than or equal to a maximum allowable light intensity of the light source module 211 .
Alternatively, as shown in FIGS. 5˜8 , the optical-electronic assembly 21 may comprise a light adjusting module 217 capable of adjusting the propagation of the light beam 214 and the reflected light beam 215 . The light adjusting module 217 may be positioned between the sample 23 and the light source module 211 , and/or between the sample 23 and the analyzing module 212 . In one example, the light adjusting module 217 comprises a collimator lens 217 a capable of adjusting propagation of the light beam 214 for ensuring propagation of the light beam 214 with less divergence. The light adjusting module 217 may comprise a first plate 217 b with a first aperture for ensuring the uniform light intensity of the light beam 214 within a specific cross-sectional area, such that only essentially parallel light is projected on the sample 23 (or such that only incident light within a specific cross-section area and with a specific light strength intensity could pass through the first plate 217 b ). The light adjusting module 217 may further comprise a second plate 217 c with a second aperture for ensuring the uniform light intensity of the reflected light beam 215 within a specific cross-sectional area (e.g. only incident light within a specific cross-section area and with a specific light intensity could pass through the second plate 217 c ). Hence, if the sample 23 is significantly improperly located (such as the sample 23 is far away from the predetermined position or the sample 23 is significantly tilted), the reflected light beam 215 will be blocked by second plate 217 c and then the light adjusting module 217 will receive no light, such that it easily finds the significantly displacement of the sample 23 . Alternatively, the light adjusting module 217 may further comprises a first focusing lens 217 d located between the second beam splitter 216 b and the first detector 212 d , which focuses the third portion 215 e of the reflected light beam 215 into the first detector 212 d.
The optical-electronic assembly means an assembly of the optical device, optoelectronic device and the electronic device. In one embodiment of the present invention, the optical-electronic assembly 21 , as shown in FIG. 6 to FIG. 8 , may include an optical device including the light adjusting module 217 and the beam splitting module 216 , an optoelectronic device including the laser diode 211 b and the position sensor device 212 a , and an electronic device including the electrostatic discharge device 211 a , the automatic gain control (AGC) circuit 212 b and the background eliminating circuit 212 c
Although the present invention has been explained in relation to some embodiments, it is to be understood that other modifications and variation can be made without departing the spirit and scope of the invention as hereafter claimed.
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An apparatus for effectively detecting and calibrating a sample of examination system. The apparatus has an optical-electronic assembly for detection of the sample initiated with a light projected to the sample and an elastic supporting assembly for providing motion freedoms to adjust the relative geometric conditions between the optical-electronic assembly and the sample. The elastic supporting assembly has a planer structure and a cubic structure, and provides both motion freedoms on a plane and motion freedoms vertical to the plane. The optics electricity optical-electronic assembly could analyze the received reflected light to get geometric information of the sample, and could adjust the light used to detect the sample.
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FIELD OF THE INVENTION
The invention relates to an apparatus for monitoring or detecting a passage of workpiece through a sewing machine.
BACKGROUND OF THE INVENTION
There are many applications which require the generation of a signal when a workpiece arrives at a predetermined location. Sensor arrangements for scanning flat, sheet like material workpieces as they progress through a sewing machine are known in many variations.
Some machines employ mechanical means for detecting the workpiece edge. Mechanical sensor arrangements, however, have been known to be particularly sensitive and are susceptible to malfunction. Also, mechanical sensors are subject to wear as well as vibration. Some mechanical sensors are too insensitive to detect the movement of a single ply workpiece and, thus, do not provide the reliability required in some operations.
Some devices employ air sensors for detecting the workpiece. These sensors also have drawbacks. The environment in which these sensors find utility is ladden with dust and lint. Many of the machines are also exposed to lubricant, which, when combined with dust and lint in the area, easily clog the air sensor arrangements and thus effect the reliability of same.
In contrast to mechanical sensors, it has been known to use optical scanners or sensors for detecting the workpiece. Such optical sensors, however, also have drawbacks associated therewith. Optical sensors are usually sensitive to light dispersion and differing material density. Further, many optical sensors are sensitive to ambient light. As mentioned above, the environment in which this type of apparatus finds utility is usually ladden with dust and lint, both of which may effect the efficiency of such sensors. Photo cells are usually not employed in the immediate area of sewing because of the vibratory surroundings which prohibit their use. Furthermore, disturbances with light sensors may arise if the operator inadvertently interrupts the light beam, thus producing incorrect detecting signals.
The device disclosed in U.S. Pat. No. 4,342,273 granted to W. A. Petzold was yet another attempted solution to the provision of a suitable workpiece sensor arrangement. Indeed, this patented device did present a solution to the problem of presenting a dense light against a reflecting surface with minimum dispersion and recordation of the reflective results. With this patented device, the delicate end face of an fiber optic cable arranged opposite the reflective surface was protected by a transparent insert. Even this latest advancement has proven to have drawbacks which are disadvantageous in practice. With this patented apparatus, the advancement and abrasive sliding motion of the workpiece pass the transparent insert results in a permanent scratching or marring of the exposed face of the insert eventually resulting in false controls. Moreover, the vibrations of the feed dogs against the insert, which are transferred or transmitted to the end of the fiber cable, are disadvantageous. Thus, this recently patented apparatus, although advantageous and effective in solving many problems was not a complete answer.
SUMMARY OF THE INVENTION
Hence, readily recognizable is the fact that this particular field of technology is still in need of an apparatus for monitoring the progressive advancement of a workpiece and which is not associated with the aforementioned drawbacks and limitations of the other proposals. In view of the above, and in accordance with the present invention, there is provided a Material Sensing Means which effectively and efficiently overcomes the aforementioned drawbacks. The sensing means of the present invention includes a fiber optic means that is capable of transmitting dense light from a removed source to the sewing area of the machine with minimal or no dispersion. One end of the optic cable is arranged opposite a reflecting surface. The problem with the other devices has been avoided by arranging the exposed end face of the optic cable such that it is vertically removed from the path of workpiece advancement. Removal of the end face of the cable from the path of workpiece advancement, although contributing to the answer, is not the complete solution. Additionally, the end face must be and, with the present invention, is arranged in a manner preventing the exposed cable end face from becoming defiled or befouled.
Photo electric means are connected to the other end of the fiber optic light guide at a positioned removed from the sewing area. The photo electric means being capable of generating a pulse or signal when the workpiece interrupts the light path between the fiber optic means and the reflective surface. This output signal of the photo electric means may be used for any of a variety of purposes, i.e. actuation of a thread cutter, actuation of a tape trimming apparatus, etc.
The advantages of the present invention over the known sensor arrangements is that the end face of the optic cable is buffered from the vibratory surroundings in which it is exposed. Moreover, because the end face of the optic cable is exposed yet removed from the path of workpiece advancement, the possibility of marring or defiling of the end face of the optic cable is minimized. Whereas, the end face of the cable in the disclosed embodiment is arranged such that the advancing workpiece offers a cleansing effect to the exposed end face thus assuring proper and effective operation of the signaling apparatus.
With the above in mind, a primary object of this invention is the provision of a novel sensor arrangement of the type in question which provides a simple yet efficient apparatus for monitoring the progressive movement or advancement of a workpiece through the machine.
Another object of this invention is the provision of a novel arrangement of a signal generating system of the type described wherein the normally disturbing vibratory environment in which the detector finds utility is minimized.
BRIEF DESCRIPTION OF THE DRAWINGS
Having in mind these and other attendent advantages that would be evident from an understanding of this disclosure, the invention comprises the devices, combinations and arrangements of parts as illustrated in the presently preferred embodiment of the invention which is hereinafter set forth in detail to enable those skilled in the art to readily understand the function, operation, construction and advantages of it when read in conjunction with the accompanying drawings in which:
FIG. 1 is a schematic side elevational view of the present invention;
FIG. 2 is an enlarged side sectional view of a portion of the apparatus shown in FIG. 1; and
FIG. 3 is a sectional elevational view of the apparatus shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more specifically now to the drawings, the present invention is illustrated for use with a sewing machine. For simplicity and inasmuch to the elements common to most sewing machines, including endwise reciprocal stitch forming instrumentalities and work feeding mechanism means, are well known and form no part of the present invention, a detailed description and illustration thereof is deemed unnecessary.
Turning now to the details of the present invention, there is shown a sensor means 1 in the form of an extended, flexible fiber optic light guide. One end 2 of the light guide or cable 1 is disposed in the direction of workpiece advancement. Preferably end 2 is fixedly accommodated within an aperture provided in the elongated sole plate 3 of the sewing machine presser foot assembly. It should be appreciated, however, that the fiber optic cable end may be otherwise arranged and have the same effect when combined with the further teachings of the invention to be subsequently described. The other end of the light guide is arranged within a housing 6 and is divided into a plurality of leads or branches 4 and 8. One branch or lead is associated with a light source 5. The other lead is associated or connected to a photosensitive receiver 7.
Arranged in the sewing machine bed (not shown) is a work supporting throat plate 9. The top surface area of the throat plate opposite the lowermost end of the light guide is polished to define a reflecting surface. The throat plate 9 is formed with slots 11 through which the feed dog of the work feeding mechanism means are adapted to operate. In the usual manner, the presser foot sole 3 is urged downwardly against the throat plate to cooperate with the feed dog in incremently advancing a workpiece through the sewing area. Both the presser foot sole and the throat plate having needle receiving apertures 12 and 13, respectively, extending vertically therethrough and which permit endwise reciprocation of the needle means.
The bottom of the presser foot sole 3 is formed with a pair of side edges 15 which are seperated by a centrally disposed longitudinal or elongated straight groove or recessed channel 14. In the preferred embodiment, the upper wall or face of the channel is planar or flat. With the presser foot sole so designed, the flat upper wall 17 of the channel 14 may be raised from the surface of the throat plate 9. That is, only the side edges 15 of the presser foot sole press against the throat plate 9. The side edges serving to firmly clamp the workpiece beneath the presser foot sole means. As best seen in FIG. 2, the width of the channel or the distance between the side edges 15 is substantially equal to the collective width of the feed dog slots; that is, the distance between the outermost edges of the feed dog slots 11.
The end face or flat surface 16 of the end 2 of the light guide secured in the presser foot sole is arranged in a flush relation with the upper wall or surface 17 of the channel 14 such that it is removed from the top surface of the throat plate 9. Although removed from the throat plate, the distance or space between the end 17 of the light guide and the reflecting surface remains such that the reflected light is adequate to sense the passage of the article therebetween. The channel 14 is relatively narrow, preferably in the range of 0.4 mm, in that area in which the end of the light guide is so disposed.
By this construction, when the article or workpiece is advanced, a workpiece portion may be pressed into the groove 14 and will pass directly beneath the end face 16 of the fiber optic cable. Such workpiece movement effectively and constantly cleanses or wipes any foreign bodies, i.e. dust and threads, from the face of the optic cable. Likewise, a soiling of the reflective surface of the throat plate is eliminated. Due to the groove 14, the normal scratching or wearing effect on the end face 16 of the fiber optic cable is minimized. The provision of the relatively shallow elongated channel also provides a buffer against the vibratory actions of the feed dog means.
In operation, the light from the incandescent bulb 5 is transmitted, without dispersion, through the fiber optics of the branch 4 through the cable 1 and is projected from the cable end 16 as an illuminated spot in the normal path of travel of the workpiece past the stitch forming instrumentalities of the machine. The light is reflected back from the top or reflecting surface of the throat plate 9 and is delivered by the fiber optic means to the optic fibers in branch 8 and is, ultimately, transmitted to the photosensitive cell 7. At the instant the leading edge of the workpiece interrupts the light path defined by the space between the fiber optic light source and the reflecting surface, the photosensitive means 7 changes state. As a result, a pulse may be provided thereby. Said pulse may be used to timely energize any one or plurality of mechanisms, i.e., a thread cutter means or tape cutting apparatus etc. Upon continued operation of the machine, the advancing work blocks the sensor means light path. Therefore, while the work is progressively moved through the sewing area, no pulse may be produced by the photosensitive means 7. The instant the trailing edge of the workpiece passes beyond the sensor means light path, the photosensitive means may again change state in the response to the receipt of light conducted by the optic fibers from the reflective suface to the photosensitive means 3. Again, the second pulse may be used for any one of a plurality of purposes.
Thus it is apparent that there has been provided, in accordance with the invention, a Material Sensing Means for Sewing Machines that fully satisfies the objects, aims, and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims.
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A device for monitoring the passage of workpiece ends through a sewing machine. The device includes a photosensitive receiver connected to one end of a fiber optic cable. The other end of the cable being arranged opposite a reflecting surface and carried by the sewing machine presser foot in a manner preventing the exposed end face thereof from being defiled.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a National Stage of International Application No. PCT/DE2004/000048 filed Jan. 16, 2004, which claims priority to German Patent Application No. DE 103 04 832.4 filed on Jan. 31, 2003. The disclosures of the above applications are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a light, especially a rear light for motor vehicles, and a carrier, preferably for such a light.
BACKGROUND OF THE INVENTION
In order to place the lighting means as close as possible to the contour of the light or light pane, it is known to attach the lighting means to partial plates that are situated in a stepped fashion in relation to one another and connected to one another by cable. This embodiment requires a large amount assembly effort and easily leads to assembly errors. The lighting means are also situated standing up from the plates, thus requiring a lot of installation space.
The object of the invention is to embody a light and a carrier of this kind in such a way that it is easy and inexpensive to manufacture and can be mounted in small installation spaces.
This object is attained by a light of the species-defining type and by a carrier of the species-defining type.
SUMMARY OF THE INVENTION
As a result of the embodiment according to the present invention, the lighting means are situated at an edge of the carrier adjacent to the light pane so that they essentially follow the contour of the light pane. Since the lighting means are situated lying against the side of the carrier, the carrier with the attached lighting means takes up only a small amount of space. This allows the carrier according to the invention to also be easily accommodated in small installation spaces, even if the carrier is equipped with a large number of lighting means.
Other features of the invention ensue from the remaining claims, the specification, and the drawings.
The invention will be explained in greater detail below in conjunction with several exemplary embodiments shown in the drawings.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic section through a part of a light according to the invention, equipped with a lighting means carrier according to the invention,
FIG. 2 is a side view of another embodiment form of a carrier according to the invention,
FIG. 3 is a section along the line III-III in FIG. 2 ,
FIG. 4 is another embodiment form of a carrier equipped with lighting means in a depiction that corresponds to that in FIG. 2 ,
FIG. 5 is a perspective view of two adjacent carriers equipped with lighting means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a light, which is embodied in the form of a rear light for a motor vehicle. It has a housing 1 whose housing opening is covered by a light pane 2 , behind and spaced apart from which is situated a carrier 3 , which supports a large number of lighting means embodied in the form of LEDs 4 . Each of the LEDs 4 is associated with a segment 5 a , which is approximately parabolic in the view according to FIG. 1 and constitutes part of a reflector 5 that is advantageously comprised of a single piece. The LEDs 4 are situated, as will be explained in greater detail below, preferably with approximately the same distance from the light pane 2 . The carrier 3 is preferably a printed circuit board and rests with a lower edge 6 against a bottom 7 of the housing 1 . The bottom 7 and the edge 6 have a step 8 in the middle. The carrier 3 can be situated edge-on and perpendicular to the light pane 2 and requires only a small amount of installation space.
In the exemplary embodiment shown, the upper edge 9 of the carrier 3 oriented toward the light pane 2 is denticulate in profile. It has right-angled, shoulder-shaped segments 10 spaced apart from one another, which are connected to one another by means of intermediate segments 11 . The segments 10 have a shoulder surface 12 , which extends obliquely in relation to the light pane 2 and transitions at an angle into a transversely extending shoulder surface 13 . The shoulder surface 13 adjoins the intermediate segment 11 at an obtuse angle, which in turn adjoins the shoulder surface 12 at an obtuse angle as well. In the exemplary embodiment shown, the intermediate segments 11 are longer than the shoulder surfaces 12 and 13 . The LEDs 4 are attached one after another to the edge 9 of the carrier 3 , preferably spaced equidistantly apart. The LEDs 4 are attached to the one side surface 15 , in the vicinity of the shoulder-shaped sections 10 of the edge 9 . As is clear from FIG. 1 , the LEDs 4 are situated parallel to one another so that their longitudinal axes are parallel to the side surface 15 of the carrier 3 . As a result, the LEDs 4 rest snugly adjacent to the side surface 15 of the carrier. The LED contact feet, not shown in FIG. 1 , are bent at angles and protrude through openings in the carrier 3 . On the other side of the carrier, the contact feet are connected to electrical conductor tracks in a known manner.
The LEDs 4 are arranged on the carrier 3 so that they protrude beyond the edge sections 13 in the direction of the light pane 2 . The carrier edge 9 extends in relation to the light pane 2 so that the LEDs 4 are situated in a series that follows the light pane contour.
The carrier 3 can also be integrally connected to the reflector 5 .
The embodiment form according to FIG. 2 differs from the one in FIG. 1 only in that the edge 6 of the carrier 3 oriented away from the light pane 2 is curved in an approximate S shape. As in the embodiment form according to FIG. 1 , the opposite edge 9 is embodied as step-like, with the LEDs 4 situated in the vicinity of the shoulder-shaped segments 12 , 13 . The LEDs 4 lie in a path that is curved convexly toward the outside, whose course corresponds to the contour of the curved light pane 2 .
FIG. 3 shows an enlarged depiction of the attachment of one of the LEDs to the side surface 15 of the carrier 3 . The contact feet 16 of the LEDs 4 are accommodated in a protected fashion inside an injection molded body 18 that is molded onto the LEDs. The injection molded body 18 advantageously has a flat contact surface 20 with which it rests against the side wall 15 of the carrier 3 . The injection molded body 18 with the LED 4 can be attached to the carrier 3 in any suitable fashion. It is also possible, with a corresponding embodiment, to mold the injection molded body 18 directly onto the carrier 3 . The carrier 3 is provided with insertion openings 21 to permit the contact feet 16 to pass through. The contact feet 16 are accommodated in a protected fashion inside the injection molded body 18 . On the plate side 17 , the contact feet 16 that have been inserted through the openings 21 of the carrier 3 are connected to the printed circuit tracks (not shown) in the manner described above, for example by means of soldering.
The LEDs 4 first come in the form of a lead frame strip in which the LEDs 4 are arranged in a row next to one another. The contact feet 16 of the LEDs 4 are first bent by 90°. The bent contact feet 16 are then extrusion coated to produce the injection molded body 18 , which is the shape of a block in the exemplary embodiment. The LEDs 4 are then individually fastened to the carrier 3 in the manner described above. In spite of their bent contact feet 16 , the LEDs 4 are brought perpendicularly to the side surface 15 of the carrier 3 and attached to it in the same way as conventional LEDs with straight contact feet.
The contact surface 20 of the injection molded body 18 permits the LEDs 4 to be perfectly aligned on the carrier 3 in relation to the light pane 2 . The radiation direction of the LEDs 4 corresponds to the main radiation direction of the light.
The fact that the carrier 3 is embodied in the form of a thin printed circuit board and the LEDs 4 lie flat against the carrier 3 allows the carrier to be mounted even in narrow lights.
The carrier 3 , which is embodied the same as the carrier according to FIGS. 2 and 3 is provided with LEDs 4 along its edge 9 on both sides 15 , 17 . The LEDs 4 spaced apart from one another on the carrier side 15 are situated in the gaps between the LEDs 4 spaced apart from one another on the carrier side 17 . The contact feet 16 of the LEDs 4 protrude through beyond the respective opposite carrier side 15 , 17 . The LEDs 4 are each provided with an injection molded body 18 that corresponds to those provided in the preceding exemplary embodiments.
The two LED rows are spaced apart from each other by a distance that corresponds to the thickness of the carrier 3 . This makes it possible to accommodate a large number of LEDs 4 in an extremely small amount of space. By contrast with the exemplary embodiment shown, the LEDs 4 of the two rows can also be situated opposite the carrier from one another.
In the embodiment form according to FIG. 5 , two essentially identically embodied carriers 3 and 3 a are situated next to and spaced apart from each other. The carrier 3 is embodied the same as the carrier according to FIG. 2 . It has the LEDs 4 spaced equidistantly apart from one another on its carrier side 15 . The other carrier 3 a differs from the carrier 3 only in that it is slightly taller and, in the side view, is approximately trapezoidal in shape. The LEDs 4 are attached to the carrier side 15 a . The LEDs 4 are thus provided on the sides 15 a , 17 of the two carriers 3 , 3 a that are oriented toward each other. Appropriate placement of the carriers 3 , 3 a in relation to each other allows them to be optimally adapted to the respective contour of the light pane 2 . Naturally, instead of the two carriers 3 and 3 a , wider carriers can also be used if larger light panes are used.
In the embodiment forms described above, the carrier 3 , 3 a is embodied in the form of a printed circuit board. Plates and the like, which support the LEDs 4 in the above-described manner can also be used as carriers 3 , 3 a . The supply of current to the LEDs 4 can in this case be provided via lines that are attached to the plates in a suitable fashion.
The lighting means can also be incandescent lamps or other light-emitting elements. The different types of lighting means can also be used in combination.
The LEDs 4 are provided on the carrier 3 , 3 a so that their axes are parallel to one another. Depending on the application, the LEDs 4 can also be inclined in relation to one another in order to achieve a desired radiating effect.
The LEDs 4 can also, if necessary, be arranged on the carrier 3 , 3 a in an unevenly distributed fashion. Depending on the function of the LEDs 4 , they can be colored and emit colored light. The carrier 3 , 3 a , with the LEDs 4 can, for example, be used for brake lights or turn signal lights.
The carrier 3 , 3 a with the lighting means 4 can be used wherever there is only a small amount of available installation space, e.g. inside the motor vehicle in places like the dashboard, the headliner, and the like.
The LEDs 4 can also be embodied without the injection molded body 18 . The contact feet 16 then protrude freely and are connected to the electrical supply line in the manner described above.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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The invention relates to a light comprising a carrier ( 3 ) which has at least one lighting means ( 4 ) and which is arranged behind a light pane ( 12 ). The aim of the invention is to form a light or a carrier which can be produced in a simple and economical manner and which can be mounted in a small space. The lighting means ( 4 ) are arranged on the carrier ( 3 ) in such a manner that they essentially correspond to the contour of the light pane ( 2 ) and the lighting means ( 4 ) is placed in a horizontal manner on one side of the carrier ( 3 ) so that the carrier ( 3 ) and the lighting means ( 4 ) require very little space. The carrier ( 3 ) and the light are used in motor vehicles.
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PRIORITY CLAIM
This application is a continuation of, and claims the benefit of: (a) U.S. patent application Ser. No. 10/654,521, filed Sep. 2, 2003, the contents of which are incorporated herein by reference in their entirety; and (b) U.S. patent application Ser. No. 11/448,605, filed Jun. 6, 2006, the contents of which are hereby incorporated by reference in their entirety.
CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to the following commonly-owned co-pending patent applications: “GAMING DEVICE HAVING A CARD MANAGEMENT SYSTEM FOR THE MEASUREMENT OF CIRCULATING DATA CARDS,” Ser. No. 10/661,229; “GAMING DEVICE INCLUDING A CARD PROCESSING ASSEMBLY HAVING VERTICALLY-STACKED CARD HOLDERS OPERABLE WITH THERMALLY-PRINTABLE DATA CARDS AND PORTABLE CARD CHANGEOVER MACHINES,” Ser. No. 11/158,478; “GAMING SYSTEM WITH REWRITABLE DISPLAY CARD AND LCD INPUT DISPLAY FOR READING SAME,” Ser. No. 10/923,568; “GAMING DEVICE HAVING AN ELECTRONIC FUNDS TRANSFER SYSTEM,” Ser. No. 10/229,772; “GAMING DEVICE HAVING AN ELECTRONIC FUNDS TRANSFER SYSTEM,” Ser. No. 10/662,618; and “ELECTRONIC FUND TRANSFER KIOSK FOR USE WITH WAGERING GAMING MACHINE,” Ser. No. 10/662,495.
BACKGROUND
This invention relates generally to gaming printers and more specifically to printers for use in cashless gaming machines that use rewritable cards.
The gaming machine manufacturing industry provides a variety of gaming machines for the amusement of gaming machine players. An exemplary gaming machine is a slot machine. A slot machine is an electro-mechanical game wherein chance or the skill of a player determines the outcome of the game. Slot machines are usually found in casinos or other more informal gaming establishments.
Gaming machine manufacturers have more recently introduced cashless enabled games to the market and these have begun to find wide acceptance in the gaming industry. Cashless enabled games are so named because they can conduct financial exchanges using a mixture of traditional currencies and rewritable cards. Typically, a cashless enabled game has a gaming printer to produce rewritable cards and a rewritable card reader that supports automatic reading of rewritable cards. To coordinate the activities of multiple cashless enabled games, one or more cashless enabled games may be electronically coupled to a cashless enabled game system that controls the cashless operations of a cashless enabled game.
When a player cashes out using a cashless enabled game coupled to a cashless enabled game system, the cashless enabled game signals the system and the system may determine the type of pay out presented to the player. Depending on the size of the pay out, the cashless enabled game system may cause the cashless enabled game to present coins in the traditional method of a slot machine, or the cashless enabled game system may cause a gaming printer in the cashless enabled game to produce a rewritable card for the value of the pay out. The rewritable card may then be redeemed in a variety of ways. For example, the rewritable card may be redeemed for cash at a cashier's cage or used with another cashless enabled game. In order to use the rewritable card in a cashless enabled game, the rewritable card is inserted into a rewritable card reader of another cashless enabled game at a participating casino and the cashless enabled game system recognizes the rewritable card, redeems the rewritable card, places an appropriate amount of playing credits on the cashless enabled game.
Cashless enabled games have found an increasing acceptance and use in the gaming industry, both with players who enjoy the speed of play and ease of transporting their winnings around the casino and casinos who have realized significant labor savings in the form of reduced coin hopper reloads in the games, and an increase in revenue because of the speed of play. Practical field experience with printers used in cashless enabled games has illustrated that there are areas for improvement in the current printer designs and implementation. These areas in need of improvement include methods and means for using rewritable card media for printing of vouchers.
SUMMARY
A rewritable card printer useful as a gaming machine printer for printing vouchers is provided. The rewritable card printer includes a print module coupled to one or more separate card magazines, each having independent card drives. The operations of the print module and one or more card magazines is controlled by a printer controller. Cards may be exchanged between multiple card magazines so that cards can be escrowed, exchanged, or selectively located and retrieved.
The print module may receive as well as dispense cards from and to an external card source so that the card magazines may be replenished without opening up a gaming machine hosting the rewritable card printer. The print module may further include a security device reader that is used to read security features embedded in the cards. The security features may be used to track individual card use and to guard against card duplication and fraud.
In another aspect of the invention, a rewritable card printer includes a print module having a print card drive and a print head with the print module mechanically coupled to a base. The rewritable card printer further includes a card magazine having a card storage location and a magazine card drive with the card magazine coupled to the base such that the magazine card drive and the print card drive may exchange cards. The rewritable card printer has a printer controller electronically coupled to the print module and the card magazine. The printer controller includes a processor and a memory coupled to the processor. The memory has program instructions stored therein, the program instructions for operation by the printer controller of the print module and the card magazine.
In another aspect of the invention, the program instructions further include receiving card information for printing onto a card, generating printable indicia using the card information, and printing onto a rewritable card the printable indicia using the print head.
In another aspect of the invention, the rewritable card printer further includes an erase head with the program instructions further including instructions for erasing the rewritable card using the erase head.
In another aspect of the invention, the rewritable card printer further includes a security feature reader, the program instructions further including reading a security signature from the rewritable card using the security feature reader.
In another aspect of the invention, the rewritable card printer may be removably coupled to an external card magazine for dispensing and receiving cards.
In another aspect of the invention, the rewritable card printer may be programmed using a rewritable card or an external controller.
In another aspect of the invention, the rewritable card printer further includes encryption/decryption means coupled to the printer controller.
In another aspect of the invention, the rewritable card printer further includes a display device coupled to the printer controller.
In another aspect of the invention, the rewritable card printer further includes a card cleaning device coupled to the input module.
In another aspect of the invention, the input module further includes a magnetic strip read/write head. In another aspect of the invention, the input module further includes an optical scanning device.
In another aspect of the invention, the input module further includes means for coupling to a static memory in a rewritable card.
In another aspect of the invention, the program instructions further include: receiving a card for storage; reading card information from the card; erasing the card; storing the card information in a static memory; and storing the card in the card magazine.
In another aspect of the invention, the card magazine further includes the static memory for storage of the card information.
In another aspect of the invention, the base is slidably coupled to a base plate fixedly coupled to a gaming machine.
In another aspect of the invention, the card magazine is slidably coupled to the base.
In another aspect of the invention, the print module is removably coupled to the base by mechanical quick disconnect means and removably coupled to the printer controller by electrical quick disconnect means.
In another aspect of the invention, the card magazine is removably coupled to the base by mechanical quick disconnect means and removably coupled to the printer controller by electrical quick disconnect means.
In another aspect of the invention, the rewritable card further comprises a second card magazine coupled to the base such that the second card magazine's magazine card drive is in communication with the first of the card magazine's magazine card drive.
In another aspect of the invention, the program instructions further include: receiving a request for a card located in the first card magazine; determining the location of the requested card located in the first card magazine; and moving cards from the first card magazine to the second card magazine until the location of the requested card is reached.
In another aspect of the invention, the rewritable card printer further includes an additional card magazine coupled to the base such that the second card magazine's magazine card drive is in communication with the print module's print card drive.
In another aspect of the invention, the program instructions further include instructions for escrowing a card or exchanging a card for another card.
In another aspect of the invention, the print module further includes an embossing detector.
Additional features and advantages are described herein, and will be apparent from, the following Detailed Description and the figures.
BRIEF DESCRIPTION OF THE FIGURES
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 is a block diagram of a cashless gaming machine and system in accordance with an exemplary embodiment of the present invention;
FIG. 2 a is an illustration of a rewritable card in accordance with an exemplary embodiment of the present invention;
FIG. 2 b is an illustration of another portion of a rewritable card in accordance with an exemplary embodiment of the present invention;
FIG. 2 c is an illustration of another portion of a rewritable card having a static memory in accordance with an exemplary embodiment of the present invention;
FIG. 3 is a block diagram illustrating a security feature employing capacitive inks in accordance with an exemplary embodiment of the present invention;
FIG. 4 is a block diagram of a security feature utilizing an optical signature in accordance with an exemplary embodiment of the present invention;
FIG. 5 is a block diagram of a security feature using randomly deposited radio sensitive fibers embedded in a rewritable card in accordance with an exemplary embodiment of the present invention;
FIG. 6 is a block diagram of the operation of a rewritable card printer in accordance with an exemplary embodiment of the present invention;
FIG. 7 a is a block diagram of a rewritable card printer in accordance with an exemplary embodiment of the present invention;
FIG. 7 b is an architecture diagram of a rewritable card printer employing components having integral controllers in accordance with an exemplary embodiment of the present invention;
FIG. 8 is an isometric view of a rewritable card printer in accordance with an exemplary embodiment of the present invention;
FIG. 9 is an isometric view of a rewritable card printer with the card magazine opened in accordance with an exemplary embodiment of the present invention;
FIG. 10 is a top plan view of a rewritable card printer in accordance with an exemplary embodiment of the present invention;
FIG. 11 a is side elevation view of a rewritable card printer in accordance with an exemplary embodiment of the present invention;
FIG. 11 b is side elevation view of a rewritable card charging process in accordance with an exemplary embodiment of the present invention;
FIG. 11 c is a side elevation view of a rewritable card printer with a card magazine having two independent magazine card drives in accordance with an exemplary embodiment of the present invention;
FIG. 11 d is a side elevation view of a card magazine having a plurality of card storage locations serviced by a single card magazine drive in accordance with an exemplary embodiment of the present invention;
FIG. 11 e is side elevation view of a rewritable card printer slidably coupled to a gaming machine in accordance with an exemplary embodiment of the present invention;
FIG. 12 is a process flow diagram of a rewritable card printing process in accordance with an exemplary embodiment of the present invention;
FIG. 13 is a process flow diagram of a card escrowing process used by a rewritable card printer in accordance with an exemplary embodiment of the present invention;
FIG. 14 is a card retrieval process used by a rewritable card printer having companion magazines in accordance with an exemplary embodiment of the present invention;
FIG. 15 is a process flow diagram of a card location process used by a rewritable card printer having multiple card magazines in accordance with an exemplary embodiment of the present invention;
FIG. 16 is a process flow diagram of a card replacement process in accordance with the present invention;
FIG. 17 is a process flow diagram of a programming process using a rewritable card in accordance with an exemplary embodiment of the present invention;
FIG. 18 is a process flow diagram of a card information storage process in accordance with an exemplary embodiment of the present invention;
FIG. 19 is a process flow diagram of a card information retrieval process in accordance with an exemplary embodiment of the present invention; and
FIG. 20 is a stored card status printing process in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 is a block diagram of a cashless enabled gaming machine coupled to a rewritable card printer in accordance with an exemplary embodiment of the present invention. A cashless gaming system includes a cashless gaming system controller 100 hosted by a system host 102 coupled 104 to one or more cashless enabled games 106 . A cashless enabled game includes a game controller 108 that controls the operation of the cashless enabled game. The game controller is coupled to a rewritable card printer 110 . The cashless enabled game uses the rewritable card printer to write rewritable card media such as rewritable card 114 . The rewritable card printer includes card identification and printing algorithms 113 used in conjunction with rewritable cards. The rewritable card includes the cash-out information for a player.
The rewritable card printer may also be coupled ( 112 ) to the host system and cashless gaming controller. The rewritable card may be redeemed ( 116 ) in a variety of ways. The rewritable card may be redeemed by a human cashier or card reader 122 at a game table 124 , or a human cashier or card reader 126 at a cashier's cage or kiosk 128 , or by a card reader 118 at another cashless enabled game 120 . Redemption is only possible after the rewritable card passes a verification of account information 130 and validation using security features 132 included in the rewritable card.
FIG. 2 a is an illustration of a rewritable card in accordance with an exemplary embodiment of the present invention. The rewritable card shown is produced from commands issued by the cashless enabled game to the gaming printer in response to a player's request to cash-out. The rewritable card 114 includes features such as a validation number, printed in both a human readable form such as a character string 200 and in a machine-readable form such as a bar code 202 , time and date stamps 204 , cash-out amount 206 , casino location information 208 , cashless enabled game identifier 210 , and an indication of an expiration date 212 . Included in the card is a security feature 132 that may take one or more forms as discussed below.
In one rewriteable card media in accordance with an exemplary embodiment of the present invention, one face of the rewriteable card includes a layer of writable and erasable thermally sensitive film. The thermal film becomes opaque at one temperature level but becomes transparent at another temperature. This effect can be used to create a thermally rewritable card.
FIG. 2 b is an illustration of another side of a rewriteable card in accordance with an exemplary embodiment of the present invention. The rewriteable card 114 may also include a read/write magnetic strip 214 for encoding of any of the information described above.
In addition, the magnetic strip may be used to transmit information to the rewritable card printer. For example, the magnetic strip may encode instructions such as configuration flags or programming instructions used to reconfigure or reprogram a rewritable card printer.
FIG. 2 c is an illustration of another portion of a rewriteable card having a static memory in accordance with an exemplary embodiment of the present invention. The rewriteable card 114 may also include a static memory 216 embedded in the rewritable card so that the rewritable card can be used as a “smart” card for encoding of any of the information described above.
In addition, the static memory may be used to transmit information to the rewritable card printer. For example, the static memory may encode instructions such as configuration flags or programming instructions used to reconfigure or reprogram a rewritable card printer.
FIG. 3 is a block diagram illustrating a security feature employing capacitive inks in accordance with an exemplary embodiment of the present invention. A rewritable card 114 may be imprinted with metallic inks to create one or more capacitors in the rewriteable card. The one or more capacitors may be used to create a security feature in the form of a capacitor structure 300 whose capacitance may be detected by a capacitance sensor 302 coupled to the rewritable card. As the card moves across the sensor (as indicated by arrow 304 ) the sensor senses changes in the localized capacitance of the card and generates ( 306 ) a security signature signal 308 corresponding to the structure of the capacitor structure 300 in the rewritable card. This security signature signal may be used to identify each rewritable card used in a cashless enabled gaming system.
FIG. 4 is a block diagram of a security feature utilizing an optical signature in accordance with an exemplary embodiment of the present invention. To use this security feature, a rewritable card 114 includes a structure 400 having a variable optical density or optical reflectivity that is not apparent under normal lighting conditions. However, when a high intensity light, such as a laser beam 402 generated by a laser diode 404 or other laser beam generating device, is transmitted through the rewritable card, a light sensor 406 may detect fluctuations in the intensity of the transmitted or reflected laser beam caused by the structure. If the card is moved past the laser beam (as indicated by arrow 408 ) the moving structure generates a changing light signal that is received by the light sensor. In response to the changing light signal, the light sensor generates ( 410 ) a time varying security signature signal 412 that may be used as a signature to uniquely identify each rewritable card used in a cashless gaming system.
FIG. 5 is a block diagram of a security feature using randomly deposited radio sensitive fibers or inks embedded in a rewritable card in accordance with an exemplary embodiment of the present invention. A rewritable card 114 may include a layer of randomly deposited radio sensitive fibers 500 embedded within the card. An excitor 502 is used to transmit short pulses of radio waves 504 into the layer of fibers. In response to the radio waves, the fibers generate a resultant radio frequency signal 506 that may be detected by a sensor 508 . If the rewritable card is moving (as indicated by direction arrow 509 ) as the fibers are being excited, the sensor receives a time varying radio frequency signal generated by the excited and moving fibers. In response to the time varying radio frequency signal, the sensor generates ( 510 ) a time varying security signature signal 512 that may be used to uniquely identify each rewritable card in a cashless gaming system.
FIG. 6 is a block diagram of the operation of a rewritable card printer in accordance with an exemplary embodiment of the present invention. A rewritable card printer includes a security feature reader 600 for reading a security feature embedded in a rewritable card 114 . The type of security feature reader is dependent on the type of security features used with the rewritable card. The security feature reader supplies the appropriate excitation energy and sensor to generate a security signature signal as previously described.
The rewritable card printer also includes an erase head 602 for erasing a rewritable card prior to printing on the rewritable card. The erase head raises the temperature of the rewritable thermal film to the erasing temperature and any images previously written to the rewritable card are erased.
The rewritable card printer also includes a print head 604 for printing on the rewritable card. The print head raises the temperature of the thermal film on the rewritable card to the writing temperature and indicia are printed onto the rewritable card as a result.
The rewritable card printer also includes an optical scanning device 605 for reading the printed indicia on the rewritable card. The operation of such a device is more fully detailed in U.S. patent application Ser. No. 10/136,897, filed Apr. 30, 2002, the contents of which are hereby incorporated by reference as if stated herein in full.
The rewritable card printer also includes a magnetic strip read/write head 607 for reading from, and writing to a magnetic strip 214 (of FIG. 2 ) on the rewritable card.
The rewritable card printer includes a printer controller 606 operably coupled to the security feature reader. The security feature reader generates a security signature signal 608 that is transmitted to the printer controller.
The printer controller is also coupled to the erase head. The printer controller generates an erase control signal 612 that is transmitted to the erase head. In response to the erase head signal, the erase head heats the rewritable card until all indicia are erased from the rewritable card.
The printer controller is also coupled to the print head. The printer controller transmits print head control signals 616 to the print head. In response to the print head control signals, the print head heats a thermal element for each dot that is to be imaged on the rewritable card. The print head typically creates dot images to a granularity of 12 dots per millimeter, each dot image using a separate thermal element to create a dot image.
The printer controller is also coupled to the optical scanner 605 . As the optical scanner scans the printed indicia on the rewritable card, the optical scanner transmits scanned signals 617 to the printer controller.
The printer controller is also coupled to the magnetic strip read/write head 607 . The printer controller transmits magnetic strip write signals and receives magnetic strip read signals to and from ( 619 ) the magnetic strip read/write head.
The printer controller may also be coupled to a static memory read/write connector 622 . The printer controller transmits static memory write signals and receives static memory read signals to and from ( 624 ) the static memory read/write head.
In one embodiment of a rewritable card printer in accordance with the present invention, a game controller 108 is operably coupled to the printer controller. The printer controller receives printer control instructions 614 , including card information for writing to the rewritable card, from the game controller. The printer controller may also transmit printer status and card identification signals 610 to the game controller.
FIG. 7 a is a block diagram of a rewritable card printer in accordance with an exemplary embodiment of the present invention. A rewritable card printer 110 includes a printer controller 606 , a print module 702 , and one or more card magazines 704 .
The print module includes a print card drive 706 that moves cards through the print module. The print card drive is reversible such that a card may be fed through the print module in more than one direction by the print card drive. The print card drive includes a card motion sensor 707 for sensing card movement within the print card drive. A more detailed discussion of printer media motion detection within a printer is presented in U.S. Patent Application entitled “PAPER MOTION DETECTOR IN A GAMING MACHINE”, Ser. No. 10/640,495 filed Aug. 12, 2003, the contents of which are hereby incorporated by reference as if stated herein in full. The print drive further includes an embossing detector 709 that may be used to sense when an embossed item, such as a conventional credit card, is inserted into the print module. The embossing detector may be a mechanical device, such as a limit switch, that contacts an inserted card and detects any embossing. If an embossed card is inserted into the rewritable card printer, the rewritable card printer may not attempt to write to the card, only read the card.
The print module further includes a security feature reading device 600 for reading any security features included in the card. The print module further includes a print head 604 for writing indicia to the rewritable card and an erase head 602 for erasing the indicia from the rewritable card.
The print module further includes an optical scanning device 605 for scanning the indicia printed onto a rewritable card. The print module further includes a magnetic strip read/write head 607 used to read and write from and to a rewritable card's magnetic strip. The print module is removably and electronically coupled to the printer controller and removably and mechanically coupled to the card magazine.
In operation, the print module receives printer control signals from the printer controller. In response to the printer control signals, the print module scans rewritable cards for the presence and value of any security feature in the rewritable card. As the print module scans the rewritable card, the security feature reading device generates a previously described security signature signal that is transmitted to the printer controller. In addition, the print module thermally prints on the rewritable cards, and thermally erases the rewritable cards, under the control of the printer controller. The print module may also receive a rewritable card from a player and transmit a rewritable card detection signal to the printer controller.
The print module may also include a static memory read/write connector 622 for coupling to a “smart” card having a readable/writable static memory. The printer controller transmits static memory write signals and receives static memory read signals to and from the static memory read/write head.
The one or more independently controlled card magazines store rewritable cards and provide the rewritable cards to the printer module on command from the printer controller. Each card magazine may includes one or more magazine card drives 710 for moving cards into and out of the magazine. Each card magazine also includes a card storage area 712 for storage of rewritable cards. In operation, the card magazine receives card magazine control signals from the printer controller. In response to the control signals, the card magazine feeds cards to the printer from the card storage area using the magazine card drive. In response to the card magazine control signals, the card magazine may also receive rewritable cards from the print module and store the rewritable cards in the card storage area. The card magazine may also include one or more card sensors 714 used to detect the number of cards stored in the card storage area. The card sensors sense the quantity of cards stored in the card storage area and transmit card count signals to the printer controller for further processing. The card magazine may also include a read/write static memory 715 for semi-permanent storage stored in the card magazine.
The printer controller include to a main memory 718 by a system information about cards a processor 716 coupled bus 720 . The printer controller also includes a storage memory 722 coupled to the processor by the bus. The storage memory stores programming instructions 113 , executable by the processor to implement the features of a rewritable card printer. The storage memory also includes printer and card information 724 stored and used by the processor. The printer and card information includes information received by the printer controller about the status of the print module and card magazine and also about the status and identity of any cards stored in the card magazines or being operated on by the print module. The types of status information may include an image of a last printed rewritable card as scanned by the optical scanning device and the current status, such as millimeters of advancement, of a card currently in the print module.
The printer controller also includes an Input/Output (I/O) device 726 coupled to the processor by the system bus. The I/O device is used by the printer controller to transmit control signals to the print module and the card magazine. The I/O device may also be used by the printer controller to receive security feature and status signals from the print module and card magazine.
One or more communications devices 728 may be coupled to the system bus for use by the printer controller to communicate with a cashless gaming system host 102 or a game controller 108 (both of FIG. 1 ). The printer controller uses the communication devices to receive commands, program instructions, and card information from the external devices.
In addition, the printer controller may use the communication devices to transmit printer status information to the external devices. Other communication devices may also be used by the printer controller to couple in a secure fashion over a local area network 732 for administrative or other purposes.
Additional communication devices and channels may be provided for communication with other peripheral devices as needed. For example, one communication device may be provided with a local communications port, accessible from an exterior of a gaming machine hosting the rewritable card printer, that a technician may use to communicate with the printer controller during servicing using an external controller 730 . The external controller may communicate with the printer controller using an infrared link, other short-range wireless communication link, are a hard link with an external connector in a secure manner.
The processor may be further coupled to an encryption/decryption module 740 that may be used to encrypt and decrypt messages encoded using the an encryption standard. This enables the printer controller to engage in secure transactions with external devices. The processor may access the display device either as a component through the bus as shown or as an external device through a communications device using a high level communications protocol. In addition, the printer controller may also include program instructions to perform encryption/decryption services as well.
The processor may be further coupled to a display device 742 that may be used to display printer status information or card information. For example, the display may used to display an “as-scanned” version of the most recently printed and scanned card. The processor may access the display device either as a component through the I/O device or as an external device through a communications device.
In operation, the processor loads the programming instructions into the main memory and executes the programming instructions to implement the features of a rewritable card printer as described herein.
As illustrated, the printer controller is shown as being electronically coupled to the print module and card magazine without any mechanically coupling. The printer controller may be mounted in a variety of ways and may be incorporated into various components of either the rewritable card printer or the game hosting the rewritable card printer. For example, the printer controller may be attached to and supported by the print module, the card magazine, or the host game as may be required to mechanically integrate the rewritable card printer into the host game.
FIG. 7 b is an architecture diagram of a rewritable card printer employing components having integral controllers in accordance with an exemplary embodiment of the present invention. A rewritable card printer 110 may be composed of a printer controller 606 that communicates with components and modules of the rewritable card printer using a communications link 749 . The communications link may use either serial or parallel communications protocols to communicate with the components of the rewritable card printer. In this embodiment a print module 750 includes a print module controller 752 coupled to the printer controller. To control the operations of the print module, the printer controller transmits high level commands and status requests to the print module. In response, the print module performs the commands and transmits the requested information.
One or more card magazines 754 may also have integral card magazine controllers that are coupled to the printer controller via the communications link. To control the operations of the card magazine, the printer controller transmits high level commands and status requests to the card magazine. In response, the card magazine performs the commands and transmits the requested information to the printer controller.
The internal architecture of the rewritable card printer may be extended to external devices 758 as well, each having its own internal controller 760 . In this embodiment, the printer controller communicates with the external device using high level commands. In response, the external device performs the commands and transmits any requested information to the printer controller. An example of an external device having its own internal controller includes an external card magazine or cassette used to load cards into, or retrieve cards from, the rewritable card printer.
FIG. 8 is an isometric view of a rewritable card printer in accordance with an exemplary embodiment of the present invention. As illustrated, the rewritable card printer 110 includes a print module 702 and one or more card magazines 704 mechanically coupled on a base 800 . The rewritable card printer includes a front bezel 802 through which a rewritable card 114 may be fed by the print module's print card drive 706 , either into or out of the rewritable card printer as previously described. The card magazine is positioned on the base such that the card magazine's magazine card drive 710 may feed rewritable cards to and receive rewritable cards from the print module as previously described. The print module and the magazine drive are separately mounted to the base and each may separately serviced in the field without affecting the operation of the other. In addition, each component may be removed from the rewritable card printer and replaced without removing the power to the rewritable card printer.
As the print module and card magazine are separately mounted and controllable, the orientation of the print module and card magazine may be altered as needed to suit the mechanical requirements of a host game. For example the distance between the print module and the card magazine may be altered in order to accommodate a shorter printer bay included in a host game.
In one card magazine in accordance with an exemplary embodiment of the present invention, the cards are stored in the card magazine at an angle, up to 90 degrees, relative to the orientation to a card as it is fed into or out of a print module. This allows the card magazine to accommodate a larger number of cards in a given space, thus enhancing the card magazine's storage capabilities. In operation, the magazine card drive receives the card from the print module or another card magazine and tilts the card as it is added to the card storage area. When a card is retrieved from the card magazine, the magazine card drive reorients the card into a proper position for presentation to the print module.
FIG. 9 is an isometric view of a rewritable card printer with the card magazine opened in accordance with an exemplary embodiment of the present invention. As illustrated, the rewritable card printer 110 includes a print module 702 and one or more card magazines 704 mechanically coupled on a base 800 . The rewritable card printer includes a front bezel 802 through which a rewritable card 114 may be fed by the print module's print card drive 706 , either into or out of the rewritable card printer, as previously described. The card magazine is positioned on the base such that the card magazine's magazine card drive 710 may feed rewritable cards to and receive rewritable cards from the print module as previously described. The magazine card drive is removably coupled to the card storage area 712 by a hinge 900 such that the magazine may be opened to allow access to the card storage area.
A cleaning device 902 (shown through a cutaway in the front bezel 802 ) is attached to the print module such that incoming rewritable cards are cleaned before they enter the print module. The cleaning device may include flexible solid or bristled wiper elements that contact the card as it is taken into the print module. The wiper elements may be conductive so as to remove static surface charges from the card as it moves in the card printer. The wiper elements may also be charged so as to electrically attract and collect particles of dust and dirt from the card. As the print module's print card drive is reversible, the incoming card may be passed repeatedly, back and forth, through the cleaning element as needed.
In other print modules in accordance with other exemplary embodiments of the present invention, the cleaning device may be located within the print module, within the card magazine, or between the print module and a card magazine. In other rewritable card printers in accordance with exemplary embodiments of the present invention, the cleaning device is a separate device and not integrated with either a print module or a card magazine. Instead, the cleaning device is a separate motorized device similar to a card magazine and is electronically coupled to a printer controller.
FIG. 10 is a top plan view of a rewritable card printer in accordance with an exemplary embodiment of the present invention. The rewritable card printer 110 includes a print module 702 and one or more card magazines 704 a , 704 b , and 704 c that are mechanically coupled on a base 800 . The rewritable card printer includes a front bezel 802 through which a rewritable card 114 may be fed by the print module's print card drive 706 , either into or out of the rewritable card printer, as previously described. The plan view also illustrates a possible relative position of a security feature reading device 600 , a print head 604 , and an erase head 602 within the print module. Card magazine 704 a is positioned on the base such that the card magazine's magazine card drive 710 a may feed rewritable cards to and receive rewritable cards from the print module as previously described.
In the top view, additional positions for card magazines are illustrated. These additional card magazine positions may be used to mount one or more card magazines in various relationships to the print module as may be dictated by an existing printer bay in a host game. In one possible configuration, a card magazine 704 a is located to the side of the print module. In another configuration, two card magazines, 704 b and 704 c , are mounted such that the card magazines may feed and receive rewritable cards to and from each other as companions. As illustrated, card magazine 704 b is the primary card magazine and may feed cards into and receive cards from the print module. Card magazine 704 c is a secondary card magazine that may feed cards to and receive cards from the primary card magazine.
Card magazines configured so as to allow movement of cards between the card magazines are herein termed “companion” magazines. Companion card magazines may be used to move rewritable cards around such that individual rewritable cards may be identified and retrieved from storage. This is because a card magazine with a single magazine card drive may be used as a Last In First Out (LIFO) rewritable card “memory” where the last rewritable card placed into the card magazine will be the first rewritable card retrieved from the card magazine when a rewritable card is requested. Through the use of multiple magazine drives serving a single rewritable card storage location, different styles of rewritable card memories may be implemented such as a First In First Out (FIFO) memory.
Companion card magazines may also be used to store different kinds of rewritable cards for use by the rewritable card printer. For example, the rewritable cards may have different permanent graphics imprinted on them indicating different user affiliations such as affiliations to different loyalty reward programs. In this way, a user may “upgrade” their affiliations by inserting a first style of rewritable card into the rewritable card printer and exchange it for a second style of rewritable card.
FIG. 11 a is side elevation view of a rewritable card printer in accordance with an exemplary embodiment of the present invention. The rewritable card printer 110 includes a print module 702 and one or more card magazines 704 d and 704 e mechanically coupled to a base 800 . The rewritable card printer includes a front bezel 802 through which a rewritable card may be fed by the print module's print card drive 706 , either into or out of the rewritable card printer as previously described. Card magazine 704 d is positioned on the base such that the card magazine's magazine card drive 710 d may feed rewritable cards to and receive rewritable cards from the print module as previously described.
In the side view, an additional position for a card magazine is shown as card magazine 704 e located beneath card magazine 704 d . This position may be used to mount a card magazine as either a previously described primary or secondary card magazine. In addition, card magazine 704 e may be replaced by a larger card storage area for card magazine 704 d that extends through the base.
FIG. 11 b is side elevation view of a rewritable card charging and retrieval process in accordance with an exemplary embodiment of the present invention. The rewritable card printer 110 includes a print module 702 and a card magazine 704 mechanically coupled to a base 800 . The rewritable card printer includes a front bezel 802 through which a rewritable card may be fed by the print module's print card drive 706 , either into or out of the rewritable card printer as previously described. Card magazine 704 is positioned on the base such that the card magazine's magazine card drive 710 may feed rewritable cards to and receive rewritable cards from the print module as previously described.
A technician may use an external controller 730 electronically coupled to the rewritable card printer and to an external card magazine 1112 removable and mechanically coupled to the rewritable card printer to load rewritable cards into and retrieve cards, such as escrowed cards, from the rewritable card printer. This may be done without opening a cabinet in a game hosting the rewritable card printer. To load cards into the rewritable card printer, the technician couples the external controller and external card magazine to the rewritable card printer. The technician then uses the external controller to send a card load signal to the rewritable card printer and the external card magazine. In response to the card load signal, the external card magazine dispenses cards into the rewritable card printer print module. In response to the card load signal, the print module accepts the dispensed cards and forwards them to an appropriate internal card magazine in the rewritable card printer.
To retrieve cards from the rewritable card printer, the technician couples the external controller and external card magazine to the rewritable card printer. In response to the card retrieval signal, the rewritable card printer retrieves cards from the rewritable card printer's one or more internal card magazines and dispenses the cards using the printer module. In response to the card retrieval signal, the external card magazine receives the dispensed cards from the rewritable card printer and stores them.
Optionally, the external print controller may store the number of rewritable cards loaded into the rewritable card printer, an identification of each of the rewritable cards loaded into the rewritable card printer, and an identifier of the rewritable card printer.
To keep track of the rewritable cards held by the rewritable card printer, the rewritable card printer may receive from the external controller a rewritable card identifier for each card dispensed by the external card magazine. The rewritable card printer may also scan each rewritable card for its identifier as each rewritable card is dispensed into the rewritable card printer.
In one rewritable card printer in accordance with an exemplary embodiment of the present invention, the rewritable card printer's printer controller contains all of the program instructions necessary to perform card loading and retrieval operations. In this embodiment, the external card magazine couples electronically with the rewritable card printer's printer controller and the rewritable card printer's printer controller commands the external card magazine to dispense and receive cards. The external controller may also communicate directly to the host game 106 or the system host 102 .
An external controller may be implemented in a variety of different external devices. For example, the external controller may be a purpose-built controller. Other external controllers may be implemented in a programmable device such a Personal Digital Assistant (PDA) or a portable or “laptop” computer.
FIG. 11 c is a side elevation view of a rewritable card printer with a card magazine having two independent magazine card drives in accordance with an exemplary embodiment of the present invention. The rewritable card printer 110 includes a print module 702 and a card magazine 1100 mechanically coupled to a base 800 . The rewritable card printer includes a front bezel 802 through which a-rewritable card may be fed by the print module's print card drive 706 , either into or out of the rewritable card printer as previously described.
Card magazine 1100 includes a first magazine card drive 1102 and a second magazine card drive 1104 . The card is positioned on the base such that the card magazine's magazine card drives may feed rewritable cards, 114 a and 114 b , to and receive rewritable cards from the print module using the same card storage area 1106 . The first magazine card drive receives and dispenses cards from a first end 1108 of the card storage location. The second card magazine drive receives and dispenses cards from a second end 1110 of the card storage location. In this way, the card magazine may be used as a LIFO card storage device or a FIFO card storage device depending on whether two drives or one drive are employed. In addition, the magazine card drives may be used to store cards in the card storage location at an angle, such as at a 90 degree angle, relative to the orientation of the card while the card is being operated on by the printer module.
FIG. 11 d is a side elevation view of a card magazine having a plurality of card storage locations serviced by a single card magazine drive. A card magazine 1112 may have a plurality of card storage locations, such as card storage locations 1114 and 1116 . A single magazine card drive 1118 may service both card storage locations. In this way, a single card magazine may be used to shuffle cards to locate specific cards or rotate cards in storage to even out erase and write cycles performed on the cards.
FIG. 11 e is side elevation view of a rewritable card printer slidably coupled to a gaming machine in accordance with an exemplary embodiment of the present invention. The rewritable card printer 110 includes a print module 702 and a card magazine 704 mechanically coupled to a printer base 1150 .
The rewritable card printer includes a front bezel 802 through which a rewritable card may be fed by the print module's print card drive 706 , either into or out of the rewritable card printer as previously described. Card magazine 704 is positioned on the base such that the card magazine's magazine card drive 710 may feed rewritable cards 114 to and receive rewritable cards from the print module as previously described.
The printer base is further slidably coupled to a base plate 1152 that is fixedly coupled to a portion 1154 of a gaming machine hosting the printer. The rewritable card printer may be accessed while still in the gaming machine by sliding the rewritable card printer out of the gaming machine.
The card magazine may be mechanically coupled to the printer base by a quick disconnect 1156 so that the card magazine may be easily removed. To facilitate easy removal, the card magazine may be coupled to the printer controller 606 (of FIG. 7 a ) by a quick disconnect electrical connector 1157 that allows the card magazine to be installed, removed, or exchanged without removing the power to the gaming machine or rewritable card printer.
The print module may be mechanically coupled to the printer base by a quick disconnect 1158 so that the print module may be easily removed. To further facilitate easy removal, the print magazine may be coupled to the printer controller 606 (of FIG. 7 a ) by a quick disconnect electrical connector 1160 that allows the print module to be installed, removed, or exchanged without removing the power to the gaming machine or rewritable card printer.
In one embodiment of a card magazine, the card magazine is slidably coupled to the printer base separately from the print module. In this embodiment, the card magazine may accessed by sliding the card magazine past the print module so that the card magazine may be separately serviced.
FIG. 12 is a process flow diagram of a rewritable card printing process in accordance with an exemplary embodiment of the present invention. During a printing process 1200 , a rewritable card printer receives ( 1202 ) rewritable card information such as cash-out value or images to print onto the rewritable card. The rewritable card printer reads ( 1204 ) any security feature embedded in the rewritable card, storing the resultant security signature signal in temporary memory. The rewritable card printer generates ( 1206 ) indicia to print onto the rewritable card using the rewritable card values or images. Additionally, the rewritable card printer may incorporate all or a portion of security signature signal into the printed indicia as either a clearly readable value or an encoded value. The rewritable card printer then optionally erases ( 1208 ) the rewritable card and then prints the indicia onto the rewritable card prior to dispensing the rewritable card. The rewritable card printer may then transmit ( 1210 ) the security signature signal, either as an encoded value or as a clearly readable value, to a game host or cashless enabled system host.
FIG. 13 is a process flow diagram of a card escrowing process used by a rewritable card printer in accordance with an exemplary embodiment of the present invention. In a card escrowing process 1300 , a rewritable card printer determines if a card should be removed from service. A card may be removed from service for a variety of reasons. Rewritable cards have a finite number of erase and write cycles and so must be removed from service as they age. A card may become damaged so that it is no longer operable within rewritable card printer or the rewritable card's security feature is no longer readable. Cards may also have physical features such as embossing that may require the card to be handled in a special manner. As the rewritable card printer includes an optical scanner and can verify if a card was printed properly immediately after printing the card, the rewritable card printer may determine that a card was printed in error and may escrow the card. In addition, the rewritable card printer may receive an identifier for a rewritable card to be removed from service. In which case, the security feature in the rewritable card may be readable but correspond to a card to be removed from service. Another reason a card may be escrowed is that the user is exchanging one kind of rewritable card for another kind of rewritable card.
Cards may be removed from service by moving the card into an escrow location within the rewritable card printer by either a magazine card drive or by a print card drive. In the escrow process, the rewritable card determines ( 1302 ) if a card should be removed from service. If the rewritable card printer determines that the card should remain in service ( 1304 ), the rewritable card continues processing ( 1306 ) the rewritable card. Otherwise, the rewritable card printer moves ( 1306 ) the rewritable card to an escrow location 1307 within the rewritable card printer and obtains ( 1308 ) a replacement card from a card magazine 1310 and continues processing ( 1312 ) the newly obtained rewritable card.
FIG. 14 is a card retrieval process used by a rewritable card printer having companion magazines in accordance with an exemplary embodiment of the present invention. As noted previously, a card magazine having a single magazine card drive may be considered as being similar to a LIFO memory device. As previously noted, a rewritable printer controller may store information about cards stored in the card magazines. This information may include where in a card magazine a particular rewritable card is stored. In this case, a specific card stored in the card magazines may be retrieved using the following process. In a card retrieval process 1400 , a rewritable card printer receives a request for a specific rewritable card from an external host or a game controller. The rewritable card printer receives ( 1402 ) the request and determines ( 1404 ) where in the storage areas of the card magazines that the specific card is located using previously stored card information 704 . For the number of cards on top of the request card, the rewritable card moves (as indicated by loop structure 1406 , to 1410 ) all of the cards on top of the requested card into a companion card magazine's storage area 1409 . The rewritable card printer then dispenses ( 1412 ) the located card. Optionally, the rewritable card printer may replace all of the moved cards from the companion card magazine (as indicated by loop structure 1414 , 1416 , and 1418 ).
FIG. 15 is a process flow diagram of a card location process used by a rewritable card printer having multiple card magazines in accordance with an exemplary embodiment of the present invention. This card location process, 1500 , may be used when the rewritable card printer does not keep an accounting of each writeable card stored in the rewritable card printer's memory. The rewritable card printer receives ( 1502 ) an identifier for a card to be located. For each rewritable card stored by the rewritable card printer in a card magazine (as indicated by the loop structure 1504 to 1514 ), the rewritable card printer moves ( 1506 ) a rewritable card from a card magazine 1507 into a read portion of the print module 702 (of FIG. 7 ) and reads ( 1508 ) an identifier, such as a previously described security feature, from the rewritable card. The rewritable card printer then compares ( 1510 ) the read identifier to the received identifier. If the comparison indicates that the requested rewritable card is located, the rewritable card printer dispenses ( 1516 ) the located card. If the comparison indicates that the retrieved rewritable card is not the requested rewritable card, the rewritable card printer moves the card into a companion card magazine's storage location 1409 and continues processing rewritable card until either the requested card is located or the last of the stored rewritable cards is retrieved.
Optionally, the rewritable card printer may put all of the moved rewritable cards back into their original locations within a card magazine. For each of the moved cards (as indicated by the loop structure 1518 to 1522 ) the rewritable card printer retrieves ( 1520 ) a moved card out of the companion storage location and places it back into the card magazine 1507 .
FIG. 16 is a process flow diagram of a card replacement process in accordance with an exemplary embodiment of the present invention. A rewritable card printer may include two or more card magazines as previously discussed. This feature allows a gaming machine to be used for more sophisticated transactions than merely accepting wagers, playing games, and printing cash-out cards. Using multiple card magazines allows a gaming machine to also function as a customer service kiosk for several types of operations wherein a player may exchange one type of rewritable card for another during a transaction. An example of such a transaction is when a player wants to join a loyalty program.
In a card replacement process 1600 , a rewritable card printer receives ( 1602 ) a card from a user for imprinting.
The rewritable card printer moves ( 1604 ) the received card into a first card magazine 1606 for storage and possible reuse. The rewritable card printer then retrieves ( 1608 ) a replacement card from a second card magazine 1610 . The rewritable card printer continues processing ( 1612 ) the replacement card such as by printing on the card as previously described. The rewritable card printer dispenses ( 1614 ) the imprinted replacement card to the user whereby the user's original card has been replaced with another type of card.
Although this invention has been described in certain specific embodiments, many additional modifications and variations would be apparent to those skilled in the art. It is therefore to be understood that this invention may be practiced otherwise than as specifically described. Thus, the present embodiments of the invention should be considered in all respects as illustrative and not restrictive, the scope of the invention to be determined by any claims supported by this application and the claims' equivalents rather than the foregoing description.
FIG. 17 is a process flow diagram of a programming process using a rewritable card in accordance with an exemplary embodiment of the present invention. A rewritable card printer may use a rewritable card to load programming instructions into memory. The rewritable card may include programming instructions in a magnetic strip readable by the rewritable card's magnetic strip read/write head, or programming instructions may be included in the printed indicia on the card and read by an optical scanning device.
In a programming process 1700 , a rewritable card printer receives ( 1702 ) a card and determines ( 1704 ) if the card includes programming instructions. A rewritable card printer may make the determination by either scanning the card and parsing the information found on the card or may be signaled by an external device that the inserted card includes programming instructions. If the card does have programming instructions, the rewritable card printer reads ( 1706 ) the programming instructions and stores the programming instructions 113 in the rewritable card printer's memory 722 .
After reading the card, the rewritable card printer dispenses the card 724 . In addition to reading rewritable cards to obtain additional programming instructions, the rewritable card printer may receive programming instructions from an external device, such as external controller 730 (of FIG. 7 a ).
FIG. 18 is a process flow diagram of a card information storage process in accordance with an exemplary embodiment of the present invention. A rewritable card printer receives ( 1802 ) a card 1804 for storage into a card magazine. The rewritable card printer reads ( 1806 ) card information from the card. The card information may include the number of erase/write cycles that the card has gone through and the unique signature of the card. The rewritable card printer stores ( 1808 ) the card information in static memory 1810 . The static memory may be on the card itself, in a card magazine, or in a static memory location in the printer controller. Once the card information has been stored, the writable card printer erases ( 1812 ) the card and stores ( 1814 ) the erased card in a card magazine 1816 .
FIG. 19 is a process flow diagram of a card information retrieval process in accordance with an exemplary embodiment of the present invention. A card retrieval process 1900 is used by a rewritable card printer to initiate writing on to an erased card. The card's information, including information about how many read/write cycles the card has gone through, is stored in static memory 1810 as previously described. This enables a rewritable card printer to safely store rewritable cards in an erased mode and still track card usage in order to determine when a card should be removed from service.
The rewritable card printer retrieves ( 1902 ) a card from a card magazine 1816 . The rewritable card printer reads ( 1904 ) the cards signature and uses ( 1906 ) the card's signature to retrieve card information from the static memory. The rewritable card printer then continues ( 1908 ) processing the rewritable card using the retrieved card information. This may include incrementing the number of erase/write cycles that the card has gone through onto the card before dispensing the card. This processing may also include removing the card from service.
FIG. 20 is a stored card status printing process in accordance with an exemplary embodiment of the present invention. A rewritable card printer uses a stored card status printing process 2000 to report on a rewritable card the status of the rewritable card printer, game host, and rewritable cards stored by the rewritable card printer. The rewritable card printer receives 2002 a request for printing a status card. The in response to the request, the rewritable card printer retrieves ( 2004 ) a card from the card magazine 1816 . The rewritable card printer retrieves ( 2006 ) card information stored in static memory 1810 about the cards stored by the rewritable card printer. The rewritable card 20 printer then uses the card information to generate printable indicia for printing ( 2008 ) on the card and prints the indicia on the card before dispensing it.
Although this invention has been described in certain specific embodiments, many additional modifications and variations would be apparent to those skilled in the art. It is therefore to be understood that this invention may be practiced otherwise than as specifically described. Thus, the present embodiments of the invention should be considered in all respects as illustrative and not restrictive, the scope of the invention to be determined by any claims supported by this application and the claims' equivalents rather than the foregoing description.
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A machine having a card processing assembly. The card processing assembly has a card drive and a heating device. The heating device is operable to cause a human-readable symbol to be viewable on a data card.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image forming apparatus such as an electrophotographic copying machine.
2. Description of the Prior Art
In the image forming apparatus such as the electrophotographic copying machine, there is used a photosensitive member which is prepared by forming a photoconductive layer of selenium-tellurium or amorphous silicon on a conductive substrate, and there are repeated cycles each of which includes the steps of charging all over surface of the photosensitive member, subjecting the charged photoconductive member to an image forming exposure to form an electrostatic image, developing the electrostatic image with toner to convert it into a toner image, and transferring the toner image attained to a transfer material such as paper to attain an image record. After the transfer of the toner image, the photosensitive member is cleared for reuse by removing a residual toner by means of a cleaning means. However, the charges are still left on or in surface of the photosensitive member so that they have to be removed before the photosensitive member is used again.
In order to neutralize the charges on the surface of the photosensitive member, there is currently adopted a method of exposing all over the surface of the photosensitive member. If the exposures are repeated, however, there appears a phenomenon that the charged potential of the photosensitive member is dropped by the influences of the repetition of the whole-surface exposures.
In the electrophotographic copying machine of the prior art such as a copying machine using a photosensitive member of selenium-tellurium, this photosensitive member can have its charge generating layer of selenium-tellurium of a relatively large thickness (e.g., about 60 microns) so that it can be charged at a high level of 700 to 1,000 V. The refer, even with the drop (ΔV: usually equal to or lower than 70 V) of the charged potential during the repeated uses, the resultant changing rate of the charged potential is relatively low.
In the photosensitive member made of amorphous silicon (which will be shortly referred to as an "a-Si"), however, the a-Si charge generating layer to be formed is usually limited to a small thickness, e.g., 15 to 30 microns by the problems of its film forming technique or the mobility of the charge carriers (or shortly "carriers"). As a result, the potential to be able to charged (or shortly "charged potential") is about 300 to 600 V at the highest so that the changing rate of the charged potential is made liable to take a large value due to the dropping (ΔV) of the charged potential. In order to form an image of high quality, therefore, it is indispensable to hold the dynamic range of the developing bias wide for the development and to stabilize the charged potential during the repeated uses. Especially in the a-Si photosensitive member, moreover, it is necessary to consider countermeasures for preventing the phenomenon called the "ghost" which is based upon fatigues due to the optical irradiation. This ghost is a phenomenon that the fatigues of the photosensitive member are made locally different or advanced by the ununiformity of the optical irradiation to leave a negative or positive image even during a subsequent copy operation so that a desired image cannot be attained (for example, the aforementioned left image appears with a high density in a half-tone image).
Incidentally, there are present in the prior art a variety of techniques using the a-Si photosensitive member, all of which have failed to satisfy the aforementioned requirements. In Japanese Patent Laid-Open No. 58-62659, for example, there is disclosed a technique in which the photosensitive member is irradiated with a ray of short wavelength lower than 600 nm as an optical ray for exposures and/or charge neutralizations. However, we found that the ghost is made liable to occur by the wavelength component of 550 nm or shorter of that short-wavelength ray and that the wavelength component of 550 to 600 nm does not always improve the repetition characteristics (i.e., the changing rate of the charged potential for the repeated uses). In the above-specified Laid-Open, moreover, there is also disclosed a concept that the aforementioned ray may contain a component of the longer-wavelength than 600 nm having an energy distribution ratio of 30% or smaller. As tne ratio of the longer-wavelength component, is too small, it is impossible to expect improvements in the repetition characteristics.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an image forming apparatus such as an electrophotographic copying machine which can effectively realize both stabilization of the charged potential after repeated uses of a photoconductive member and prevention of ghosts.
The above-specified object is achieved by an image forming apparatus having an image forming cycle for obtaining a visible image by forming an electrostatic image on a photosensitive member of amorphous silicon and by developing said electrostatic image, comprising means for irradiating the whole surface of said photosensitive member for each said image forming cycle with an optical ray which contains a ray having a longer-wavelength than 600 nm but does hot relatively contain essentially a ray having a wavelength of 550 to 600 nm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing an essential portion of an apparatus to be used for measuring the charge potential of a photosensitive member;
FIG. 2 is a diagram showing the energy distributions of respective peak wavelengths;
FIG. 3 is a graph plotting the charged potential drops against the peak wavelength of used lamp relating to table-1; and
FIG. 4 is a schematic section showing an electrophotographic copying machine.
DETAILED DESCRIPTION OF THE INVENTION
First of all, the development, in which I have examined a variety of charge erasing light sources and have reached the present invention on the basis of the examined results.
FIG. 1 shows the essential portion of the apparatus which has been used for the tests. The apparatus is constructed such that a charge erasing light source 12, a corona charger 10 and a surface potentiometer 13 are arranged around a rotatable photo-sensitive drum 9 (e.g., the a-Si photosensitive member illustrated in FIG. 1 is as follows; Containing a hydrogen H.
The thickness of the layer thereof: 20±1 μm;
Charged potential: 740 V at 70 μA of charged current;
Residual potential: Not higher than 10 V;
White-light sensitivity: 0.3 Lux-sec. that is, a light-quantity requires for reducing a voltage from the initial 450 V down to one half; and
Dark-attenuation constant: 0.82 in a state 3 seconds after the initial stage of 450 V.) so that a reflected ray 14 from a document (although not shown) may be incident upon the drum 9 at the back of the charger 10.
Light emitting elements for emitting optical rays having wavelength distributions, as shown at A, B, C, D, D+D', and E (all of these lamps are fluorescent lamps made by TOSHIBA®) in FIG. 2, were used as the charge erasing light source, and the resultant effects were compared. The drum 9 was exposed by means of the respective lamps, and the exposures were repeated 100 times for each lamp. The drops (ΔV) in the charge potential of the photosensitive members before and after each repetition were obtained in accordance with the document density, as enumerated in the following Table-1. Incidentally, the initial potentials (V 0 ) were set at 500 V, 250 V and 50 V for the document densities 1.3, 0.3 and 0.0, respectively, and the emissions of the charge erasing lamps were set at 10 to 20 luxes second.
TABLE 1______________________________________ Charge Potential Drop ΔV (Potential Changing Rate ΔV/V.sub.0)Lamp Document DensityKind Peak Wavelength 1.3 0.3 0.0______________________________________A 570 nm -35 V -30 V -20 V(FL 2S-WWA) (7%) (12%) (40%)B 600 nm -85 V -85 V -15 V(FL 2S.Pk) (17%) (34%) (30%)C 630 nm -15 V -35 V -15 V (3%) (14%) (30%)D 650 nm -10 V -30 V -15 V (2%) (12%) (30%)D + D' 650 nm + 500 nm -5 V -30 V -5 V(FL 2S-BRF) (1%) (12%) (10%)E 680 nm -8 V -28 V -15 V (1.6%) (11.2%) (30%)______________________________________
As is apparent from the above results, it was found that the charge potential drop or changing rate for each document density was far lower, in case the rays (C, D and E) having a light of the wavelength >600 nm, especially, ≧630 nm were used, than in the case of the wavelength ≦600 nm, and that the values ΔV and ΔV/V 0 were far lower if the rays composed mainly of the ray (D) having a wavelength of 650 nm and the rays (having two wavelength components superposed) having two peaks and containing the ray (D') of wavelength 500 nm were used. In FIG. 3, the charge potential drops ΔV for the respective frequency components are plotted for each understanding. It will be understood in view of FIG. 3 that the aforementioned tendencies are prominent.
Moreover, the ray of the lamp B had its component of wavelength equal to shorter than 600 nm cut by means of a filter on the basis of the aforementioned results, and the charge erasures were conducted. It was then confirmed that the potential drops were remarkably reduced, as enumerated in the following Table- 2.
TABLE 2______________________________________ Charge Potential Drop ΔV (Potential Changing Rate ΔV/V.sub.0) Document Density 1.3 0.3 0.0______________________________________Lamp B -85 V -85 V -15 V (17%) (34%) (30%)Lamp B -15 V -45 V -15 V(wavelength lower than (3%) (18%) (30%)600 nm is cut)______________________________________
It was made apparent from the above results that the potential could be held stably during the repeated uses by using the ray having wavelength >600 nm as that for erasing the charges of the photosensitive member and that the more better results could be attained by using the ray having a wavelength <550 nm together with the ray having a wavelength >600 nm. As is apparent from FIG. 3, too, it was confirmed that the irradiation of the whole surface with the ray having a wavelength of 550 nm to 600 nm undesirably augmented the potential drop to a remarkably extent.
It is desirable to use the ray having a wavelength ≧630 nm, more preferably, ≧650 nm as the ray having a wavelength >600 nm. Since the a-Si photosensitive member has a high sensitivity in the neibourhood of 680 nm, moreover, the ray having the wavelength within the above-specified range is remarkably preferably for the charge erasure of the a-Si photosensitive member.
As the light source of the ray having the above-specified wavelength >600 nm, there can be used either a light emitting element having a narrow light emitting band such as a light emitting diode having a light emitting peak in the region >600 nm, or a light source in which a light emitting element having a wide light emitting band including a ray >600 nm such as an incandescent lamp is used with a filter for absorbing a ray having a wavelength ≦600 nm. As the light source containing the ray >600 nm and the ray <550 nm, on the other hand, there can be used together a light emitting element having a narrow light emitting band, which has a light emitting peak in a range >600 nm, and a light emitting element such as a light emitting diode which has a light emitting peak in a range <550 nm. Likewise, there may be used a light source in which a light emitting element such as the incandescent lamp having wide ranges >600 nm and <550 nm is used with a filter for absorbing a ray having a band of 550 nm to 600 nm. Alternatively, there can be used a single light emitting element which has light emitting peaks in the ranges >600 nm and <550 nm.
FIG. 4 shows an example of the electro-photographic copying machine according to the present invention, in which the photosensitive drum 9 having the a-Si photosensitive layer is built. In this copying machine 41, there are arranged in the upper portion of a cabinet 31 both a document table 43 for placing a document 42 thereon and a platen cover 44 for covering the document 42. Below the document table 43, there is so disposed an optical scanning carriage which is composed of a light source 45 and a first mirror unit 47 having a first reflecting mirror 46 that it can move linearly to the right and left of FIG. 4. A second mirror unit 20 for making constant the length of the optical path between the document scanning point and the photosensitive member is moved in accordance with the speed of the first mirror unit so that the reflected ray 14 from the document table 43 may be formed into a slit shape to enter the photosensitive drum 9 acting as the image carrier. Around the drum 9, there are arranged the corona charger 10, a developer 11 having a developing sleeve 2 therein, a transfer unit 52, a separating unit 53, a cleaning unit 54, and the whole-surface exposing light source 12 for the charge erasure. Sheets of copy paper 58 supplied from a paper supply box 55 through paper feed rollers 16 and 17 have the toner image of the drum 9 transferred thereto and are then fixed with the toner image by a fixing unit 59 until they are discharged to a tray 35. In the fixing unit 59, the copy paper developed is fixed while passing through a heating roll 23 having a heater 22 therein and a pressure roll 24.
As the whole-surface exposing light source 12, there is used the aforementioned light source for emitting the ray having the wavelength >600 nm or the wavelengths >600 nm and <550 nm according to the present invention.
By using the copying machine thus constructed, the electrophotographic process was actually executed to form the image while varying the ray of the whole-surface exposing light source together with the light source for comparisons. By observing the occurring status of the aforementioned ghosts, it was found, as enumerated in the following Table-3, that the occurrence of the ghosts was prominent in the case of the light source A having the peak wavelength of 570 nm and used for the comparison but was remarkably reduced in case the whole-surface exposure was conducted by using the light sources (B to E) having the wavelength >600 nm or the light sources (D+D') having the wavelengths >600 nm and <550 nm according to the present invention.
TABLE 3______________________________________ Peak Wavelengths of Light Sources A B C D D + D' E______________________________________Judgement of Ghost x ○ ⊚ ⊚ ⊚ ⊚______________________________________
In the above Table-3: symbol x designates that the ghosts are prominent; symbol O designates that the ghosts raise no practical problem; and symbol designates that the ghosts are hardly generated.
The foregoing results reveal that the use of the ray having the peak in the wavelength >600 nm, especially, ≧630 nm, preferably, ≧650 nm for the whole-surface exposure will be remarkably effective for the repeated uses and for the ghost prevention, and that better effects can be attained by using the ray having the peak in the aforementioned range >600 nm together with the ray having the peak in the range <550 nm. In case the rays having the wavelengths >600 nm and <550 nm are used together, it is desired that the energy ratio of the ray wavelength component [D] of not less than 600 nm of the rays emitted from lamp D and the ray wavelength component [D'] of not more than 550 nm of the rays emitted from lamp D' be expressed by 30 (%) <[D]/([D]+[D'])≦90 (%) (e.g., 67% in the aforementioned example).
The causes for the aforementioned results are thought to come from that, since the ray for the whole exposure is composed mainly of the longer-wavelength component ≧600 nm, especially the a-Si photosensitive member fatigues all over its surface so that its local fatigue is reduced.
In case the ray ≦550 nm is used together, it is also thought that the shorter-wavelength component is liable to be absorbed by the surface of the photosensitive member, because it has a high absorption coefficient, so that the actions of those two wavelength components are suitably multiplied.
Although the present invention has been exemplified hereinbefore, the aforementioned embodiment can be further modified in accordance with the technical concept of the present invention.
For example, any ray having two or more peaks in each range can be used if it has peaks in the wavelengths ≧600 nm and ≦550 nm, respectively. Moreover, the present invention can also be applied to another copying or recording machine such as an apparatus using a chromatic copying or screen photosenstive member.
In the image forming apparatus according to the present invention, as has been described hereinbefore, the fatigue of the photosensitive member can be reduced to realize safety of the charge potential for repeated uses and the prevention of the ghosts.
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An image forming apparatus and method having a series of cycles for obtaining a visible image by forming an electrostatic image on a photosensitive member of amorphous silicon and by developing the electrostatic image by irradiating the surface of the photosensitive member for each image forming cycle with a light having wavelength longer than 600 nm and containing substantially no rays having wavelengths of 550 to 600 nm.
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FIELD OF THE INVENTION
[0001] The invention generally relates to medical devices, and more particularly to a bite block assembly for an endotracheal tube.
BACKGROUND OF THE INVENTION
[0002] Endotracheal tubes, used in various medical procedures for delivering gas to a patient, generally consist of a long tube which may be inserted into a patient's mouth and down the trachea to provide an air supply to a patient. The use of an endotrachial tube ensures that the airway is not closed off and that air is able to reach the lungs. Typically, the tube is flexible and somewhat resilient in order to easily bend through the airway of a patient and not cause tissue damage. It is often desirable to incorporate a bite block with the tube, in order to prevent a patient from biting down on the tube. The bite block consists of a relatively rigid member having a hollow interior to which encircles the tube at its upper (inlet) end where the tube enters the patient's mouth. The bite block is inserted into the patient's mouth and is retained or positioned between the patient's teeth. This is particularly useful for certain patient population groups who may have only limited control over their biting reflex. A sufficiently hard bite on a tube can pinch or even rupture the tube, thereby critically interrupting the gas flow to the patient. In response to this problem, a bite block may be provided to surround or partially surround the tube, to resist such biting. For example, bite blocks are disclosed in U.S. Pat. No. 4,896,667 (Magnussen), U.S. Pat. No. 5,649,534 (Briggs, III), and the SMedic™ bite block sold by SouthMedic Incorporated.
[0003] When a bite block is used, it is critical that that it not become disengaged from the tube or that the tube slide within the block, since this can result in the block becoming dislodged or even in some cases sliding down a patient's trachea.
[0004] Endotracheal tubes are typically supplied in a range of sizes, and it is desirable to provide a bite block which is suitable for accommodating this range of sizes. For example, the SMedic system accommodates a range of generally conventional endotracheal tube sizes. One end of the endotrachial tube (the outlet end) is for insertion into the patients trachea, and the opposed end (the inlet end) is dimensioned for fitting a standard air supply tube.
[0005] While a typical bite block is dimensioned to accommodate even a relatively narrow endotracheal tube, slippage of the tube (especially a narrow tube) within the block can still occur. In order to prevent or reduce this, the bite block can be fastened to the tube by a tie strap. For this purpose, a tie strap may be fitted around the bite block and tube to cinch the tube and bite block together. However, especially when used with a smaller diameter endotracheal tube, it is still possible for slippage of the bite block to occur, in particular if the caregiver neglects to properly cinch the bite block to the endotrachial tube with the supplied strap, or in situations when the use of a strap is not practical. There is thus a need for an improved bite block that addresses at least some of the drawbacks within prior art devices.
[0006] Since endotracheal tubes are supplied in a range of sizes to accommodate different patient populations, some bite blocks such as the SMedic products are configured to accept a range of endotracheal tube sizes. This provides the convenience that one need only have on hand a single size of bite block, rather than a range of sizes capable of fitting a bite block. It is desirable to provide an improved bite block that securely fastens the endotrachial tube to the block while also accommodating a range of tube sizes.
SUMMARY OF THE INVENTION
[0007] According to one aspect, the invention relates to an improved bite block for an endotracheal tube. The bite block includes a body having opposed forward and rearward ends, both of which are open, and a hollow cavity extending between the ends to receive an endotrachial tube. The forward end of the body is for insertion into the mouth cavity of a patient, and the rearward end is for protruding from the patient's mouth and attachment to a gas supply tube. The bite block further comprises a tether to engage the endotracheal tube, consisting of a flexible arm protruding from the body rearwardly beyond the rearward end of the body. The arm terminates in a ring, configured to encircle the endotracheal tube so as to tether the bite block to the tube. The arm is configured to flex in an arc when the endotracheal tube is tethered to the bite block wherein the proximal end of the arm (adjacent to the bite block body) remains generally horizontal, curving towards a vertical position towards its distal end at the ring. It is preferable that the arm possesses sufficient resiliency such that the flexure of the arm about an arc imparts an angular bias to the ring when the ring is fitted over the endotrachial tube. This angular bias effectively engages the ring to the endotracheal tube by causing it to grip the tube. Preferably, the body comprises opposing inwardly curved walls that are generally C-shaped in section to define an essentially cylindrical internal cavity. The walls rise upwardly from a base and converge towards a central slot opposed to the base. The slot is defined by the spaced-apart opposed upper edges of the walls. The walls are suitably resilient to permit the user spread them outwardly with reasonable ease when an endotracheal tube is inserted into the interior of the bite block. The resiliency of the walls biases them together when a tube is engaged within the block, thereby gripping and frictionally engaging the tube.
[0008] According to one aspect, the arm and ring are substantially coplanar when the arm is unflexed, prior to assembly of the bite block to an endotracheal tube. The ring itself is planar, and is disposed on a plane parallel to the elongate axis of the body extending between the forward and rearward ends thereof. Preferable, the bite block includes a slot which extends laterally across a portion of the bite block for insertion of a tie strap for engaging the gas supply tube. The slot may be sized to fit a selected tie strap, or be sufficiently large to accommodate a range of conventional tie strap sizes.
[0009] The ring is preferably circular. However, other configurations are contemplated, such as multi-sided. The term “ring” as used herein is not limited to a circular ring, but includes and suitable configuration which serves the functions described herein.
[0010] According to another aspect, the invention relates to a combination or assembly of a bite block as described above, and an endotracheal tube dimensioned to fit into and be retained within said bite block. The endotracheal tube comprises an outlet end and an opposed inlet end for connection to a gas supply tube. The endotracheal tube may include a flange inboard from its inlet end. The combination may comprise a plurality of endotracheal tubes of varying sizes.
[0011] According to another aspect, the invention relates to a method of retaining a bite block as described herein to an endotracheal tube. The method includes the steps of:
engaging an endotracheal tube within the hollow interior of the bite block to protrude through the open ends of the bite block wherein an inlet end of said tube protrudes from said rearward end and an outlet end of said tube protrudes from said forward end; engaging the ring to the inlet end of said endotracheal tube; and engaging the endotracheal tube to a gas supply tube.
[0015] The above steps need not be performed in the order listed above, but may be carried out in any convenient order or sequence.
[0016] In the above method, it is preferable that the ring is initially disposed on a plane parallel to the elongate axis defined the forward and rearward ends of said bite block. Normally, this is a horizontal plane when the bite block is oriented with the slot facing upwardly and the body being disposed horizontally. The endotrachial tube is inserted into the hollow interior of the bite block such that the inlet end of the tube protrudes outwardly from the bite block. The ring is fitted over the protruding inlet end of the tube. Since the ring must normally be oriented such that its opening is generally aligned with the bite block, the arm is flexed about an arc of about 90 degrees as the ring is fitted over the tube.
[0017] After being engaged to the endotrachial tube, the ring is will tend to be initially disposed on the endotracheal tube at position somewhat displaced from the end of the bite block. In this position, the ring (which is typically larger in diameter than the endotracheal tube) is disposed at a slightly non-vertical angle. This angular displacement of the ring causes it to grip the bite block, thereby loosely holding the ring in position on the tube. This permits the ring to remain in position on the endotracheal tube without the caregiver having to hold it in place before the air supply tube is engaged to the endotrachial tube/bite block assembly. According to one aspect, the air supply tube is then fastened to the endotracheal tube by sliding the two tubes together with the air supply tube overlapping the endotrachial tube. This effectively urges the ring towards the bite block, and firmly retains the ring in position close to the bite block, protruding only minimally from the bite block.
[0018] The endotrachial tube may include a flange which is inwardly displaced from its inlet end, which provides a stop for the air supply tube and wherein the ring is lodged between the flange and the outlet end of the air supply tube. The flange also prevents the bite block from moving past the patient's lips.
[0019] The invention will now be further elucidated by reference to a detailed description of certain embodiments thereof. It will be appreciated that numerous variations and departures from the particulars described herein may be made while still remaining within the scope of the invention. The full scope of the invention is defined by this patent specification as a whole, including the claims. It will also be understood the strict compliance with the description of the invention presented herein may not be necessary, and those experienced in the art will appreciate that equivalent elements may be substituted for at least some of the elements described herein. As well, any references to particular dimensions and configurations are intended merely by way of illustration and are not intended to limit the invention. Any directional references herein, such as “forward”, “rearward”, “horizontal” etc. are intended only for ease of description, and refer to the device in a generally horizontal position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a side elevational view of a bite block and endotracheal tube assembly according to the present invention.
[0021] FIG. 2 is a plan view, from above, of a bite block according to the present invention, with a retainer strap engaged thereto.
[0022] FIG. 3 is a perspective view of a bite block and retainer strap.
[0023] FIG. 4 is a plan view, from above, of the bite block.
[0024] FIG. 5 is a side elevational view of the bite block.
[0025] FIG. 6 is an end view, from the front, of a bite block of the present invention.
[0026] FIG. 7 is an exploded view of a bite block according to the present invention, with an endotracheal tube and tie strap.
[0027] FIG. 8 is a perspective view of an assembled bite block, endotracheal tube and tie strap, prior to fastening of the gas supply tube with the endotracheal tube.
DETAILED DESCRIPTION
[0028] Turning to the figures, a bite block according to the present invention consists of a generally tubular body 10 , having opposed forward and rearward ends 12 and 16 respectively. When an endotracheal tube 20 is installed within the bite block, the forward end faces towards the outlet end 14 of the endotracheal tube 20 and the rearward end 16 faces the inlet end 18 of the endotracheal tube 20 . When inserted into the mouth of a patient, the forward end 12 of the bite block is inserted in the patient's mouth, while the rearward end 16 protrudes outwardly from the patient's teeth. The bite block is formed from a semi-rigid molded plastic such as PVC, TPU or TPE. The material is selected to provide sufficient resiliency to permit the walls of the body to flex so as to grip an endotracheal tube, as will be described below. As well, the body 10 should have sufficient resiliency and softness to provide adequate patient comfort.
[0029] As seen more particularly in FIGS. 4 , 5 and 6 , the body 10 comprises a pair of opposing curved side walls 15 . The side walls 15 when seen in section are generally C-shaped, and define an essentially cylindrical hollow space therebetween. At their upper edges, the walls 15 curve towards each other to define a slot 22 where their opposed upper edges face each other. The slot 22 extends lengthwise along the body 10 and communicates with the hollow interior of the body 10 . The slot 22 comprises a central portion 23 where the upper edges of the walls 15 are parallel to each other and spaced closely together. At the forward end 12 of the bite block, the upper edges of the walls 15 diverge to define a V-shaped diverging slot region 26 . At the opposed, reardward end of the body 10 the slot 22 defines a cutaway, downwardly stepped portion 32 . The walls 15 at the stepped portion 32 define an open trough-like configuration, wherein the top edges of the sidewalls 15 are widely spaced apart, as seen in FIGS. 4 , 5 and 6 . This can facilitate insertion of the endotracheal tube into the interior of the body.
[0030] An elongate keel 36 extends along the lower face of the body 10 and protrudes downwardly from the body. Preferably, the keel 36 extends the full length of the body 10 so as to provide additional bite resistance. However, it is also contemplated that the keel 36 extends only partway along the body 10 . A slot-like opening 38 extends through the keel in a direction transverse to the long axis of the body, adjacent to the rearward end 16 of the body 10 . The opening 38 is configured to accept an optional tie strap 40 (see FIGS. 3 , 7 and 8 ) for fastening the endotracheal tube 20 to the bite block 10 , as will be described below. The opening 38 is sized to accept a range of conventional tie straps.
[0031] The bite block 10 includes a tether 50 for retaining the endotracheal tube. The tether 50 serves to prevent inadvertent separation of the bite block 10 from the endotracheal tube 20 , in particular if the optional tie strap 40 is not used to fasten the tube 20 to the bite block 10 . The tether 50 protrudes rearwardly from the rear of the body 10 , as seen in FIGS. 4 and 5 . Preferably, the tether effectively forms a rearward extension of the keel 36 , and is molded together with the bite block body 10 as a single unit. The tether 50 includes an elongate arm 52 disposed along same axis as the keel 36 , namely an axis which is parallel to the elongate axis of the body 10 of the bite block. The arm 52 is linear and straight when unstressed and unflexed, that is, in its relaxed position with no external force applied to flex the arm. The arm comprises a resilient material and is dimensioned to provide a relatively high degree of flexibility and resiliency, whilst still maintaining sufficient strength to resist breakage with repeated use. It is also contemplated that the arm 52 may depart from a linear configuration when unstressed and unflexed, for example it may be arcuate when in its unbiased position.
[0032] The arm terminates in a circular ring 54 which is planar (flat) when seen in side view. As seen in FIGS. 4 and 5 , the long axis of the arm lies on the same plane as the ring. Preferably, the plane of the ring is horizontal when the bite block is disposed in a horizontal orientation as seen in FIG. 5 . It will be seen that the ring 54 need not be precisely planar nor need it be precisely aligned with the axis of the arm 52 . It is contemplated that slight departures from the configurations described herein may exist, although it is generally preferred that the ring be substantially planar and horizontal when the bite block is horizontally disposed. In this configuration, the bite block is reasonably easy to manufacture, transport, store and use.
[0033] The system further comprises the endotracheal tube 20 , as seen in FIGS. 1 and 7 . The endotracheal tube 20 is pliable and flexible, for insertion into a patient's air passageway without causing tissue damage and/or damage to the patient's teeth. It is contemplated that the endotracheal tube 20 is generally conventional in form and configuration, and multiple such tubes may be supplied having a range of dimensions or configurations. The endotracheal tube 20 comprises an outlet end 14 , for insertion into the patient's airway, and an opposed inlet end 18 for connection with an air supply tube 60 (see FIG. 7 ). The endotracheal tube 20 includes an outwardly protruding flange 62 adjacent to its inlet end 18 , and inwardly spaced from the inlet end 18 by about 2-4 cm. The flange 62 is suitably dimensioned to abut the patient's lip region, to block movement of the bite block when retained within the patient's mouth. The endotracheal tube 20 includes an attachment section 64 consisting a length of tube at its inlet end, outboard from the flange 62 , which has an outside diameter for frictionally engaging the air supply tube 60 , wherein the air supply tube may be slid over the section 64 . The attachment section 64 is of a size for fitting a standard air supply tube 60 .
[0034] In use, the endotracheal tube 20 is clipped into the interior of the bite block 10 prior to intubation into the patient. The bite block 10 is engaged to the tube 20 at a position adjacent to and inboard (towards the outlet end 14 ) from the flange 62 , as seen in FIG. 1 . For this step, there are several ways in which the endotracheal tube 20 may inserted in the bite block. For example, the tube 20 may be initially pressed into the diverging region of the slot 26 , thereby flexing the side walls 15 of the bite block 10 apart. The endotracheal tube 20 is then fully inserted into the of the interior bite block. Alternatively, the tube 20 may be threaded into the open rearward end of the bite block. The resiliency of the side walls 15 ensures a snug fit of the endotracheal tube, within a conventional range of sizes of such tubes, wherein the side walls 15 grip the tube 20 in a clamping engagement. In order to secure the bite block to the tube, the tie strap 40 is fitted through the slot, and cinched tightly around the tube. The strap 40 may be provided with the bite block 10 as part of a kit, and may consist of a generally conventional tie strap configured to fit through the slot 38 and around the bite block 10 and endotracheal tube 20 . The bite block 10 may be supplied with a pre-engaged retaining strap 40 , fitted within the slot 38 in an open position for fastening around the endotracheal tube when required.
[0035] It is contemplated that once the bite block 10 has been clipped to the endotracheal tube 20 , the block 10 may be anchored to the tube 20 with the tether 50 , and the tube 20 then engaged to an air supply tube. The caregiver may then insert the tube 20 into the patient's trachea. It is also possible to employ a different order of assembly, for example to assemble the bite block, anchor and air supply tube after insertion of the tube into the patient's trachea.
[0036] The step of anchoring the bite block 10 to the endotracheal tube 20 consists of engaging the tether 50 to the tube 20 , which may be done either before or after the step of clipping the tube 20 into the interior of the bite block 10 . In one approach, the assembly is initiated by fitting the ring 54 over the inlet end 18 of the tube 20 , as seen in FIG. 1 . In this position, the ring 54 is slid into a position adjacent to the flange 62 . The arm 52 is thereby caused to flex about a curvature of approximately ninety degrees. It is also possible to slide the tube 20 into the ring 54 before the tube 20 is clipped into the bite block 10 . Once the ring 54 is engaged to the tube 20 , and the tube 20 is clipped into the bite block, the flexure of the arm 52 imparts an angular bias to the ring 54 acting against the engaged tube 20 . Depending on the respective tube and ring diameters, the ring is more or less angled relative to the elongate axis of the tube, as seen in FIG. 1 . This angular biasing retains the ring in position on the tube such that the caregiver does not have to hold onto the ring to then fasten the air supply tube 60 to the attachment section 64 of the tube 20 . When the air supply tube is engaged to the endotrachial tube, the tether 50 is effectively pushed forwardly, towards the flange 62 , such that the tether 50 protrudes only minimally away from the patient's face. In practice (and with practice) the ring 54 may be fitted to the endotracheal tube 20 with one hand, which can be convenient if the user's other hand is gripping the bite block.
[0037] The gas supply tube 60 is frictionally engaged to the end portion 64 of the endotracheal tube 20 by fitting the tube 60 over the end portion 64 of the endotrachial tube to ensure a gas-tight and secure fit. It is also contemplated that other attachment means between these tubes may be provided. The ring 54 is interposed between the flange 62 and the gas supply tube 60 , thereby retaining the ring in position on the endotracheal tube 20 . Once thus configured, the endotrachial tube and bite block assembly may be inserted into the patient's trachea (if this has not already been done) and the gas supply turned on.
[0038] Although the present invention has been described above in part by reference to detailed embodiments and other aspects, it will be understood that the full scope of the invention is not limited to the particulars described above. The full scope of the invention may be better appreciated by the present specifications and claims as a whole, including mechanical and/or structural equivalents of and to elements described herein.
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A bite block for an endotrachial tube includes a hollow body extending between open ends to receive an endotrachial tube such that opposing ends of the tube protrude through the open ends of the bite block. The bite block includes a tether to retain the bite block to the tube to prevent unwanted separation or movement of the tube within the bite block. The tether consists of a flexible arm which protrudes rearwardly from the bite block towards the inlet end of the tube and terminates in a ring configured to encircle the endotrachial tube, thereby effectively tethering the bite block to the tube. The arm and ring are configured such that the arm flexes in an arc when tethering the tube, thereby permitting the ring to engage the tube when fitted to thereto.
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BACKGROUND OF THE INVENTION
This invention relates to cementing of liners in wellbores, and more specifically to an improved method of cleaning a cement plug from the top of a liner after it has been cemented in place.
In the drilling of oil and gas wells, it is common to place one or more casing strings in the wellbore extending downward from the surface. These casing strings are typically held in place by cement placed between the borehole wall and the exterior of the casing string(s).
In many cases, a "liner" is run into the uncased portion of a wellbore. A liner is a truncated section of casing that is used to case open hole below a previously set casing string. The liner extends from the bottom of the open hole section and overlaps up into the previously set casing string. The overlap can range from 100 feet to 500 feet. Liners are usually suspended from the previously set casing string by means of a liner hanger/packer assembly. The liner is cemented in place to create a bond between the pipe and the formation. In cementing the liner, typically the cement is pumped down to the liner and through a running-in tool, followed by a displacement fluid that forces the cement into the annulus between the borehole wall and the liner, and into the overlap between the liner and the previously set casing string, and above the running-in tool. After removing the running-in tool, it is common to end up with a cement "plug" in the lower casing above the top of the liner that has to be drilled out before the well can be placed on production. A further complication is that part of the cement plug, before it sets, settles into the top portion of the liner, and must also be drilled out. Normal cleanout practice is to drill out the cement plug above the liner top with a large diameter bit, and then replace the bit with a smaller one and drill out the plug in the top of the liner. This obviously requires a time consuming "round trip" of the drill pipe in order to change the drill bit.
SUMMARY OF THE INVENTION
In accordance with the present invention, the need for a round trip of the drill pipe is eliminated by using a drill bit having extendible cutting elements that can drill the larger diameter casing plug when the extendible elements are set in the extended position, and that can drill the plug from the liner interior when the extendible elements are set in the retracted position.
The broad concept of a drill bit having remotely extendible cutting elements is not new, and is shown, for example, in U.S. Pat. Nos. 3,126,065 and 3,289,760 to Chadderdon and Kammerer, respectively.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1-6 are a series of views the progression of steps involved in carrying out the process of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention will be described having reference to the several views of the drawings, but it will be understood that certain elements as shown in the drawings are representative of more complex, but presently available, hardware. For example, the liner hangar/packer setting tool and the drill bit with extendible cutting elements are not depicted in detail, and the well as shown indicates only a single casing string, whereas the invention is equally applicable for a well having multiple casing strings.
The essence of this invention lies in the procedure as described below, and not in the particular hardware involved.
The setting for the process of the invention is shown in FIG. 1, which shows a casing 10 surrounded by cement 12 in a wellbore. An open hole portion 14 of the wellbore extends below casing 10, and contains a liner 16 which extends from near the bottom of the open hole portion up into the lower portion of casing 10. Liner 16 is supported by pipe string 18, and a liner hanger/packer assembly 20 is attached to the upper end of liner 16 to hold the liner in place when the hangar is set. A liner hangar/packer setting tool 22 is shown schematically at the juncture of liner 16 and pipe string 18.
Liner 16 must be secured in place prior to completing and producing the well. This procedure is illustrated in FIGS. 2-4, where a cement slurry shown being pumped down through the liner interior and into the annulus between the open hole section and the liner exterior. A displacement fluid 26 pumped through pipe string 18 provides a cement/fluid interface 28, which in actual practice usually involves use of plug wiper systems (not shown) to provide better control of the cementing operation.
As shown in FIG. 3, pumping of displacement fluid 26 is stopped when cement/fluid interface 28 reaches the bottom of liner 16, at which point a considerable amount of cement slurry extends above the top of liner 16. At this point in the procedure, liner hangar/packer 20 is set via operation of setting tool 22, and setting tool 22 is released from liner 16.
As shown in FIG. 4, pipe string 18 with setting tool 22 is pulled upward out of the still unset cement slurry, a which point some of the slurry above the liner top settles down into the top of liner 16.
Moving now to FIG. 5, after a suitable waiting period in which the cement slurry sets up, a drill bit 30 including extendible cutting elements 34 above the leading cutting surface 35 is lowered on drill string 32. Extendible cutting elements 34 are initially positioned by fluid pressure, mechanical action or other operating system in the extended position where they contact the outer annulus of cement not removed by the lower part of bit 30. These cutting elements, in addition to cutting the cement, effect a scraping or cleaning action on the interior of casing 10.
Moving to FIG. 6, after drilling down to the top of liner 16, cutting elements 34 are retracted by remote operation so that the bit can drill down through liner 16 without the need to remove drillstring 32 to change to a smaller diameter bit. Once they are inside liner 16, cutting elements 34 can be extended slightly to clean out any cement remaining on the liner wall after passage of the lower portion of bit 30.
After the cement plug is completely drilled out, bit 30 is retrieved, and normal completion operations can be carried out.
The procedure as described above eliminates the need for "tripping" the drill string to change bits, and results in an improved liner clean out procedure.
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A procedure for drilling out a cement plug from a liner top using a drill bit with extendible cutting elements to avoid the need for changing bits during the procedure.
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TECHNICAL FIELD
[0001] The invention relates to methods of optical communication and optical communication systems.
BACKGROUND OF THE INVENTION
[0002] The amount of information communicated within networks, such as voice and data networks, has increased dramatically in recent years. Accordingly, such has resulted in demands for increased bandwidth in networks to communicate more information at increased rates of data transfer. As the demands for bandwidth of data communications continues to increase, improved devices and methodologies to accommodate the demands are desired.
[0003] One example of data transmission technology uses low power, high data rate and wavelength division multiplexing to achieve high bit rate data transmission. An exemplary implementation utilizes a relatively large number of optical sources at different wavelengths. However, such configurations can be relatively difficult to fabricate and relatively expensive to package.
[0004] Another solution has been to directly modulate light sources, such as laser diodes. However, the rate of modulation within such systems is less than desirable to accommodate the increasing bandwidth demands.
[0005] More specifically, conventional fiber optic communications systems typically rely on a separate source for each optical wavelength used in a wavelength division multiplexed system. However, as more and more optical wavelengths are used, larger numbers of active devices must be packaged in transmitter modules. Removing the heat from these devices constrains the package design and complicates the ability to inject high speed data signals into the devices. Also, since the optical sources are typically laser diodes, the performance of the sources varies significantly over temperature. In addition, data is encoded on each optical signal by modulation of the optical intensity at that wavelength.
[0006] Accordingly, there exists a need for an improved approach to generating frequency multiplexed optical signals.
SUMMARY OF THE INVENTION
[0007] Aspects of the present invention provide for multiplexing individually modulated components of a source light. A broad-spectrum light source provides the source light; an optical divider divides the source light into plural carrier beams. A multi-channel modulator modulates each carrier beam responsive to a respective data signal to yield a respective encoded beam. An optical combiner multiplexes the encoded beams. The optical combiner can also inject the multiplexed signal into a communication medium for reception elsewhere.
[0008] According to a realization of the present invention, the optical combiner frequency multiplexes the encoded beams. To this end, the encoded beams can have different wavelengths. The differences in wavelengths can be imposed originally by an optical divider as it generates carrier beams having different wavelengths. Alternatively, the carrier wavelengths need not differ; instead, the modulator itself causes the encoded beams to have different wavelengths.
[0009] According to additional exemplary aspects, optical modulators pass a desired portion of a received optical signal having at least one predefined wavelength. The modulators optically modulate the desired portion of the optical signal having the at least one predefined wavelength responsive to a respective data signal.
[0010] Additional aspects of the invention disclose methods which include passing a plurality of desired portions of an optical signal using a plurality of respective optical modulators. The desired portions of the signal individually have at least one predefined wavelength. The method also includes optically modulating the desired portions of the optical signal using the respective optical modulators responsive to data signals. In one exemplary implementation, the optically modulating is implemented using frequency modulation.
[0011] As is apparent from the foregoing, the present invention has both method and structural aspects. By using a single broadband light source for the multiple components of a multiplexed signal, the present invention overcomes many of the problems faced by prior art systems that use multiple light sources. It much easier and more cost-effective to manufacture a single broad-spectrum light source than multiple single-frequency light sources. Furthermore, more channels can be implemented without encountering heat-dissipation limits. Also, since the light source is not modulated, switching speed limitations associated with modulating a light source directly are not encountered. More specifically, aspects of the invention disclose arrangements and methodologies wherein signal bandwidths are limited by the response of the modulator which can be much faster than the bandwidth of a laser. Certain embodiments of the invention provide other advantages in addition to or in lieu of the advantages described above, as is apparent from the description below with reference to the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Preferred embodiments of the invention are described below with reference to the following accompanying drawings depicting examples embodying the best mode for practicing the invention.
[0013] [0013]FIG. 1 is a functional block diagram of an exemplary optical communication system.
[0014] [0014]FIG. 2 is an illustrative representation of one exemplary implementation of the optical communication system depicted in FIG. 1.
[0015] [0015]FIG. 3 is a top view of an array of exemplary optical modulators.
[0016] [0016]FIG. 4 is a cross-sectional view of the array shown in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Referring to FIG. 1, an exemplary optical communication system 10 is illustrated. The depicted optical communication system 10 includes one or more data source 12 , a light source 20 , an optical divider 22 , an optical modulator array 24 and an optical combiner 26 . Light source 20 , optical divider 22 , optical modulator array 24 , optical combiner 26 and optical communication medium 28 are optically coupled with one another.
[0018] Light source 20 is configured as a broad spectrum optical source in the described exemplary embodiment. For example, light source 20 is configured as an edge emitting light emitting diode (EELED) configured to emit a broad spectrum optical signal 21 , also referred to as a source-light beam, having a plurality of wavelengths. In the described exemplary arrangement, broad spectrum optical signal 21 is approximately 200 nm wide. Other configurations of light source 20 configured to emit other optical signals are possible.
[0019] The light of broad spectrum optical signal 21 is provided to an optical divider 22 . Optical divider 22 divides the light of the broad spectrum optical signal 21 into a plurality of optical signals 23 , also referred to as carrier light-beams. In exemplary arrangements, optical divider 22 is configured as a beam splitter, array waveguide (AWG), prism or other wavelength dispersive element.
[0020] Optical signals 23 outputted from optical divider 22 have respective different portions or segments of the wavelength spectrum of broad spectrum optical signal 21 . In one exemplary arrangement, optical signals 23 individually comprise a portion of optical signal 21 having one or more respective different wavelength than the other optical signals 23 as determined by optical divider 22 .
[0021] According to aspects of the invention, the number of channels within optical communication system 10 is determined by the number of optical signals 23 outputted from optical divider 22 . According to one exemplary embodiment of the present invention, individual channels correspond to respective different wavelengths of optical signal 21 . The number of optical signals 23 generated by optical divider 22 may be varied according to the desired implementation of optical communication system 10 .
[0022] Optical modulator array 24 comprises a plurality of optical modulators (exemplary optical modulators are described below with respect to references 34 , 34 a, 34 b, 34 c illustrated in FIGS. 3 and 4). Such optical modulators within array 24 are individually configured to pass a desired portion of the optical signal 21 and to optically modulate the desired portion of the optical signal 21 for encoding data thereon. In the embodiment illustrated in FIG. 1, desired portions of optical signal 21 correspond to respective optical signals 23 as described in further detail below.
[0023] According to aspects of the present invention, optical modulators of array 24 are configured to implement frequency modulation of the respective desired portions of optical signal 21 . Alternatively, amplitude modulation or other modulation schemes may be utilized to encode data upon the portions 23 of optical signal 21 .
[0024] Depending upon the configuration of optical communication system 10 shown in FIG. 1 or provided in other arrangements, optical modulators of array 24 also operate to filter undesired portions of optical signal 21 or optical signals 23 . Individual optical modulators of optical modulator array 24 have passbands configured to pass and to modulate light within a desired portion (passing light having one or more predefined wavelength) and to filter light within undesired portions (at other wavelengths outside of the respective passbands of the optical modulators). For example, optical modulators of optical modulator array 24 are individually configured to pass and modulate a portion of optical signal 21 within the respective passband and to not pass or modulate portions of optical signal 21 outside of the respective passband. In an exemplary arrangement, one or more of the optical modulators is configured to pass one or more wavelength of light different than at least one wavelength of light passed by the others of the optical modulators.
[0025] The optical modulators of array 24 are configured to provide appropriate spacing of the desired portions of optical signal 21 from one another. Passbands of the optical modulators are separated by appropriate guard bands to avoid cross-talk or other interference between channels in one embodiment.
[0026] In the described optical communication system 10 depicted in FIG. 1, optical signals 23 are provided to respective optical modulators of modulator array 24 . Desired portions of the optical signal 21 to be passed and modulated within the respective optical modulators may be substantially provided as respective optical signals 23 as determined within divider 22 and corresponding to the respective passbands of the optical modulators leaving minimal or no filtering of light of the optical signals 23 . In such an arrangement, optical divider 22 is configured to divide the optical signal 21 into optical signals 23 substantially comprising the desired portions having wavelengths of light corresponding to the passbands of the respective optical modulators. Alternatively, filtering of light from individual optical signals 23 is implemented by the optical modulators to remove undesired light from optical signals 23 . Optical signals modulated and outputted from modulator array 24 have reference 25 in FIG. 1.
[0027] In an alternative implementation of optical communication system 10 , divider 22 provides no wavelength division but rather divides optical signal 21 into optical signals 23 which individually have substantially the same wavelength spectrum as signal 21 . Accordingly, optical signals 23 comprise broad spectrum signals in such an embodiment. Optical modulators of array 24 filter and modulate the broad spectrum signals 23 providing optical signals 25 as described above. In such an arrangement, the optical modulators are configured to filter undesired portions of optical signals 23 outside of the respective passbands of the optical modulators and to pass and to modulate the respective desired portions of optical signals 23 .
[0028] Data source(s) 12 are configured to provide a plurality of data signals 13 containing information to be communicated within optical communication system 10 . Data source(s) 12 are arranged in the described embodiment to provide a plurality of data signals 13 corresponding to the channels within optical communication system 10 . For example, the number of data signals 13 corresponds to the number of optical signals 23 , 25 within optical communication system 10 . The data signals 13 are utilized to modulate the desired portions of optical signal 21 to form optical signals 25 . At any given time, one or more of the channels may not be utilized. Other embodiments are possible.
[0029] Data source 12 outputs the data signals 13 comprising electrical signals. Exemplary data signals 13 individually have a frequency utilized to control modulation of desired portions of the optical signal 21 using optical modulators of array 24 . Exemplary data signals 13 have MHz or GHz frequencies, with the higher frequencies, such as 1-100 GHz for example, providing increased bandwidth compared with the lower frequency signals.
[0030] The optical modulators of array 24 have respective filter frequencies. The filter frequencies of the optical modulators of array 24 are different in one exemplary embodiment to provide different communication channels of optical communication systems 10 . The passbands of the respective optical modulators of array 24 are designed to be electronically tunable as described below. Accordingly, data signals 13 are utilized to control the electronic tuning of the respective optical modulators 34 to encode the data upon the respective desired portions of optical signal 21 by modulating the filter frequencies and passbands of the respective optical modulators 34 at the data rates of data signals 13 .
[0031] Modulator array 24 outputs the plurality of modulated desired portions as optical signals 25 , also referred to as encoded light-beams, to combiner 26 . Combiner 26 is configured to receive the desired modulated optical signals 25 and to combine such signals 25 into an optical signal 27 , also referred to as a multiplexed-light beam in at least one embodiment, for communication using optical communication medium 28 . In one configuration, combiner 26 is configured to frequency multiplex signals 25 to combine signals 25 .
[0032] Optical communication medium 28 is implemented in any desired configuration configured to communicate one or more optical signal. Exemplary optical communication media include an optical waveguide comprising one or more optical fiber, air or other appropriate optical transmission medium.
[0033] Other arrangements of optical communication system are possible in addition to those described with reference to FIG. 1.
[0034] Referring to FIG. 2, one exemplary implementation of optical communication system 10 of FIG. 1 is depicted. Light source 20 is configured as an edge emitting light emitting diode 30 coupled with optical divider 22 implemented as an array waveguide 32 . Optical modulator array 24 is coupled with array waveguide 30 . Although not shown in FIG. 2, data source 12 supplies desired data signals to optical modulator array 24 . Optical combiner 26 is coupled intermediate optical modulator array 24 and optical communication medium 28 . Optical communication medium 28 is implemented as a single optical fiber 28 configured to communicate the modulated desired portions of optical signal 21 outputted from array 24 and combined in combiner 26 .
[0035] Decoding of communication data can be accomplished by one or more standard technique. For example, one decoding technique includes demultiplexing the optical signals at different wavelengths into separate channels and then converting frequency modulation to intensity modulation which can be monitored with an optical detector. Other decoding arrangements may be used.
[0036] Referring to FIGS. 3 and 4, an exemplary configuration of optical modulator array 24 is depicted. Modulator 24 comprises a plurality of modulators 34 , 34 a, 34 b, 34 c in the depicted embodiment corresponding to four communication channels within optical communication system 10 . More or less channels are provided according to other optical communication systems and methodologies of the present invention.
[0037] The depicted modulators 34 , 34 a, 34 b, 34 c are configured as Fabry-Perot cavities in the described embodiment. Modulators 34 , 34 a, 34 b, 34 c are tuned to one or more respective wavelength (i.e., passbands) and are configured to modulate desired portions of optical signal 21 having the respective wavelengths. As described above, modulators 34 , 34 a, 34 b, 34 c pass and modulate portions of optical signal 21 within the respective passbands of the modulators. If wavelengths of light outside of the respective pass bands are provided to modulators 34 , 34 a, 34 b, 34 c , such light is filtered and not passed according to the exemplary arrangement.
[0038] Individual modulators 34 , 34 a, 34 b, 34 c include a respective one of cavities 42 , 42 a, 42 b, 42 c, electrodes 44 , 46 , insulators 48 and mirrors 50 as shown. Modulators 34 , 34 a, 34 b, 34 c are provided upon a substrate 40 which is transparent to wavelengths of light to be communicated within optical communication system 10 in the described exemplary embodiment. An exemplary substrate 40 comprises silicon. Insulators 48 are provided intermediate electrodes 46 and cavities 42 , 42 a, 42 b, 42 c as illustrated and comprise silicon in one example.
[0039] Referring specifically to FIG. 4, mirrors 50 are provided upon upper and lower portions of respective cavities 42 , 42 a, 42 b, 42 c. Exemplary mirrors 50 in one instance comprise high reflectivity mirrors, such as Bragg mirrors, comprising two or more even number of layers of transparent material having different refractive indices, such as silicon dioxide, titanium oxide or silicon nitride, for example.
[0040] In the described embodiment, light from optical signal 21 is received within the upper surfaces of cavities 42 , 42 a, 42 b, 42 c and passed through the lower surfaces of the respective cavities and through substrate 40 for application to combiner 26 illustrated in FIG. 1.
[0041] Respective data signals 13 (not shown in FIGS. 3 and 4) are provided to electrodes 44 , 46 to electronically tune respective cavities 42 , 42 a, 42 b, 42 c. Optical path lengths of the modulators 34 , 34 a, 34 b, 34 c dictate the frequencies of the respective passbands of the respective modulators. The optical path lengths of modulators 34 , 34 a, 34 b, 34 c, are defined by the physical length and refractive indices of cavities 42 , 42 a, 42 b, 42 c. Varying the physical length and/or refractive indices varies the passband of the respective modulator 34 , 34 a, 34 b, 34 c.
[0042] In the described exemplary embodiment, the respective cavities 42 , 42 a, 42 b, 42 c have different physical lengths, as illustrated, tuned to the desired portions of optical signal 21 to be passed and modulated. In the described embodiment, cavities 42 , 42 a, 42 b, 42 c contain a material having a relatively high electrooptic coefficient. Exemplary materials include electrically controllable birefringent material, such as lithiumniobate, barbarium titanate or other materials including polymer materials having high electro-optic coefficients. Cavities 42 , 42 a, 42 b, 42 c contain the same or different birefringent material depending upon the configuration of array 24 and frequencies of light to be modulated.
[0043] The material(s) within cavities 42 , 42 a, 42 b, 42 c may be varied to further tune optical modulators 32 , 32 a, 32 b, 32 c to the desired passbands. In such an arrangement, the physical length of cavities 42 , 42 a, 42 b, 42 may be held constant or varied depending upon the desired configuration and desired passbands. In general, the effective cavity length may be shorter if distributed Bragg mirrors are utilized as mirrors 50 inasmuch as mirror thickness can be a reasonable fraction of overall cavity length.
[0044] Data signals 13 applied to the electrodes 44 , 46 vary the refractive indices of the birefringent material in cavities 42 , 42 a, 42 b, 42 c providing modulation of the filter frequencies of modulators 34 , 34 a, 34 b, 34 c and modulation of the desired portions of optical signal 21 passing therethrough. The wavelengths or frequencies of the desired portions of the optical signal 21 are modulated within modulators 34 , 34 a, 34 b, 34 c responsive to the varying of the refractive indices of materials within cavities 42 , 42 a, 42 b, 42 c.
[0045] As described, the present invention provides improved devices and methods for encoding data on an optical signal. In one example of the invention, frequency modulation obtained by modulation of a filter illuminated with a broadband source provides signal bandwidths which are limited by the response of the tunable filter which can be much faster than the bandwidth of a laser which is limited by capacitance and carrier dynamics. Accordingly, aspects of the invention provide usage of a bright, broad spectrum incoherent optical source together with high speed tunable filters to achieve high data rate transmission over a broad range of operating temperatures. Other aspects are provided as described above.
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Methods of optical communication and optical communication systems are described. According to a first aspect, a method of optical communication includes providing an optical signal and providing a plurality of data signals. This aspect also includes passing a plurality of desired portions of the optical signal using a plurality of respective optical modulators, the desired portions individually having at least one predefined wavelength. The method also includes optically modulating the desired portions of the optical signal using the respective optical modulators and responsive to respective ones of the data signals and outputting the desired portions of the optical signal to an optical communication medium after the modulating.
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The Government of the United States of America has rights in this invention pursuant to Contract No. DE-AC05-780R03054, (as modified) awarded by the U.S. Department of Energy.
CROSS-RELATED APPLICATIONS
This application is a continuation-in-part of Ser. No. 543,201, filed Oct. 19, 1983, now abandoned all of the teachings of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
This invention relates to a process for the liquefaction of carbonaceous solid fuels, particularly coals, enhanced with respect to the production of asphaltene-rich solvent refined coal wherein the recycle stream passed back to the slurry mix tank contains a predominant amount of preasphaltenes and solid residue in the near or relative near absence of asphaltenes to mitigate the amount of total hydrogen consumed in the process.
This process is directed to the liquefaction of a coal material to prepare, as a product of the process, an asphaltene-rich solvent refined coal, which may be hydrotreated to different products. Many such processes have been directed to such solvent refinement of coal in the presence of a hydrogen donor. This process is different from the prior art in re the type and content of the recycle stream passed from a solvent deashing zone to the slurry mix tank. This recycle stream is a predominant preasphaltene and solid residue stream, which is antithetical to the prior art which normally transfers in the recycle stream from a critical solvent deashing zone either asphaltenes, or hydrotreated asphaltenes with distillate product in admixture therewith, to the slurry mix tank. In such a liquefaction process the heating and the liquefaction of the coal yields light gases and a slurry which is further processed by vacuum distillation to produce a light distillate product, a recycle solvent, and a heavy fraction having residual solvent, dissolved coal products, undissolved minerals and ash materials plus unconverted coal macerals.
PRIOR ART
It is well known that coal liquefaction product separation may be achieved by subjecting the vacuum still bottoms to a deashing process. One such technique is referred to as "critical solvent deashing." Such a process is disclosed in U.S. Pat. No. 4,070,268. As indicated in that patent, the products of the critical solvent deashing process include a stream which is rich in coal products, soluble in pyridine, benzene, or toluene, but which is essentially free of ash and unconverted particulate coal. A bottom stream is also produced which includes insoluble coal products and ash. Finally, an overhead stream of distillate is produced which is recycled as solvent in the deashing process.
As shown by U.S. Pat. No. 4,164,466, the solvent deashing stage often comprises several separation zones, each maintained at successively higher pressures and at high temperatures. This patent also discloses a process wherein the underflow stream of the second zone in the deashing stage is recycled to the entry mixing zone in the deashing stage.
In the process disclosed in U.S. Pat. No. 4,189,372, a portion of the underflow from the third and fourth separators is hydrogenated and recycled to the coal liquefaction slurry tank. Substantially all other intermediate streams from the second through the fourth separators are recycled to the entry mixing zone of the solvent deashing stage as in the '466 patent.
In U.S. Pat. No. 4,119,523, the underflow from the first separator in the solvent deashing stage is extracted to separate the resulting ash and undissolved coal, and the remaining extract recycled to the coal liquefaction stage.
U.S. Pat. No. 4,230,556 discloses the recycling of separator bottoms from immediately downstream of the coal liquefaction reactor. It is known that recycle of a mineral-containing stream to the slurry mix zone enhances the conversion of normally solid dissolved coal in the liquefaction reactor.
U.S. Pat. Nos. 4,377,464 and 4,338,182 describe liquefaction processes wherein a solid residue material is withdrawn from a vacuum distillation zone. If these disclosures were combined with U.S. Pat. No. 4,070,268 they would result in a process tantamount to the flow scheme shown in instant FIG. 1 from the coal in conduit 4 through the supercritical extraction performed in supercritical extraction unit 45. However, the recycle in these two coal liquefaction processes is very different from that recycled in this invention.
U.S. Pat. No. 4,251,346 utilizes a supercritical separator to remove unreacted material and ash residue from the liquefaction process. This exorcism is shown in conduit 4 of FIG. 1 or conduit 13 of FIG. 2. After a downstream distillation from the supercritical separator, a composite recycle stream is formed of distillates and all of the heavy material that boils above 450° C. egressing from the bottom of the distillation column. This recycle stream will contain both asphaltene and preasphaltene materials alike in addition to the distillate obtained in the 100° to 200° C. range. This disclosure lacks any supercritical extraction downstream of the fractionation unit to treat the residual bottoms, i.e. conduit 9 of FIG. 1 and conduit 12 of FIG. 2, and does not separate any asphaltene from preasphaltene materials before recycle. The product sought in '346 is gasoline and crude distillate oil products in deference to the asphaltene product sought in this invention.
In U.S. Pat. No. 4,334,977 a middle distillate material is withdrawn from an atmospheric distillation unit downstream of a liquefaction reactor and hydrotreated for passage back to the liquefaction zone as recycle solvent. The heavy materials commonly denoted as residue and preasphaltene materials are extracted in solvent extractor 40 and removed from the process in conduit 42. A portion of the solvent extractor effluent containing the asphaltene materials is removed through conduits 48 and 47 and a portion of it may be recycled back to the liquefaction unit as recycle solvent. Thus, the recycle stream is an admixture of hydrotreated distillate products, unhydrotreated distillate products and asphaltene material.
Notwithstanding the above prior art, there remains a need for a different type of recycle system of different composition to mitigate the amount of hydrogen utilized in the reaction zone during liquefaction while maximizing the amount of asphaltene product and avoiding undesirable preasphaltenes in the asphaltene product. The preasphaltenes in the asphaltene product are to be avoided because of their high softening point and high heteroatom content. An asphaltene product relatively free of preasphaltenes can be hydrotreated to acquire a substitute for No. 6 fuel oil.
It is therefore a general object of the present invention to provide such a novel recycle stream for a coal liquefaction process and thereby improve the same.
BRIEF DESCRIPTION OF THE INVENTION
The present invention involves a solvent coal refining process in which, following liquefaction and light gas separation, the coal slurry is subjected to vacuum distillation, the bottom stream of which is solvent extracted. This solvent extraction includes one or more separation steps at elevated temperature and pressure, using a supercritical extraction solvent which extracts oils (pentane soluble organics) and asphaltenes (pentane insoluble, benzene soluble organics), from preasphaltenes (benzene insoluble, pyridine soluble organics), solid organic residue materials (pyridine insoluble organics) and ash.
The materials extracted from the supercritical extraction unit may be classified as extract oils and asphaltenes in one stream and preasphaltenes and solid residue material in another or second stream. These particular components, i.e. asphaltenes and preasphaltenes, are not generally nomenclated by their boiling point because of their disposition to chemically decompose upon heating at high temperatures. While it may be possible in theory to obtain a boiling point of any substance, by the time these substances boil, their characteristics will have been changed by thermal cracking of the material and thereby a boiling point of the asphaltenes and preasphaltenes cannot be ascertained in practice. Therefore, these streams can be defined only by their solubility factors. As recognized by those familiar in defining products of coal liquefaction processes, asphaltenes are defined as those materials which are pentane insoluble and benzene soluble, while preasphaltenes are defined as those materials which are benzene insoluble and pyridine soluble. The desired product of this invention, that is asphaltenes which can contain some oils may be hydrotreated to yield an acceptable substitute for No. 6 fuel oil.
The technique of supercritical extraction exploits the optimum combination of fluid properties near their critical point. This is performed in process step 45 of FIGS. 1 and 2 of the instant drawings. These properties are inclusive of liquid-like densities yielding liquid-like dissolving power, and gas-like diffusivities yielding high mass transfer rates. The rapid changes in density with only slight changes in temperature or pressure can be exploited in separation of the solvent from the extract following supercritical extraction. A portion of the preasphaltene and solid residue materials can continuously or intermittently be withdrawn from the process to avoid solids build-up, however, it is preferred that recycle of a predominant amount of these preasphaltenes and solid residue material be channeled to the slurry tank. While it is within the scope of this invention that some asphaltene material may be recycled in concomitant interaction with the preasphaltene materials, it is preferred that at least a 8:1 ratio of preasphaltenes to asphaltenes be maintained in the recycle stream. By performing this process, with this particular preferred recycle stream, there results a net reduction in the amount of undesirable preasphaltenes made in the process and recovered by supercritical extraction. There also results an increaase in the solids loading of the liquefaction reactor. This ultimately results in a reduction in the amount of hydrogen consumed in the liquefaction step when one is attempting to acquire an asphaltene porduct, which is highly desirable in this type of process. Another advantage is that the process can be regulated to be nearly preasphaltene consuming, i.e. nearly all of the preasphaltene is consumed within the process.
One embodiment of this invention resides in a process for solvent refining coal to make an asphaltene-rich product stream by forming a slurry of finely divided coal and a process solvent therefore, contacting said slurry with a hydrogen-rich gas, heating said slurry in the presence of said hydrogen-rich gas, permitting said heated slurry to react and to dissolve at least some of said coal, adding fresh hydrogen as required to form a liquefied coal slurry, passing said liquefied coal slurry to a separator in which a vapor product stream and a condensed product stream are separated, passing the condensed product stream to a vacuum distillation still, and removing therefrom a residual bottoms product, wherein said residual bottoms product from said vacuum distillation still is mixed with a suitable extraction solvent and passed to an extraction system to separate an extract asphaltene-rich product stream from a preaphaltene-rich stream containing solid residue material, withdrawing and recycling at least a portion of said preasphaltene-rich stream containing said solid residue material in the near absence of asphaltenes to said slurry of finely divided coal as process solvent, withdrawing said asphaltene-rich stream and passing said asphaltene-rich stream to a solvent recovery system to recover an asphaltene-rich product stream and an extraction solvent stream, recovering and recycling said extraction solvent stream to said admixture with said vacuum still residual bottoms and recovering said asphaltene-rich stream from said solvent recovery system as said product stream.
Yet another embodiment of this invention resides in a process for solvent refining coal to make an asphaltene-rich product stream by forming a slurry of finely divided coal and a process solvent therefor, contacting said slurry with a hydrogen rich gas, heating said slurry in the presence of said hydrogen rich gas, permitting said heated slurry to react and to dissolve at least some of said coal, adding fresh hydrogen as required to form a liquefied coal slurry, passing said liquefied coal slurry to a separator in which a vapor product stream and a condensed product stream are separated, passing the condensed product stream to a vacuum distillation still, and removing therefrom a residual bottoms product which is passed from the vacuum distillation still to mix with a solvent and then passed to a supercritical extraction system to separate an extract asphaltene-rich stream as the product stream of the process and a preasphaltene-rich stream containing solid residue material, withdrawing and recycling a portion of said preasphaltene-rich materials with asphaltenes in a ratio of at least eight times the amount of preasphaltenes in the recycle to the amount of asphaltenes in the recycle and hydrotreating the asphaltene material to provide a substitute for No. 6 fuel oil.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic flow diagram of a coal liquefaction process with a supercritical extraction stage and a preasphaltene-rich recycle to the slurry mix tank, which is a process improvement of the present invention.
FIG. 2 is a schematic flow diagram of a coal liquefaction process with a supercritical extraction stage, a hydrotreatment stage and a preasphaltene-rich fraction recycling step, which is a process improvement of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
For a better understanding of the present invention, reference may be made to the detailed description which follows, taken in conjunction with the accompanying figures and the claims.
As shown in FIG. 1, the improved liquefaction process of this invention comprises a coal liquefaction slurry mix zone 5 to which is introduced a feed stream 4 of finely divided coal and solvent (to the extent required) and a recycle stream 71. Slurry from mix zone 5 is pressurized and passed through line 8 to preheater 10 and then through transfer line 15 to dissolver 18. Liquefaction of coal in the heated slurry is enhanced by hydrogenation; for that purpose, hydrogen is introduced to the slurry through feed line 9 in transfer line 8.
After suitable residence time in dissolver 18, the coal solvent slurry mixture is passed through transfer line 20 to separator zone 26, in which light stream 24 is flashed off, following which the slurry is passed through transfer line 27 to a vacuum distillation stage 37, from which a distillate product is recycled through transfer line 101 and a vacuum distillation bottom stream is passed through transfer line 39 to a supercritical extraction stage 45. The extract fraction is passed through transfer line 43 to a solvent recovery stage from which extraction solvent is recycled through transfer line 47 to the input to the extraction stage. Extraction step 45 will separate asphaltene from preasphaltene components. The heavier material, i.e. the preasphaltenes in admixture with solid residue material such as unreacted coal and ash, is removed in conduit 41 while a portion of the solvent plus the asphaltene materials, those being pentene insoluble and benzene soluble, are passed from extraction unit 45 through conduit 43 to solvent recovery unit 51. The asphaltenes are separated therein and can be removed from the process through conduit 105 or a very minor portion (less than 10% of the total recycle stream) of the asphaltenes can be recycled to the slurry tank by means of conduits 103 and 101 through conduit 71. It is preferred in this invention, however, that the predominant portion of the recycle is the preasphaltenes and solid residue material. It is also preferred that this relationship be maintained in at least an 8:1 relationship in favor of the preasphaltenes and solid residue material in order to mitigate hydrogen consumed in the process. It is also possible to remove some of the preasphaltenes from the solid materials in conduit 117. To avoid solids build-up in the liquefaction dissolver, some residue, ash and some tag-along preasphaltenes should be exorcised from the process in conduit 117. If necessary, an additional separation zone may be placed in conduit 117 to extract preasphaltenes from the solid residue and ash. In this manner, the process could be regulated to be nearly preasphaltene-consuming, i.e. nearly all the preasphaltenes will be consumed in the total process scheme and need not be handled extrinsic from the process.
A further embodiment of the present invention is shown in FIG. 2. The output stream of transfer line 105 of FIG. 1 is passed through transfer line 107 to hydrotreatment zone 84. Hydrogen rich gas is fed to hydrotreater 84 through line 11. The bottom stream from hydrotreater 84 is passed through line 109 and withdrawn as product via line 113. A portion of the hydrotreated material may be recycled to the head of the process through line 115. The light overflow stream from hydrotreater 84 is passed through transfer line 111 to gas treatment zone 86.
The following examples are given as being representative of this invention but should not be considered as an unduly limited restriction thereon. The examples succinctly show a liquefaction process wherein the recycle stream consists in at least a 8:1 ratio of preasphaltenes to asphaltenes.
EXAMPLE 1
A slurry mixture of 30 wt% Ky. #9 coal, 15 wt% SRC ash concentrate, and 55 wt% SRC process solvent was fed at a rate of 1650 g./hr., together with 48 g./hr. hydrogen gas, to a one liter coal liquefaction reactor. Based on solvent separation analysis of the slurry feed components, it had the following composition:
TABLE I______________________________________ wt %______________________________________MAF Coal 25.5Moisture in coal 0.6Ash in Coal 3.9Pentane - soluble organic (oils) 53.6Benzene - soluble/pentane - insoluble 1.3(asphaltenes)Benzene - insoluble organics (preasphaltenes 11.1and solid organic residue material)Ash (from solvent & ash concentrate) 4.0Total 100.0______________________________________
The reactor was operated at 840° F. (454° C.) and 2000 psig (13794 kPa).
Based on average yields of two experimental trials, the resulting reactions consumed 10 g./hr. of hydrogen (equivalent to 0.6 wt% of the slurry feed), and yielded the following product:
TABLE II______________________________________ wt % (of slurry feed)______________________________________Ash 7.9Preasphaltenes and solid organic 16.1residue materialAsphaltenes 12.6Oils 60.4C.sub.1 -C.sub.5 hydrocarbon gas 1.5Other gases & water 2.1Total 100.6______________________________________
The separation of the gross product stream (i.e., only to that fraction (97%) which is neither water nor gas), into a recycle stream, an ash-containing reject stream, and a "product" stream results in the following compositions:
TABLE III______________________________________Stream Recycle Reject Product Total______________________________________Flow rate (g./100 g. feed slurry)Ash 4.0 3.9 0.0 7.9Preasphaltene and solid 11.1 5.0 0.0 16.1organic residue materialsAsphaltenes 1.3 0.0 11.3 12.6Oils 53.6 0.0 6.8 60.4Totals 70.0 8.9 18.1 97.0______________________________________
The net products of the overall process expressed in terms of feed coal are as follows:
TABLE IV______________________________________Product Yield (g./100 g. feed coal)______________________________________Asphaltene-rich product 60.3Reject 29.7Hydrocarbon gases 5.0Other gases & water 7.0H.sub.2 consumed (2.0)Total 100______________________________________
The asphaltene-rich product consists primarily (approximately 62 wt%) of non-distillate material. Thus, this example shows that distillation alone is insufficient to effect the necessary separation.
EXAMPLE 2
The following example is given as being representative of a liquefaction process without a preasphaltene-rich recycle stream.
A slurry mixture of 30 wt% Ky. #9 coal and 70 wt% SRC process solvent was fed at a rate of 1650 g./hr., together with 48 g./hr. hydrogen gas, to a one liter coal liquefaction reactor. Based on solvent separation analysis of the slurry feed components, it had the following composition:
TABLE V______________________________________ wt %______________________________________MAF Coal 25.5Ash in Coal 3.9Moisture in Coal 0.6Oils 68.2Asphaltenes 1.3Preasphaltenes + Solid Organic Residue 0.5Total 100.0______________________________________
The reactor was operated at 840° F. (454° C.) and 2000 psig (13794 kPa). The resulting reactions consumed 8 g./hr. of hydrogen (equivalent to 0.5 wt% of the slurry feed), and yielded the following product:
TABLE VI______________________________________Ash 3.9Preasphaltenes + Solid 11.7Organic ResidueAsphaltenes 9.1Oils 72.4C.sub.1 -C.sub.5 Hydrocarbon Gas 1.5Other Gas + Water 1.9Total 100.5______________________________________
Recovery of recycle and a comparable asphaltene plus net oil product leads to the following:
TABLE VII______________________________________Flow Rate (g./100 g. feed slurry)Stream Recycle Reject Product Total______________________________________Ash 0.0 3.9 0.0 3.9Preasphaltenes + 0.5 11.2 0.0 11.7Solid Organic ResidueAsphaltenes 1.3 0.0 7.8 9.1Oils 68.2 0.0 4.2 72.6Totals 70.0 15.1 12.0 97.1______________________________________
The net products of the overall process expressed in terms of feed coal are as follows:
TABLE VIII______________________________________Product Yield (g./100 g. feed coal)______________________________________Asphaltene-rich Product 40.0Reject 50.3Hydrocarbon Gases 5.0Other gases + Water 6.3H.sub.2 Consumed (1.6)______________________________________
These examples verify the goals sought by the applicants in their process for the production of asphaltene-rich compositions which could be hydrotreated to arrive at a No. 6 fuel oil with corresponding consumption of as little hydrogen as necessary to acquire the asphaltene compositions. A comparison of the products produced from this invention, wherein the recycle is comprised substantially of recycle oil and preasphaltenes (Example 1), with that of the case where no preasphaltenes are recycled (Example 2), demonstrates that preasphaltene recycle results in favorable conversion to desirable asphaltene-rich products.
This invention (Example 1) produces 20% more desirable asphaltene-rich products than is derived in Example 2 where no preashaltenes were recycled, and consequently 20% more reject resulted. Furthermore, a comparison of the data points of these two examples shows that the increased amount of hydrogen necessary to acquire the asphaltene-rich compositions through reactions of preasphaltenes and coal is surprisingly small (2.0% in Example 1 as compared to 1.6% in Example 2). When viewed in lieu of the increased yields of asphaltene product from this invention, the amount of hydrogen consumed per amount of desired product is unexpectedly significantly better. In a process using this invention (in Example 1) there is 33.3 mg H 2 consumed/g. product as compared to 40.0 mg H 2 consumed/g. product for a process performed with no preasphaltene recycle (Example 2) and yielding 20% fewer asphaltenes. That is, in our invention, the higher yields of desirable product favor the overall conservation of hydrogen.
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A coal liquefaction system is disclosed with a novel preasphaltene recycle from a supercritical extraction unit to the slurry mix tank wherein the recycle stream contains at least 90% preasphaltenes (benzene insoluble, pyridine soluble organics) with other residual materials such as unconverted coal and ash. This subject process results in the production of asphaltene materials which can be subjected to hydrotreating to acquire a substitute for No. 6 fuel oil. The preasphaltene-predominant recycle reduces the hydrogen consumption for a process where asphaltene material is being sought.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a deodorizer device suitable for use in a refrigerator which stores foods and other materials.
2. Description of the Prior Art
A conventional deodorizer device for use in a refrigerator has a case charged with an absorbent such as activated carbon and is placed in the path of chilled air in the refrigerator so as to absorb and remove any smell generated in the refrigerator. A typical example of the deodorization device of this kind is disclosed in, for example, Japanese Unexamined Utility Model Publication No. 47-22566.
As explained above, the conventional deodorization device makes use of an absorbent such as activated carbon. The absorbent tends to reduce its deodorization effect when used in air having a strong smell. There is a practical limit or saturation level in the capacity of the absorbent for holding odor components. Thus, the absorbent has to be demounted from the deodorization device for replacement or regeneration after a predetermined time of use.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a deodorizer device which can maintain the deodorizing ability for a long time without requiring substantial maintenance work.
To this end, according to the present invention, there is provided a deodorizer device comprising: an absorption unit including an odor absorbent capable of absorbing an odor component and a layer of a photocatalyst deposited on a surface of the absorbent and capable of decomposing the odor component absorbed in the absorbent when excited by irradiation with light; a light source for applying the exciting light to the layer of photocatalyst; and a blower which causes air containing the odor component to pass through the absorption unit.
In the deodorization device of the invention, light having an energy of a level not smaller than the band gap energy of the photocatalyst layer is applied to the photocatalyst layer on the absorbent so as to excite the photocatalyst layer. In consequence, the photocatalyst of the catalytic layer is effective to decompose the odor components, so that the odor components in the absorbent are progressively decomposed and removed from the absorbent surface.
When the light source is of a type which does not produce any appreciable heat, the decomposition proceeds in accordance with diffusion of the odor components caused by the difference in the density of the components between the outer and inner portions of the absorbent, so that the decomposition and removal are effected gradually from the surface of the absorbent.
In contrast, when the light source is of a type which produces heat, the temperature of the absorbent is raised to reduce its capacity for holding the odor components, so that the odor components are released from the inner portion of the absorbent, and the thus released odor components are further decomposed by the photocatalyst layer on the surface of the absorbent.
It is, therefore, possible to regenerate the absorbent so that the deodorization device can stably maintain its deodorization effect for a long time.
In a preferred embodiment of the present invention, the deodorization device has suction and discharge chambers which are separated from each other by the absorption unit. This arrangement prevents undesirable mixing of the air before deodorization and the air after deodorization, so that the odor components are effectively trapped by the absorption unit.
According to the preferred embodiment of the invention, a control circuit substrate, a reflective means, an ultraviolet lamp and the absorption unit are arranged in line in the mentioned order so that the absorption unit can be irradiated over its whole surface with the ultraviolet rays.
In the preferred embodiment of the invention, the ultraviolet lamp and a resistor of a stabilizer of the lamp are arranged on both sides of the absorption unit so that the temperature of the absorption unit is raised by the heat from the resistor to promote the exudation of the odor components to the surface of the absorption unit, whereby the decomposition of the odor components is effected at a high efficiency.
In the preferred embodiment of the invention, the control circuit substrate and the resistor of the lamp stabilizer are installed separately from each other so as to enable the substrate to be hermetically sealed.
In the preferred embodiment of the present invention, heat-generating components of the control circuit are disposed on the lower side of the control circuit substrate and in the vicinity of connection terminals. In this arrangement, heat generated by the heat-generating components effectively prevents any trouble due to dew which may form on the terminals when air of high humidity is introduced into contact with these terminals.
In the preferred embodiment of the invention, the deodorizer device is sized to have a height smaller than and approximating the minimum dimension between shelves in the refrigerator chamber. Thus, the deodorizer device can have a reduced length and width so as to minimize the installation space, thereby assuring an efficient use of the space in the refrigerator chamber.
The above and other objects, features and advantages of the present invention will be made more apparent by the following description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partly cut-away perspective view of an embodiment of a deodorizer device of the present invention;
FIG. 2 is a perspective view of the internal structure of the deodorizer device of FIG. 1;
FIG. 3 is a chart illustrative of the operation of a control circuit;
FIG. 4 is a block diagram of an electrical circuit incorporated in the device shown in FIG. 1;
FIG. 5 is a plan view of a control circuit substrate in the device shown in FIG. 1; and
FIG. 6 is a perspective view of the deodorizer installed on a shelf in a refrigerator chamber.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an embodiment of a deodorizer device 12 of the present invention in a perspective view with a part thereof cut and removed. FIG. 2 is a perspective view of the same deodorizer device with a cover 1 of the device removed to show the internal structure.
The deodorizer device 12 of the illustrated embodiment of the invention is designed for use in a refrigerator chamber and includes an odor absorption unit 3 which comprises a honeycomb structure formed of a molded absorbent and a layer of a photocatalyst deposited on the surfaces of the honeycomb structure and adapted to be excited by an ultraviolet ray to decompose the components of odors (hereinafter referred to as "odor components") already absorbed in the honeycomb structure of the absorbent. The deodorizer device 12 further includes an ultraviolet lamp 9 operative to radiate an ultraviolet ray to the photocatalyst layer of the odor absorption unit 3 to excite the photocatalyst. Such a deodorizer device is fully described in U.S. patent application Ser. No. 295,754 filed Jan. 11, 1989, now U.S. Pat. No. 4,954,465 the disclosure of which is incorporated herein by reference.
A metallic cover serving as reflection means 4 is disposed in the vicinity of the ultraviolet lamp 9 so as to direct the ultraviolet ray from the lamp 9 towards the absorption unit 3. The deodorizer device 12 further has a stabilizer resistor 7 for the ultraviolet lamp 9, a support plate 7a supporting the resistor 7, a blower 8 for forcibly causing air containing odor components to pass through the absorption unit 3, a motor 6 for driving the blower 8, and a control circuit substrate 5 carrying thereon an electric control circuit for controlling the operation of the ultraviolet lamp 9 and the operation of the driving motor 6.
As will be seen from FIG. 1, the deodorizer device 12 has upper and lower covers 1 and 2 which cooperate to define a suction chamber 1b and a discharge chamber 1a which are separated from each other by the absorption unit 3. The lower cover 2 is provided with a row of suction openings 2a communicating with the suction chamber 1b, while the upper cover 1 is provided with a row of discharge openings 1c communicating with the discharge chamber 1a. The control circuit substrate 5, the reflection means 4 and the ultraviolet lamp 9 are arranged in series in the mentioned order within the suction chamber 1b. The discharge chamber 1a accommodates the stabilizer resistor 7 for the ultraviolet lamp 9, the support plate 7a for the resistor 7, the blower 8 and the drive motor 6 for driving the blower 8.
Air containing odor components is sucked through the suction openings 2a into the suction chamber 1b. The air is then caused to pass through the absorption unit 3 so that odor components are trapped by the absorption unit 3. The air with a reduced content of the odor components is then discharged from the discharge chamber 1a into the refrigerator chamber through the discharge openings 1c. The ultraviolet ray from the ultraviolet lamp 9 excites the photocatalyst layer on the absorbent of the absorption unit 3 so that the photocatalyst produces an effect to decompose the odor components, whereby the odor components absorbed in the absorbent are progressively decomposed and removed from the surface of the absorbent.
Since the suction chamber 1b and the discharge chamber 1a are isolated from each other by the absorption unit 3, there is no risk that the air after deodorization and the air before deodorization are mixed with each other within the deodorizer device, so that the odor components carried by the air are effectively absorbed by the absorption unit 3.
The reflective means 4 may be formed by a cover of, for example, aluminum and be designed to reflect the ultraviolet ray from the lamp 9 to allow the entire area of the absorption unit 3 to be irradiated with the ray and, at the same time, shield the control circuit substrate 5 from the ultraviolet ray. The stabilizer resistor 7 of the ultraviolet lamp 9 is disposed on the side of the absorption unit 3 opposite to the lamp 9, so that the absorption unit 3 is heated at both of its sides by the heat from the ultraviolet lamp 9 and the heat from the stabilizer resistor 7, whereby exudation of the odor components from the inner portions of the absorbent is promoted to ensure a high efficiency of decomposing action performed by the photocatalyst layer.
The outline of the refrigerator deodorizer device of the present invention has been described. Description will now be made of some details of the embodiment of the invention.
Referring to FIG. 4, there is shown a block diagram of an electrical circuit which can be used in the refrigerator deodorizer device of the present invention.
An electrical circuit 5e, which is carried by the control circuit substrate 5, controls a semiconductor control element 7c for selectively supplying electrical current to the ultraviolet lamp 9 and the stabilizer resistor 7, and a semiconductor control element 7d which selectively supplies electrical current to the driving motor 6 of the blower 8. A power supply 13 supplies a voltage to the electrical circuit 5e of the deodorizer device 12 through a power supply adapter 10 designed to lower the voltage from the power supply 13. This arrangement makes it possible to reduce the size of the stabilizer resistor 7 and, hence, the size of the refrigerator deodorizer device 12. The aforementioned semiconductor control elements 7c and 7d are carried by the substrate 5.
Referring to FIG. 3, there is shown an example of the control of operation of the ultraviolet lamp 9 and the blower driving motor 6 performed by the electrical circuit 5e on the control circuit substrate 5.
The supply of the electrical current to the driving motor 6 is conducted for a period T 3 and interrupted for a period T 4 . The ultraviolet lamp 9 is supplied with a current for a period T 2 so that it emits light once in a period T 1 of one cycle of operation. The period T 1 of one cycle of the operation of the deodorizer device is, for example, 6 to 8 hours. Period T 2 , T 3 and T 4 are, for example, 12 minutes, 24 minutes and 24 minutes, respectively.
FIG. 5 schematically shows component parts of the electrical circuit 5e on the control circuit substrate 5. The electrical circuit 5e has a terminal device 5a for the power supply lines to the driving motor 6 and the ultraviolet lamp 9, a semiconductor switching element 5c, a gate-current limiting resistor 5b, and an integrated control circuit 5d. Heat-generating elements such as the semiconductor switching element 5c and the gate-current limiting resistor 5b are disposed in the vicinity of the terminal device 5a so that the heat produced by these elements effectively prevent an accident which may otherwise be caused by dew forming on the terminal device 5a when air having a high humidity is introduced into contact with the terminal device 5a.
These heat-generating elements may be arranged on the lower side of the control circuit substrate 5 so that the whole control circuit substrate 5 is heated. This arrangement prevents any accident which may otherwise be caused by dew forming on the substrate 5 when it is cooled.
The stabilizer resistor 7, which is comparatively large in size, is installed separately from the control circuit substrate 5. This arrangement makes it possible to hermetically seal the control circuit substrate 5 and the circuit elements carried by the substrate 5, thus preventing any accident which may otherwise be caused by dew forming.
FIG. 6 shows the manner in which the deodorizer device 12 of the present invention is installed in a refrigerator chamber. The deodorizer device 12 has a height h which is slightly smaller than the minimum shelf interval H between shelves 11 in the refrigerator chamber. The minimum shelf interval H is usually 110 mm or greater in ordinary refrigerator chambers, so that the height h of the deodorizer device 12 is determined to be, for example, 100 mm. This design minimizes the length and width of the deodorizer device 12 to allow the space in the refrigerator chamber to be fully utilized.
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A deodorizer device for use in a refrigerator has an absorbent capable of absorbing odor components from air, a layer of a photocatalyst deposited on the surface of the absorbent, and a light source for illuminating the photocatalyst layer to excite the same. Air containinig odor components is forced by a blower to flow through the absorbent.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a national stage entry of PCT/ES2009/070080 filed Mar. 30, 2009, under the International Convention.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to the search and selection of wild vegetal species adapted to severe edaphologic conditions in soils polluted by pollutants, which plants are capable of surviving in most parts of the world and cannot enter the trophic chain. The genetic transformation thereof considerably enhances their metal absorption rate and capacity and also makes it easier for said absorption to cover the majority of pollutants or harmful substances.
[0003] The method of said transformations belongs to the field of biotechnology and may be defined as the set of techniques modifying live organisms (or parts thereof), transforming substances of organic origin or using biological processes to bring forth new knowledge, develop products and services.
BACKGROUND OF THE INVENTION
[0004] The industrial revolution birthed very pernicious consequences to the environment due to accumulation of pollutants in the soil, water and the atmosphere.
[0005] The soil, being the most stable of these media, allows for longer permanence of pollutants which cannot be degraded during a very long period of time and thus, generate a progressive accumulation, provoking in the first place biodiversity diminishment and initial absence of vegetation, also transferring these elements to other media as air and water, polluting surface as well as underground waters, thus entering in the food chain.
[0006] Nevertheless, we observe the existence of a wide variety of vegetal species adapted to these circumstances through a genetic transformation process along time, colonizing even these polluted soils.
[0007] These vegetal species known as metalophites have suffered genetic transformations to be able to live in these soils.
[0008] Due to their specialization to be able to live in these polluted environments, with specific minerals, in specific areas and edaphic conditions, makes the survival of these species very difficult in other places and if the climate is added to these conditions, there is an increased difficulty for their development in other latitudes.
[0009] However, the use of vegetal species to eliminate or accumulate environmentally harmful pollutants is known as phytoremediation, defined as the use of vegetal species to carry on pollutant elimination or transformation actions.
[0010] Techniques employed for decontamination of soils basically consist in soil isolation or decontamination.
[0011] Isolation techniques avoid propagation of pollution based on the loading of pollutants in appropriate sewers, sealing them in situ or destroying them.
[0012] Decontamination and thus soil recuperation techniques pertain to:
[0013] The extraction of pollutants through action of a fluid; be it by air (dragging) or water (washing away).
[0014] Once dragged the pollutants are cleansed
[0015] These are all expensive and inefficient methods
[0016] Chemical treatment, that is to say, cleansing the soil through pollutant degrading by chemical reactions, normally oxidation or de-chlorination. Employed in oil products stabilization.
[0017] Expensive, complicated and very selective techniques ending up in more soil degradation, un-fertilizing them.
[0018] Electrochemical treatment consisting in the displacement of pollutants creating electrical fields, benefiting this displacement by adding water.
[0019] It owes to a migration of pollutants phenomena in ionic form through the electrical field.
[0020] Electro-osmosis, through movement of liquid in relation to solid surfaces of the electrical field.
[0021] Electrophoresis, consisting in the displacement of charged colloidal particles in suspension
[0022] These are all very expensive and ineffective procedures.
[0023] Thermal treatment, degrading pollutants through heat conveyance.
[0024] It is an ex situ treatment with no efficacy for metals.
[0025] These treatments leave the soil totally transformed, with no organic matter, without micro-organisms and without any type of biodiversity, rendering said treatments totally inappropriate, besides being, all of them, very expensive.
[0026] Microbiological treatment employing certain micro-organisms having degradation capacity (Bio-remediation).
[0027] Decontamination by this method is employed in organic pollutants aerobically degraded, though other organic pollutants exist as aliphatic chlorinated ones that must be degraded anaerobically.
[0028] This treatment besides being practically only for organic pollutants, needs continuous vigilance so that micro-organisms multiply themselves without loosing their strength; a constant elimination of old micro-organisms having lost degrading power thus enabling them to develop into invasive/mutant species, is also necessary. Besides the aforementioned facts, temperature conditions, pH, micro-organisms strength, etc, also need vigilance.
[0029] All of these aforementioned procedures are very expensive and of dubious efficacy.
[0030] Phytoremediation, as previously defined, is the technique that employs vegetal species to eliminate pollutants.
[0031] Vegetal species employed in phytoremediation have a very selective character, that is to say, they only accumulate one or two metals and they exhibit very low biomass, thus granting them low loading capacity. They grow in very specific areas and possess very short roots, whereby they absorb these metals, whereas their absorption is very superficial.
[0000] U.S. Pat. No. 5,364,551—Phytoremediation of Metals
[0032] Relates to a process to eliminate ions of metals and describes methods to carry out this purpose.
[0033] The method consisting in the extraction of a quantity of metal from a polluted soil containing heavy metals, thus employing transformed members with the adequate vector containing a cDNA codifying sequence for metalothioneine. As already known, it is a protein showing great affinity for divalent heavy metals, such as lead and chrome, thus being claimed in claim 8 , that is to say, this patent is selective of said two metals.
[0034] Vegetal species with higher absorption capacity, known as hyper-accumulating were discovered afterwards.
[0000] Patent WO 0028093—Recovering Metals from Soil
[0035] This patent relates to the recovery of metals, such as nickel and cobalt by phytoremediation or phytoextraction from soils rich in metals, where the desired metal is selectively accumulated in hyper-accumulating vegetal species by adjusting the soil pH.
[0036] Metals are finally extracted from the tissues of aerial parts of the vegetal species.
[0037] But phytoremediation is still slow since these species develop very small biomass and thus, small loading capacity. Besides, they possess a short life cycle, circumstances rendering soil phytoremediation doubtful.
[0038] The plants claimed by said patent belong to the Alyssum family.
[0039] The main problem with these vegetable hyper-accumulating species, in spite of their high relative metal content, is that they generate small biomass, and thus having small total absorption capacity and thereby the amount of metal extracted is small. Besides, they have a very short life cycle and only grow in much delimited areas.
[0040] The unsolved problem to date is the elimination of pollutants with efficacy, that is, to accomplish lower limits than those set by the European Economic Community allowing time periods from one to two years instead of time periods greater than 150/200 years, which is the actual performance of the so called hyper-accumulating plants, that is, a hundred fold decrease in time would render the best solution to eliminate pollutants from the soil.
[0041] The present invention solves this problem through search and selection of wild vegetal species adapted to severe edaphological conditions in polluted soils, that is, wild species that have already suffered a natural genetic transformation and have adapted to these conditions, and among these species, those that do not having the possibility to enter the food chain.
[0042] Another required condition is its ability to adapt their growth to a great climatic diversity in order to procure a vegetable species able to grown in different climatic conditions. This method has also extended to very wet soils, selecting in this case an arboreal species.
[0043] Afterwards a genetic transformation has been accomplished to considerably increase the loading capacity of pollutants and the absorption rate of said elements.
[0044] The elements or mixture of same that can be eliminated have been classified in two main groups: noxious and non noxious. Among noxious, by these vegetal species heavy metals as lead, cadmium, mercury, silver, boron, aluminium, iron, manganese, copper, nickel and chromium can be eliminated. Radioactive elements as uranium, rhodium, thorium and plutonium and non noxious elements as sodium, magnesium, lithium, potassium, calcium can also be eliminated.
BRIEF EXPLANATION OF THE FIGURES
[0045] FIG. 1 . Represents measurements of the different soil characteristics, for polluted soils type M 4 , M 15 , M 3 and limits for agricultural soil required by the European Union.
[0046] Units of these measurements are indicated in the left hand side column. n.d. means: not determined.
[0047] FIG. 2 . Shows a bar diagram representing growth height (mt) of plants after six months.
[0048] The ordinate axis indicates the length in meters of Nicotiana glauca wild plants (wt) after said time and the ones genetically modified with the TaPCS1 OMG gene.
[0049] It is confirmed that wild plants grow some three and a half meters high while the genetically modified ones reach up to five meters high. It is to be assumed that in six months time the plants genetically modified have grown a more than 40% in comparison with the wild ones.
[0050] FIG. 3 . The effect of polluted soils M 4 and M 15 on biomass production expressed in grams of total biomass (T), aerial biomass (A), stems and leafs and radicular biomass concentration (R) in mg/kg in Populus tremula×tremuloides cv. Etropole is shown in the figure.
[0051] Total accumulated of these following two results expressed in micrograms (μg) are shown: concentrations in stems and leafs (BCF), and concentration in roots (RCF), for wild plants (wt) and genetically modified ones.
[0052] FIG. 4 . Increase in biomass in Populus tremula×tremuloides cv. Etropole is shown in figure. This figure represents two lines of introduced gene TaPCS1, and two of gene AtPCS1, vs. biomass of a wild plant (the one at the right of the figure), all in M 4 medium, that is to say in a very polluted soil.
[0053] It is observed that plants containing anyone of the two genes suffer less the presence of metal in the soil thereby growing more.
[0054] FIG. 5 . A bar diagram representing in numbers, development of plants Nicotiana glauca (wt) not modified, and those modified with the YCFgene at 26 days.
[0055] It is observed that in all cases genetically modified plants with the YCF gene develop more foliage than wild ones.
[0056] FIG. 6 . A bar diagram representing lengths accomplished by roots in centimetres after 21 days of Nicotiana glauca wild plants (wt) in comparison to those genetically modified with the YCF gene.
[0057] It is observed that in all cases root length of modified plants is larger than in wild plants.
DESCRIPTION OF THE INVENTION
[0058] Method for the recovery of degraded spaces using vegetal species genetically modified consists in a series of steps.
[0059] It pertains in the first place, to the study (to make a selection complying with a series of requisites) of vegetal species having the capacity to adapt in climatic and edaphological terms.
[0060] To that end a series of polluted soils have been defined and classified.
[0061] It is to be understood that polluted soil is such whose physical, chemical or biological characteristics have been negatively altered due to the presence of harmful components of human origin, in such concentrations as to impose a risk to human health or to the environment.
[0062] A series of samples of polluted soils in mining, industrial and fluvial areas have been taken.
[0063] Afterwards, their characteristics have been analyzed from different view points: morphological, food rejection by animals to said vegetal species, environmental and edaphological adaptability, also studying species that would survive in said soils.
[0064] With these data three types of polluted soils have been defined, naming them M 3 , M 4 , M 15 and an MT soil (soil selected from the Turia River bed—Valencia) adjoined in separate table designated as FIG. 1 . In said table the quantities of the specified characteristics are indicated in the left hand side column, in units indicated in said column for the three types of soils M 3 , M 4 , M 15 . The last column shows the concentration limits established by the European Union for heavy metals in agricultural soils.
[0065] Of the species developed in the M 3 , M 4 , M 15 soils and thus adapted to these soils, those that eventually could be part of the trophic chain and those suffering climatic stress upon variation of climatic conditions for a stated time period, have been rejected.
[0066] The method went on to the morphological study of vegetal species analyzing their root depth, aspect of great importance in the present method, since it is the organ through which the pollutants are absorbed, considering a profound pursuance of a phytoremediation and not merely a surface one, though acknowledging a slow dissolution of pollutants in the ground.
[0067] Afterwards the place or places of the vegetal species where the pollutants extracted from the soil (roots, stems and leafs) were analyzed, since according to their accumulation places they would have a higher or lesser loading capacity of said metals. In FIG. 3 the production of biomass in highly polluted M 4 and M 15 soils can be appreciated, as well as lead and zinc concentrations in mg/kg, their totals, expressed in micrograms (μg), concentrations by bio-concentration (BCF) and radicular concentrations (RCF) in wild (wt) and genetically modified (PTa3 and PTa5) vegetal species of Populus tremula×tremuloides cv. Etropole.
[0068] Another determining characteristic controlled in this method is the amount of biomass produced by these vegetal species, since its increase generates an increase in loading capacity and thus phytoremediation.
[0069] Lastly, vegetal species had to be selected not only having a very easy reproduction but also complying with the requisite of a very abundant reproduction that is, of easy multiplication.
[0070] With these criteria vegetal species are selected by exclusion, resulting as best option Nicotiana glauca for dry grounds and Populus tremula×tremuloides cv Etropople for wet grounds.
[0071] Moreover the wild Nicotiana glauca (wt) selected has a series of characteristics making it ideal: Could be finally employed as fuel, since It germinates in open ground and its germinating power is very good. It reproduces by cuttings.
[0072] When cutting a branch or part of the plant, the plant regenerates that part and goes on growing.
[0073] It withstands high ground temperatures and also quite low ones.
[0074] It withstands drought and salinity.
[0075] It is herbaceous in the first development stages allowing same to have a broad planting frame.
[0076] It lignifies soon allowing same to be of good combustion and thus produce caloric and/or electrical energy.
[0077] It is seldom or not attacked at all by parasites or diseases favouring stable production efficiency.
[0078] It needs very small watering.
[0079] Genes TaPCS1 and TaPCS1-AtPCS1 have been respectively introduced in these vegetal species ( Nicotiana glauca and Populus tremula×tremuloides ).
[0080] The selected method was continued by studying the behaviour of vegetal species in their planting and growth, different samples were taken to study the development of same in non polluted control soil (M o ) and in polluted soils (M 3 , M 4 , M 15 and MT).
[0081] It was observed that the biomass of the selected vegetal species in all types of soils increased in both cases in more than 40% due to their genetic modification with TaPCS1 and AtPCS1 genes.
[0082] FIG. 4 represents two lines of TaPCS1 and two of ATPCS1 of genes introduced in Populus tremula×tremuloides cv. Etropole , in comparison with the wild plant (the one at the right hand side of FIG. 4 ), in polluted ground M 4 .
[0083] These experiments were also carried out in non polluted soils, confirming in all soils the same result: an increase of biomass of modified species, thus constituting a true novelty, that is, the introduction of said genes in a vegetal species increases biomass production in polluted as well as in non polluted soils.
[0084] One of the most important characteristics in phytoremediation techniques is the amount of biomass developed by selected vegetal species, even though increase of biomass was surprising upon introduction of TaPCS1 and AtPCS1 genes, the increase of this characteristic with other genes has been investigated revealing that through introduction of the YCF gene, the production of biomass increased in more than 30%, wherefore adding this transformation to those previously obtained with the introduction of the TaPCS1 and AtPCS1 genes, a very important total increase of biomass of plants would be accomplished, besides a considerable time shortening in phytoremediation.
[0085] A comparative study of growth in Nicotiana glauca plants genetically modified (GMOs) and not modified was carried out. To that end, the following lines of plants were set out:
[0086] wt
[0087] L1, L7 and L3 transformed with YCF1 gene.
[0088] A study on growth of each of the lines was carried out firstly evaluating the number of leafs in each plant and in a second experiment, the length of roots.
[0089] From FIG. 5 the number of leafs developed by non modified plants (wt), and modified with this gene at 26 days can be observed.
[0090] In plants transformed with the YCF1 gene homogenous growth values are observed within the lines and also, superior to the values of wt plants in practically all cases, as may be observed in FIG. 6 regarding he length of roots at 21 days.
[0091] Within each group of lines a homogenous radicular growth is observed, since there are no big differences in the length of roots of lines in the same group.
[0092] The plants transformed with the YCF1 gene are the ones presenting greater radicular growth, the length of their roots being superior to that of wt plants.
[0093] In studying the 3 lines results altogether it is observed that they show a common growth pattern, that is, in the 3 experiments it can be appreciated that the lines transformed with the YCF1 gene provide higher growth values.
[0094] As a conclusion, for modified vegetal species the time needed to decontaminate the soil decreases from 100 to 200 fold.
[0095] The present methodology employed to introduce the genes through which the increase in the synthesis of phytochelatines is obtained, is as follows:
[0096] First, the genes in the adequate plasmid for the vegetal species were included.
[0097] In case of the Nicotiana glauca vegetal species the yeast plasmid pYESTaPCS1 containing the phytochelatine synthase gene of Triticum aestivum (TaPCS1) was used. The cDNA of the previously cloned gene in yeast was designated as pYESTaPS1 plasmid.
[0098] The plasmid is digested in only one linear cut with XHo I and said cut turned into blunt extremes with the help of the DNA polymerase I. After the change to blunt extremes, the rest of the pYESTaPCS1 plasmid is directed with BamHI to produce a fragment of 2 Kb containing the cDNA of TaPCS1 gene and with extreme 5′ BamHI and 3′ blunt.
[0099] Simultaneously, the pBII21 intact plasmid is digested with BamHI and ECL136 II (leaving extreme 3′ blunt to complement with the 3′ of the insert). The insert of 2 Kb binds the sites BamH I-EcI 136 II of the recently cut plasmid, obtaining the new pBITaPCS1 construction.
[0100] The new construction (pBITaPCS1) is electropored in a strain of Agrobacterium tumefaciens , C58C1 Rif R Rif (Van Larebeke et al. 1974). The leaf explants of Nicotiana glauca are infected with A. tumefaciens after two days of culture in organogenic medium NB2510 [salts MS (Murashige and Skoog, 1962) including Gamborg vitamins B5, 3% sucrose, 2,5 SYMBOL 109 \f‘Symbol’\s 12 g mL −1 acetic naphthalene (NAA), 1 SYMBOL 109 \f‘Symbol’\s 12 g mL 1 aminopurina bencil (BA) 0.8% agar in darkness. The explants of adult and young leafs are infected through immersion in culture of Agrobacterium during 10 minutes. After one day of co-culturing the explants are transferred to a selective medium NB2510 containing 100 SYMBOL 109 \f ‘Symbol’\s 12 g mL −1 of kanamicin and carbencilin (350 SYMBOL 109 \f ‘Symbol’\s 12 g mL.). Two months after infection, the plants are individually extracted from the explants and transferred to jars containing 30 ml of the B1 medium (MS salts including Gambog B5 vitamins, 0,3 SYMBOL 109 \f ‘Symbol’\s 12 g mL −1 acetic indol acid of 0,2 SYMBOL 109 \f ‘Symbol’\s 12 g mL −1 NAA, 1% sucrose, 100 SYMBOL 109 \f ‘Symbol’\s 12 g mL −1 , 0.7% agar).
[0101] Besides the TaPCS1 gene, the YCF1 gene (Yeast Cadmium Factor) of Saccharomyces cerevisiae was also introduced in Nicotiana glauca . It is a vacuole carrier enabling the entrance and accumulation of metals in the vacuole. To the sequence of the cDNA of yeast YCF1 gene ( Saccharomyces cerevisiae ) previously cloned, the cutting sequence of XbaI was added in the extreme 5′ together with that of the 35s promoter (CaMV-Virus of the cauliflower mosaic), to increase gene expression, and in the 3′ extreme, the sequence of the ‘ocs’ terminator together with the cutting site for Sacl. Simultaneously the intact plasmid pGREEN 0179 is digested with SacI and XbaI. The insert binds the sites Sac I-XbaI of the recently cut plasmid obtaining a new construction named pGYCF1. The transformation method is the same, but in this case with 1 to new pGYCF1 construction.
[0102] In case of the vegetal species Populus tremula×tremuloides cv. Etropole , the genes introduced are TaPCS1 and AtPCS1 (phytochelatine synthase of Arabidopsis thaliana ). Gene AtPCS1 of phythochelatine synthase of Abrabidopsis thaliana was cloned by PCR in an incomplete ORF (in its extreme 5′) of 1458 nt, to which 44 nt were added to complete the codifying sequence in the extreme 5′, together with the sequence GCTggATccACC containing the cutting place of BAMHI enzyme and ‘kozac’ fragment (CACC) in said extreme to over express the AtPCS1 gene. A restriction sequence for EcoRV was also added to the end of the codifying sequence (extreme 3′) allowing its further insertion in the plasmid. Simultaneously the intact pBII21 plasmid is digested with BamHI and EC1136II (leaving extreme 3′ blunt to complement with the 3′ of insert), extracting the uidA gene in its place. The insert of 1.6 Kb (AtPCS1) binds sites BamHI and Ec1136II of the recently cut plasmid, obtaining a new construction named pBIAtPCS1. The transformation method is the same, but in this case with the two constructions, pBIAtPSC1 and pBITaPCS1.
[0103] The problem solved with this method consists in identifying the ideal vegetal species for soil decontamination, solving previously exposed problems as:
[0104] Decrease of phytoremediation time in 100 to 150 folds.
[0105] Increase in biomass production.
[0106] Adaptation to different climatic and edaphologic conditions.
[0107] Increase of heavy metals extraction range.
[0108] Thus, these vegetal species will have the adapting capacity to different climatic and edaphologic conditions, producing a great amount of biomass and accumulating elements or mixtures thereof previously classified in two big groups: noxious and non noxious. Among noxious, with these vegetal species heavy metals as lead, cadmium, mercury, silver, boron, aluminium, iron, manganese, copper, nickel and chromium can be eliminated. Radioactive elements as uranium, rhodium, thorium and plutonium and non noxious as sodium, magnesium, lithium, potassium, calcium, etc. . . .
[0109] Besides, the modified N. glauca species has a pleasant appearance, that is to say.
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The present invention relates to the search for and choice of forest plants adapted to severe edaphological conditions in soils contaminated by pollutants, which plants are capable of surviving in most parts of the world and cannot enter the trophic chain. The genetic transformation thereof considerably enhances the metal absorption rate and storage capacity thereof and also makes it easier for said absorption to cover the majority of pollutants or harmful substances.
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BACKGROUND
[0001] Embodiments of the present invention pertain to resistive heaters, apparatus incorporating resistive heaters and methods of heating substrates such as semiconductor wafers.
[0002] Resistive heaters are widely employed in the heating systems of chemical vapor deposition (CVD) systems. Temperature uniformity is an important consideration in CVD processes, and as a result, multi-zone resistive heaters have been developed to provide greater control over the heating characteristics of the heating apparatus in CVD systems. For example, U.S. Pat. No. 6,646,235 to Chen et al., the entire content of which is incorporated herein by reference, discloses a CVD resistive heater that has an inner zone and an outer zone, where the outer zone completely surrounds the inner zone. By providing these concentric zones, it is possible to compensate for the different rates of heat loss exhibited by the inner and outer regions of the heating apparatus, and so provide more uniform heating across the entire diameter of a wafer.
[0003] Even slight variations in temperature uniformity across a wafer, on the order of just a few degrees Celsius, can adversely affect a CVD process. Limitations in manufacturing tolerances make it extremely difficult to make a multi-zone heater that has consistent heating power characteristics around its entire circumference. Hence, at a given radius, one region of the resistive heater may provide more or less heating power than another region at that same radius. The resulting temperature variations introduce one layer of complexity that must be controlled to insure process repeatability across multiple wafers for the same resistive heater. Moreover, putatively identical resistive heaters display different heating power characteristics amongst themselves, which introduces yet another layer of complexity that is adverse to process repeatability. In addition, the CVD chamber itself may have regions that exhibit irregularities in temperature uniformity, introducing further possible temperature irregularities.
[0004] Accordingly, it would be desirable to provide a resistive heater that can provide compensation for heating irregularities to enhance process repeatability in high temperature deposition systems, such as reactors incorporating CVD chambers.
SUMMARY
[0005] Aspects of the present invention provide methods, apparatus and systems related to resistive heaters. One aspect pertains to an apparatus that includes a stage, and a shaft coupled to the stage. The stage includes a body with a surface for supporting a wafer. At least a first heating element is disposed within a central region of the body. Additional heating elements may be provided in the central region. At least two other heating elements are disposed in the body, each partially surrounding the central region, and each circumferentially adjacent to the other. In one embodiment, only one temperature sensor, for example, a thermocouple, disposed in the central region, is used to control the heating power of all of the heating elements. In another embodiment, four heating elements are provided in the body that each partially surround the central region. In yet another embodiment, the heating element in the central region is disposed adjacent to a top side of the body, and the other heating elements are disposed adjacent to a bottom side of the body.
[0006] Another aspect of the invention provides a heating system that includes a resistive heater, a temperature sensor for the resistive heater, a power supply for the resistive heater, and a control system to control the power supply. The resistive heater has a stage and a shaft coupled to the stage. The stage has a body with a surface for supporting a wafer. In one or more embodiments, a first resistive heating element is disposed within a central region of the body. At least second and third resistive heating elements are disposed in the body, each partially surrounding the central region, and each circumferentially adjacent to the other. The first, second and third heating elements provide heat to respective first, second and third zones of the stage. The power supply includes first, second and third power sources for respectively providing power to the first, second and third resistive heating elements. In one embodiment, the control system controls the first, second and third power sources according to an output from the temperature sensor and a power ratio of the power to the second and third resistive heating elements. In one embodiment, only the temperature sensor is used to measure the temperature of the resistive heater. In another embodiment, the temperature sensor is a thermocouple disposed within the central region of the body of the stage. In another embodiment, additional temperature sensors such as thermocouples may be provided for temperature control of the individual zones.
[0007] Another aspect pertains to a method for providing process repeatability in resistive heating systems. A heating surface is divided into a central region and at least two outer regions, with each outer region only partially surrounding the central region. Each outer region is given a respective power ratio with respect to the central region. The temperature of the central region is measured during a heating process, and heating power is delivered to the central region according to the measured temperature. Heating power is delivered to each outer region according to the heating power delivered to the central region and the respective power ratio of each outer region. In one embodiment, a calibration procedure is performed to obtain the power ratios.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows a cross-sectional view of a CVD system with a heating apparatus according to one embodiment;
[0009] FIG. 2 is a top perspective view of the heating apparatus depicted in FIG. 1 ;
[0010] FIG. 3 is a bottom perspective view of the heating apparatus depicted in FIG. 1 ;
[0011] FIG. 4 is a partial cross-sectional view of the heating apparatus depicted in FIG. 1 ;
[0012] FIG. 5 illustrates a control system for the heating apparatus depicted in FIG. 1 ; and
[0013] FIG. 6 is a top perspective view of the heating apparatus according to shown in FIG. 1 depicting a substrate disposed thereon and the heating regions of the apparatus shown in phantom.
DETAILED DESCRIPTION
[0014] Before describing several exemplary embodiments of the invention, it is to be understood that the invention is not limited to the details of construction or process steps set forth in the following description. The invention is capable of other embodiments and of being practiced or being carried out in various ways.
[0015] FIG. 1 presents a cross-sectional view of a CVD system 105 . A heating apparatus 10 is disposed within a reaction chamber 100 of the CVD system 105 . The reaction chamber 100 may support, for example, a CVD reaction process, an LPCVD reaction process or the like, and is defined and surrounded by chamber body 110 . The heating apparatus 10 includes a stage 20 for heating and supporting a wafer, and a shaft 30 , shown partly in cross-section, for supporting the stage 20 .
[0016] As shown in FIG. 2 , the stage 20 has a body 21 with a top surface 22 , which forms a susceptor 24 for supporting a wafer. Body 21 has a central region 41 , and outer region 49 that surrounds the central region 41 . Disposed just under the top surface 22 of central region 41 is a first resistive heater 51 that heats the central region or zone 41 . It will be appreciated that the central region or zone 41 can be heated by a single heater 51 or multiple heaters.
[0017] As shown in FIGS. 3 and 6 , the body 21 has a bottom surface 26 , to which is connected the shaft 30 . The shaft 30 is centrally mounted within the central region 41 , and has an opening 32 that extends along the longitudinal length of the shaft 30 . The outer region 49 of bottom surface 26 is divided into four substantially equal-sized zones 42 , 43 , 44 , 45 . A second resistive heater 52 heats zone 42 ; a third resistive heater 53 heats zone 43 ; a fourth resistive heater 54 heats zone 44 , and a fifth resistive heater 55 heats zone 45 . Consequently, the second, third fourth and fifth resistive heaters 52 - 55 each partially surrounds the first resistive heater 51 , and the second, third, fourth and fifth resistive heaters 52 - 55 are circumferentially adjacent to each other. The second, third, fourth and fifth resistive heaters 52 - 55 are each disposed just under the bottom surface 26 . However, in an alternative embodiment, the second, third, fourth and fifth resistive heaters 52 - 55 may each be disposed just under the top surface 22 . Similarly, in an alternative embodiment the first resistive heater 51 may be disposed just under the bottom surface 26 within the central region 41 . For example, in one embodiment, the first resistive heater 51 may be disposed just under the bottom surface 26 in the central region 41 , and the second through fifth resistive heaters 52 - 55 may be disposed just under the top surface 22 in their respective zones 42 - 45 in the outer region 49 . FIG. 6 shows the apparatus with the zones 41 - 45 shown in phantom and a substrate or wafer 301 disposed on the apparatus.
[0018] FIG. 4 illustrates a cross-sectional view along line IV-IV in FIG. 2 . The body 21 and shaft 30 may be made from any suitable material that can withstand the high temperatures and corrosive materials associated with CVD processes, such as aluminum nitride, graphite, aluminum nitride or pyrolytic boron nitride. In one or more embodiments, a dielectric material 67 , for example, pyrolytic boron nitride, is disposed across the top surface 22 to form the susceptor 24 , upon which a wafer to be processed is placed. The susceptor 24 includes lip edges 69 to ensure the wafer is held snugly and in a well-defined position on the susceptor 24 during processing. First resistive heating element 51 is disposed in the body 21 , just under the dielectric layer 69 . Third and fifth resistive heating elements 53 , 55 are disposed in the body 21 just above the bottom surface 26 . Of course, second and fourth resistive heating elements 52 , 54 (not shown) would be visible in a similar cross-section that is ninety degrees to line IV-IV. All of the resistive heating elements 51 - 55 may be made from any suitable material known in the art, and ideally should have thermal expansion properties that are similar to those of the body 21 . An example of a suitable material for the resistive heating elements 51 - 55 includes pyrolytic graphite. Each resistive heating element 51 - 55 has a corresponding power line 61 - 65 , running through opening 32 of shaft 30 that provides respective electrical power to the resistive heating element 51 - 55 , and thereby allows independent control of the heating power delivered to the inner region 41 , and to each of the outer region zones 42 - 45 . Of course, one or more ground lines (not shown) may be provided, also running through opening 32 , to complete the circuit of each resistive heating element 51 - 55 .
[0019] A thermocouple 70 may be provided to measure the temperature of the central region 41 . In one embodiment, an opening 74 , extending up from the bottom surface 26 , is used to position thermocouple 70 between the first resistive heating element 51 and resistive heating elements 52 , 53 , 54 and 55 , thereby thermally coupling the thermocouple 70 with the central region 41 of the body 21 . A signal line 72 may extend from the thermocouple 70 through the opening 74 of the stage 20 , and through the opening 32 of the shaft 30 , to provide temperature information about the central region 41 to a control system of the heating apparatus 10 . Of course, other temperature sensor configurations are possible. For example, an optical pyrometer may be used to measure the temperature of the central region 41 .
[0020] A control system 200 , depicted in FIG. 5 , may be used to control the heating apparatus 10 . The control system 200 may be part of the control system for the CVD system 105 depicted in FIG. 1 , and is electrically connected to the heating apparatus 10 . Together, the heating apparatus 10 and the control system 200 form the heating system for the CVD system 105 . Numerous possibilities are available for the physical implementation of the control system 200 , and an exhaustive review of the various permutations of digital and analog circuits that may be employed to create the control system 200 is beyond the scope of this disclosure. Any suitable implementation of the control system 200 may be used, and providing a detailed control system 200 should be a routine task for one of ordinary skill in the art, after reading the following disclosure.
[0021] According to one embodiment, the control system 200 includes a user input/output (I/O) system 210 , a temperature input 210 , a feedback control circuit 230 and a power supply 240 . The user I/O system 210 provides a user interface that allows a user to select a target temperature 211 for the central region 41 of the susceptor 22 , and to select second, third, fourth and fifth power ratios 212 , 213 , 214 , 215 for the second third, fourth and fifth resistive heaters 52 , 53 , 54 , 55 , respectively.
[0022] The temperature input 220 is electrically connected to the signal line 72 of the thermocouple 70 to obtain, in real-time, the current temperature 221 of the central region 41 of the stage 20 . The temperature input 220 then passes this current temperature 221 to the feedback control circuit 230 . In a manner familiar to those in the art, the feedback control circuit 230 accepts as input the current temperature 221 and the target temperature 211 and generates a heating power control output 231 . The purpose of the heating power control output 231 is to control the power delivered to the first resistive heater 51 so that the temperature of the central region 41 as measured by the thermocouple 70 tracks as closely as possible the target temperature 211 . The feedback control circuit 230 may be designed to employ any suitable feedback control method known in the art.
[0023] The power supply 240 provides the electrical power needed to individually power the resistive heating elements 51 , 52 , 53 , 54 , 55 in the heating apparatus 10 . The power supply 240 includes a first power output 241 that is electrically connected to the first power line 61 to provide electrical power for the first heating element 51 , and thus to heat the central region 41 . Similarly, the power supply 240 includes second, third, fourth and fifth power outputs 242 , 243 , 244 and 245 , each of which is respectively electrically connected to the second, third, fourth and fifth power lines 62 , 63 , 64 and 65 to heat the second, third, fourth and fifth zones 42 , 43 , 44 and 45 .
[0024] The first power output 241 accepts as input the heating power control output 231 from the feedback control circuit 230 , which may be an analog or digital signal, and in response provides corresponding electrical power on the first power line 61 . Hence, the power provided to the first resistive heater 51 by the first power output 241 is directly related to the heating power control output 231 generated by the feedback control circuit 230 .
[0025] The second power output 242 accepts as input the heating power control output 231 from the feedback control circuit 230 , and also the second heater power ratio 212 from the user I/O circuit 210 . In response, the second power output 242 provides electrical power on the second power line 62 such that the ratio of electrical power on the first power line 61 to that on the second power line 62 equals the second heater power ratio 212 . Hence, the power provided to the second resistive heater 52 by the second power output 242 equals the electrical power provided on the first power line 61 multiplied by (or divided by) the second heater power ratio 212 . Similarly, the power provided to the third, fourth and fifth resistive heaters 53 , 54 and 55 by the third, fourth and fifth power outputs 243 , 244 and 245 equals the electrical power provided on the first power line 61 multiplied by (or divided by) the third, fourth or fifth heater power ratios 213 , 214 and 215 , respectively. As a result, individual control of the heating power provided to the zones 42 , 43 , 44 , 45 with respect to the power provided to the central region 41 is possible by respectively adjusting the power ratios 212 , 213 , 214 , 215 , and hence variations in the heating characteristics of the zones 42 , 43 , 44 and 45 may be individually compensated for with respect to each other and the central region 41 . Of course, other designs for the power supply 240 are possible; whatever design may be chosen, the power supply 240 should individually control the heating power of each outer region zone 42 - 45 based upon the power supplied to the central region 41 and the respective power ratio 212 - 215 of that outer region zone 42 - 45 .
[0026] By dividing the outer region 49 of the stage 20 into a multiplicity of zones 42 - 45 that surround the central region 41 , and by further providing each of these outer region zones 42 - 45 a respective heater power ratio 212 - 215 with respect to the heating power provided to the central region 41 , the instant heating system makes it possible to provide compensation for variations in the heating characteristics of different heating apparatuses 10 , and to further provide compensation for variations in the heating characteristics of the CVD chamber 100 itself. By providing appropriate values for the heater power ratios 212 - 215 , a consistent heating pattern may be provided across the susceptor 24 , which should enhance process repeatability.
[0027] A calibration procedure may be performed for an individual heating apparatus 10 within a particular CVD chamber 100 to determine the appropriate heater power ratios 212 - 215 at any desired target temperature 211 . With reference to FIGS. 1-6 , one possible method for doing this is to initially set all heater power ratios 212 - 215 to default values, such as 1.0, or values obtained from an earlier calibration step. Then, a test wafer 301 may be placed onto susceptor 24 of heating apparatus 10 , and the central region 41 may be heated to the desired target temperature 211 . Subsequently, individual temperature measurements may be made in each of the outer region zones 42 - 45 on the wafer 301 , for example by the use of thermocouples attached to each zone 42 - 45 , or with one or more pyrometers. By way of the user I/O circuit 210 , the heater power ratios 212 - 215 may then be adjusted, while the feedback control circuit 230 keeps the central region 41 at the target temperature 211 , until the entire wafer 301 achieves a heating pattern that is as optimal as possible for the desired process. The resulting heater power ratios 212 - 215 may subsequently be used in production runs at that target temperature 211 .
[0028] Of course, the heater power ratios 212 - 215 need not be constant values. On the contrary, the heater power ratios 212 - 215 may vary as functions of the target temperature 211 , and consequently, an entire calibration procedure may involve a series of individual calibration steps at predetermined temperatures to obtain sets of heater power ratios 212 - 215 at each of these predetermined temperatures. Interpolation may then be used to determine heater power ratios 212 - 215 at target temperatures 211 that are between the predetermined temperatures.
[0029] It will be appreciated that the control system for controlling the heating apparatus 10 may comprise a plurality a temperature sensors. Each temperature sensor may measure the temperature of a single region or zone of the stage. The temperature sensors may include thermocouples, pyrometers or other suitable temperature sensing devices. Combinations of different types of temperature sensors may be used as well.
[0030] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It will be apparent to those skilled in the art that various modifications and variations can be made to the method, apparatus and system of the present invention without departing from the spirit and scope of the invention. For example, the outer region of the body of the stage may be divided not into only four zones, but into any number of zones greater than one. In certain embodiments, each of these zones would be provided its respective heating power ratio. Also, the resistive heater zones may overlap with each other. The various heating elements may be on the top surface, bottom surface or embedded in the body of the stage. Zonal temperature measurement may be provided by utilizing multiple temperature measurement devices (thermocouple, pyrometer, etc). Thus, it is intended that the present invention include modifications and variations that are within the scope of the appended claims and their equivalents.
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Apparatus, reactors, and methods for heating substrates are disclosed. The apparatus comprises a stage comprising a body and a surface having an area to support a substrate, a shaft coupled to the stage, a first heating element disposed within a central region of the body of the stage, and at least second and third heating elements disposed within the body of the stage, the at least second and third heating elements each partially surrounding the first heating element and wherein the at least second and third heating elements are circumferentially adjacent to each other.
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FIELD OF THE INVENTION
The invention concerns actively tuned liquid dampers for use in reducing the vibrations of large civil structures, such as tall buildings and suspension bridges, which are excited by high winds or earthquakes.
BACKGROUND OF THE INVENTION
Large civil structures are frequently exposed to severe dynamic loading from several sources including earthquakes and high winds. During high winds, the sway motion at the top of a tall building and the vertical deflection on long suspension bridges may reach tens of feet. Therefore, one of the most important problems facing civil engineers today is to find ways to reduce the motions of a large civil structure to ensure structural integrity and human comfort.
Until recently, large civil structures have been built as passive structures. The external dynamic loads were resisted solely by the mass and stiffness of the structure. However, as the structures have become longer, taller and more flexible, and the demand for safety has increased, the need for building structures with some degree of adaptability to external forces has been recognized.
In the last two decades, structural control concepts have received considerable attention for the design of large civil structures. Several tall buildings have been constructed with various types of movement control devices installed. Most of these movement control devices are passive devices. The most commonly used passive systems are base isolation, viscoelastic dampers, and tuned mass dampers.
Viscoelastic dampers are installed in the World Trade Center buildings in New York, in the Columbia Center building, and a new building at 2 Union Square; in Seattle. Tuned mass dampers are installed in the Centrepoint Tower in Sidney, Australia, the Canadian National Tower in Toronto, the John Hancock Tower in Boston, and the Citicorp Center in New York. Tuned liquid dampers were recently installed in several buildings in Japan, including the Yokohama Marine Tower, the Shin Yokohama Prince Hotel, and a new control tower at the Narita Airport. Model test results indicate that tuned liquid dampers are effective in reducing wind-induced vibrations.
Liquid dampers have long been used to reduce the roll motion of ships. A typical antirolling tank will have an H configuration when viewed from above. The horizontal channel which connects the two wing tanks is designed to control the speed of the flow. Some of the antirolling tanks have also incorporated semi-active control devices to improve their effectiveness. The principles employed to achieve semi-active control is to adjust the flow through the horizontal channel by valves. Thus, the range of adjustment is very limited but is adequate for ship roll control..
Passive control devices are tuned to particular frequencies. A passive control device is thus only effective if the forcing frequency is close to the device's tuned frequency. Excitations that affect large civil structures are often multi-frequency forces. For example, seismic excitations have energies spread over a band of frequencies. When the excitation is a multi-frequency force, passive control devices are much less effective. Active control devices are needed to improve damping effectiveness against multi-frequency excitation forces. Several active structural control devices have been developed and installed. These active devices include active tendon systems and active mass dampers.
Active mass dampers are usually installed on the top floor of a tall building. They have a solid mass of several hundred tons (at least one percent of the building mass). The motion of this mass is regulated by hydraulic actuators during an earthquake so that the building motion can be reduced. The effectiveness of control devices can be improved by the addition of such active control. However, current active mass damper systems have many drawbacks. For example, these systems have an excessive peak power requirement. There are also reliability problems inherent with infrequently used equipment.
Tuned liquid dampers are similar to tuned mass dampers. Tuned liquid dampers utilize a large mass of liquid. As discussed above, tuned liquid dampers are only effective when the forcing frequency is near the natural frequency of the system. Tuned liquid dampers could be, made responsive to different forcing frequencies by utilizing active control. However, if the conventional active control concept were used, for example, to regulate the motion of the tank, peak power requirements and reliability problems would again be the severe limitations.
It is an object of the invention to provide active control of a tuned liquid damper system with a minimum power requirement.
It is another object of the invention to provide an actively tuned liquid damper system that is simple to construct and has relatively low cost in relation to previous structural motion control systems.
It is another object of the invention to provide an actively tuned liquid damper system that may be easily adjusted or altered during or after installation.
It is a further object of the invention to provide an actively tuned liquid damper system with multiple degrees of freedom.
It is a further object of the invention to provide an actively tuned liquid damper system that may be regularly tested without imparting motion to the structure to which the system is attached.
SUMMARY OF THE INVENTION
An actively tuned liquid damper is provided that utilizes liquid as a damper for structural control. The actively tuned liquid damper has a container or tank which retains a liquid mass, similar to a passive tuned liquid damper. The tank is attached to the structure whose motion is to be damped. Active control of the damper's response frequencies is accomplished through active tuning of the length of the liquid compartment or the liquid depth. Tuning of the damper is achieved by controlling a rotatable baffle to regulate the effective length of the tank. The tank's effective length dictates the natural frequency of the liquid, and thus the response frequency of the damper. Additional control of the actively tuned liquid damper may be achieved by utilizing combinations of multiple baffles in a tank and through the use of multiple tanks.
As a general guideline, a motion damping system should have a mass of at least 1% of the structure to which it is attached and an optimum damping coefficient of about 5%. Thus, the liquid mass for the actively tuned liquid damper should utilize a liquid mass of at least 1% of the structure mass. However, when a tank is deeply filled with a liquid, only the liquid in the surface layer sloshes as the tank moves. Thus, most of the liquid in the tank does not contribute to the damping action. Accordingly, shallow-filled tanks are more efficient for structural control. An actively tuned liquid damper should thus consist of many tank groups each containing ten to twenty shallow tanks stacked on top of each other.
High winds and earthquakes will usually induce structural motion predominantly in the structure's fundamental mode. Accordingly, the basic component of the actively tuned liquid damper is a liquid damper tuned to the structure's fundamental frequency. Although liquid sloshing is a highly nonlinear phenomenon, the frequencies of sloshing can be approximated by the following equation which is based on a linear theory: ##EQU1## where ω n is the n th natural frequency of the liquid in radians/second, 2a the tank length, D the fill depth, n the mode number, and g the acceleration due to gravity. Distances 2a and D, and acceleration g are measured in meters and meters/second/second, respectively, or in any other consistent units.
When a tuned liquid damper is excited at its fundamental frequency, a large slosh force will be produced. This force is 90 degrees out of phase with the structural motion and thus contributes to damping the structure's motion. At higher excitation frequencies, however, liquid motion will be in higher modes. Although these higher modes also produce significant slosh forces, experimental results indicate that these forces will not be sufficiently out of phase with structural motions. Therefore, the higher mode slosh forces do not contribute much to damping the structure's motion.
The equation above shows that the liquid's natural frequency is proportional to the liquid fill depth but is inversely proportional to tank length. Therefore, tuning of the liquid can be achieved by either adjusting the fill depth or the effective tank length. The effective tank length can be adjusted by controlling the orientation of one or more baffles. When the baffles are parallel to the tank's longitudinal axis, the tank is at its full length and is effective at the designed fundamental frequency. When the baffles are perpendicular to the tank's longitudinal axis, the tank is effectively divided into two or more shorter tanks, each with a higher fundamental frequency. Thus:, the tuned liquid damper becomes effective at higher frequencies. When the baffles are in an in-between orientation, the resonance frequency will be between the endpoint frequencies produced by placing the baffles either parallel or perpendicular to the tank's longitudinal axis. Therefore, by controlling the orientation of the baffles, the tuned liquid damper become,,; effective over a range of frequencies.
The actively tuned liquid damper eliminates the need to regulate the motion of the tank in order to achieve active control. Thus, it requires a very small amount of power and is more reliable as compared with other active control devices such as active mass dampers. When there is no external excitation, the baffles' positions may be freely adjusted without imparting motion to the building. Therefore, the baffle position control systems may be regularly tested without discomfort to a structure's occupants.
Further objects and features of the invention will be apparent to those skilled in the art from the following detailed description of preferred embodiments, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a longitudinal cross section of the device.
FIG. 1B shows a transverse cross section of the device through section A--A of FIG. 1A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1A-B, one embodiment of the actively tuned liquid damper is shown. A tank 10 is mounted to the top of a structure, such as a building 12. Supports 14 are used to insure adequate support of the weight of the tank 10 and the liquid 15. In the preferred embodiment, the ratio of the liquid depth to the length of the tank is at least 0.08:1, but generally should not be more than 0.15:1. The container height should be at least twice the liquid depth to preclude impairment of the damper's effectiveness. Transverse baffles 16 are rotatably mounted to the tank 10 so that they rotate about axes 18. In the preferred embodiment, multiple baffles 16 are used to increase the range of frequencies to which the tank 10 can be tuned. The rotational position of each baffle 16 is controlled by an externally mounted stepping motor 20. In the preferred embodiment, fixed baffles 22 are transversely mounted in the tank 10 so that, when the rotatable baffles 16 are rotated into a vertical position, the tank 10 is completely subdivided into chambers which are not in fluid communication with each other. A further feature of the preferred embodiment is that multiple tanks 10 are used so that each tank 10 contains a fraction of the total liquid mass. The tanks 10 may be mounted on top of each other or in any other manner which fits the available space. Stacks of ten to twenty tanks 10 are preferred.
In the preferred embodiment, measurements of the ground's motion are made by ground motion sensors 24. The structure's motion is measured by building motion sensors 26. Motion sensors suitable for this purpose are Model 8306 Low Frequency Accelerometers manufactured by B&K Instruments, Inc., 5111 W. 164th Street, Cleveland, Ohio 44142. Signals from the ground and building motion sensors 24, and 26 are analyzed and compared using a microcomputer 28. In the preferred embodiment, a time-varying, moving-window Fourier analysis is used to determine the time-frequency distribution of the signals. Because analysis speed is critical in providing sufficiently rapid control of the actively tuned liquid damper, the computer 28 must have sufficient capacity and speed to facilitate this real-time control. One computer possessing the requisite capabilities is the 486DX266 PC, manufactured by Dell Computer Corp., 9505 Arboretum Blvd., Austin, Tex., utilizing the following additional equipment: a standard signal conditioning/amplifier unit 30, a DAS 20 analog-to-digital converter board 32, and an RTI-815 digital-to-analog converter board 34.
The determination of how to position the baffles 16 is made as follows: Low frequency accelerometers 24 measure ground motion. Additional low frequency accelerometers 26 measure structure responses. Placement of accelerometers 24 and 26 is determined by the building site and the mode shapes of the structure. The "mode shapes" of the structure are determined by how the structure moves when exited by a particular vibrational mode. In general, the accelerometers 26 should not be place at nodes, that is, at locations where the structure will not move. The output of accelerometers 24 and 26 are processed through a signal conditioning/amplifier unit 30. The signal conditioning/amplifier unit 30 removes unwanted high frequency noise, preferably eliminating frequencies above 20 Hertz. The conditioned signal is then amplified by the signal conditioning/amplifier unit 30. The output of the signal conditioning/amplifier unit 30 is converted to a digital signal by an analog-to-digital converter 32. The analog-to-digital converter 32 is preferably installed in the processing microcomputer 28.
At least two alternate methods of analyzing the digital signals output by the analog-to-digital converter 32. The preferred method is accomplished by frequency analysis of the ground motion and the building response. This analysis utilizes either the time-varying moving-window Fourier analysis technique described in the paper by W. Chen, N. Keltarnowaz, and T. W. Spancer, "An Efficient Recursive Algorithm for Time-Varying Fourier Transform," IEEE Trans. Signal Processing, Vol. 41, No. 7, July 1993, pp. 2488-2490, or the wavelet method described in the book by C. K. Chui, "An Introduction to Wavelets," Academic Press, 1992. The time-varying moving window Fourier analysis allows determination of the frequency-time distribution of the building response. The analysis also provides information on the energy concentrations at each frequency range. Both the time-varying moving window Fourier analysis and the wavelet method are well developed and offer rapid data analyses sufficient to meet the real-time requirements of this invention. Computer software based on these methods is readily available, for example, the wavelet software is available in the software package "MATLAB" and the time-frequency analysis software is available in the "Gabor Spectrogram" software package by National Instruments, Inc. The second method of analyzing the digital signals output by the analog-to-digital converter 32 is to determine the modal participation factors of the building response. Because wind and earthquake excitations are basically low frequency phenomena, building response will be predominantly in the first two or three modes. Modal analysis techniques are well developed and have been widely used by structure engineers. For example, see "Dynamics of Structures" by Hurty and Rubenstein, Prentice-Hall, 1964. Because only a few modes need to be analyzed, signal processing can be performed quickly enough to meet real time control constraints.
If the structure's 12 response is primarily in the structure's 12 fundamental mode, no active control is necessary and the baffles 16 will remain in the lay down position. However, if the building response involves higher modes, the liquid tanks 10 can be controlled in groups. Each group is used to damp the structure's 12 response at a particular frequency. The number of tanks 10 in each group will depend on the relative intensity of the, energy level associated with the target frequency. The orientation of the baffles 16 in each group will depend on the targeted frequency for that group. The baffles 16 may have to be rotated to a vertical position to completely divide the tank 10 into several short compartments, or the baffles 16 may be rotated into an inclining position.
The microcomputer 28 generates a digital control signal to position the stepping motor 20. This digital signal is convened to an analog signal via an digital-to-analog converter 34. The resulting analog signal drives the stepping motor 20. The stepping motor 20 rotates the baffle 16 into the desired positions.
Many modifications and variations may be made in the embodiments described herein and depicted in the accompanying drawings without departing from the concept of the present invention. Accordingly, it is understood that the embodiments described and illustrated herein are illustrative only and are not intended as a limitation upon the scope of this invention.
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The invention concerns the use of actively tuned liquid dampers to quench vibrations in large civil structures. Such vibrations may be induced by earthquakes or high winds. The effective length of the liquid damper tank determines the natural frequency of the liquid, and thus the effectiveness of the damper at particular excitation frequencies. The liquid damper is tuned by rotating baffles to regulate the effective length of the damper tank.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to bar-locks, and more particularly to an encased bar-lock provided with a cylinder lock mounted on a pivotal bar, enabling barring and locking functions with a high degree of security against tampering and breakage.
BACKGROUND OF THE INVENTION
[0002] The bar-lock is a type of lock known for thousands of years. This type of lock was in use in ancient walled cities, in which a large brace, typically a piece of timber wood, or an entire tree trunk, was placed against the width of a gate from the inside, the gate normally opening inward as shown in prior art FIG. 1A . In later prior art, a metal bar was placed in U-shaped or L-shaped anchor braces fastened to each side of the gate posts to hold the bar firmly against the gate, thus preventing the gate from opening, as shown in prior art FIG. 1B . With advances in technological developments, the locking function of the bar-lock was limited to locking stables, barns, sheds, and the like, where the brace locks the doors from the outside and prevents the exit of livestock from secure areas. Additional prior art designs of bar type locks are shown in FIGS. 2-5 .
[0003] A modern example of the prior art use of bar-locks is described in U.S. Pat. No. 4,548,058 to the present inventor, in which protected hasps are mounted alongside the opening of, for example, a double-door (see FIG. 6 ) so as to mesh when the doors are closed, with a padlock body being inserted within one opening in the hasps to join with a shackle inserted into an opposing opening in the hasps and locked in place with a key. This is known as a protected hasp lock.
[0004] Protected hasp locks, such as that described, are inconvenient to use. This is because once the padlock is opened, the padlock body and shackle must be stored until the lock is re-closed, and they may be misplaced and difficult to find. In addition, it is inconvenient and sometimes difficult for a user to operate the prior art padlock with only one hand free, since it needs both hands in order hold the lock body at the same time as using a key.
[0005] Therefore, it would be desirable to provide a lock having the advantageous security features of the protected hasp lock, and the simplicity of a bar-lock.
SUMMARY OF THE INVENTION
[0006] Accordingly, it is a principal object of the present invention to overcome the disadvantages associated with the prior art and to provide a bar-lock having a cylinder lock, with the entire lock being encased and fully protected from tampering or breakage by unauthorized intrusion.
[0007] In accordance with a preferred embodiment of the present invention, there is provided a pivotal bar-lock comprising:
[0008] an anchor hasp comprising a locking hub and a first locking means integrally formed with a first mounting plate;
[0009] a locking hasp integrally formed with a second mounting plate and having a mating element and a second locking means formed therein; and
[0010] a locking bar rotatably mounted on said anchor hasp, said locking bar having a cylinder lock encased therein and an engagement means formed therewith;
[0011] said cylinder lock being operable such that when rotated into an unlocked mode, said locking bar is pivotally enabled to assume one of open, in-transit, and closed positions in interaction with said first and second locking means, and when said cylinder lock is rotated into a locked mode, said engagement means of said locking bar engages said mating element of said locking hasp.
[0012] In an exemplary embodiment, the key-operated cylinder lock is mounted on the locking bar of the bar-lock, and a locking cam operated by the cylinder lock engages a locking channel formed between the first and second mounting plates, enabling locking of the locking bar when closed on the locking hasp integrally formed on the second mounting plate, with the locking bar being secured in place when the bar-lock is locked.
[0013] In the preferred embodiment, the cylinder lock and locking cam are entirely encased in a locking bar having an increased thickness and mass, to provide additional security. The locking bar is designed as an integrally formed unit, without external openings except for a key opening which is kept to a minimal size so as to discourage and prevent tampering, drilling, and other attempts at forced intrusions, such as with a crowbar, saw, wire cutter, drill or other similar implements.
[0014] A feature of the invention is that the locking bar is spring-loaded to establish the open and closed positions, enabling the bar-lock to be operated with one hand.
[0015] Another feature of the invention is that the locking hasp and the anchor hasp are laterally joined in the same plane by a tightening assembly to define a mounting template for complete, accurate, safe and easy installation, using auxiliary, small diameter mounting screws to assist in the installation.
[0016] In one embodiment the first mounting plate of the anchor hasp and the second mounting plate of the locking hasp are co-planar.
[0017] In an alternative embodiment, the locking hasp has a mounting surface additional to the second mounting plate, which is not co-planar with the second mounting plate, enabling mounting of the locking hasp on various types of doors.
[0018] The bar-lock of the present invention is designed so that the anchor hasp is mounted with a single main, massive fastening means coincident with an axis defining the locking bar rotation, with the fastening means being tamper-resistant.
[0019] An advantage of the present invention is that the entire locking bar serves as a locking bolt.
[0020] In one embodiment of the present invention, the locking means is a channel having formed therein a first locking bay defined as a closed position locking bay, and a second locking bay defined as an open position locking bay, the first and second locking bays being disposed at opposing ends of the channel.
[0021] When the locking bar is pivoted to engage the mating element of the locking hasp, the channel engages a locking cam in the closed position locking bay, locking the pivotal bar-lock.
[0022] When the locking bar is pivoted to disengage from the mating element and the locking hasp, the channel engages the locking cam in the open position locking bay, thus securing the locking bar in the open position.
[0023] A feature of the invention is the design of the locking cam, which is formed with a partial circumferential collar, with the collar being supported on the cylinder lock, thereby eliminating forced-opening pressure acting on an internal mechanism associated with the cylinder lock.
[0024] An additional feature of the invention is that the collar is formed with at least one notch which engages a spring-loaded plunger, to define at least one of the open, in-transit and closed positions.
[0025] Another additional feature of the invention is that the anchor hasp and locking bare are integrally formed, respectively, with first and second sets of connecting lugs which are rotatably interlocked in the open and closed positions, preventing disassembly of the locking bar from the anchor hasp. The locking bar can be disassembled from the anchor hasp for maintenance purposes when the locking bar is the in-transit position to enable clearance of the first and second connecting lugs.
[0026] Yet another additional feature of the invention is the provision of a spring to establish the open and closed positions of the locking bar, with the spring additionally assisting in maintaining the locking bar on the anchor hasp, preventing its accidental removal until the spring is removed for disassembly of the locking bar.
[0027] The present invention also features the provision of engagement means as a latch portion of the locking bar which is rotatable to engage said mating element of the locking hasp in the closed position, with the cylinder lock being operable to lock it therein. The latch portion may be designed to have a latching channel, to enable locking of sliding doors.
[0028] Another feature of the present invention is the provision of an adapter means for mounting at least one of the anchor hasp and the locking hasp. The adapter means enables mounting of the pivotal bar-lock on glass doors, aluminum frame doors, or mounting to a metal frame without fasteners.
[0029] Another feature of the invention is the ability to mount the anchor hasp and locking hasp on at least one of a variety of door types and opening directions, including reversible doors, single and double doors, swinging, sliding, folding, accordion-type, and rotating doors. The doors may be constructed from materials selected from at least one of the group of wood, plastic, metal, and glass.
[0030] Additional features and advantages of the present invention will become apparent from the following drawings and description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] For a better understanding of the invention with regard to the embodiments thereof, reference is made to the accompanying drawings, not shown to scale, in which numerals designate corresponding elements or sections throughout, and in which:
[0032] FIG. 1A is a prior art illustration showing a fortified gate as seen from within a walled fort which is barred using a timber beam;
[0033] FIG. 1B is a prior art illustration showing double doors, which are locked using a classic type bar-lock engaged between anchors attached to the door frames;
[0034] FIG. 2 is a prior art illustration showing double doors, which are locked using a shortened bar-lock engaged between anchors attached to the doors themselves,
[0035] FIG. 3 is a prior art illustration showing double doors, which are locked using a shortened bar-lock arranged to pivot on an axle attached to one of the doors and engaged in an anchor attached to the second door;
[0036] FIG. 4 is a prior art illustration showing double doors, which are locked using a shortened, pivotal bar-lock as in FIG. 3 , but additionally secured by a conventional padlock;
[0037] FIG. 5 shows a prior art illustration of a single, right-hand door locked with a short pivotal bar secured in a bar keeper attached to a door frame and locked with a padlock;
[0038] FIG. 6 is a prior art illustration showing double doors locked using a protected hasp lock provided as a split padlock per the invention of U.S. Pat. No. 4,548,058;
[0039] FIG. 7A illustrates a single door locked with a short, pivotal bar-lock in accordance with a preferred embodiment of the invention;
[0040] FIG. 7B shows an enlarged detail of a portion of the door of FIG. 7A locked with a preferred embodiment of a pivotal bar-lock, constructed and operated in accordance with the principles of the present invention;
[0041] FIG. 7C shows a rear, detailed view of the lock shown in FIGS. 7A and 7B ;
[0042] FIG. 7D shows a portion of the door of FIG. 7A with an enlarged, detailed view of the lock mounted thereon in an unlocked condition and pivoted in a halfway open position allowing the door to be opened;
[0043] FIG. 7E shows a rear, detailed view of the lock shown in FIG. 7D ;
[0044] FIG. 7F shows a portion of the door of FIG. 7A with an enlarged, detailed view of a lock mounted thereon in an unlocked and secured position, enabling the door to be opened;
[0045] FIG. 7G shows a rear, detailed view of the lock shown in FIG. 7F ;
[0046] FIG. 8 shows a prior art locking system for a conventional shipping container based on a pivotal bar-lock with a padlock as in FIGS. 4-5 ;
[0047] FIG. 9 shows a locking system for a conventional shipping container in accordance with a preferred embodiment of the present invention;
[0048] FIG. 10A shows a single, right-hand door, opening outwardly, which is locked using a bar-lock in accordance with an embodiment of the present invention,
[0049] FIG. 10B shows an enlarged, detailed view of the lock of FIG. 10A with a view of a portion of the door opened and the bar-lock unlocked and secured in position;
[0050] FIG. 1A shows a portion of a single, left-hand door, opening inwardly, which is locked with a bar-lock in accordance with an embodiment of the present invention;
[0051] FIG. 11B shows a portion of the door of FIG. 11A opened, with the bar-lock unlocked and secured;
[0052] FIG. 12 shows a partial cut-away view of a portion of an open, single, right-hand door, opening inwardly, with the bar-lock being pivoted upwardly, unlocked and secured in place;
[0053] FIGS. 13 A-B show exploded views of a bar-lock in a preferred embodiment of the invention;
[0054] FIG. 14 shows an exploded view of an adapter and related mounting hardware used for attaching the locking hasp of FIG. 13 to a glass door in accordance with the principles of the invention;
[0055] FIG. 15 shows an exploded view of an adapter and fasteners for mounting the bar-lock of FIG. 13 onto an aluminum frame door in accordance with the principles of the invention;
[0056] FIG. 16A is a perspective view of a portion of double glass doors with the bar-lock of FIG. 13 mounted thereon, using the adapter of FIG. 14 ;
[0057] FIG. 16B is a cross-section view of a glass door mounted with the bar-lock of FIG. 16A seen along the axis of a mounting bolt;
[0058] FIG. 17 is a partial cut-away, perspective view of the bar-lock of FIG. 13 , with the adapter and fasteners shown in FIG. 15 , mounted onto the fires of an aluminum frame door in accordance with the principles of the invention;
[0059] FIG. 18 is a perspective view of the bar-lock of FIG. 1-3 weld-mounted onto a right-hand, outwardly opening gate shown in a shut and locked condition;
[0060] FIG. 19 is a front view of a preferred embodiment of the invention;
[0061] FIG. 20 is a vertical, cross-sectional side view taken along section line XX-XX of the bar-lock of FIG. 19 ;
[0062] FIG. 21 is a vertical, cross-sectional side view taken along section line XXI-XXI of the bar-lock of FIG. 19 in a locked condition and unopened position;
[0063] FIG. 22 is a horizontal, cross-sectional top view taken along section line XXII-XXII of the bar-lock of FIG. 19 ;
[0064] FIG. 23 is a top view of the bar-lock of FIG. 19 ;
[0065] FIG. 24 is a horizontal, cross-sectional front view taken along section line XXIV-XXIV of the bar-lock of FIG. 23 ;
[0066] FIG. 25 is a horizontal, cross-sectional front view taken along section line XXV-XXV of the bar-lock of FIG. 23 ;
[0067] FIG. 26 is a horizontal, cross-sectional front view taken along section line XXVI-XXVI of the bar-lock of FIG. 23 ;
[0068] FIG. 27 is a top view of the bar-lock of FIG. 19 in a half-open position;
[0069] FIG. 27X is a vertical, cross-sectional view taken along section line XXXVI-XXXVI of the bar-lock of FIG. 27 ;
[0070] FIG. 28 is a horizontal, cross-sectional front view taken along section line XXVIII-XXVIII of the bar-lock of FIG. 27 ;
[0071] FIG. 29 is a horizontal, cross-sectional view taken along section line XXIX-XXIX of the bar-lock of FIG. 27 ;
[0072] FIG. 30 is a horizontal, cross-sectional view taken along section line XXX-XXX of the bar-lock of FIG. 27 ;
[0073] FIG. 31 is a front view of a preferred embodiment of the invention with the barlock in an unlocked and secured position;
[0074] FIG. 32 is a horizontal, cross-sectional view taken along section line XXXII-XXXII of th bar-lock of FIG. 31 ;
[0075] FIG. 33 is a horizontal, cross-sectional view taken along section line XXXIII-XXXIII of the bar-lock of FIG. 31 ;
[0076] FIG. 34 is a horizontal, cross-sectional view taken along section line XXXIV-XXXIV of the bar-lock of FIG. 31 ;
[0077] FIG. 35 is a front view of a preferred embodiment of the invention illustrating the locked position of a bar-lock and showing the position of an exposed spring and the vector forces applied thereto for resisting unauthorized attempts to open the bar-lock;
[0078] FIG. 36 is a front view of the bar-lock from FIG. 35 in a halfway open, unlocked position with an exposed view of the position of a spring;
[0079] FIG. 37 is a front view of the bar-lock from FIG. 35 , unlocked and secured in position, with an exposed view of the position of a spring and an associated vector diagram indicating the forces acting thereon;
[0080] FIG. 38 is a front view of an alignment washer for aligning and joining a first mounting plate with a second mounting plate of a pivotal bar-lock in accordance with an embodiment of the invention;
[0081] FIG. 39 is a horizontal, cross-sectional top view taken along section line XXXIX-XXXIX of the alignment washer of FIG. 38 ;
[0082] FIG. 40 is a horizontal, cross-sectional top view taken along section line XL-XL of the alignment washer of FIG. 38 ; and
[0083] FIG. 41 is an enlarged, exploded view of the alignment washer assembly of the invention, in a preferred embodiment thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0084] Referring now to FIG. 1A there is shown an example of an ancient prior art configuration of fortified, double doors 40 barred with a timber member 42 which is secured within keepers 44 formed in the stone walls 46 . In FIGS. 1 B and 2 - 4 , there are shown alternative prior art configurations of double doors 50 with supporting door posts 52 adapted to use simple bars 54 , 60 , 62 , 66 , and 67 , respectively, for securing the doors in a closed, barred condition. In FIG. 1B , the bar 54 is mounted between the doorposts 52 using bar keepers 58 to hold bar 54 securely in place. In FIG. 2 , a short bar 60 is mounted across the doors 54 and secured in place using bar keepers 58 attached directly to double doors 50 . In FIG. 3 , bar 62 is pivotal about an axis 64 of a bar anchor 65 and secured in bar keeper 58 , both bar keeper 58 and bar anchor 65 being mounted on double doors 50 . In FIG. 4 , double doors 50 are barred with a pivotal bar 66 rotatable at axis 64 of bar anchor 65 which is mounted to one of the doors 50 . Bar 66 is rotated and secured into bar keeper 59 which is disposed on the second door and adapted to be locked with a conventional padlock 68 .
[0085] FIG. 5 shows an alternative prior art configuration of a single, left-hand, reverse door 70 , supported on door posts 52 and locked with a pivotal bar 67 rotatable at axis 64 of bar anchor 65 and secured in bar keeper 69 which is adapted to be locked with a padlock 68 .
[0086] FIG. 6 shows a prior art configuration of a double door 50 adapted to use a pair of prior art locks in the form of a protected hasp lock 72 , as described in U.S. Pat. No. 4,548,058, to the present inventor. Hasp lock 72 in the lower portion of doors 50 is shown in a locked condition and the manner for assembly of the major components of hasp lock 72 , shown mounted in the upper portion of doors 50 , are indicated by the arrows. The lock shackle 74 is inserted into a protective body 78 of hasp lock 72 at an upper end thereof and engages a padlock body 76 inserted from a lower end of protective body 78 . Since the parts of padlock 72 are inside protective body 78 , they are tamper-proof and the padlock 72 is protected against forced breakage.
[0087] Referring now to FIG. 7A , there is illustrated a single, left-hand, reverse door 70 supported on door posts 52 , locked with a short, pivotal bar 80 rotatable at axis 64 of bar anchor 57 and secured in bar keeper 58 which is attached to one of door posts 52 . Pivotal-bar 80 is provided with an integral bar-lock 82 having a cylinder lock 84 (see detail FIG. 7B ) in accordance with a preferred embodiment of the invention.
[0088] FIG. 7B is an enlarged detail of the door 70 and door post 52 from FIG. 7A having a preferred embodiment of a pivotal bar-lock, constructed and operated in accordance with the principles of the present invention.
[0089] Bar-lock 82 , in the embodiment of the present invention shown in FIG. 7 ; comprises the elements: an anchor plate 86 , integral to bar anchor 57 , configured with a channel 90 having a locked position bay 90 a and an unlocked and secured position bay 90 b formed at opposing ends thereof; pivotal bar 80 ; cylinder lock 84 ; and cylinder housing 88 forming an integral part of bar 80 .
[0090] FIG. 7C shows a rear, detailed view of the lock from FIGS. 7A and 7B . In FIG. 7C , anchor plate 86 is seen from a rear perspective to be formed integral to bar anchor 57 , and having formed therein an arc-shaped channel 90 , having at one end thereof a locked position bay 90 a and at the other end thereof, an unlocked and secured position bay 90 b. Locking cam 92 is shown engaged within channel 90 , by way of example, in locked position bay 90 a with bar 80 locked in bar keeper 58 .
[0091] FIG. 7D is an enlarged, detailed view of door 70 from FIG. 7A showing bar-lock 82 mounted thereon in an unlocked condition and pivoted, as indicated by the curved arrow, in a halfway open position allowing the door to be opened. Bar 80 is not locked when locking cam 92 is in-transit between bays 90 a and 90 b.
[0092] FIG. 7E shows a rear, detailed view of the lock of FIG. 7D .
[0093] Using a key 96 to unlock bar-lock 82 allows pivotal bar 80 to pivot as indicated by the curved arrow around axis 64 of bar anchor 57 . Thus, as bar 80 pivots on axis 64 between the unlocked position at bay 90 b and locked position at bay 90 a, locking cam 92 (visible in FIGS. 7C and 7E ) moves in channel 90 .
[0094] When locking cam 92 is in one of the extreme positions of channel 90 , in either of locked position bay 90 a or unlocked and secured position bay 90 b, it can be rotated respectively, to a locked or unlocked position by use of key 96 , which is inserted into cylinder lock 86 .
[0095] FIG. 7F shows an enlarged, detailed view of door 70 of FIG. 7A , with bar-lock 82 mounted thereon, in an unlocked and secured position, enabling the door to be opened.
[0096] FIG. 7G shows a detailed, rear view of the bar-lock of FIG. 7F .
[0097] It will thus be appreciated that pivotal bar-lock 82 can be locked in place both in the locked position while secured in bar anchor 58 and in the opened and secured position as shown in FIG. 7F . While it is clearly apparent and essential that pivotal bar-lock 82 be lockable in the locked position, it may be less apparent why bar-lock 82 should be lockable in the open position. However, this is an important feature of the invention, as it increases the level of security against accidental or malicious closure of locking bar 80 on door 70 of a room while people are inside.
[0098] It can be readily seen that bar-lock 82 is simpler, more convenient, and more secure to use than the prior art bar-locks described heretofore, since all of its component parts are integrated and the user can operate bar-lock 82 using only key 96 , to open and lock it. The present invention is thus more useful than a common padlock, which must be removed and stored separately from the hasp once it is opened, and must be retrieved when it is desired to secure the hasp. An unused hasp is subject to abuse and the present invention prevents it from being locked by an unauthorized person.
[0099] Bar-lock 82 is also more secure in use, since it does not use a shackle as in the protected hasp lock of the prior art shown in FIG. 6 , and is therefore not vulnerable to attempts to break the lock by using a bar cutter to cut the shackle, or a crowbar to pry open the lock.
[0100] FIG. 8 shows a prior art locking system for a conventional shipping container. Note that rotatable bar 66 is secured in bar keeper 69 as in FIG. 5 and is adapted to be locked with padlock 68 .
[0101] FIG. 9 shows a locking system for a conventional shipping container in accordance with a preferred embodiment of the present invention. The ease of use and security are apparent in contrast to the, prior art lock shown in FIG. 8 . Pivotal bar-lock 98 in this embodiment of the invention is provided with a handle 100 for pivoting it so that the locking cam (not visible) engages stopping bay 90 a or 90 b, and can be locked into either position by use of the cylinder lock 140 and a key (not shown). Anchor plate 86 is mounted in a horizontal plane and fixed to a door around a vertical, door-locking rod 99 used to lock shipping containers.
[0102] FIG. 10A shows a single, left-hand, reverse door, which is locked using a bar-lock in accordance with an embodiment of the present invention. Door 70 is shown closed and locked with bar-lock 102 which is attached to door 70 and an adjoining door-post 52 .
[0103] FIG. 10B shows an enlarged, detailed view of the bar-lock 102 of FIG. 10A with a view of a portion of door 70 from FIG. 10A , shown opened, and locking bar 104 in an unlocked and secured position.
[0104] The locking hasp 106 is integrally formed with a keeper 83 for engaging a latching channel 110 formed in latch portion 119 . The latch portion 119 forms an end of locking bar 104 , which, when engaged with keeper 83 , prevents sliding type doors fitted and locked with bar-lock 102 from being opened or moved. When a bar-lock 102 is installed and locked on swinging type doors, the doors are prevented from opening by the inside face of wall 85 and by abutment with an inner face of mounting plate 112 .
[0105] It should be appreciated that this embodiment of the invention uses a novel, shaped cylinder lock key opening 108 for receiving key 96 to unlock or lock a cylinder lock (not shown) mounted integrally on locking bar 104 . Locking bar 104 is attached to door post 52 via a mounting plate 114 of anchor hasp 155 . Locking hasp 106 is attached to door 70 of FIG. 10A via mounting plate 112 using fasteners 105 , such as screws. Fasteners 105 serve as auxiliary mounting hardware until larger sized bolts 122 are inserted to secure bar-lock 102 onto a mounting surface of a door or door post. One-way screws, which are not subject to unscrewing, can be employed for initial mounting of bar-lock 102 , or the drives on ordinary auxiliary screws can be destroyed since they are left in place for convenience and for added security.
[0106] FIG. 11A shows a single, right-hand door portion 75 , which is locked shut against door post portion 73 using a bar-lock 102 in accordance with a preferred embodiment of the present invention FIG. 11B shows the door portion 75 of FIG. 11A unlocked and opened, and locking bar 104 unlocked and secured in position.
[0107] Locking hasp 106 is attached to door post portion 73 through a hexhead bolt 122 inserted in a hole 81 formed in locking hasp 106 . Locking bar 104 is mounted to door portion 75 using mounting plate 114 and secured with a fastener 122 (see cut-away in FIG. 12 ), such as a hexbolt and a nut 116 . Key 96 is turned a quarter-turn in its slot to unlock bar-lock 102 and open door portion 75 inwards as indicated by the curved arrow shown in FIG. 11B . Locking bar 104 rotates when unlocked with key 96 and latch portion 119 is shown, by way of example, secured in a downward position. In other applications, latch portion 119 may be unlocked and secured in an upward position as shown, by way of example, in FIG. 12 .
[0108] FIG. 12 shows a partial cut-away view of a portion of a single, left-hand door 69 . Door 69 is shown partially opened and locking bar 104 is shown pivoted upwardly with an engaging means, such as latch portion 119 , unlocked and secured in place. Locking hasp 106 is attached to door post 128 with a sturdy listener, such as a hardened bolt 126 (Allen head), as shown in a partial cut-away view. Hardened bolt 126 is inserted through pre-formed hole 81 in keeper 83 , enabling use of a much larger and sturdier bolt than usual so as to give bar-lock 102 stronger protection. The locking bar 104 is attached to a portion of door 69 with a hexbolt 122 , and locked with lock nut 116 .
[0109] FIGS. 13A and 13B show respective right and left exploded views of a bar-lock in a preferred embodiment of the invention.
[0110] Referring to FIG. 13A , the pivotal bar-lock is shown from a right perspective view and includes the major elements: an anchor hasp 155 laterally joined with a locking hasp 106 , and a locking bar 104 . A locking washer assembly comprising a locking washer 162 , a fastener 160 , and a threaded end-cap 164 which is seated flush with the outer faces of the first and second mounting plates 114 and 112 .
[0111] Locking hasp 106 is formed with bar keeper 83 and a convenient pre-formed hole 81 for a fastener 126 for lateral mounting of locking hasp 106 on a door post of an inward-opening door as in FIGS. 11-12 . Another hexbolt 122 is inserted through keeper 83 to extend beyond the mounting plate 112 and is secured on its proximal threaded end with a washer and nut (not shown).
[0112] Locking bar 104 encases a cylinder lock 140 operable by key 96 . Cylinder lock 140 is fitted with a cylinder plug 143 for interacting with a locking cam assembly 150 which rotates with the rotation of cylinder plug 143 . This rotation effectuates movement of the cam portion 146 and enables rotation of locking bar 104 . Cam portion 146 movement occurs in a locking means, such as that formed within mounting plate 112 (see FIG. 26, 30 , 34 ), or, alternatively, such as a channel as in FIGS. 7 and 9 .
[0113] In the embodiment of the invention shown in FIGS. 13 A-B, an engagement means, such as latch portion 119 formed in locking bar 104 is illustrated. A spring assembly 131 is disposed within a well 118 which is oriented in a manner so as to assist in rotating locking bar 104 in either direction, to a closed or open position, Spring assembly 131 comprises: a retaining ring 130 , a round cover 120 having a small notch 123 on one edge, a small rivet 132 mounted to the inside surface of cover 120 and attached to spring 136 . The other end of spring 136 is attached to a small screw 134 mounted on hub 156 .
[0114] The shaped key opening 108 ( FIG. 13B ) of the cylinder lock 140 also helps to reduce the size of the opening which makes it more difficult for an intruder to force open the lock.
[0115] Mounting plates 112 , 114 , when joined together with tightening assembly 167 ( FIG. 41 ) in a common plane, serve as a built-in template for accurate placement and perfect alignment of the drilling holes to mount inventive bar-lock 102 on various types of doors and door posts using common fasteners, such as metal screws, bolts, and the like.
[0116] FIG. 13B is a left perspective view of bar-lock 102 revealing further construction details. Latch portion 119 is formed with a latching channel 110 . Cam assembly 150 iis formed with a partial circumferential collar 177 , with the collar being supported on the cylinder lock 140 , by way of surface 170 , thereby eliminating forced-opening pressure acting on an internal mechanism associated with the cylinder lock 140 . Hexagonal recesses 115 and 173 , respectively associated with locking hub 156 and locking hasp 106 , are also shown. Anchor hasp 106 and locking hasp 155 are each mounted with a single main, massive hexbolt 122 . In the case of anchor hasp 155 , the bolt 122 is coincident with an axis defining the locking bar 104 rotation. Hexbolts 122 are tamper-resistant by virtue of being seating within respective hexagonal recesses 115 and 173 and by virtue of a hardened insert 121 . Shaped key opening 108 is formed in hardened wall 107 of locking bar 104 .
[0117] FIG. 14 shows an exploded view of an adapter 168 and related mounting hardware including gaskets 171 , 172 and capnuts 175 used for attaching the locking hasp and anchor hasp of FIGS. 13 A-B to a glass door in accordance with the principles of the present invention.
[0118] FIG. 15 shows an exploded view of adapters 176 and fasteners for mounting the bar-lock of FIG. 13 onto an aluminum frame door in accordance with the present invention.
[0119] Because aluminum frame doors generally are extruded or formed in curved sections, it is difficult to attach a bar-lock to such doors and to assure that there is sufficient contact between adjacent joining surfaces. Adapters 176 are shown with two large, hex-head mounting bolts 122 for anchoring the adapters 176 to a metal-frame door so as to provide a surface to which to attach the invention which will provide more contact between the attached parts and, hence, greatly increase the strength of the attachment. They are secured on the inside of doors with washers 103 and nuts 116 .
[0120] FIG. 16A is a perspective view of the bar-lock of FIG. 13 mounted, with the adapter of FIG. 14 , onto the rim of a double glass door shown as a portion thereof. Mounting plates 112 , 114 provide a flat, metallic surface for the attachment of pivotal bar-lock 102 and are therefore separated by non-metallic gaskets 171 , 172 to prevent damage or marring of the glass doors 178 .
[0121] FIG. 16B is a cross-section view B-B taken along the axis of mounting bolt 122 of FIG. 16A shown with a portion of a glass door 178 mounted with bar-lock 102 . Non-metallic gasket 172 , backup plate 174 and capnuts 175 are shown on the other side of the door.
[0122] FIG. 17 is a partial cut-away, perspective view of the barlock of FIG. 13 mounted, in accordance with the principles of the invention, with the adapters and fasteners shown in FIG. 15 , onto aluminum frames of a glass door. Adapters 176 provide greater contact surface between adjoining parts and therefore greater strength and security of attachment. Fasteners, such as metal screws 105 are used to attach the pivotal bar-lock 102 across the aluminum door frames 182 . Both exterior and interior sides of the door frames 182 are fitted with the flange adapters 176 and secured using a large bolt 122 . The adapters 176 are designed to strengthen the connection to the aluminum profile.
[0123] FIG. 18 is a perspective view of the pivotal bar-lock of FIG. 13 featuring an arrangement in which bar-lock 102 is metal weld-mounted (as seen at bead 101 ) onto a right-hand gate shown shut and locked against its gate posts. Optionally, the bar-lock 102 is connected to the metal gate 184 and posts 186 using fasteners, such as bolts. The advantage of welding a bar-lock 102 to the metal gate 184 is to reduce the number of parts, to strengthen the bonding, and to save costs.
[0124] FIG. 19 is a front view of a preferred embodiment of the invention. The pivotal bar-lock is illustrated in a locked position. Tool insert notch 125 enables insertion of a tool such as a screwdriver for adjusting the tension in spring 136 so that cover 120 remains in place as established by the alignment of notch 123 and protrusion 124 .
[0125] FIG. 20 is a vertical, cross-sectional side view taken along section line XX-XX of the bar-lock of FIG. 19 . Locking cam assembly 150 is shown seated in aperture 137 of locking bar 104 . In addition, roll pin 144 can be seen seated inside slot 139 of cylinder plug 143 , forming the rotational connection between the locking cylinder 140 and the cam assembly 150 .
[0126] FIG. 21 is a vertical, cross-sectional side view taken along section line XXI-XXI of the bar-lock of FIG. 19 . The cross-section reveals the well 118 enclosing spring 136 fixedly connected to fasteners 132 , 134 mounted on opposing surfaces within well 118 so as to casue locking bar 104 to be spring-loaded, thereby establishing the open and closed positions.
[0127] FIG. 22 is a horizontal, cross-sectional top view taken along section line XXII-XXII of the bar-lock of FIG. 19 . This view shows the two large hexbolts 122 for mounting pivotal bar-lock 102 to a door. In addition, locking cam assembly 150 is visible, seated on cylinder assembly 140 , and rotationally connected to slot 139 of cylinder plug 143 . Also visible are spring-loaded plunger 148 and spring 152 , which engages locking notch 151 of locking cam 150 .
[0128] FIG. 23 is a top view of the bar-lock of FIG. 19 shown in a locked position.
[0129] FIG. 24 is a horizontal, cross-sectional front view taken along section line XXIV-XXIV of the bar-lock of FIG. 23 . The latching channel 110 of locking bar 104 is shown engaging the keeper 83 formed integrally with locking hasp 106 . The circumferential collar 177 is shown with surface 170 in contact locking cylinder 140 . Also visible is stopper 113 which limits travel of locking bar 104 when in the open position.
[0130] FIG. 25 is a horizontal, cross-sectional front view taken along section line XXV-XXV of the bar-lock of FIG. 23 . Spring loaded plunger 148 and spring 152 engage a locking notch 151 formed on locking cam assembly 150 to produce an audible click which can also be sensed to positively indicate the locking and unlocking action of cylinder lock 140 when key-operated. Roll pin 144 can is visible, shown mounted inside locking cam assembly 150 , which engages slot 139 of cylinder plug 148 .
[0131] FIG. 26 . is a horizontal, cross-sectional front view taken along section line XXVI-XXVI of the bar-lock of FIG. 23 . The locking cam 146 is revealed seated in closed position locking bay 192 formed between mounting plates 112 and 114 . The closed position locking bay 192 and the open position locking bay 194 are disposed at opposing ends of locking channel 191 .
[0132] FIG. 27 is a top view of the bar-lock of FIG. 19 in the in-transit position.
[0133] FIG. 27X is a vertical, cross-sectional view taken along section line XXXVI-XXXVI of the bar-lock of FIG. 27 . The spring 136 is seen at a different angle attached to its supporting fasteners. The locking bar 104 is spring-loaded to establish the open and closed positions, and spring 136 additionally assists in maintaining the locking bar 104 on the anchor hasp 155 , preventing accidental removal of the locking bar 104 by exerting a pulling force in the direction of vector b.
[0134] FIG. 28 is, a horizontal, cross-sectional front view taken along section line XXVIII-XXVIII of the bar-lock of FIG. 27 . First connecting means 138 a and second connecting means 138 b are shown, as well as the clearance “y” between them. The locking bar 104 can be disassembled from the anchor hasp 155 for maintenance purposes, when clearance “y” is established between the first and second connecting means 138 a and 138 b.
[0135] FIG. 29 is a horizontal, cross-sectional front view taken along section line XXIX-XXIX of the bar-lock of FIG. 27 . Spring-loaded plunger 148 can be seen engaging unlocking notch 159 , defining the in-transit position of locking bar 104 .
[0136] FIG. 30 is a horizontal, cross-sectional front view taken along section line XXX-XXX of the bar-lock of FIG. 27 . Illustrated is the in-transit position of cam 146 along locking channel 191 .
[0137] FIG. 31 is a top view of a preferred embodiment of the invention with the bar-lock in an unlocked and secured position.
[0138] FIG. 32 is a horizontal, cross-sectional front view taken along section line XXXII-XXXII of the bar-lock of FIG. 31 . The locking bar 104 is disposed in a downward orientation, unlocked and secured. Locking surface 170 of locking cam assembly 150 is shown in contact with locking cylinder 140 .
[0139] FIG. 33 is a horizontal, cross-sectional front view taken along section line XXXIII-XXXIII of the bar-lock of FIG. 31 . Spring-loaded plunger 148 engages locking position notch 151 , defining the locked position of locking cylinder 140 .
[0140] FIG. 34 is a horizontal, cross-sectional front view taken along section line XXXIV-XXXIV of the bar-lock of FIG. 31 . Cam 146 is clearly visible in a secured position engaging open position locking bay 194 .
[0141] FIGS. 35-37 are front views of a preferred embodiment of the invention illustrating the forces exerted by spring 136 on locking bar 104 , using a force vector diagram. The illustrations reveal spring 136 via a cutout portion defined by the dashed line 196 . In FIG. 35 , the spring 136 exerts force c, at offset distance “x”. causing the locking bar 104 to rotate into the closed position, as indicated by the curved arrow. The spring 136 will hold the locking bar 104 in this position until it will be locked by locking cylinder 140 . This enables one-handed operation.
[0142] In FIG. 36 , spring 136 does not exert any rotational forces on locking bar 104 , while in the in-transit position, because there is no offset distance.
[0143] In FIG. 37 , spring 136 exerts a rotational force in the opposite direction, to bring locking bar 104 into the unlocked position, by exerting force c, at offset distance “x” in the direction of the curved arrow.
[0144] FIGS. 38-41 are illustrations showing tightening assembly 167 for joining anchor hasp 155 and locking hasp 106 in a common plane, to serve as a built-in template for complete, accurate, safe and easy installation of bar-lock 102 .
[0145] FIG. 39 is a horizontal, cross-sectional view taken along section line XXXIX-XXXIX of the tightening assembly 167 of FIG. 38 .
[0146] FIG. 40 is a horizontal, cross-sectional view taken along section line XL-XL of the tightening assembly 167 of FIG. 38 .
[0147] FIG. 41 is an enlarged, exploded view of the tightening assembly 167 of the invention.
[0148] When bolt 160 is tightened, capnut 164 is drawn inwardly, thus drawing together mounting plates 112 and 114 in the direction of the arrows, by action of sloped recess 165 of capnut 164 against sloped protrusion 169 of each of mounting plates 112 and 114 . The alignment between mounting plates 112 and 114 is guided by oppositely-situated protrusions 163 of locking washer 162 . Once the alignment is achieved and the mounting template is established, the mounting installation can proceed, after which the tightening assembly 167 is removed.
[0149] Having described the invention with regard to certain specific embodiments, it is to be understood that the description is not meant as a limitation, since further modifications may now suggest themselves to those skilled in the art, and it is intended to cover such modifications as fall within the scope of the described invention and with reference to the accompanying drawings.
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A pivotal bar-lock comprising an anchor hasp having a locking hub and a first locking element integrally formed with a first mounting plate; a locking hasp integrally formed with a second mounting plate and having a mating element and a second locking element formed therein; and a locking bar rotatably mounted on the anchor hasp, the locking bar having a cylinder lock encased therein and an engagement element formed therewith, the cylinder lock being operable such that when rotated into an unlocked mode, the locking bar is pivotally enabled to assume one of open, in-transit, and closed positions in interaction with the first and second locking elements, and when the cylinder lock is rotated into a locked mode, the engagement element of the locking bar engages the mating element of the locking hasp.
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This is a continuation of application Ser. No. 08/393,640, filed Feb. 24, 1995, which is a continuation of application Ser. No. 08/061,645 , filed May 13, 1993, now U.S. Pat. No. 5,399,567.
BACKGROUND OF THE INVENTION
This invention relates to a novel method of inhibiting glycolipid synthesis and, more particular, to the use of N-alkyl derivatives of 1,5-dideoxy-1,5-imino-D-glucitol for inhibiting glycolipid biosynthesis in cells capable of producing glycolipids, in which said alkyl groups contain from about 2-8 carbon atoms.
1,5-Dideoxy-1,5-imino-D-glucitol (which is also known as 1-deoxynojirimycin or DNJ) and its N-alkyl derivatives are known inhibitors of the N-linked oligosaccharide processing enzymes, α-glucosidase I and II. Saunier et al., J. Biol. Chem. 257, 14155-14161 (1982); Elbein, Ann. Rev. Biochem. 56, 497-534 (1987). As glucose analogs they also have potential to inhibit glucosyltransferases. Newbrun et al., Arch. Oral Biol. 28, 516-536 (1983); Wang et al., Tetrahedron Lett. 34, 403-406 (1993). Their inhibitory activity against the glucosidases has led to the development of these compounds as antihyperglycemic agents and antiviral agents. See, e.g., PCT Int'l. Appln. WO 87/03903 and U.S. Pat. Nos.: 4,065,562; 4,182,767; 4,533,668; 4,639,436; 4,849,430; 5,011,829; and 5,030,638.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the present invention, a method is provided for inhibiting the biosynthesis of glycolipids in cells capable of producing glycolipids which comprises treatment of said cells with a glycolipid inhibitory effective amount of an N-alkyl derivative of 1,5-dideoxy-1,5-imino-D-glucitol (DNJ) in which said alkyl contains from 2-8 carbon atoms and preferably from 4-6 carbon atoms. The length of the N-alkyl chain has been found to be important to said inhibitory activity since the non-alkylated DNJ and the N-methyl derivative of DNJ were each found to be inactive for such inhibition. Thus, a minimum alkyl chain length of 2 carbon atoms has been found to be necessary for efficacy.
Illustratively, the N-butyl DNJ was also unexpectedly found to be a substantially more potent inhibitor of glycolipid biosynthesis than it is as an α-glucosidase I inhibitor. That is, it was inhibitory of glycolipid biosynthesis at relatively low concentrations (about 50 μM) compared to the mM level of concentration in cell culture systems for α-glucosidase I inhibition Karlsson et al., J. Biol. Chem. 268, 570-576 (1993)!. Also illustratively, the N-butyl and N-hexyl derivatives of DNJ inhibited the biosynthesis of all glucoceramide based glycosphingolipids.
The inhibitory effect of these compounds on the biosynthesis of glycolipids is illustrated herein in myeloid cell lines (e.g., HL-60 and K-562) as well as in lymphoid cell lines (e.g., MOLT-4 and H9). These are well-known, widely distributed and readily available human cell lines. For example, HL-60 cells are promyelocytic cells described by Collins et al., Nature 270, 347-349 (1977). They are also readily available from the American Type Culture Collection, Rockville, Maryland under accession number ATCC CCL 240. K-562 cells are of myeloid origin described by Lozzio and Lozzio, Blood 45, 321-324 (1975). They are also readily available from the same depository under accession number ATCC CCL 243. MOLT-4 cells are lymphoid cells described in J. Nat'l. Cancer Inst. 49, 891-895 (1972). They are also readily available from the same depository under accession number ATCC CRL 1582. H9 cells are of lymphoid origin described by Gallo and Popovic, Science 224, 497-500 (1984). They are also readily available from the same depository under accession number ATCC HTB 176.
The inhibition of glycolipid biosynthesis by these N-alkyl derivatives of DNJ is further demonstrated herein by the reduction of the binding of cholera toxin to these four illustrative cell lines when cultured in the presence on N-butyl DNJ. These compounds thus are also useful as anti-microbial agents by inhibiting the surface expression on glycolipid receptors for bacteria and bacterial toxins as illustrated hereinafter in Tables 1 and 2, respectively.
The inhibitory effect upon the biosynthesis of glycolipids is still further illustrated by the ability of N-butyl DNJ to offset glucoceramide accumulation in a standard, state-of-the-art in vitro model of Gaucher's disease in which the murine macrophage cell line WEHI-3B was cultured in the presence of an irreversible glucocerebrosidase inhibitor, conduritol β epoxide (CBE), to mimic the inherited disorder found in Gaucher's disease. The compound prevents lysosomal glycolipid storage which is useful for the management of this and other glycolipid storage disorders as illustrated hereinafter in Table 3.
Illustratively, the N-butyl-DNJ is also shown herein to be a more effective inhibitor of glycolipid biosynthesis than either PDMP or PPMP. PDMP, which chemically is DL-threo-1-phenyl-2-decanoylamino-3-morpholino-1-propanol, is known to be an effective inhibitor of the glycosyltransferase that makes glucosylceramide. See, for example, Shukla et al., Biochim. Biophys. Acta 1083, 101-108 (1991), and Shukla and Radin, J. Lipid Res. 32, 713-722 (1991), for reports on this activity of PDMP. Its analog PPMP, chemically is DL-threo-1-phenyl-2-hexadecanoylamino-3-morpholino-1-propanol. Thus, the glycolipid biosynthesis inhibitory activity of N-butyl-DNJ is correlatable to the corresponding activity of conventional compounds in this field.
TABLE 1______________________________________GLYCOSPHINGOLIPID RECEPTORS FOR BACTERIAL CELLSMicroorganism Target Issue Presumed Specificity______________________________________E. coli Urinary Galα4GalβE. coli Urinary G1cNAcβPropionibacterium Skin/Intestine Galβ4GlcβSeveral bacteria Diverse Galβ4GlcβStreptococcus pneumoniae Respiratory GlcNAcβ3GalE. coli CFA/I Intestine NeuAcα8E. coli Urinary NeuAcα3GalE. coli Intestine NeuGcα3Galβ4GlcβCer GalNAcβ4(NeuAcα3)- Galβ4GlcβCerStaphylococcus Urinary Galβ4GlcNAcsaprophyticusActinomyces naeslundi Mouth Galβ, GalNAcβ, Galβ3GalNAcβ, GalNacβ3GalβPseudomonas Respiratory GalNAcβ4GalNeisseria gonorrhoeae Genital Galβ4Glcβ NeuAcα3Galβ4GlcNAc______________________________________
TABLE 2______________________________________GLYCOSPHINGOLIPID RECEPTORS FOR BACTERIAL TOXINS Presumed ReceptorMicroorganism Toxin Target Tissue Sequence______________________________________Vibrio cholerae Cholera toxin Small Intestine Galβ3GalNAcβ4- (NeuAcα3)Gal- β4GlcβCerE. coli Heat-labile Intestine Galβ3GalNAcβ4- toxin (NeuAcα3)Gal- β4GlcβCerClostridium Tetanus toxin Nerve Galβ3GalNAcβ4-tetani (NeuAcα8Neu- Acα3)Galβ4Glc- βCerClostridium Botulinum Nerve Membrane NeuAcα8Neu-botulinum toxin A and E Acα3Galβ3Gal- NAcβ4(NeuAcα- 8NeuAcα3)Galβ- 4GlcβCerClostridium Botulinum toxin Nerve Membrane NeuAcα3Galβ3-botulinum B, C and F GalNAβ4(Neu- Acα8NeuAcα3)- Galβ4GlcβCerClostridium Botulinum toxin Nerve Membrane GalβCerbotulinum BClostridium Delta toxin Cell lytic GalNAcβ4-perfringens (NeuAcα3)Galβ- 4GlcβCerClostridium Toxin A Large Intestine Galα3GalβGlc-difficile Nacβ3Galβ4- GlcβCerShigella Shiga toxin Large Intestine Galα4GalβCerdysenteriae Galα4Galβ4Glc- βCer GlcNAcβ4Glc- NAcE. coli Vero toxin or Intestine Galα4Galβ4- Shiga-like GlcβCer toxin______________________________________
TABLE 3______________________________________HERIDITARY GLYCOLIPID STORAGE DISORDERSDisease Lipid Accumulation Enzyme Defect______________________________________Gaucher's Glucocerebroside Glucocerebroside-β- glucosidaseCeramide Lactoside Ceramide Lactoside Ceramidelactoside-β-Lipidosis galactosidaseFabry's Ceramide Trihexoside Ceramidetrihexoside-α- galactosidaseTay-Sach's Ganglioside GM2 Hexosaminidase ASandhoff's Globoside and GM2 Hexosaminidase A and BGeneral Ganglioside GM1 β-GalactosidaseGangliosidosisFucosidosis H-isoantigen α-FucosidaseKrabbe's Galactocerebroside Galactocerebroside-β- galactosidaseMetrachromatic Sulfatide SulfatidaseLeukodystrophy______________________________________
DETAILED DESCRIPTION OF THE INVENTION
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter regarded as forming the invention, it is believed that the invention will be better understood from the following illustrative detailed description taken in conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1, in two parts A and B, shows by autoradiographic visualization the effects on glycolipid biosynthesis in HL-60 cells that were metabolically labelled with 14 C! palmitic acid, FIG. 1A: in the presence of 0.5 mM N-butyl deoxynojirimycin (+NB-DNJ) or FIG. 1B: absence of NB-DNJ (untreated -UT).
FIG. 2 is a bar chart which shows the cholera toxin binding sites per cell for four different cell lines (HL-60, H9, K-562 and MOLT-4) in which the cholera toxin was fluorescein conjugated and the levels of binding to the cell surfaces of untreated (UT) cells and cells treated with 0.5 mM N-butyl deoxynojirimycin (+NB-DNJ) were measured by flow cytometry.
FIG. 3 shows by thin layer chromatography (TLC)the effects on WEHI-3B cells cultured in the presence (+) or absence (-) of an irreversible glucocerebrosidase inhibitor, conduritol β epoxide (CBE), to mimic the inherited disorder found in Gaucher's disease in which the cells were cultured in the presence (5 to 500 μM) or absence (-) of N-butyl deoxynojirimycin (NB-DNJ) and in which the glucosylceramide (Glc-Cer) levels were examined by TLC analysis.
FIG. 4, in four parts, A, B, C and D, shows the effects as in FIG. 3 but in which the glucosylceramide (Glc-Cer) levels were measured by transmission electron microscopy instead of TLC. FIG. 4A shows untreated representative lysosome; FIG. 4B shows lysosome treated with CBE; FIG. 4C shows lysosome treated with CBE plus 500 μM plus NB-DNJ; FIG. 4D shows lysosome treated with CBE plus 50 μM NB-DNJ. The scale bar of FIG. 4 is shown in FIG. 4D and represents 0.1 μm.
FIG. 5 is a graphical representation which shows the inhibition of cholera toxin binding in HL-60 cells cultured in the presence of various N-alkyl-DNJ compounds as indicated at a range of doses (0.0 to 1.0 mg/ml) or untreated (UT) for three days at each dose and assayed by flow cytometry following staining with FITC-cholera toxin. The data are plotted as dose of compound (mg/ml) on the x-axis against mean channel fluorescence intensity (mean channel number) on the y-axis.
FIG. 6, in four parts, A, B, C and D, shows by autoradiographic visualization the effects as in FIG. 1, compared to similar treatment with PDMP or PPMP. FIG. 6A: untreated (UT); FIG. 6B: in the presence of 0.5 mM N-butyl deoxynojirimycin (NB-DNJ); FIG. 6C: in the presence of 5 μM PDMP; FIG. 6D: in the presence of 5 μM PPMP.
In order to further illustrate the invention, the following detailed examples were carried out although it will be understood that the invention is not limited to these specific examples or the details described therein.
EXAMPLE 1
To investigate the effects of the imino sugar N-butyldeoxynojirimycin (NB-DNJ) on glycolipid biosynthesis, HL-60 cells were metabolically labelled with 14 C!-palmitic acid in the presence or absence of 0.5 mM NB-DNJ. Total cellular lipids were solvent extracted and separated by two dimensional thin layer chromatography (2D-TLC) and the individual components visualized by autoradiography (FIG. 1). The major cellular phospholipid species were unaffected by NB-DNJ treatment as verified by TLC spot elution, recovery and scintillation counting. However, both the neutral glycolipids and gangliosides were absent from treated cultures (FIG. 1B). This implied that a very early step in glycolipid biosynthesis was affected by NB-DNJ treatment. To establish whether this activity was a common property of imino sugars and related compounds, a number of N-linked oligosaccharide processing inhibitors were assayed for their ability to inhibit HL-60 glycolipid biosynthesis using 2D-TLC analysis (Table 4). The glucosidase inhibitors DNJ and castanospermine, and the mannosidase inhibitors swainsonine and deoxymannojirimycin (DMJ), had no effect. When the N-alkylated derivatives of DNJ were tested the N-methyl analogue had no effect but both the N-butyl and N-hexyl analogues surprisingly inhibited the biosynthesis of glycolipids. This indicated that the length of the alkyl chain was a critical parameter for this inhibitory activity. In addition, NB-DNJ was inhibitory at relatively low compound concentrations (approximately 50 μM) indicating that this compound is a more potent inhibitor of glycolipid biosynthesis than it is as an α-glucosidase I inhibitor (mM range in cell culture systems). It is believed that the N-butyl and N-hexyl derivatives are specifically inhibiting UDP-glucose:N-acylsphingosine glucosyltransferase Basu et al., J. Biol. Chem. 248, 1388-1394 (1973)! (EC 2.4.1.80). This transferase is pivotal in generating glucosyl ceramide (Glc-Cer) which is the precursor for the more complex glycosphingolipids and gangliosides. The inhibition of the glucosyltransferase is consistent with the uniform loss of all glycolipid species observed in the presence of the two compounds (FIG. 1). In cell free assays NB-DNJ but not DNJ inhibited the transfer of glucose from UDP-glucose to a ceramide acceptor.
EXAMPLE 2
This example illustrates that glycolipid expression at the cell surface is also inhibited in cells cultured in the presence of NB-DNJ. Four cell lines (of both myeloid and lymphoid origin) were grown in medium containing 0.5 mM NB-DNJ for three days and the level of cell surface GM1 (Galβ3GalNAcβ4(NeuAcα3)-Galβ4Glcβ3Cer) glycolipid expression was measured by flow cytometry. As a specific probe, advantage was taken of the GM1 binding specificity of the cholera toxin B chain van Heyningen, Nature 249, 415-417 (1974); Karlsson, Ann. Rev. Biochem. 58, 309-350 (1989)!. The toxin was fluorescein conjugated and the levels of binding to the cell surface of treated and untreated cell lines was measured (FIG. 2). The number of cholera toxin binding sites per cell was determined by including fluoresceinated microbead standards in the assay. The four cell lines showed different levels of cholera toxin binding. The two myeloid cell lines (HL-60 and K-562) both expressed approximately 1×10 5 copies of cholera toxin binding sites per cell while the two lymphoid cell lines (MOLT-4 and H9) expressed approximately 2.5-5.0×10 5 copies per cell. The binding of cholera toxin to the four cell lines cultured in the presence of NB-DNJ was reduced by approximately 90% in all cases. This was consistent with the loss of GM1 from the cell surface and provided further evidence for the inhibition of glycolipid biosynthesis by NB-DNJ. It also suggests that imino sugar derivatives have use as potential anti-microbial agents by inhibiting the surface expression of glycolipid receptors for bacteria and bacterial toxins as shown in Tables 1 and 2, respectively.
EXAMPLE 3
The identification of NB-DNJ and N-hexyl DNJ as novel inhibitors of glycolipid biosynthesis offers an alternative approach for manipulating cellular glycolipid levels. The glycolipid storage disorder, Gaucher's disease, results from the autosomal inheritance of a defective glucocerebrosidase enzyme (β-D-glucosyl-N-acylsphingosine glucohydrolase, EC 3.2.1.45) which prevents the complete catabolism of Glc-Cer in the lysosome Barranger and Ginns, The Metabolic Basis of Inherited Disease, 1677-1698 (McGraw-Hill, New York, 1989); Tybulewicz et al., Nature 357, 407-410 (1992); Beutler, Science 256, 794-799 (1992)!. However, in contrast with the impaired degradation of Glc-Cer, the rate of glycolipid biosynthesis in these individuals remains normal. As a consequence, Glc-Cer is accumulated over time leading to lysosomal storage in cells of the monocyte-macrophage system which is diagnostic of this disorder Parkin and Brunning, Prog. Clin. Biol. Res. 95, 151-175 (1982)!. One approach for the management of this and related disorders Neufeld, Ann. Rev. Biochem. 60, 257-280 (1991)! is to use specific inhibitors of glycolipid biosynthesis Vunnam and Radin, Chem. Phys. Lipids 26, 265-278 (1980); Inokuchi and Radin, J. Lip. Res. 28, 565-571 (1987); Abe et al., J. Biochem. 111, 191-196 (1992)! to reduce cellular glycolipid production to a level which can be completely catabolized by the defective glucocerebrosidase, thereby preventing glycolipid accumulation. This example illustrates that glycolipid storage can be prevented by NB-DNJ in an in vitro model of Gaucher's disease. The murine macrophage cell line WEHI-3B was cultured in the presence of an irreversible glucocerebrosidase inhibitor, conduritol β epoxide (CBE), to mimic the inherited disorder found in Gaucher's disease Newburg et al., Exp. Molec. Pathol. 48, 317-323 (1988)!. WEHI-3B cells are described in Cancer Res. 37, 546-550 (1977), and are readily available from the American Type Culture Collection, Rockville, Md., under accession number ATCC TIB 68. The WEHI-3B cells were cultured in the presence or absence of NB-DNJ and glucosylceramide levels were examined by TLC analysis (FIG. 3). Following CBE treatment the cells accumulated Glc-Cer relative to untreated controls. However, in cultures containing 500 μM or 50 μM NB-DNJ, this accumulation was prevented. At the lower dose (50 μM) cultures contained Glc-Cer levels comparable to untreated controls whereas at the highest dose (500 μM) cultures contained almost undetectable levels of Glc-Cer. Cells treated with 5 μM NB-DNJ were identical to CBE treated cells demonstrating that in this in vitro Gaucher's disease model a compound dose of 50 μM NB-DNJ will prevent Glc-Cer accumulation. The lysosomes of CBE treated cultures and CBE plus NB-DNJ cultures were examined by transmission electron microscopy (FIG. 4). There was evidence of lipid accumulation in the lysosomes of CBE treated cells, FIG. 4B, relative to untreated controls, FIG. 4A, but not in CBE+NB-DNJ treated cultures FIG. 4C, 500 μM and FIG. 4D 50 μM, thereby confirming that NB-DNJ prevented CBE induced glycolipid accumulation by the partial inhibition of glycolipid biosynthesis.
The identification herein of N-alkyl derivatives of DNJ capable of modulating cellular glycolipid levels is useful for the management of several glycolipid storage disorders. These compounds affect Glc-Cer biosynthesis which is the precursor of glycolipids accumulating in many storage disorders, independent of the individual enzyme defects of these diseases (Neufeld supra). See Table 3, hereinbefore, which lists hereditary glycolipid storage disorders and their corresponding lipid accumulation and enzyme defect. In addition, these compounds have therapeutic use for the treatment of infectious disease agents which utilize cellular glycolipid receptors (Karlsson, supra) and as modulators of cell proliferation Hakomori, Ann. Rev. Biochem. 50, 733-764 (1981); Felding-Habermann et al., Biochemistry 29, 6314-6322 (1990)!, tumor growth Inokuchi et al., Cancer Lett. 38, 23-30 (1987)! and metastasis Inokuchi et al., Cancer Res. 50, 6731-6737 (1990); Mannori et al., Int. J. Cancer 45, 984-988 (1990)!, where roles for glycolipids have been implicated.
The detailed procedures for obtaining the results of Examples 1 to 3 above, as shown by FIGS. 1 to 6 and Table 4 are as follows:
FIG. 1
Effects of NB-DNJ on total HL-60 lipid composition.
Lipid identities were determined by comparison to authentic lipid standards, differential chemical detection of phospholipids and glycolipids and laserdesorption mass spectrometry analysis of the mono and dihexaside species. Lipids were assigned as follows (untreated cells, FIG. 1A--left hand panel): 1. gangliosides; 2. lysophospatidylcholine; 3. ceramide phosphorylcholine; 4. ceramide phosphorylethanolamine; 5. phospatidylcholine; 6. phosphatidylinositol; 7. phosphatidylethanolamine; 8. phosphatidylglycerol; 9. diglycosylceramide; 10. monoglycosylceramine; 11. cholesterol/fatty acids/neutral lipids; N and N* are unknowns and 0 is the sample origin. Following NB-DNJ treatment (FIG. 1B--right hand panel) species 1 (gangliosides), 9 (diglycosylceramide), 10 (monoglycosylceramide) and N* (unknown) were absent. Method: HL-60 cells were cultured (10 ml) by conventional procedures as previously described Platt et al., Eur. J. Biochem. 208, 187-193 (1992)! at a seeding density of 5×10 4 cells per ml in the presence or absence of 0.5 mM NB-DNJ (G.D. Searle & Co., Skokie, Ill.) for 24 hours. For labelling and 2D-TLC, the conventional, published method of Butters and Hughes was followed In Vitro 17, 831-838 (1981)!. Briefly, 14 C!-palmitic acid (ICN-Flow, High Wycombe, Bucks. UK., 56.8 mCi/mmol) was added as a sonicated preparation in fetal calf serum (0.5 μCi per ml) and the cells were cultured for a further three days maintaining NB-DNJ in the cultures. The cells were harvested, washed three times with PBS and extracted in 1 ml chloroform:methanol (2:1 v/v) overnight at 4° C. The extracts were centrifuged, the chloroform:methanol extract was retained and the pellet was re-extracted as above for two hours at room temperature. Pooled extracts were dried under nitrogen and redissolved in 50 μl chloroform:methanol (2:1, v/v). One percent of the sample volume was taken for the determination of radioactivity by scintillation counting and a 1×10 6 cpm loaded as a single spot onto a 20 cm 2 TLC plate (Merck, BDH, Poole, Dorset, U.K.). The samples were separated in the first dimension in chloroform:methanol:water (65:25:4) and the plate dried overnight under vacuum. Separation in the second dimension was achieved using a solvent of tetrahydrofuran:dimethoxymethane:methanol:water (10:6:4:1). Plates were air dried and exposed to Hyperfilm-MP high performance autoradiography film (Amersham International, Amersham, UK).
Table 4
Effects of sugar analogues on HL-60 glycolipid biosynthesis.
The data are summarized from 2D-TLC analysis on each compound at the indicated concentrations (see FIG. 1 method, above). Compounds: The synthesis of alkylated derivatives of DNJ is well known. See, e.g., Fleet et al., FEBS Lett. 237, 128-132 (1988). DMJ was purchased from Boehringer Mannheim (Lewes, Sussex, U.K.), swainsonine and castanospermine were obtained from Sigma (Poole, Dorset, UK). Compound doses were selected that were close to the tolerated upper limit of the individual compounds which maintained ninety percent cell viability. HL-60 cells were cultured as described in FIG. 1 procedure, above.
TABLE 4______________________________________Compound Dose (mg/ml) Glycolipid Inhibition______________________________________DNJ 0.2 -N-methyl DNJ 0.1 -N-butyl DNJ 0.1 +/-" 0.001 +" 0.01 +N-hexyl DNJ 0.2 +DMJ 0.06 -Castanospermine 0.1 -Swainsonine 0.1 -______________________________________
FIG. 2
Quantitative analysis of cholera toxin binding to human cell lines following three days treatment with NB-DNJ.
Methods: Cells were maintained in logarithmic phase growth in RPMI-1640 medium. Cholera toxin B chain (Sigma) was conjugated to fluorescein isothyocyanate (Sigma) and flow cytometric analysis was carried out by conventional procedure as described by Platt et al., supra. Analysis was performed on a FACScan Cytometer (Becton Dickinson, Sunnyvale Calif., USA). Data on viable cells were collected on a four decade log 10 scale of increasing fluorescence intensity. The data are presented as mean copy number of cholera toxin bindings sites per cell on the y-axis against the four cell line on the x-axis, in the presence or absence of 0.5 mM NB-DNJ. The specificity of cholera toxin:cell surface binding was established by inhibiting this interaction with a one hundred fold molar excess of GM1 derived oligosaccharide, GalβGalNAcβ4(NeuAcα3)Galβ4Glcβ3Cer. Seventy to ninety percent inhibition was achieved depending on the individual cell line. A control oligosaccharide (lacto-N-tetarose) was not inhibitory.
FIGS. 3 and 4
Effects of NB-DNJ on an in vitro model of aucher's disease.
FIG. 3: 1 dimensional TLC analysis in WEHI-3B cells treated as indicated. FIG. 4: transmission electron microscopy of WEHI-3B Gaucher cell lysosomes: A. untreated representative lysosome, B. lysosome showing extensive accumulation of dense material in the presence of CBE consistent with Glc-Cer accumulation, C. CBE plus 500 μM NB-DNJ and D. CBE plus 50 μM NB-DNJ, each of C and D showing lysosomes with normal density contents. No changes were observed in the lysosomes of cells treated with NB-DNJ alone.
Methods: The murine macrophage cell line WEHI-3B was maintained in logarithmic phase growth for 14 days in RPMI-1640 in the presence or absence of 50 μM conduritol β epoxide (CBE, Toronto Research Chemicals, Downsview, Canada) with or without NB-DNJ at the indicated concentrations. Cells were passaged every three days in the presence of the stated concentrations of compounds. Equal cell numbers (5×10 6 ) were harvested, extracted as described hereinbefore (FIG. 1 procedure), separated by one dimensional TLC (first dimension solvent, FIG. 1 procedure) and visualized using α-naphthol (1% w/v in methanol) followed by 50% (v/v) sulphuric acid. Similar data were obtained using the independent mouse macrophage cell line P388D-1. These cells are described in J. Immunol. 114, 894-897 (1975), and are readily available from the American Type Culture collection, Rockville, Md., under accession number ATCC TIB 63. The authentic Glc-Cer standard from human Gaucher spleen (arrows) was purchased from Sigma.
Cells for electron microscopy were harvested (1×10 7 cells per treatment), washed three times in serum free RPMI-1640 medium and fixed in medium containing 2% glutaraldehyde (v/v) on ice for two hours. Cells were washed in 0.1M cacodylate buffer containing 20 mM calcium chloride (w/v). Fixed cells were stained with 1% osmium tetroxide in 25 mM cacodylate buffer (w/v) containing 1.5% potassium ferrocyanide (w/v) for 2 hours on ice. Samples were dehydrated through an ethanol series (50, 70, 95 and 100% v/v), transferred to propylene oxide and embedded in Embed 800 (Electron Microscopy Sciences, Pa., USA). The samples were polymerized at 60° C., sections cut, stained with uranyl acetate/lead citrate and observed with a Hitachi 600 microscope at 75 v.
FIG. 5
Dose response curves of cholera toxin binding to HL-60 cells following three days treatment with various N-alkyl-DNJ compounds.
The test method employed for FIG. 5 was the same as for FIG. 2, above, but the data are plotted as dose of compound on the x-axis against mean channel fluorescence intensity on the y-axis. The N-methyl, N-ethyl, N-propyl, N-butyl and N-hexyl derivatives of DNJ were thus tested and compared with the untreated (UT) control sample.
FIG. 6
Effects of NB-DNJ, PDMP and PPMP on total HL-60 lipid composition.
The test method employed for FIG. 6 was the same as for FIG. 1, above, but was extended to include for comparison treatment with DL-threo-1-phenyl-2-decanoylamino-3-morpholino-l-propanol (PDMP) or DL-threo-1-phenyl-2-hexadecanoylamino-3-morpholino-1-propanol (PPMP), both obtained from Matreya Inc., Pleasant Gap, Pa. FIG. 6A: untreated cells as in FIG. 1A--left panel; FIG. 6B: cells treated with 0.5 mM NB-DNJ as in FIG. 1B--right panel; FIG. 6C: cells treated with 5 μM PDMP from 10 mM stock solution in ethanol; FIG. 6D: cells treated with 5 μM PPMP from 10 mM stock solution in ethanol.
In addition to their use as antimicrobial agents and as inhibitors of glycolipid biosynthesis in cells, the inhibitory agents described herein also can be used for administration to patients afflicted with glycolipid storage defects by conventional means, preferably in formulations with pharmaceutically acceptable diluents and carriers. These agents can be used in the free amine form or in their salt form. Pharmaceutically acceptable salt derivatives are illustrated, for example, by the HCl salt. The amount of the active agent to be administered must be an effective amount, that is, an amount which is medically beneficial but does not present toxic effects which overweigh the advantages which accompany its use. It would be expected that the adult human daily dosage would normally range from about one to about 100 milligrams of the active compound. The preferable route of administration is orally in the form of capsules, tablets, syrups, elixirs and the like, although parenteral administration also can be used. Suitable formulations of the active compound in pharmaceutically acceptable diluents and carriers in therapeutic dosage form can be prepared by reference to general texts in the field such as, for example, Remington's Pharmaceutical Sciences, Ed. Arthur Osol, 16th ed., 1980, Mack Publishing Co., Easton, Pa.
Various other examples will be apparent to the person skilled in the art after reading the present disclosure without departing from the spirit and scope of the invention. It is intended that all such other examples be included within the scope of the appended claims.
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A method is disclosed for inhibiting the surface expression of glycolipid receptors for bacteria by subjecting bacteria cells to an inhibitory effective amount of an N-alkyl derivative of 1,5-dideoxy-1,5-imino-D-glucitol in which said alkyl contains from 2-8 carbon atoms.
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TECHNICAL FIELD
This invention relates generally to the delivery of reagent to a remote reaction zone, and is particularly useful for providing reagent to a remote reaction zone of a furnace for the conversion of nitrogen oxides (NOx) to nitrogen.
BACKGROUND ART
It is sometimes desired to provide reagent to a remote reaction zone such as at a specific location within the interior of a furnace. For example, in reburning wherein hydrocarbon radicals convert NOx to nitrogen gas for pollution control purposes, it is desired to provide hydrocarbon fuel such as natural gas or coal, which serves as a source of hydrocarbon radicals, to a remote area which contains flue gas. In another example it may be desired to provide ammonia or urea deep within a furnace to react with the NOx to form nitrogen gas.
One way to accomplish such reagent provision is to pass the reagent to the remote reaction zone using a long lance or other long provision means, but this is complicated to carry out and would require frequent replacement of the lance if the reaction zone were associated with a hot or corrosive environment such as a furnace. Another way to deliver reagents to a specific location in the boiler or furnace is to use. high velocity jets which typically penetrate deep into an enclosure before mixing is complete. However, this approach can lead to significant increases in the formation of pollutants in burners, such as NOx, and consumption of reagent prior to reaching the reaction zone. Both effects are due to the high entrainment rates characteristic of turbulent jets. Further, the high entrainment rates lead to recirculation of hot flue gas, which can contain particulate or corrosive gases, to the boiler or furnace wall, exacerbating deposition on the wall and corrosion. Yet another method is through the use of computational fluid dynamics modeling of a reaction zone such as a furnace environment. In this method detailed calculations are made to describe the furnace environment and nozzles or lances can then be placed in appropriate locations. This method can be effective but is quite complex to execute.
Accordingly, it is an object of this invention to provide a method whereby reagent may be provided to a reaction zone which is separated by a distance from the point where the reagent passes out from the injection device.
SUMMARY OF THE INVENTION
The above and other objects, which will become apparent to those skilled in the art upon a reading of this disclosure, are attained by the present invention one aspect of which is:
A method for providing a reagent to a reaction zone comprising:
(A) providing reagent to a carrier gas and passing reagent-containing carrier gas as a gas jet into an injection space from an injector through a distance (d);
(B) surrounding the gas jet with a flame envelope from the injector through the distance (d) so as to maintain the gas jet coherent through the distance (d);
(C) passing the reagent-containing carrier gas further into the injection space beyond the distance (d) into a reaction zone past the leading edge of the flame envelope as a non-coherent gas stream; and
(D) providing reagent from the non-coherent gas stream to the reaction zone.
Another aspect of the invention is:
A method for providing a reagent to a reaction zone comprising:
(A) passing gaseous reagent as a gas jet into an injection space from an injector through a distance (d);
(B) surrounding the gas jet with a flame envelope from the injector through the distance (d) so as to maintain the gas jet coherent through the distance (d);
(C) passing the gaseous reagent further into the injection space beyond the distance (d) into a reaction zone past the leading edge of the flame envelope as a non-coherent gas stream; and
(D) providing gaseous reagent from the non-coherent gas stream to the reaction zone.
As used herein the term “coherent gas jet” means a gas stream whose diameter undergoes no substantial increase along the length of the stream and the rate of entrainment of the surrounding gas into the gas stream is substantially less than that into a nonreacting turbulent jet.
As used herein the term “non-coherent gas stream” means a gas stream whose diameter increases as it entrains the surrounding gas.
As used herein the term “flame envelope” means an annular combusting stream coaxial with a gas stream.
As used herein the term “reagent” means a fuel or other chemical compound or mixture of compounds that takes part in a reaction after injection into an injection space.
BRIEF DESCRIPTION OF THE DRAWING
The sole FIGURE is a cross sectional representation of one preferred embodiment of the practice of the invention wherein reagent is provided to a carrier gas and then provided with the carrier gas to the reaction zone.
DETAILED DESCRIPTION
The invention will be described in detail with reference to the Drawing. Referring now to the FIGURE, carrier gas 1 is provided to central passageway 2 of injector 3 from a carrier gas source which is not shown. Any effective carrier gas may be used in the practice of this invention, examples of which include recirculated flue gas, oxygen, nitrogen, argon and air. Recirculated flue gas is particularly preferred as the carrier gas when NOx reduction is the aim of the invention. The carrier gas is passed from central passageway 2 to converging/diverging nozzle 4 and from there is passed out from nozzle 4 of injector 3 into injection space 5 as gas jet 6 .
Reagent 8 is provided to the carrier gas. Preferably, as shown in the FIGURE, the reagent is provided to the carrier gas from reagent provision means 7 which communicates with a source of reagent (not shown) and which passes the reagent to nozzle 4 wherein it mixes with the carrier gas. The reagent may be in gaseous, solid or liquid form. Preferably the reagent is in liquid or particulate solid form and is atomized within the carrier gas stream as it passes through nozzle 4 , thus being well mixed with the carrier gas within gas jet 6 . Any effective reagent may be used in the practice of this invention, examples of which include one or more liquid hydrocarbons, powdered coal, ammonia and urea.
A flame envelope flows coaxially along and around gas jet 6 serving to maintain gas jet 6 as a coherent gas jet from injector 3 through a distance (d) within injection space 5 . Preferably, as illustrated in the FIGURE, flame envelope 9 is formed by the combustion of separate oxidant and fuel streams provided into injection space 5 from injector 3 annular to coherent gas jet 6 . In the embodiment illustrated in the FIGURE, fuel 10 , such as natural gas, is provided to inner annular passageway 11 from a fuel source (not shown), and oxidant 12 , such as air, oxygen-enriched air or pure oxygen, is provided to outer annular passageway 13 from an oxidant source (not shown). If desired, the oxidant for the flame envelope may be provided through the inner annular passageway and the fuel for the flame envelope may be provided through the outer annular passageway. This arrangement may be particularly useful if the carrier gas is an inert gas. The fuel and oxidant pass through their respective passageways and out from injector 3 into injection space 5 wherein they combust to form flame envelope 9 which flows coaxially with coherent gas jet 6 through distance (d).
In the practice of this invention the flame envelope forms a fluid shield or barrier around the gas jet 6 . Preferably the flame envelope has a velocity which is less than the velocity of the gas jet. The fluid shield or barrier formed by the flame envelope around the gas jet greatly reduces the amount of ambient gases which are entrained into the gas jet, thereby serving to keep the jet coherent while it is housed within the flame envelope. This also serves to keep the reagent within the carrier gas jet while it is coherent.
Reaction zone 14 is within injection space 5 but remote from, i.e. not adjacent to, injector 3 . In one embodiment of the invention, within reaction zone 14 there resides one or more species with which it is intended that reagent 8 react. For example, reaction zone 14 may contain one or more NOx species, such as nitrogen oxide (NO) or nitrogen dioxide (NO 2 ), with which the reagent may react to form nitrogen gas (N 2 ) thus serving pollution control purposes.
The reagent-containing gas stream passes beyond distance (d) further into injection space 5 past the leading edge of the flame envelope into reaction zone 14 as a non-coherent gas stream or turbulent jet 15 . As the gas jet flows past the leading edge of the flame envelope, ambient gas is entrained into the gas jet causing it to become turbulent or otherwise lose its coherency. The reagent, e.g. liquid or solid particles, is kept within coherent gas stream 6 through distance (d), but as the carrier gas stream degrades into a non-coherent gas stream beyond the leading edge of flame envelope 9 , the reagent particles gasify and disperse out from the carrier gas stream and react with the target specie(s), i.e. NOx, within the reaction zone. In this way reagent is effectively provided to a remote reaction zone, such as the central area of a furnace, without need for a long lance extending from the furnace wall to the reaction zone.
In another embodiment of the invention, the reagent is fuel such as powdered coal and the carrier gas is an oxidant such as air, and the reagent and carrier gas are delivered to the reaction zone where the resulting turbulence enables them to combust. In this way a combustion reaction is caused to occur in a specific location within a boiler or furnace away from the furnace wall. In this embodiment there is no significant combustion within the coherent gas jet 6 and the combustion occurs only after the reagent and carrier gas mixture has become turbulent. The carrier gas oxidant need not be provided in a stoichiometric amount. Some of the oxidant for combustion with the reagent could come from another source such as the oxidant provided for the establishment of the flame envelope.
Typically injector 3 would be located generally in the area of the furnace wall. Typically distance (d) would be in the range of from 20 to 100 nozzle diameters and typically the diameter of nozzle 4 is within the range of from 0.25 to 2 inches. The velocity of coherent gas jet 6 may be supersonic and generally is within the range of from 0.3 to 3.0 mach.
When the reagent is a gaseous reagent, for example methane or other gaseous hydrocarbon, the need to employ a carrier gas may be eliminated. In this case the reagent acts in the same way as does the carrier gas in the previously described embodiment. In this gaseous reagent embodiment, using the arrangement illustrated in the FIGURE, items 7 and 8 shown in the FIGURE are eliminated and the gaseous reagent acts as does item 1 of the FIGURE, all other aspects being the same.
With the practice of this invention one can effectively deliver reactive materials to specific locations such as in a boiler or furnace where the desired reactions take place. The invention enables a burner to operate such that the flame is some distance into the furnace to prevent wall overheating and maximize the desired heat transfer without creating additional pollutants or enhancing recirculation of flue gas to the boiler or furnace wall. Moreover, the invention enables one to intimately mix reagents with gas in the center of a reaction zone, such as a boiler, without significantly impacting the flow field of the bulk gas within the reaction zone. That is, one can mix reagent with the flue gas in the middle of a boiler without requiring large scale changes in the velocity or direction of the bulk gas in the boiler. This invention further allows the delivery of a reactive component at a specific point without consumption of that component that would be due to mixing before the jet reaches the desired reaction zone.
Although the invention has been described in detail with reference to particularly preferred embodiments, those skilled in the art will recognize that there are other embodiments of the invention within the spirit and the scope of the claims.
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A method for providing reagent to a remote reaction zone wherein reagent preferably is mixed with carrier gas and maintained within the carrier gas as it is passed as a coherent jet through a distance to the reaction zone. The jet passes the leading edge of a confining flame envelope, loses its coherency and delivers the reagent to the reaction zone for reaction therein.
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FIELD OF THE INVENTION
[0001] The invention pertains to a device for sexual stimulation.
STATE OF THE ART
[0002] Devices for sexual stimulation, which can carry out rotational movements or translational movements are known from the prior art. US 2005/022819 A1 discloses a unit for sexual stimulation having a back-and-forth movable “shuttle”. In principle, the unit of US 2005/022819 A1 may be used for both female and male stimulation. However, the use in male stimulation leads to difficult handling. The reason being that the device must be re-configured for this purpose in such a way that it becomes extremely large and unwieldy.
[0003] Basically, there is a demand for handy units and devices for male stimulation. In general and herein, the term “male stimulation” is apprehended as a stimulation of the male member.
DISCLOSURE OF THE INVENTION
[0004] An object of the invention is to provide a device, in particular, a handy unit for male stimulation, which is improved with respect to the prior art.
[0005] The object is achieved with a device for sexual stimulation having a hollow piston, a drive cylinder, and transmission means for the transmission of a rotational movement of the drive cylinder into an axial movement of the hollow piston, wherein the drive cylinder encloses the hollow piston at least partially.
BRIEF DESCRIPTION OF THE FIGURES
[0006] Embodiments are described with reference to the figures, whereby the figures show:
[0007] FIG. 1 shows a schematic view of an embodiment of the invention;
[0008] FIG. 2 shows schematically parts of the embodiment shown in FIG. 1 in a partially cut view;
[0009] FIG. 3 shows one variation of a drive of the embodiments;
[0010] FIG. 4 shows a further variation of a drive of the embodiments;
[0011] FIG. 5 shows a snap lock, which can be used in embodiments; and
[0012] FIG. 6 shows a schematic view of a further embodiment.
DESCRIPTION OF EMBODIMENTS
[0013] Hereinafter, typical exemplary embodiments are described, whereby to some extend identical reference signs are used for identical or in part similar embodiments, to some extend also for several different embodiments. Basically, the application is not limited to the different embodiments but rather the scope is determined by the claims. To some extent, individual parts are merely exemplified in connection with one figure, however, if these parts are shown in other figures, they are not necessarily described a second time.
[0014] FIG. 1 shows a typical embodiment of a device 1 . The device 1 of FIG. 1 comprises a hollow piston 3 and a drive cylinder 5 . The drive cylinder 5 encloses the hollow piston 3 at least partially.
[0015] Thereby, enclosing typically means that the hollow piston has a smaller outer diameter than the inner diameter of the drive cylinder. Further, depending on the operational state, the hollow piston is typically at least partly or fully inserted in the drive cylinder.
[0016] The device 1 of FIG. 1 comprises transmission means for converting a rotational movement of the drive cylinder 5 to an axial movement of the hollow piston 3 . For the purpose thereof, a guide 7 is provided in the drive cylinder 5 . Acting as a guide element, a pin 9 that is firmly connected with the hollow piston engages with the guide. The guide 7 has a sinusoidal progression in circumferential direction. Upon rotation of the drive cylinder 5 , a translational movement of the hollow piston 3 in the direction of its longitudinal axis, i.e. axially, is accomplished by entrainment of the pin 9 in the axial direction in the guide 7 . The drive cylinder 5 of the embodiment of FIG. 1 can be driven manually by means of handles 10 .
[0017] Further driving possibilities are described in connection with the other figures.
[0018] Typical embodiments of the device comprise a hollow piston and a drive cylinder, whereby transmission means are provided for converting the rotational movement of the drive cylinder in an axial movement of the hollow piston. Axial movements are to be apprehended as translational movements in direction of the longitudinal axis of the hollow piston. In typical embodiments, the transmission means are adapted to exclusively allow a translational and, in particular, to prevent a rotational movement of the hollow piston.
[0019] According to further embodiments, the hollow piston can also be set into a rotational movement by the transmission means. Typical transmission means comprise guiding elements like, for example, screws, wheels, bearings or pins, which may be guided in guides such as grooves, cranks or notches. Typically, in embodiments the pin is provided on an outer side of the hollow piston and the guide in the drive cylinder. According to further embodiments, the guiding element, for instance, the pin, the wheels or the bearing is provided on the inner side of the drive cylinder and the guide in the hollow piston. Further transmission means comprise gears, for instance, linear gears with a gear rack or spindle. The advantage of guided pins or screws is a simple construction; the advantage of gears is a high load-bearing capacity. The advantage of wheels or bearings is a low friction.
[0020] According to embodiments, a wheel or wheels, in particular, two wheels are provided as guiding element, which engage with a guide. In this way the friction may be reduced.
[0021] According to embodiments, the guide progresses wavelike in a circumferential direction along at least a portion of the circumference of the drive cylinder or the hollow piston. Thereby “wavelike” comprises a sinusoidal or a continuous curve with an ascending and descending portion, whereby typically a first derivative of the curve may also be continuous in order to allow uniform movements. Typical waveforms comprise one or more upward and downward periods or amplitudes.
[0022] Typically, the drive cylinder may be rotated in both directions relative to the hollow piston.
[0023] According to embodiments, the guide is provided as a notch or a slot. According to an embodiment as slot, the drive cylinder is separated into an upper and lower part. These parts can be, for example, connected via handles provided on the outside of the drive cylinder. According to an embodiment as notch on the inner side of the drive cylinder, the drive cylinder may be provided in one piece. Other possibilities include a division of the drive cylinder in longitudinal direction in order to facilitate the manufacture of the drive cylinder or the assembly.
[0024] Typically, the pin or the screw is spring mounted in order to enable a reliable guidance without, for example, the pin jumping out of the groove or notch. An unsprung mounting in contrast allows for a more simple set-up.
[0025] A slip joint 11 is provided in the hollow piston 3 , in which a rail 13 is mounted for guiding the pin 9 in axial direction.
[0026] FIG. 2 shows a partially sectioned view of parts of the embodiment of FIG. 1 . In particular, FIG. 2 shows the guidance of the pin 9 in the axially aligned rail 13 . In this way, the rotational degree of freedom of the hollow piston 3 is locked with respect to the rail 13 . A rotation of the drive cylinder 5 results in an up- and downward movement in axial direction of the hollow piston 3 . Thereby, the hollow piston 3 moves in the direction of its two openings. Since the rotational degree of freedom of the hollow piston 3 is locked, it cannot rotate together with the drive cylinder 5 .
[0027] Typical embodiments comprise a linear guide for the hollow piston so that the rotational degree of freedom of the hollow piston is locked. The linear guide typically comprises a rail, a carrier system, a joint, a pin in a groove or a slip joint for a rail.
[0028] The hollow piston 3 in FIG. 2 comprises a padding 17 arranged on the inner side of the hollow piston 3 .
[0029] The padding is provided in typical embodiments and optionally comprises a gel cushion, silicone or foam. According to further embodiments, in order to simplify the set-up, the inner side of the hollow piston is unpadded.
[0030] According to the embodiment shown in FIG. 2 , the padding 17 is arranged on a ring insert 20 . The ring insert 20 has a snap lock 22 , which is shown in FIG. 5 . The snap lock 22 allows an installation of the padding 17 or also cushions or further pipes. The snap lock can function similarly to a fastener of a lens cap. Further possibilities for attaching include Velcro fasteners or adhesive tabs with adhesion material. Embodiments lacking a snap lock are assembled more easily. A snap lock offers the possibility to insert additional extensions or padding within the hollow piston. Such insertion can take place recursively so that a plurality of sizes and lengths can be used.
[0031] The configuration of the inner surface of the ring inserts of typical embodiments may be smooth, corrugated or rough. Also threads or other surface characteristics may be provided.
[0032] In typical embodiments, a sleeve of flexible material is provided at the openings or at one of the openings of the hollow piston. Typical embodiments of such sleeves are waterproof or dustproof. Typical materials for such sleeves include silicone, rubber or flexible plastics. A further possibility is a tube-shaped inlet, which is guided through the hollow piston. In typical embodiments, the drive cylinder is connected via the sleeve with the hollow piston. The drive cylinder is typically mounted with bearings, sliding disks, Teflon, ceramic bearings, epoxides or sliding material.
[0033] FIG. 3 schematically shows parts of a typical drive for a device 1 according to an embodiment. A drive cylinder 5 of the device 1 of FIG. 3 is equipped with a rotating ring gear 24 that is driven by a gear wheel 26 . In typical embodiments, the gear wheel 26 is driven by an electro motor (not shown). By controlling the power of the electromotor with a control unit (not shown) the rotational speed of embodiments may be adjusted. Further drives comprise hydraulic motors, a combustion motor or a turbine, for example, a wind turbine. A further possibility for controlling the speed of movement is the incorporation of a reduction gearbox.
[0034] FIG. 4 shows a further embodiment of a drive with drive belts 28 that are driven by a shaft 30 and that also enclose the drive cylinder 5 at least partly. The shaft 30 is put into motion via a gear wheel 32 . The drive with the drive belts 28 provides the advantage that in the case of overload, the drive belts 28 on the drive cylinder 5 may slip through so that an overload of a drive does not occur.
[0035] FIG. 6 schematically shows a further optional embodiment of device 1 with a hollow extension body 40 . The hollow extension body 40 is fitted into or onto the hollow piston 3 and allows an extension of the interior space of the device, for example, for an improved stimulation.
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The invention relates to a device ( 1 ) for sexual stimulation having a hollow piston ( 3 ), a drive cylinder ( 5 ), and transmission means ( 7, 9 ) for converting a rotational movement of the drive cylinder into an axial movement of the hollow piston, wherein the drive cylinder ( 5 ) encloses the hollow piston ( 3 ) at least partially.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention concerns a method for the automatic analysis of security requirements in information technology systems.
[0003] Its purpose is to analyse the security requirements of information technology systems so as to prevent omissions or conflicting requirements that might lead to major weaknesses in the system, and to provide justifications for the countermeasures required to ensure the security of the system.
[0004] 2. Description of the Prior Art
[0005] The security of information technology systems is becoming both more and more complex and increasingly crucial for modern companies. The management of risks, which was initially the exclusive expertise of the military area and certain specific industrial sectors, has long been a very confidential topic with secret and company specific practices. Current risk management processes are based on:
either empirical approaches, which are by essence subjective and difficult to justify or objective or formal (mathematically grounded) methods, which are rigorous but difficult to apply to concrete situations and rather inflexible. In addition such methods require a strong expertise in the mathematical theories involved, which is a strong limitation for a wider use.
[0008] In both cases, there is a lack of automatic tools which would allow the security analysis task to be automated.
OBJECT OF THE INVENTION
[0009] This invention therefore has the particular aim of filling the gap between pragmatic but non systematic methods on one hand and methods which are more rigorous but also more difficult to apply on the other hand.
SUMMARY OF THE INVENTION
[0010] To this end, it proposes an automatic analysis method, implemented on a processor, and which allows:
[0011] taking account of all security aspects, both organisational and technical,
[0012] interacting with the users (security experts, decision makers, etc.) and synthesizing relevant information which can then be easily compared with the actual situation,
[0013] systematically checking security information for completeness and consistency in order to detect potential weaknesses of the system (or future system).
[0014] The method according to the invention enables the description and comparison of different structured views of the information. This information structuring principle meets requirements which are increasingly difficult to satisfy by human reasoning, because of the growing complexity of information technology systems and the vast increase in volumes of parameters and information to be considered.
[0015] The process according to the invention involves:
[0016] Actors (including, for example, human beings, companies, organisations, applications, etc.) capable of performing certain actions (whether authorised or malicious) on the system. For reasons of convenience, these actors can be grouped into classes (or roles), which makes it possible to treat them in a uniform manner. With each actor (or class of actors), it is possible to associate attributes such as a, for example, its confidence level, or its means (characterising its ability to carry out certain attacks). Such attributes can be numerical values or values of a more complex nature allowing the information to be described more precisely. As far as means are concerned, for example, it is possible to distinguish the hardware means (oscilloscope, etc.), the qualifications (knowledge of specific techniques, etc.), the determination, and the potential benefits that the actor could gain from a malicious action.
[0017] Assets, which are the valuable items to be protected, such as, for example, data in memory, hardware (processor, hard disk, diskette, cable, etc.), applications in memory, electromagnetic radiations, etc. Included in this list are items such as electromagnetic radiations, whose value is indirect in the sense that it supplies information on other assets (what is usually referred to as “information flow”). For reasons of convenience, assets can be grouped into classes, which make it possible to treat them in a uniform way. With each asset (or class of assets), it is possible to associate attributes such as its required protection types (integrity or authenticity for example) or its sensitivity levels characterising its degree of sensitivity in a predefined scale. Such sensitivity levels can be numerical values or information of a more complex nature distinguishing, for example, between the types of possible attacks or the types of actors capable of performing these attacks.
[0018] Locations, such as, for example, geographical zones (whether secure or not), memory pages (volatile or not), electric cables used as a communication media, etc. In general, a location corresponds to an asset container. The distinction between assets and locations makes it possible to deal with both “access control” and “control flow” security policies. However the method according to the invention does not prevent some locations themselves to be also considered as assets. For reasons of convenience, the locations can be grouped into classes, so that they can be treated in a uniform manner. With each location (or class of locations), it is possible to associate attributes such as, for example, a physical type (hard disk, diskette, ROM, RAM, EEPROM, cable, electromagnetic emission, etc.) or a level of protection (provided by the location) against certain types of attacks. Such protection levels can be numerical values or information of a more complex nature enabling the protection to be described in a more precise manner.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The method according to the invention concerns the automatic analysis of the security requirements of information technology systems. It involves the construction and the analysis of a security model associating:
[0020] with each actor (or class of actors) a set of access rights and interdictions to certain locations (or classes of locations),
[0021] with each actor (or class of actors), a set of access rights and interdictions to certain assets (or classes of assets),
[0022] with each asset (or class of assets), a set of locations (or classes of locations) which can contain the said asset (or class of assets).
[0023] These associations can be defined by means of tables constructed systematically through interactions with one or several users, and then analysed in an automatic way.
[0024] The construction and analysis of the above security model enables to:
[0025] derive the threats in an automatic manner, and thus provide a way for designers to rely on objective and rational grounds to make the design and development choices,
[0026] provide users with means to manipulate the security information and to measure the impact of each decision on the security model, thereby detecting, for example, whether an access right granted to a particular actor for functional purposes conflicts with the presence of a confidential asset in a given location, potentially leading to a security weakness,
[0027] communicate with and convince a broader community (beyond the circle of security experts) regarding the security choices and consequences thereof,
[0028] make explicit the security assumptions and the choices which have led to the design of an information technology system.
[0029] Embodiments of the invention can thus be used to support the growing need for transparency and better understanding of security issues which is currently manifesting itself in various ways such as the use of public and standard encryption algorithms (as opposed to company specific, secret algorithms), the publication of protection profiles in accordance with standards such as the Common Criteria—The “Common Criteria for Information Technology Security Evaluation” is a widely used international standard (ISO/IEC 15408) for security evaluations. Although the process according to the invention can be used in the context of the Common Criteria, it is not restricted to it in any way, the obligation to make public the security target in order to receive the mutual recognition of Common Criteria certificates, etc.
[0030] The six types of relations describing a basic security model according to the invention can be implemented as tables (which is a preferred embodiment but not a limitation of the invention) as follows:
[0031] the table of access rights to locations, associating with each actor (or class of actors) a set of access rights to certain locations (or classes of locations),
[0032] the table of access interdictions to locations, associating with each actor (or class of actors) a set of access interdictions to certain locations (or classes of locations),
[0033] the table of access rights to assets, associating with each actor (or class of actors) a set of access rights to certain assets (or classes of assets),
[0034] the table of access interdictions to assets, associating with each actor (or class of actors) a set of access interdictions to certain assets (or classes of assets),
[0035] the location table associating with each asset (or class of assets) a set of locations (or classes of locations) which can contain this asset,
[0036] the inclusion table associating with certain actors (or classes of actors) the classes of actors which include them, with certain assets (or classes of assets) the classes of assets which include them and with certain locations (or classes of locations) the classes of locations which include them.
[0037] A simple version of these tables can contain Boolean information (access authorised or forbidden, location possible or not). It may nevertheless be preferable in some cases to introduce more precise information into these tables so as to be able to describe the actual situations in a more detailed manner.
[0038] The process according to the invention proposes the following refinements:
[0039] each of the aforementioned tables can store information on the contexts in which the access rights are granted or forbidden, and in which the locations are possible or not, where the said contexts can, for example, involve information about the internal state of the system, the stages in its life cycle, or the values of certain data or parameters, etc.;
[0040] the first four tables can store information on the types of access, distinguishing, for example, read access, write access, execution access, use access, etc.;
[0041] the location table can store information on the form of the asset in a given location, distinguishing, for example, un-ciphered data, data ciphered using a given algorithm and key length, data split into several parts in order to make its extraction more difficult, data associated with information used to verify its integrity (checksum for example).
[0042] In the same way, and still with a view to a more detailed analysis of the security requirements and the countermeasures needed to address certain types of threats, the method according to the invention can be used to characterise the assets (and classes of assets) and the actors (and classes of actors) in the following way:
[0043] the assets (and classes of assets) can be associated with attributes such as, for example, a required protection type (integrity, authenticity, etc.) or levels of sensitivity, where the said sensitivity levels can be numerical values or information of a more complex nature allowing to describe the sensitivity more precisely, identifying, for example, the types of attacks possible upon the asset or the types of actors capable of conducting these attacks;
[0044] the actors (and classes of actors) can be associated with attributes such as, for example, a level of confidence, or a set of means characterising their ability to conduct certain attacks; said means can be numerical values or information of a more complex nature used to describe the information more precisely, including for example, the hardware means (oscilloscope, etc.), qualifications (knowledge of specific techniques, etc.), determination, and the potential benefits that an actor may gain through a malicious action.
[0045] The model according to the invention can also include the following relations, such relations can also be implemented as tables (which is a preferred embodiment but not a limitation of the invention), which can be used to refine the security analysis:
[0046] a dependency table, which stores the dependencies, or information flows, between the assets (or classes of assets); this table enables to store the fact that the knowledge of an asset (or a class of assets) indirectly provides information on another asset (or class of assets);
[0047] a collusion table, which stores the relations, known as collusion relations, between the actors (or classes of actors), which can group together their means and their information in order to perpetrate attacks; this table can be used, for example, to store the fact that knowledge of an item of information by an actor (or class of actors) can lead to the same knowledge by another actor (or another class of actors);
[0048] a transition table which stores the possible transitions between the contexts and the actors (or classes of actors) capable of triggering such transitions; from the knowledge of an initial context, this table can be used to determine all of the attainable contexts and the actors (or classes of actors) capable of triggering context changes.
[0049] The process according to the invention allows cross checks to be performed between the different sources of information represented in the model, so as to detect any potential security weakness of the system. Such weaknesses can manifest themselves in two ways during the security analysis:
[0050] inconsistency, which indicates the supply (or derivation by logical reasoning) of contradictory information.
[0051] incompleteness, which indicates the omission of certain information;
[0052] The process according to the invention proposes the following consistency verifications:
[0053] verification on the table of access rights to locations and the table of access interdictions to locations in order to detect any contradiction that could reveal the existence of potential threats, where these contradictions can be expressed, for example, by the fact that an actor (or class of actors) can be, in a given context, associated with both the right and the interdiction of a certain type of access;
[0054] verification on the table of access rights to assets and the table of access interdictions to assets in order to detect any contradictions that could reveal the existence of potential threats, where these contradictions can be expressed, for example, by the fact that an actor (or class of actors) can be, in a given context, associated with both the right and the interdiction of a certain type of access;
[0055] verification on the table of access rights to locations, the table of access interdictions to locations, and the location table, in order to detect any contradictions that could reveal the existence of potential threats, where these contradictions can be expressed, for example, by the fact that an actor (or class of actors) can be, in a given context, associated with the interdiction of a certain type of access to an asset (or class of assets) when it can obtain this access indirectly through an access to a location (or class of locations) which may contain this asset (or class of assets);
[0056] verification on the table of access rights to assets, the table of access interdictions to assets and the dependency table, in order to detect any contradictions that could reveal the existence of potential threats, where these contradictions can be expressed, for example, by the fact that an actor (or class of actors) can be, in a given context, associated with the interdiction of a certain type of access to an asset (or class of assets) when it can obtain this access indirectly through an access to an asset (or class of assets) providing information on the former (such that there exists a flow of information between the two assets).
[0057] verification on the table of access rights to locations, the tables of access rights and interdictions to assets, the location table, and the transition table, in order to detect any contradictions that could reveal the existence of potential threats, where these contradictions can be expressed, for example, by the fact that an actor (or class of actors) can be, in a context C, associated with the interdiction of a certain type of access to an asset (or class of assets) when it can obtain this access indirectly through a transition used to reach another context C′ in which the actor (or class of actors) has the right to access this asset (or class of assets) or can get access to a location (or class of locations) which may contain this asset (or class of assets);
[0058] verification on the table of access rights to assets, the table of access interdictions to assets, and the collusion table, in order to detect any contradictions that could reveal the existence of potential threats, where these contradictions can be expressed, for example, by the fact that an actor (or class of actors) A can be, in a given context, associated with the interdiction of a certain type of access, the actor (or classes of actors) A′ is associated (in the same context) with the access right, and the collusion table indicates that the actors (or classes of actors) A and A′ are able to exchange information;
[0059] verification on the table of access rights to locations, the table of access interdictions to locations and the collusion table, in order to detect any contradictions that could reveal the existence of potential threats, where these contradictions can be expressed, for example, by the fact that an actor (or class of actors) A can be, in a given context, associated with the interdiction of a certain type of access, whereas the actor (or classes of actors) A′ is associated with this access right, and the table of collusions indicates that the actors (or class of actors) A and A′ are able to exchange information;
[0060] verification on the inclusion tables and one or more of the other tables, in order to detect any contradictions expressed by the fact that an actor (or class of actors) A is included in a class of actors C and that A and C possess contradictory access rights and/or interdictions;
[0061] verification on the inclusion table and one or more of the other tables, in order to detect any contradictions expressed by the fact that an asset (or a class of assets) A is included in a class of asset C and that A and C are associated with contradictory access rights and/or interdictions;
[0062] verification on the inclusion table and one or more of the other tables, in order to detect any contradictions expressed by the fact that a location (or class of locations) L is included in a class of location (C) and that L and C are associated with contradictory access rights and/or interdictions.
[0063] In an embodiment of the invention, the security model can be constructed through of a series of interactions with one or several users (such as security experts, issuer, designer, etc.). The embodiment of the invention can include output facilities to display questions to the users, the answers to such questions being used to fill in the tables defining the model.
[0064] The detection of an inconsistency in the model can trigger one of the following processes:
[0065] display of a message to the user with a description of the inconsistency accompanied by a question to the user who must then resolve the detected inconsistency by modifying one (or several) of the tables making up the model;
[0066] display of a message to the user with a description of the inconsistency accompanied by one or several suggestions for strengthening the model and solving the inconsistency. An example of such strengthening could be, for example, the deletion or limitation of an access right to a location (or class of locations) or to an asset (or class of assets), and the user can then select one of the proposed suggestions.
[0067] The completeness of the information contained in the model can be ensured in one of the following ways:
[0068] the tables defining the security model are filled in through interactions with the user, who has to supply the necessary information until the model is complete;
[0069] the tables defining the security model are completed automatically in accordance with a “caution assumption” (or maximum security assumption), expressed, for example, by the fact that an access which is not explicitly granted in a given context is automatically considered as forbidden.
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This invention concerns a method for the automatic analysis of security requirements in information technology systems. To this end, it proposes an automatic analysis process, implemented on a processor, and which allows: taking account of all security aspects, both organisational and technical, interacting with the users (security experts, decision makers, etc.) and synthesizing relevant information which can then be easily compared with the actual situation, systematically checking security information for completeness and consistency in order to detect potential weaknesses of the system (or future system). The method according to the invention enables the description and comparison of different structured views of the information. This information structuring principle meets requirements which are increasingly difficult to satisfy by human reasoning, because of the growing complexity of information technology systems and the vast increase in volumes of parameters and information to be considered.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to application Ser. No. 08/106,256 entitled "AUTOMATIC CARTRIDGE FEEDER WITH PRIORITY SLOT" filed Aug. 13, 1993 by Dale A. Christiansen et at., and to application Ser. No. 08/068,366 entitled "CARTRIDGE MAGAZINE WITH CARTRIDGE PROCESSING STATUS INDICATOR" filed May 27, 1993 by Donald C. Acosta and Paul Yu-Fei Hu, both applications assigned to International Business Machines Corporation.
1. Field of the Invention
This invention relates generally to automatic data cartridge feeders for use with data storage medium drive units, and, more particularly, to a magazine having an interface to such a feeder while also having an interface to a robotic picker or human operator.
2. Description of the Related Art
Computer system tape drive units can be configured to receive tape cartridges, such as Model 3480 and 3940E cartridges by International Business Machines Corporation (IBM Corporation). The cartridges contain a length of magnetic tape upon which data can be written and read. Many tape drive units can mate with an automatic cartridge feeder (ACF) that accepts a tape cartridge and transports it to the drive unit tape transport mechanism and read/write heads. ACF's are available in configurations that accept cartridges one at a time through a single feed slot and configurations that mate with removable cartridge magazines, containing a plurality of tape cartridges, from which cartridges are accepted one at a time.
ACF's having a feed slot for single cartridges permit an operator to sequentially insert tape cartridges that are automatically transported to a drive unit. In this way, the operator has complete control over the order in which cartridges are processed. However, an automatic cartridge feeder with only one slot is inefficient because an operator is occupied with loading and unloading cartridges substantially the entire time the drive unit is being used. Moreover, loose cartridges can be lost, mishandled, or placed out of sequence.
Automatic cartridge feeders that accept removable cartridge magazines can greatly increase operating efficiency and also increase throughput of cartridges to be processed by the drive unit. A cartridge magazine typically includes a plurality of cartridge shelves, each of which receives a cartridge, and is coupled to the cartridge feeder such that the cartridge feeder can transport cartridges from the magazine to the drive unit in the sequence they are stored in the magazine or in a sequence selected by the drive unit, including a random sequence. Typical magazines have a capacity of seven to twelve cartridges.
The cartridge magazine frees an operator from being occupied with the feeder and drive unit and also reduces the number of times an operator must manually intervene to provide fresh cartridges. In a manual library all tasks of loading cartridges into the magazine are performed by humans rather than robots. However, in a manual library containing many ACF's, the repetitive task of providing fresh cartridges is only augmented by the repetitive task of providing fresh magazines. While this greatly increases the efficiency of the operator, there is still a requirement for the operator to perform repetitive tasks.
It is well known that repetitive physical tasks, such as loading and unloading cartridge magazines, can lead to injuries such as carpal tunnel syndrome and soreness of muscles, joints, and tendons. In general, injuries in the work place are costly to business and painful for those injured, such as the operator described above. For this reason, businesses have spent vast sums of money on ergonomics design, also referred to as human factors engineering.
Another objective of human factors engineering is making a product easier to use which in turn makes the user's job easier to do. Unfortunately, such human factors engineering has not thus far provided a data cartridge magazine that enables an operator to complete the task of inserting and removing them in a manner that is easy, fast, and safe from injury.
In addition to manual libraries there are several well known automatic data storage libraries, such as the IBM Corporation 3494 and the IBM Corporation 3495 libraries. These libraries descended from the IBM Corporation 3850 Mass Storage Subsystem introduced in the 1970's. An automated tape library having a robotic picker having at least one gripper for handling a cartridge is disclosed in U.S. Pat. No. 4,654,727. This patent is herein incorporated in its entirety by this reference. Another magnetic tape cartridge library having a robotic picker is described in U.S. Pat. No. 4,864,438, which is also incorporated in its entirety by this reference.
It would be an improvement to the automated data storage library art if automated cartridge feeders could be used in combination with such libraries, to provide a "mechanical cache" of frequently required data in the library. In other words, a bank of multiple automatic cartridge feeders could each be accessed through their respective magazines, by a robotic picker if a magazine providing an interface for such a robot was available. The primary problem with creating such an interface has been the failure to provide an interface, from the magazine to the robot, that would allow continuous processing of the ACF when cartridges are accessed by the robot. If the ACF is interrupted, then the drive unit also must be interrupted, in turn preventing reading or writing, and writing of data, and thus negating the effectiveness of the mechanical cache.
This problem can best be illustrated with reference to FIG. 1 showing a typical prior art magazine 10 having a handle 15 for carrying and a door 11 which is a closed interface to cartridges. The door blocks access to cartridges when the cartridges are being accessed on the other side of the magazine by an automatic cartridge feeder. In such prior art schemes, the door must be moved before any of the cartridges can be removed. However, for safety reasons it is necessary to disable the ACF that accesses the cartridges in the magazine whenever the door is opened. It should be apparent to those skilled in the art that it would be a great improvement to the data processing art to enable the accessing of cartridges in a magazine by robotic pickers without interrupting the operation of any ACF also accessing other cartridges in the magazine. With reference to manual libraries described above, it should also be apparent to those skilled in the art that a closed interface, such as door 11, blocks access to any cartridge in the magazine the ACF is operating.
A typical example of cartridge magazines having a door or closed interface that prevents access of single cartridges while a cartridge feeder is operating can be seen in U.S. Pat. No. 5,231,552, to Schneider et al. The loader for receiving the magazine in the '552 patent is a tilting access door that must be closed to operate the feeder. Another example of a tilting access door for receiving a magazine is shown in European Pat. Application No. EP 0238752 by Andrew. In the Andrew disclosed-device the door must remain closed to operate the feeder and drive mechanism. Still another example of a closed access system is shown in European Patent Application No. EP 0392620 by Fago. In the Fago disclosed-device the magazine has a curved-bar that is pivotable like a door so that it must be pivoted one way to provide access to the cartridges and another way to block access. Access must be blocked in order for the feeder unit to access cartridges from the other side.
Some prior art magazines are equipped with a handle that is small and therefore not well configured for varying hand sizes, and, in particular, is not well adapted for large hands. Such a sizing configuration lends itself to motivating the operator to carry the magazine with his or her wrist facing upward (i.e., with the knuckles of the hand pointing downward, toward the operator's feet). A typical cartridge weighs about one-half pound, and a typical magazine can carry an average of about 10 cartridges. Since the magazine itself weighs about 1 to 1.5 pounds, this means that the wrist of the operator is supporting most of the 6 to 6.5 pounds of weight of the magazine and its contents. It is well known that more of this weight would be carried by other stronger parts of the arm, if the magazine could be carried so that the operator's wrist is pointing downward (knuckles upward). But such a configuration of the handle dictates that the operator must pull upwards on it in order to remove the magazine from an automatic cartridge feeder. Another problem with typical prior art magazines is that many have rigidly fixed handles that have no degrees of freedom. A fixed handle tends to make a magazine difficult to remove and is not well-suited to varying heights of installation, especially relative to operators of varying heights. Further, a fixed handle may add to the risk of injury to an operator because it requires him to bend over or lift weight over his head. Thus, it would be an advancement in the data cartridge processing art if risks to human safety, such as with the problems described above, were greatly reduced while also solving the other interface problems described above.
SUMMARY OF THE INVENTION
An objective of this invention is to provide a data cartridge storage magazine that has an interface to an automatic cartridge feeder (ACF) that allows each stored data cartridge to be engageable by a cartridge transport mechanism in the ACF, while another interface is provided to make the cartridges capable of being engaged and removed by either a human operator or a robotic picker mechanism for a library, without interrupting the active operation of the ACF.
A further objective of this invention is to meet the above described objective while further enabling the magazine's ACF interface to allow for easy and speedy placement and removal of the magazine.
Another objective oft his invention is to further enable the magazine's ACF interface with a mechanism that secures the magazine in place in the ACF until an operator engages the interface to remove the magazine.
A still further objective of this invention is to meet the above described objectives while reducing the risk of injury to a human operator who performs the placement and removal task.
To meet these objectives and to overcome the limitations in the prior art described above, and those that will become apparent upon reading and understanding this specification, this invention discloses a magazine having interfaces to automatic cartridge accessing devices as well as to a robot or human. On one side, the magazine has an open "doorless" interface to an operator or a robotic picker for an automatic data storage library. On the other side, the magazine is accessible to an automatic cartridge feeder (ACF) that transports a cartridge to a drive unit. The magazine's ACF interface includes a handle that is used by an operator to place the magazine in the ACF. The handle engages with a latch bar in the ACF to secure the magazine in place. The ACF interface enables the continuous functioning of the ACF without interruption, when a magazine is present. Removal of the magazine is accomplished by an operator pulling or lifting the handle to release the magazine. Once removed, the handle may be used by an operator to carry the magazines to another ACF or remote storage.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
FIG. 1 shows a prior art embodiment of a magazine;
FIG. 2 shows a perspective view of a library comprising the magazine and automatic cartridge feeder (ACF) of this invention, along with a drive unit to which they are attached;
FIG. 3 shows an exploded view of the magazine and automatic cartridge feeder of FIG. 2;
FIG. 4 is a functional block diagram of the library of FIG. 2 together with a block diagram of a robotic control unit and a robotic picker useful with this invention;
FIG. 5 shows a gripper mechanism of the robotic picker of FIG. 4 engaging a cartridge stored in the magazine of this invention;
FIG. 6 shows a perspective view of the magazine of FIGS. 2 and 3 including the ACF interface and the open doorless interface for a human operator or the robotic picker gripper of FIG. 5;
FIG. 7 shows another perspective view of the magazine of FIG. 5 showing the handle member of the magazine's ACF interface in an extended position useful for carrying the magazine;
FIG. 8A shows the magazine of FIGS. 6 and 7 being inserted into the ACF of FIGS. 2 and 3;
FIG. 8B shows the magazine of FIGS. 6 and 7 in a secure position in the ACF of FIGS. and 3 after being inserted as shown in FIG. 8A;
FIG. 8C shows the magazine of FIGS. 6 and 7 being removed from the ACF of FIGS. 2 and 3;
FIG. 9 is an isometric view of the latch bar member of the ACF of FIGS. 2 and 3, that is adapted to be engaged by handle of the magazine of FIGS. 6 and 7;
FIGS. 10A, 10B, 10C, 10D, 10E, 10F, and 10G show the interrelationship of the members of the ACF interface of FIGS. 6 and 7 during the cycle of insertion, securement, and removal depicted in FIGS. 8A, 8B, and 8C, respectively.
FIG. 11 is a cut-away perspective view of the ACF of FIGS. 2 and 3 engaging the ACF interface of FIGS. 6 and 7 and showing the interaction of the latch bar member of FIG. 10 with a sensing device that indicates the presence of absence of the magazine in the ACF; and
FIGS. 12 and 13 are side views of the latch bar member of FIGS. 10 and 11 showing the respective activation and deactivation of the sensing device of FIG. 11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 2 shows an automatic cartridge feeder 31 constructed in accordance with this invention that includes a magazine slot 12 for mating with a cartridge magazine 14. The tape cartridge can comprise, for example, an IBM Corporation 3480 or 3490E tape cartridge. The automatic cartridge feeder is adapted for engagement with a drive unit 20, which contains a tape transport mechanism and read write heads. The cartridge magazine 14 can be filled with cartridges for processing by the drive unit. When the magazine is mated with the magazine slot 12 of the automatic cartridge feeder 31, cartridges are automatically removed from the magazine, transported to the drive unit and processed, and then returned to the magazine.
FIG. 2 shows that the automatic cartridge feeder 31 includes a display assembly 22 having a liquid crystal display (LCD) panel 24 and a control panel 25 having control buttons 26. The LCD panel is used to display system messages and instructions to an operator. The control buttons 26 are used by an operator to change operating modes, begin and stop procedures, and otherwise control the operation of the cartridge feeder. The display assembly 22 is pivotable for adjustment of viewing angle. Cartridges from the feeder enter and leave the drive unit 20 through an interface slot 27.
The cartridge magazine includes a plurality of cartridge shelves 28, each of which can support a cartridge 18. The cartridge feeder 31 includes a plurality of status indicators 30 located such that an indicator is adjacent each shelf when the magazine is mated with the cartridge feeder. The status indicators are used to inform an operator about the status of the cartridge associated with the indicator. Additionally, the status indicators are used to indicate whether or not the magazine 14 is securely installed in the feeder 31. For example, in a preferred embodiment, when a particular indicator, associated with a particular shelf, is steadily illuminated green that indicates the cartridge stored on that shelf is being processed by the drive unit. Whereas, a non-illuminated state indicates the associated cartridge has already been processed by the drive unit and has been returned to the magazine. An "alert condition" can be indicated by steadily illuminating the indicator yellow, while a more urgent "attention condition" can be indicated by flashing the particular indicator yellow. All the indicators are steadily illuminated green immediately after the magazine is placed in the ACF indicating the ACF is ready to operate. Likewise, a steady yellow illumination of all the indicators means that the magazine has been removed.
FIG. 3 shows the cartridge feeder 31 in greater detail, along with a cartridge magazine 14. The drive unit 20 is not shown in FIG. 3 for simplicity. FIG. 3 shows that the cartridge feeder 31 includes a housing 40 to which the remaining feeder components are attached. A side panel 42 of the cartridge feeder has been removed to reveal a rear opening 44 in the housing. An opposite side panel 43 is also removed in FIG. 3. The rear opening comprises a feeder/drive unit interface through which cartridges are delivered to the interface slot 27 of the drive unit (FIG. 2). That is, cartridges 18 that are removed from a shelf of the magazine 14 are transported through the feeder rear opening 44. A feeder transport assembly 46 is used for all movement of cartridges within the cartridge feeder, including removal and return of cartridges from the magazine, and also transport of cartridges to and withdrawal of cartridges from the drive unit.
A priority slot 16 is provided in a preferred embodiment, so that the operator can predetermine the order of processing the cartridges. For example, a cartridge placed on the priority shelf will be processed before any others once the drive is no longer busy. The priority shelf is also used for safety purposes. When the magazine is no longer securely positioned, i.e., the operator has begun to remove it by pulling or lifting on the handle, this invention enables almost instantaneous sensing that the magazine has moved. In response the elevator platform 53 attached to lead screw 68 is immediately raised to the level of the priority shelf so that an operator cannot accidentally be hurt by its movement. The enabling of the sensing mechanism will be described in detail below.
FIG. 3 further shows that the from portion of the cartridge feeder 31 comprises a cartridge feeder bezel 48 including the priority slot 16 and the cartridge status indicators 30. The cartridge status indicators 30 comprise a slotted indicator window 52 in the bezel adjacent each cartridge receiving position, such positions including the shelves 28 of the magazine 14, as well as the priority slot which is part of the bezel. In a preferred embodiment, each indicator is illuminated by a two-color light emitting diode (LED) 54 mounted on an indicator board (not shown) that is attached to the bezel shroud behind the cartridge feeder bezel 48. The bezel 48 attaches to a magazine slot frame 58 that in mm is attached to the feeder housing 40. The display 22 is attached to the bezel.
The cartridge magazine 14 holds cartridges on the shelves in position so they can be removed from a shelf by a cartridge feeder tray 62 of the cartridge transport assembly 46 and transported through the rear opening 44 to the drive unit 20 (FIG. 2). The cartridge feeder tray 62 is coupled to three vertical shafts 64, 66, and 68. Two of the vertical shafts 64 and 66 are mounted on opposite sides of the feeder tray 62 and ensure proper positioning and vertical travel of the feeder tray. The third vertical shaft 68 is a threaded lead screw that is coupled to the tray by a fixed nut 70. A system of drive motors 72 rotate the shafts in a prescribed sequence, including the lead screw 68. Because the nut 70 is fixed in place relative to the feeder tray 62, the tray is moved vertically as the shaft 68 is rotated by the motors 72. As is known to those skilled in the art, the lead screw 68 can be coupled to the feeder tray 62 so that rotation of the lead screw also can cause horizontal movement of the tray when a cartridge is to be removed or returned from the magazine, and when a cartridge is to be withdrawn or inserted into the drive unit. The top of the cartridge feeder housing 40 is closed with covers 73 and 74. Finally, the bottom of housing 40 is closed with a bottom cover 76.
Operation of the automatic cartridge feeder 31 will be further understood with reference to the block diagram of FIG. 4. FIG. 4 shows that the cartridge feeder 31 does not include a dedicated microprocessor, rather, all cartridge feeder operations are performed under control of the drive unit 20. In particular, a drive unit central processor unit (CPU) 80 communicates with feeder through a logic card 81 interface. It is to be understood, therefore, that references to the feeder taking action or completing tasks refer to operation of feeder components under control of the drive unit CPU. It also is to be understood that the automatic cartridge feeders can be constructed so that it also includes a central processor unit that controls some or all of the feeder operations.
In addition to controlling the feeder 31, the drive unit CPU also controls read/write heads 82 of the drive unit and controls a tape transport mechanism 84 of the drive unit. The tape transport mechanism winds tape around the heads and controls the tape direction. It is to be understood that if the data storage cartridges handled by the cartridge feeder are not tape cartridges, then the drive unit would include other systems for appropriate processing. For example, magnetic disks would be handled by a disk drive rather than a tape transport, and optical disks would be handled by an optical drive. FIG. 4 also shows that the drive unit CPU 80 controls the feeder motors 72, drives the cartridge feeder LCD operator display panel 24, controls the cartridge status indicators 30, controls a cartridge sensor system 86 and a magazine sensor system 87 in which either sensor system can control the feeder transport assembly 46. Although not shown in FIG. 4, CPU 80 also receives inputs from the cartridge feeder input buttons 26 (FIG. 2). Additionally, FIG. 4 shows that the drive unit CPU 80 is coupled to a host computer 88, also referred to as an initiator, from which the drive unit can receive commands and requests for data.
Library Manager logic 89 provides an interface from the CPU 80 to a coupled robot control unit 96 that is in communication with and provides control commands for robotic picker 92. In a preferred embodiment the Library Manager is software that is loaded into some form of electronic memory, such as random access memory that is typically part of a well-known personal computer (not shown). The robot control unit is alerted by the CPU 80 to the status of a cartridge so that the robot can be commanded properly to only retrieve cartridges that are finished processing.
FIG. 5 shows the magazine 14 with cartridges 18 in place and the open interface 94 providing unencumbered access to the cartridges. Thus, any cartridge identified by CPU 80 as not being processed by the ACF is accessible to robot 92 because, based on the inventor's critical recognition of the need to provide such an access, the magazine 14 is adapted to work without a door. Since there is no door there is no need to interrupt the ACF operation when a cartridge is accessed, thus an open interface 94 is provided by this invention. Since the invention provides a quick magazine position sensing device, there is no concern for the safety of the operator because the transport assembly cannot be reached with the magazine in place. In a preferred embodiment, robot 92 has a gripper 95 for grasping cartridge 18. For the sake of simplicity robot 92 is not shown in FIG. 5. However, in a preferred embodiment the robotic picker can be a well-known robot used in an automated data storage library, such as the robot described in the incorporated '727 or '483 patents. Also the robot used in the known IBM Corporation 3495 automated data storage library will also work with this invention. It is to be understood that the open interface alternatively provides access to cartridges for a human operator without interrupting the processing of the ACF.
Referring to FIGS. 6 and 7, the magazine is shown facing opposite sides in each respective perspective view. FIG. 6 shows the magazine with the open interface 94 for either a robot or a human facing outward of the plane of the paper. The handle 102 of the magazine is shown in a non-raised position. The handle has a groove 120 that can be aligned with a groove 124 on the parallelly-disposed rail-guide 130. The grooves are provided for engaging a latch bar (discussed below with reference to FIG. 9) that is integrally attached to the ACF 31. The latch bar, handle, and rail-guide form an ACF interface for the magazine.
A cartridge retaining rib 108 (FIG. 6) is adapted by a spring and lever (not shown) in communication with lock 110 to hold the rib in position across the from of the magazine when it is removed from the ACF. The rib forces the cartridges to stay in the magazine when the magazine is removed from the feeder and carried by a human to another location. However, when the magazine is placed into the feeder the lock 110 is automatically opened, and the spring pulls the rib 108 away from the open interface 94. Thus, the cartridges are available for removing and replacing by a human or a robot without having to open a door or some other form of closed interface as is typical in prior art magazines.
In FIG. 7, the transport access opening 140 is shown facing backwardly from the plane of the paper. Cartridges may be transferred through this opening and transported to the drive unit for processing, at the same time that cartridges are accessible on the opposite side through open interface 94 to either a robot or human operator. FIG. 7 also shows that pivot and sliding slot 144 impart the unique ability of handle 102 to be used to remove the magazine from any elevation. Based on the inventor's critical recognition that the ACF 31 may be placed at varying elevations, this invention provides "elevation-sensitive" removal of the magazine. If the ACF 31 is placed at a position below the operator's normal reach, then the magazine may be removed in the following fashion. The operator may simply lift the handle 102 near the center 105, and then pull the handle toward himself (away from the ACF). If, however, the elevation of the ACF is above the operator the handle may be simply pulled toward the operator. The inclined slot 144 allows the handle to slide when pulled or pushed, depending on the position of the handle in the slot.
FIG. 7 further shows the handle 102 in an upright extended position that can be used for carrying the magazine. The inventors have recognized that such a slidable pivotable configuration coupled with a sufficiently large handle (relative to the width of the magazine) allows an operator to carry the magazine with the wrist downward thus relieving the wrist of the stress of the magazine weight and thereby reducing the risk of injury to the operator.
FIGS. 8A, 8B, and 8C show the magazine in insertion mode, secured mode, and in the removal mode, respectively. In FIG. 8A the magazine 14 is shown being inserted into the ACF 31. In a preferred embodiment the magazine is lifted at the handle to clear the lip 150 of the ACF magazine slot 12. Once the magazine has cleared the lip it extends at an approximately 45-degree angle from the ACF. The operator simply needs to push on the magazine in direction 152 until an "audible click" is heard indicating the magazine is securely in position. Such a securely positioned arrangement is shown in FIG. 8B. FIG. 8C shows the magazine being removed by an operator simply pulling on handle 102 in direction 160. The pull on the handle causes the magazine to become unlocked. As described above, such a removal technique is important when the magazine is placed at a level relatively high compared to the operator's reach. When the magazine is placed low compared to the operator's reach, the pivoting and sliding configuration of the handle allows the magazine to be removed by pulling up on the handle.
FIG. 9 shows an isometric view of the ACF latch bar 170 that is configured to mate with handle 102 of the magazine. The mating aspect is discussed below, with reference to FIGS. 10A-10G that describe the relationship of the handle and latch bar during the insertion, secure, and removal cycle of FIGS. 8A, 8B, and 8C. The latch bar is preferably substantially U-shaped, having a cross member 172 supporting a sensor flag 174, and two handle receiving arms 176. At the end of each arm is a substantially V-shaped plunger 178 having a plunger nose 180 at its tip. Pivot pins 182 allow the latch bar to move in relation to the other members of the ACF interface including the handle 102 and rail-guide 130. A support arm 181 attaches to a side of magazine 14. The sensor flag is equipped with a window 188 that is positioned to allow a beam to pass when the magazine is inserted. Moving the magazine also moves the flag which blocks the sensor. The sensor remains blocked until the handle and latch bar are re-engaged.
FIGS. 10A-10G illustrate the relationship of the members of the ACF interface including the latch bar 170 attached to the ACF, the handle 102, and guide-rail 130 attached to the magazine during the stages of magazine insertion, locking, and removal shown in FIGS. 8A-8C. FIG. 10A shows the ACF latch bar at a starting position of insertion, wherein guide-rail ramp 200 just begins initial contact with plunger nose 180 of the latch bar 170 when the handle's pivot pin 204 is slid to end point 210 in slot 144. The pivot pin is initially slid to the end point by the operator pushing on the handle in direction 152 after placing the magazine in the insert begin position shown in FIG. 8A. (Note, the directions indicated are relative to the magazine body.) Once the pivot pin reaches that end point, then operator pushing the handle in direction 152 causes the ramp 200 of the guide-rail to approach and eventually contact the nose 180 of the ACF latch bar. FIG. 10B shows that the continued pushing in direction 152 essentially pushes the guide-rail 130 under the nose 180 and causes it to climb past ramp 200 to the flat portion 220 of the guide-rail.
FIG. 10C shows the nose 180 of latch bar 170 translated to position 224 at the edge of groove 124 on the guide-rail. The translation of the nose is caused by the relative motion of the guide-rail and attached handle as the handle is pushed in direction 152. FIG. 10D shows that as the handle is pushed further in direction 152, the plunger nose 180 drops into seat 228 of groove 124 of the guide rail. Because of the steep dropoff, caused by the height and approximately perpendicular angle relationship of groove back wall 232 to seat 228, two advantages are created. The first advantage is that when the accelerating plunger nose 180 contacts the seat 228, the "audible click" noise is made, thus alerting the operator that the magazine is securely locked with the latch bar of the ACF. This signals that the insertion stage is complete and the magazine is now in the locked or secured stage. A simplified overview of the locked stage is shown in FIG. 8B. The second advantage of the relationship is that a considerable force is needed to dislodge the latch bar, unless the handle is pulled in the opposite direction of 160 to release the latch bar, thereby ensuring that an operator or robot will not accidentally remove the magazine from the ACF when a single cartridge is removed from the magazine.
The removal stage is shown beginning in FIG. 10E. The removal stage is begun by an operator pulling outward or upward (i.e., lifting) in essentially direction 160 on the handle 102. It should be understood that the removal force could be imparted by an essentially lifting action because the handle pivot pin 204 slides and pivots in guide-rail slot 144. Whether the operator pulls or lifts depends on his reach position relative to the position of the handle. In either case the pivot pin moves from the bottom end point 210 of slot 144 toward its top end point 250. Once the pivot pin is at the top of the slot, further pulling in direction 160 causes the magazine handle and the latch bar to become disconnected, thereby unlocking the magazine. The disconnection occurs as a result of relative motion between the handle and the guide rail that is caused by pulling on the handle when the pivot pin is at the top of the slot. This motion causes groove 120 in the handle 102 to move relative to the guide-rail groove 124, which causes a prying force to be exerted on the plunger nose 180, in turn forcing the entire plunger 178 out of both grooves. This prying force separates the latch bar plunger from both of the respective grooves so that the magazine may be removed. To facilitate the separation, it is preferred to configure guide-rail groove 124 with a slightly curved front wall 254 to make the translation of the latch bar easier.
FIG. 1OF shows the guide rail groove 124 having been moved further away from latch bar plunger nose 180, as the removal process is continued by pulling or lifting the handle in direction 160. Finally, FIG. 10G shows the plunger nose 180 returned to a position relatively distant and disconnected from the groove 124 as the removal process is near the very end, before the magazine is carried away from the ACF. The near end position of removal corresponds to the overall view shown in FIG. 8C.
FIG. 11 is a cut-away perspective view of the latch bar shown in relationship to the side 260 of the magazine slot frame 58 and the sensor device which is part of the ACF. Recall that the positioning of the latch bar 170 in side 260 of the magazine slot frame is also shown. The handle and other parts of the magazine and ACF are not shown for simplicity's sake. When the handle is pushed in direction 160 during the magazine insertion stage, the latch bar is effectively elevated onto the guide-rail (FIGS. 10A-1OF). In so doing, the sensor flag 174 is moved into a position that allows a light beam to pass from a light emitter 266 of the sensor 270 through the window 188 (FIG. 9) in the flag 174 to the sensor's photoelectronic light receiver 274. Any well known optical light sensor will work well for this purpose. When the magazine is removed, receiver 274 does not receive light, because the optical path is blocked by a non-windowed section 276 of the flag. The slightest movement of the handle, typically caused by an operator removing the magazine, moves the window out of position and the beam is broken. When this happens a signal is sent to CPU 80 and the ACF operation is interrupted. Safety is enhanced because the signal is sent very quickly, therefore no door is needed on the front of the magazine and the open interface of this invention is made possible. To keep the sensor from flickering a metal spring 280 is attached to the side 260 of the magazine slot frame 58 that extends a pawl 282 outward to support the latch bar. When the magazine is inserted causing spring activation button 280 is depressed by the side of the magazine, releasing the latch bar 170.
For the sake of clarity, FIGS. 12 and 13 further illustrate the interaction of the flag 174 on the latch bar 170, as the latch bar is moved on the guide-rail. Sensor 270 has light emitter 266 that normally emits light beam 290. FIG. 12 shows that when the latch bar is placed in a seated position in the respective grooves of the handle and the guide-rail, the window 188 of the flag allows the light beam 290 to pass through itself. This indicates to the CPU 80 that the feeder may be operated. FIG. 13 shows that when the magazine handle and latch bar release each other, the latch bar is moved and the window also moves so that light beam 290 is blocked by the non-windowed portion of the flag. This indicates to the CPU that the feeder may not be operated.
Regarding materials of construction, it is best to assemble the entire magazine, including the ACF interface parts of the handle and guide-rail and the open-interface shelves of a polycarbonate material available from the General Electric Corporation. Similarly, the ACF interface latch bar is best composed of a polycarbonate material. However, any high-strength and resilient material, such as well-known plastics having these characteristics will also work well.
This invention provides a magazine that provides an interface to an ACF that ensures safe and easy insertion and removal of the magazine from a variety of elevations, and also ensures secure retention of the magazine until the insertion or removal is initiated by an operator. The magazine of this invention further provides an open interface that allows a robotic picker or a human to access a cartridge stored in the magazine without interrupting the operation of an automatic cartridge feeder. In this way, this invention overcomes the disadvantages of the prior art while enabling new advantages not possible with prior art configurations, such as a mechanical data cache in an automated storage library.
The present invention has been described in terms of a presently preferred embodiment so that an understanding of the present invention can be conveyed. There are, however, many configurations for cartridge feeders not specifically described herein, but for which the present invention is applicable. The present invention should therefore not be limited to the particular embodiment described herein, but rather, it should be understood that the present invention has wide applicability with respect to cartridge feeders generally. Additionally, this invention has been described with reference to tape cartridges but the principles of the teachings apply to any type of medium storing data cartridge that is housed, such as a magnetic or optical disk. All modifications, variations, or equivalent arrangements that are within the scope of the attached claims should therefore be considered to be within the scope of the invention.
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A cartridge magazine with interfaces to automatic cartridge feeder devices. On one side, the magazine has an open interface that provides unencumbered access by a robotic picker that accesses cartridges for a library. The magazine is accessible on another side by a transport mechanism of an automatic cartridge feeder (ACF). The transport carries a cartridge from the magazine to a drive unit where the data stored on the cartridge is read or new data is written. The interface to the ACF includes a handle member for placing the magazine into the feeder. The magazine is mounted by loading it into the feeder and pushing the handle inward allowing a plunger on the ACF to engage a groove on the handle member that locks the magazine into place. Locking the magazine in place activates a sensor, thereby enabling the operation of the feeder. The interface securely engages the ACF so that the magazine cannot be accidentally dislodged from it. The magazine may be released from the feeder by pulling the handle forward, thereby activating the sensor which sends a signal to disable operation of the feeder. Pulling the handle forward also unlocks the magazine for easy removal. The handle may be extended for ease of carrying the magazine.
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FIELD
[0001] The invention relates to a method and a device for nondestructive testing of a carrier element in an elevator installation.
BACKGROUND
[0002] An elevator installation is installed in a building and substantially consists of a car which is carried by one or more carrier elements. In a known elevator installation a drive acts on the carrier elements in order to displace the car along substantially vertical guide rails. The elevator installation is used to convey people and goods over individual or a number of floors within the building.
[0003] The carrier elements can be embodied as individual round ropes made of metal (steel). By way of example, each round rope has a diameter of approximately 8-10 mm and is stranded from individual strands, which in turn consist of individual wires. The round ropes are usually not sheathed, and so the stranding is visible on the surface thereof. Depending on the application, it is also possible for these carrier elements to be sheathed; then the individual strands or wires are not visible.
[0004] However, the carrier elements can also be flat ropes or flat belts, which have a rectangular cross section; i.e., such flat belts are wider than high (thick). A flat belt consists of individual thin steel ropes or tension members, which are embedded in a plastic and are sheathed by the latter. The steel ropes, or tension members, take up tensile forces while the plastic, inter alia, protects the steel ropes from external environmental effects and, for example, ensures a desired traction on a drive pulley of the elevator installation.
[0005] The carrier elements can also consist of tension members in the form of non-metallic ropes and strands. Such non-metallic strands, or tension members, can for example be made of carbon or silicon fibers, of aramid or glass fibers, etc. These non-metallic ropes or strands are generally embedded in a plastic sheath. The ropes or strands take up tensile forces while the plastic sheath, inter alia, protects the ropes or strands from external environmental effects and, once again, ensures a desired traction on a drive pulley of the elevator installation. These non-metallic carrier elements can likewise be embodied with a round design in the form of flat ropes or as flat belts.
[0006] In order to ensure the safety of elevator installations, the utilized carrier elements are tested at regular intervals. In the process, a test is undertaken to see whether defects, such as kinks, loop formation, breaks of strands and wires, loosenings of the outer layer, or pinches have occurred. Use can be made of various technologies and methods for testing. By way of example, known methods are based on a visual inspection by a servicing engineer or a measurement of electrical (e.g. resistance) or magnetic (e.g. magnetic flux) properties.
[0007] In order to test the carrier elements having metallic ropes or strands, use can for example be made of methods in which the carrier element is exposed to magnetic fields and changes in the magnetic flux are determined. U.S. Pat. No. 5,198,765 has disclosed a method in which a magnetic field is generated by means of a magnetizing head, with a carrier element being moved through said field in the axial direction. In the process, the carrier element is magnetically saturated at a first location. Provision is made at a further location for a scanning apparatus, by means of which magnetic flux changes in the carrier element are determined, with said magnetic flux changes being related to a cross-sectional change in the carrier element. U.S. Pat. No. 5,804,964 describes that leakage flux can also occur if individual wires are interrupted and that this leakage flux emerges from the carrier element and is detected by means of a Hall sensor.
[0008] In order to test carrier elements with non-metallic carrier elements, solutions with so-called indicator strands are known, with the latter being inserted into the carrier element. Wear and tear of the carrier elements can be identified by means of these indicator strands.
[0009] The inspection of the carrier element becomes more difficult if it has a sheath. Damages which are already so serious that they are already visible from the outside can be identified despite the sheath. However, the sheath prevents emerging damage, which is initially still small, from being visible from the outside. This externally non-visible damage to the tension member constitutes a potential risk to safety. A purely visual inspection by a servicing engineer therefore does not suffice.
SUMMARY
[0010] The present invention is therefore based on the object of specifying a technology for reliable and nondestructive testing of a carrier element, more particularly a carrier element provided with a sheath, in an elevator installation. Testing the carrier element should provide reliable data which render it possible to establish relevant information in respect of the actual state of the carrier element such that the replacement state of wear thereof can be determined. Here, measurement results should where possible not be influenced by sheaths, deposits and dirtying, such as lubricant, plastic sheaths, oil splatters, wear debris particles etc., which may surround the carrier element under certain circumstances or be deposited thereon.
[0011] In order to achieve this object, the technology described here uses a reception unit for electromagnetic radiation which is directed at a carrier element to be tested in order to generate test data from received electromagnetic radiation. The test data is evaluated in a processing apparatus in order to determine a deviation of the test data from an intended state of the carrier element. This technology preferably serves for nondestructive testing of at least one carrier element in an elevator installation, in which the carrier element carries a car. The test data are prepared by means of edge extraction such that boundary edges of the carrier element 21 and/or of tension members 21 A, 21 B, 21 C of the carrier element 21 are extracted and evaluating the test data comprises an assessment of boundary edges or contours of the carrier element 21 and/or of the tension members 21 A, 21 B, 21 C of the carrier element 21 .
[0012] According to one embodiment, recordings (or a series of recordings) are made of the carrier element and these recordings are compared to ideal state patterns, i.e. to state patterns which represent a good or acceptable state of the carrier element. This evaluation of the recordings is preferably performed by means of automated computer-assisted evaluation algorithms, for example by means of software for evaluating recordings. Thus, transitions between materials of differing density, differing electrical conductivity or differing transparency on the carrier element can be captured, for example by edge extraction in the recordings. It is expected that these edge transitions should result in a line pattern determined in accordance with the longitudinal alignment of the carrier element. Irregularities, such as interruptions, indentations or bulges, in this line pattern indicate wear and tear or a defect of the carrier element and, if such irregularities occur frequently, the carrier element needs to be replaced or inspected more selectively.
[0013] According to another exemplary embodiment, reference images of a carrier element are created after the carrier element is installed and these images are stored in a database. These reference images represent the intended state of a carrier element. In these reference images, it is mainly the surface of the carrier element or, depending on the type of test radiation or depending on the transparency state of the sheath, also surfaces of ropes, strands and wires which are embedded in a sheath that is/are visible. During the use of the carrier element, these surfaces of the carrier element and the embedded elements change, particularly after relatively long use. By way of example, if wires break or buckle, groups of wires or individual strands project from the carrier element or from a laid rope present in the carrier element. These projecting strands can penetrate a sheath and be visible from the outside. If an image recording (or a series of image recordings) is then made of the same location and compared to the stored image, the broken strands or buckling can be identified. These image recordings are preferably also evaluated by means of automated computer-assisted evaluation algorithms, for example by means of software for evaluating images.
[0014] The exemplary embodiments of the technology, described here, firstly enable the testing of carrier elements which merely consist of metallic laid wire ropes or which have a sheath in which at least one (laid) wire rope or one strand is integrated or embedded. Here, the integrated wire ropes and strands can be tested without the sheath being opened or removed. In one embodiment of the technology, it is furthermore possible to test the state of the sheath. In a further embodiment of the technology, it is also possible, on the other hand, to test carrier elements with non-metallic rope and strand structures.
[0015] In one exemplary embodiment, provision is made for at least one transmission unit and at least one reception unit, which are respectively suitable for emitting and for receiving electromagnetic radiation. The wavelength of this electromagnetic radiation lies in the range of between approximately 400 nm and approximately 950 μm, i.e. in the visible and non-visible, infrared wave-length range. In one embodiment, the wavelength is in the non-visible range of between approximately 30 μm and approximately 950 μm. In a further exemplary embodiment, the wavelength is in the visible range of between approximately 400 nm and approximately 800 nm. The received electromagnetic radiation is used to form transmission patterns and/or reflection patterns in an evaluation unit, which patterns are evaluated in order to establish surface or contour changes on the carrier element, or of the ropes and strands embedded in the carrier element.
[0016] In order to capture test radiation which lies in the range of visible light, daylight or artificial light is used in a simple embodiment, said light being emitted by a shaft illumination. Light radiation reflected at the surface of the carrier element can therefore be captured by means of photosensors which are present in the reception unit. Furthermore, the visible shadow cast by the carrier element can be recorded. The reception unit, for example a camera (preferably a digital camera, or a digital video camera, which generates digital image recordings from light reflected by the surface of the carrier element), and the transmission unit or the light source (should daylight be insufficient) can therefore be arranged on the same side or, preferably, on mutually diametrically opposed sides of the carrier element. It is generally sufficient to identify relatively large damage. Hence low resolutions, for example a resolution of less than 1 megapixel, are already completely sufficient. This test radiation is preferably used if the visible surface of the carrier element needs to be monitored, which is generally sufficient in the case of unsheathed carrier ropes or in the case of transparent sheaths.
[0017] Non-visible test radiation, the wavelength of which lies in the range of between 30 μm and 950 μm, preferably in the range of between 90 μm and 120 μm, is emitted along a transmission axis by an appropriately designed transmission unit and is acquired by a reception unit which is provided on the opposite side of the carrier element or by a reception unit which is aligned along one or more reflection axes and originates in the carrier element. In this case, the reception unit is designed to receive electromagnetic radiation in this wavelength range. This test radiation is preferably used for testing carrier elements with a non-transparent sheath, such as rubber or colored polyurethane. Electromagnetic radiation in this range penetrates such sheaths. Accordingly, these sheaths are transparent to this test radiation. It is naturally also possible to use this electromagnetic radiation to test carrier elements with a transparent sheath.
[0018] In one embodiment the reception unit comprises a plurality of reception sensors which are arranged along different axes. This renders it possible to generate a 3-dimensional image of the surface.
[0019] In general, it is by all means sufficient if accumulations of breaks of wires or fiber regions can be identified. Such accumulations create damages of more than 1/10 mm in the contours. The aforementioned test radiation, the wavelength of which lies in the region of approximately 100 μm, is suitable for identifying such errors. In order to identify such damages, significantly reduced resolutions of the capturing units are also sufficient. By way of example, thermal imaging cameras can be used for this, the resolution of which for example lies in the region of 480×320 pixels, or, in a particularly expedient embodiment, use can also be made merely of individual or a few sensor rows, for example corresponding to a resolution of 3×320 pixels. The reception unit is then moved continuously, like in a photocopier, along the carrier element, as a result of which a complete image of the carrier element is created. Naturally, it is irrelevant here whether the carrier element is moved past the reception unit or whether the reception unit is guided along the carrier element.
[0020] In a development of this test methodology, it is feasible to heat the carrier elements a little, for example by means of an induction coil. In the process, only metallic tension members, or strands or ropes, are heated by the induction. The heated tension members generate radiation corresponding to this temperature. A thermal imaging camera can be used to capture the thermal profile of the tension member. This thermal imaging camera is provided with a lens which renders it possible to capture test radiation with a wavelength then lying in the range below 30 μm, typically in the region of approximately 10 μm. In the case of faults in the metallic cross section of the tension members there are also deviations in the thermal profile of the tension member. This thermal profile can in turn be evaluated by means of one of the methods described above, by means of image comparison or by means of an edge extraction method.
[0021] Practically all changes that occur e.g. in a rope or strand can have a significant influence on the surface condition of the rope or of the strand. The peripheral strands, wires or fibers of a rope are normally exposed to increased load because they are in contact with guide and deflection elements of the elevator installation and therefore greatly exposed to mechanical stresses. Furthermore, stronger tension or bending forces usually occur in peripheral strands, wires or fibers rope, which forces can lead to a complete or partial break of strands, wires or fiber strands. Furthermore, environmental influences, aging influences or other external effects mainly cause changes on the outer surface of a metallic object. Corrosion therefore occurs firstly and predominantly on the surface of wire ropes. However, environmental or aging influences and other external effects also influence non-metallic materials or also influence the plastic sheath of the carrier elements.
[0022] Defects therefore occur nearly exclusively in the peripheral region of the rope, which is why testing the surface condition can already for this reason provide essential information in respect of the condition of the carrier element.
[0023] By contrast, to the extent that optically unidentifiable interruptions occur within the rope, the peripheral strands, wires or fiber strands experience stretching under the acting load, likewise leading to a change in the surface condition and the dimension (diameter) of the rope. By capturing and analyzing the dimensions, and/or the surfaces of the carrier element, or of the embedded ropes, strands or wires, it is possible to assess the state thereof. As already explained above, it is generally only necessary to identify summations of errors, which then bring about damage of a number of 1/10 mm. Such defects can be captured sufficiently accurately by means of radiation in the aforementioned wavelength range of 90 μm to 120 μm.
[0024] The described embodiments of the technology therefore permit the establishment of status information which suffices for determining the replacement state of wear of the carrier elements. There moreover is the option of combining the present technology with more complicated further testing methods, or the evaluation by means of test radiation in the visible and non-visible range can be combined. To the extent that a change of the contour or surface structure of a rope was determined, it is also possible, for example, to X-ray the rope using X-ray methods. If this more complicated method, which harbors safety risks, is required, it can therefore be reduced to a single region of the carrier element. Thus there is greatly reduced complexity, even in the case of combination with further methods.
[0025] The apparatus which contains the reception units and an associated evaluation unit is preferably equipped with a marking apparatus. The marking apparatus marks the relevant point of the carrier element, for example by means of a colored dot, if a defect is detected. As a result, this point can be found easily for a more detailed analysis.
[0026] Preferably electromagnetic test radiation with a wavelength in the range of between 30 μm and 950 μm, i.e. in the long-wave region of infrared radiation, is used in a first exemplary embodiment. Here, the wavelength is selected such that, firstly, it passes through dielectric materials and that, secondly, electrically conductive materials, such as e.g. metallic materials, reflect the test radiation. In order to penetrate the sheath of a carrier element, which for example consists of rubber or polyurethane (PU), use is preferably made of test radiation with a wavelength in the range of between 90 μm and 120 μm. For test radiation with wavelengths in this range, the sheath of the carrier elements, and possible deposits such as oils and fats, are transparent or they have a relatively low transmission resistance. Accordingly, this embodiment is particularly recommendable in the case of dirtied carrier elements.
[0027] As a result of scanning the carrier elements by means of the test radiation it is therefore possible to form transmission patterns which correspond to the “shadow cast” by the metallic portion of the carrier element. If the shadow cast deviates from a substantially regular straight-lined profile, this is typically caused by peripheral defects of the carrier element such as compressed or broken wires or other faults in the carrier element. In one exemplary embodiment, these defects can be captured and evaluated by evaluating the transmission pattern. To the extent that the faults in the rope or the strands have an influence on the surface of the carrier element itself, for example by broken or compressed wires emerging from the sheath, these defects can, according to another exemplary embodiment, naturally also be captured in an alternative or complementary fashion by means of an image generation in the visible wavelength range on the basis of the reception unit provided for this.
[0028] As a result of scanning the carrier elements by means of the test radiation, these are reflected by the metallic portion of the carrier element. This reflected test radiation extends along a reflection axis to a further reception unit, which is able to capture this reflected radiation and images the latter as reflection pattern. This reflection pattern contains valuable information in respect of the state of the metallic portion of the carrier element and thus enables the analysis of the carrier element or of the metallic portion of the carrier element. In the process, it is possible to identify further faults in the carrier element, particularly damage to the surface structure. Naturally, it is also possible here to apply further detailed analyses, as described above.
[0029] Provided that defects occur within the cross section of the carrier element, these can be detected by inspecting resulting changes on the surface, such as compressions or constrictions.
[0030] The test can be carried out in a particularly exemplary fashion by virtue of using reference patterns. Advantageously, reference patterns can be used which were recorded of the test item itself, for example recorded prior to use thereof, and constitute an intended state. Particularly precise measurement results can be achieved if stored transmission patterns and reflection patterns (for example recorded by a video camera) are precisely assigned to the individual sections of the carrier element and compared to currently recorded transmission patterns and reflection patterns of the same sections. Reference patterns corresponding to the sections are then used to establish irregularities.
[0031] To this end, use is for example preferably made of carrier elements which are marked over the whole length. These markings can be stamped into the sheath. The carrier elements can furthermore be marked by means of colors. RFID chips are integrated into the sheath in other embodiments. The markings can be read by means of readers, optical scanning devices or RFID readers, and the individual sections of the carrier element can be identified and the appropriate reference patterns can be loaded. Furthermore, it is possible to identify a section of the carrier element by calculation on the basis of the position of the elevator car.
[0032] Naturally, the test can also be carried out by merely evaluating the contours or edges of the transmission and reflection patterns. In the case of an intact carrier element, all contours on and in the carrier element form substantially straight lines which extend in parallel. Indentations or bulges or frays of these contours indicate a fault in the carrier element and can be analyzed in detail. This embodiment requires little storage space because, in particular, there is no need to store reference data.
[0033] Such a test is advantageous if existing carrier elements, which in part have already been in operation for years, have to be evaluated. There are no specific reference data for these carrier elements.
[0034] All these method variants, firstly recording and evaluating transmission patterns and secondly recording and evaluating reflection patterns, and the associated evaluations by means of reference data or evaluation of the contours and edges, can be applied individually and they enable an appropriate test of the carrier element. As a result of an optional combination of these method and evaluation options, it is possible, where necessary, to obtain a significantly higher reliability. Here questions which occur in one method variant can be answered on the basis of test results which are established by the other method variant. Furthermore, it is possible to increase the reliability of the test by virtue of carrying out measurements in various wavelength regions.
[0035] Thus, provision is made in one exemplary embodiment for the capture of reflection patterns and transmission patterns to take place in a plurality of test steps by means of electromagnetic test radiation with different wavelengths. As a result of using test radiation with wavelengths in the range of between 30 μm and 950 μm, preferably in the range of 90 μm-120 μm, it is possible to establish the shadow cast and the surface condition of the metallic portion of the carrier element. As a result of using test radiation with wavelengths in the visible range, it is possible to establish and test the shadow cast and the surface condition of the sheath itself. At the same time, it is possible to detect optionally provided markings on the carrier element.
[0036] Reflections are preferably captured along a reflection axis, which, together with the transmission axis, includes an angle, which—with an arc extending from the transmission unit to the reception unit—includes an angle lying in the range of between 0° and 90° or in the range of between 0° and −90°, or between +/−π/2. Radiation captured in this angular range permits the imaging of substantial portions of the carrier element. In one embodiment variant, two reception sensors are associated with a transmission unit, said reception sensors being arranged in different angular ranges. This renders it possible to capture a substantially three-dimensional element. Two receptions units are preferably respectively arranged at an angle of +/−45° with respect to the reception unit, i.e. offset by 90° from one another.
[0037] Alternatively, or in combination, the transmission unit and the at least one reception unit are held by a rotatable carrier device and rotated, or swiveled, between at least two positions about the carrier element in order to scan the carrier element from at least two sides. As a result of using the rotatable or swivelable carrier device, it is possible to carry out a complete test of the carrier element using few reception sensors. The carrier device is preferably controlled by means of a calculation unit, which likewise serves to evaluate the test radiation. The evaluation unit is preferably connected to a data storage medium or a database, from which stored data relating to the utilized carrier elements can be recalled.
[0038] The transmission unit for generating wavelengths in the non-visible range preferably uses lasers, for example two-color diode lasers, which generate two different light frequencies. A beat is created by superposing these two light frequencies. A photoconducting antenna acts as low-pass filter and emits the resultant radiation. The use of a quantum cascade laser is also possible. This transmission unit can be used to set wavelengths in the range of between approximately 30 μm and 500 μm.
[0039] The transmission unit and the reception unit aligned along the reflection axis are preferably integrated into a module such that a simple and cost-effective design of the test device can be realized. As a result of this, it is possible to use two or more of the integrated modules, which are for example held by controllable mechanical arms. Here, the reception unit of one module can receive reflected test radiation from the same module and test radiation, transmitted from another module, along the transmission axis.
[0040] In one embodiment, the transmission unit and the reception unit are coupled directly to the carrier element and kept at a defined distance therefrom. This is how it is possible always to capture transmission patterns and reflection patterns in the same fashion and with an optimized quality. The transmission unit and the reception unit are preferably arranged in a housing that can be displaced along the carrier element, or along which the carrier element is guided. In the first case, the housing with transmission unit and reception unit is, for example, arranged on an elevator car and is displaced along the carrier element therewith and, in the second case, the housing is, for example, affixed in the shaft and the carrier element is guided along the housing. Naturally, the housing with integrated transmission and reception unit also has appropriate guide means, such as rollers, wheels or sliding elements, which enable exact positioning of the carrier element in relation to the housing.
DESCRIPTION OF THE DRAWINGS
[0041] In the following text, the invention will, in conjunction with the figures below, be explained in more detail on the basis of a plurality of exemplary embodiments. In detail;
[0042] FIG. 1 shows a schematic illustration of an exemplary embodiment of an elevator installation with carrier elements which are tested by means of a test device;
[0043] FIG. 2 shows a schematic illustration of an exemplary embodiment of the test device from FIG. 1 ;
[0044] FIG. 3 shows a schematic illustration of a further exemplary embodiment of a test device, by means of which a flat carrier element is tested in a first arrangement;
[0045] FIG. 4 shows a schematic illustration of a further exemplary embodiment of a test device, by means of which a flat carrier element is tested in a second arrangement;
[0046] FIG. 5 shows a schematic illustration of a further exemplary embodiment of a test device which is directly coupled to a flat carrier element as per FIG. 3 or FIG. 4 ;
[0047] FIG. 6 a shows a schematic illustration of a section of a carrier element;
[0048] FIG. 6 b shows an evaluation of the section from FIG. 6 a by means of edge extraction in the case of an intact carrier element; and
[0049] FIG. 6 c shows an evaluation of the section from FIG. 6 a by means of edge extraction in the case of a damaged carrier element.
DETAILED DESCRIPTION
[0050] FIG. 1 shows a schematic illustration of an exemplary embodiment of an elevator installation 2 , which has an elevator car 22 which can be displaced vertically in an elevator shaft 6 and is connected to a drive unit 23 via carrier elements 21 and a drive pulley 24 . Further components of the elevator installation 2 (e.g. counterweight and safety apparatuses) or details in respect of the suspension of the elevator car 22 (e.g. 1:1, 2:1, etc. suspension) are not shown in FIG. 1 for reasons of clarity. However, it is understood that the exemplary embodiments described here can be used independently of these components or details, mentioned in an exemplary fashion, in the elevator installation 2 .
[0051] The elevator installation 2 is furthermore provided with a test device 1 by means of which a carrier element 21 can be tested. In the illustrated exemplary embodiment, the carrier element 21 comprises a sheath 215 made of plastic in which, for example, two wire ropes 21 A, 21 B are integrated. However, it is understood that more than two wire ropes can be embedded in the sheath 215 in a different exemplary embodiment. The plastic in this exemplary embodiment is not transparent to visible light, and so the wire ropes 21 A, 21 B cannot be seen from the outside. Depending on the embodiment of the carrier element 21 —round rope or flat rope/belt—the sheath 215 has a curved surface, as indicated in FIG. 1 for a round rope, or at least one flat surface for a flat rope. As mentioned above, a flat rope is wider than high/thick.
[0052] It is understood that the test device 1 is not restricted to testing sheathed carrier elements 21 . In principle, the test device 1 is also suitable for testing carrier elements 21 which have no, only a thin or a transparent sheath. By way of example, it may be the case that the surface of part of a non-sheathed carrier element 21 has deposits, wear debris or dirtying such that the actual surface of the carrier element 21 is not visible. The test device 1 preferably renders it possible to test such a surface part as well.
[0053] In one exemplary embodiment, the test device 1 has one transmission unit 11 and two reception units 12 D, 12 R, which are connected to a calculation unit 13 . The calculation unit 13 serves to control the test device 1 and to evaluate the data received from the reception units 12 D, 12 R. A result or part of a result of the evaluation can be displayed on a monitor or screen in the illustrated example, for example as intended and actual states. The calculation unit 13 can be a mobile unit, which is or can be connected to a central elevator control, for example via an interface unit, when required or during service works. As an alternative thereto, the calculation unit 13 can be part of the elevator installation 2 which permanently remains in the elevator installation 2 . In one embodiment variant, the calculation unit 13 works together with the elevator control. Thus, for example, the elevator control for example actuates the drive unit 23 in accordance with the evaluation progress of the calculation unit 13 in order to move the carrier elements 21 past the transmission unit 11 and the reception units 12 D, 12 R. The calculation unit 13 accordingly activates the transmission unit 11 and the reception units 12 D, 12 R. Naturally, all safety functions of the elevator control are also activated during such a test operation, although the movement is generally at a reduced travel velocity in this case.
[0054] In general, the test device is only used temporarily for the purpose of testing the carrier elements in the elevator installation. To this end, the elevator installation is closed for passenger transportation and the test device is attached together with the evaluation units, preferably in the vicinity of the elevator drive, such that a carrier element can be tested. The car is subsequently displaced at a low, uniform velocity of approximately 0.1 m/s over the whole operating range. In the process, the test device measures faults in the carrier element and outputs these by means of a test log, signal tone or by marking this, etc. In this fashion, the servicing staff measures all carrier elements installed in the elevator installation. As a final step, the servicing specialist inspects the points of the carrier elements marked as critical and makes a decision in respect of possibly replacing the carrier element.
[0055] Deviating from the exemplary embodiment shown in FIG. 1 , the test device 1 can have only one reception unit 12 D, 12 R. As shown in FIG. 1 , this reception unit can be arranged in the shaft 6 . FIG. 3 (see below) illustrates an exemplary arrangement. If enough daylight or another light source is present in the shaft 6 , it is likewise possible to dispense with the transmission unit 11 . An exemplary embodiment of this arrangement is shown in FIG. 4 (see below).
[0056] As illustrated, the calculation unit 13 is connected to a storage unit or a database 131 , in which reference data (reference patterns) are stored. In one exemplary embodiment (not illustrated), the database 131 is present in the calculation unit 13 or integrated into the latter. The reference data describe “ideal”, i.e. undamaged, carrier elements 21 in an intended state. The test device 1 then uses these reference data to carry out an intended state/actual state comparison, as described in more detail below, the result of which the calculation unit 13 can illustrated pictorially.
[0057] In one exemplary embodiment, the calculation unit 13 is a computer unit in which, inter alia, a processor and an evaluation program are installed. The evaluation program executes a fixed evaluation algorithm, as described in an exemplary fashion below. The computer unit communicates with the transmission unit 11 , the reception units 12 D, 12 R and the drive 23 . The computer unit processes received radiation as per the installed evaluation program and outputs processing results or parts thereof on the monitor or screen.
[0058] The carrier elements 21 can be tested during the normal operation of the elevator installation 2 or else during a test operation of the elevator installation 2 . When the user is not using the elevator installation 2 (for example at night or over the weekend), the latter could for example independently change into a test mode, in which specific sections of the carrier elements 21 are tested. Here, in one exemplary embodiment, the calculation unit 13 can register which sections have already been tested.
[0059] A reception unit, as used in the exemplary embodiments described here, has a sensor unit (e.g. a multiplicity of sensors (e.g. CCD sensors for the substantially visible radiation range and micro-bolometers for the non-visible range) which can be arranged in a sensor array) which is sensitive to the wavelength range of the utilized electromagnetic radiation. Such sensors are known, for example, from use in a digital camera or in thermal detectors.
[0060] FIG. 2 schematically shows an exemplary embodiment of a test device, in which electromagnetic test radiation 8 emitted by the transmission unit 11 is fed to the first reception unit 12 D via the transmission axis sx and to the second reception unit 12 R via a reflection axis rx, which has its origin on the carrier element 21 . Using test radiation 8 T received along the transmission axis sx (downstream of the carrier element 21 as viewed from the transmission unit 11 ) transmission patterns TM are formed in the calculation unit 13 , of which transmission patterns one is shown symbolically in FIG. 2 . Reflection patterns RM are formed in the calculation unit 13 on the basis of the test radiation 8 R received along the reflection axis rx, of which reflection patterns one is likewise shown symbolically in FIG. 2 .
[0061] The transmission pattern TM shows the silhouette of or the shadow cast by the carrier element 21 . Depending on the wavelength of the electromagnetic test radiation, the silhouette of the sheath 215 (in the case of wavelengths in the nm range) or the silhouette of the metallic wire ropes 21 A, 21 B (in the case of wavelengths in the μm range) is measured. The reflection pattern RM, formed on the basis of reflected electromagnetic test radiation, shows the structure of the surface of the metallic wire ropes 21 A, 21 B in a detailed illustration and typically has a greater information content than the transmission pattern TM.
[0062] FIG. 2 shows that a peripherally arranged wire 211 of one of the wire ropes 21 A has broken open and the wire ends thereof protrude outward or are frayed out. As a result of this damage, there is an influence on both the transmission pattern TM and the reflection pattern RM, as indicated in FIG. 2 . The laterally protruding wire ends 211 interrupt the test radiation at the relevant point and reflect a corresponding radiation portion back via the reflection axis rx. Thus radiation portions are missing in the relevant region for the formation of the transmission pattern TM while there are additional radiation portions in the relevant region for forming the reflection pattern RM. Increased reliability can therefore be achieved by simultaneously forming and monitoring the transmission pattern TM and the reflection pattern RM. In the process, it is sensible to compare the results of the two test channels to one another. As a result, it is possible not only to make the measurement results more precise but the correct function of both channels is also tested at the same time.
[0063] It is possible to determine changes by comparing the transmission patterns TM and reflection patterns RM, recorded by the reception units 120 , 12 R, with respectively one reference pattern RM of the intended state. In FIG. 1 , a reference pattern RM REF and a currently recorded reflection pattern RM ACT , which are compared to one another, are shown on the screen of the calculation unit 13 . The reflection pattern RM consists of a strip pattern in e.g. different levels of gray and corresponds to a “fingerprint” of the carrier element 21 and can be processed accordingly in order to determine relevant differences. By way of example, a method for comparing fingerprints is known from U.S. Pat. No. 7,333,641. This method serves to analyze striped image patterns, as also occur when recording reflection patterns. In the reflection patterns recorded according to the invention, strips are caused by the individual strands of the carrier element 21 A or 21 B.
[0064] Methods for automatic face recognition are also based on a comparison between a stored image (reference face) and a currently recorded image (actual image). The article “Video-based framework for face recognition in video” by Dmitry O. Gorodnichy, Proceedings of Second Canadian Conference on Computer and Robot Vision, pages 330-338, British Columbia, Canada, May 9-11, 2005, describes how faces can be identified from a video sequence and mentions a number of citations. The document “FRVT 2006 and ICE 2006 Large-Scale Results” by P. Jonathon Philips et al., Mar. 29, 2007, also deals with the identification of faces from digital image recordings and the algorithms used therein. This document in particular describes and evaluates the identification power of algorithms that are offered by various providers.
[0065] The aforementioned method for analyzing fingerprints or one of the algorithms on which the automatic recognition of faces is based can be implemented as image-processing software in the calculation unit 13 . This can be used to determine precisely and evaluate differences in the reflection patterns occurring in the technologies described here.
[0066] In one exemplary embodiment, the image data are illustrated and evaluated in a coordinate system. Here, different evaluations of the image data are possible. By way of example, the profiles of the contours of the strands or wires are captured and analyzed. The wire contours typically have the same brightness profile over relatively long paths and it can be measured. Furthermore, the contours typically extend at least approximately in a straight line and in parallel. Intact contours therefore bring about straight and parallel contour profiles. If an anomaly, i.e. interruptions, bulges, etc., is now determined to occur within the extent of a contour, a corresponding error can be identified. As already mentioned previously, there are only blurred contours with a reduced image contrast if faults are present in and on the carrier element. An evaluation of such a contour profile is illustrated in exemplary and schematic fashion in FIGS. 6 a to 6 c . The transmission pattern and/or reflection pattern, recorded by the reception units ( FIG. 6 a ), is resolved by means of edge extraction. In the case of an intact carrier element ( FIG. 6 b ), this results in substantially straight lines which describe the peripheral edges of the individual ropes or strands ( 21 A, 21 B, 21 C). A substantially intact, continuous line means that there is no substantial damage to the edge profile and hence to the carrier element. If the edge profile exhibits bulges ( FIG. 6 c , 21 A), indentations ( FIG. 6 c , 21 B) or interruptions ( FIG. 6 c , 21 C), this indicates that the relevant rope or the strand is compressed, kinked or ripped in this region, or that a bundle of individual fibers of the rope or of the strand emerge from the rope or strand group. This can assess a state of the carrier element particularly well without needing to consult a reference image.
[0067] All possibly occurring defects are preferably classified and provided with associated feature data, which render it possible to search selectively for errors in the image data. This is how it is possible to analyze the image data quickly with a high hit probability.
[0068] As mentioned previously, interruptions, bulges or frays in contours of a reflection pattern can be associated with a fault in a wire 211 or strand. Areal, diffuse images can typically be identified as the formation of corrosion or wear debris.
[0069] The comparison of the transmission patterns and reflection patterns with a reference pattern which was generated for the relevant type of carrier elements is particularly advantageous. Further improvements can be obtained by virtue of reference patterns being newly formed after the installation of a carrier element 21 by virtue of the newly installed carrier element being run along and scanned. That is to say the “fingerprint” of a new carrier element 21 is recorded as the intended state thereof after it has been installed, and said fingerprint is stored in the storage unit 131 for future comparison measurements.
[0070] Comparison measurements according to the invention can be carried out with great precision within a short period of time. The carrier elements 21 can therefore be tested permanently and with minimal effort.
[0071] Here, provision can be made for various configurations of transmission units 11 and reception units 120 , 12 R. In particular, a transmission unit 11 and a reception unit 12 D or 12 R can be integrated in a common module, which, for example, can be driven into any position by means of a controllable arm.
[0072] FIG. 2 shows a possible embodiment of the test device 1 with only one transmission unit 11 and two reception units 12 D, 12 R, which are installed on a rotatable or swivelable carrier ring 155 of an assembly device 15 by means of support element 151 , 152 , 153 . The carrier ring 155 , which is held and driven by means of a drive unit 150 , can in this case be rotated or swiveled about the carrier element 21 such that the latter can be scanned from any side. The swivelable carrier ring is advantageous in that it does not need to enclose the carrier element 21 over the whole circumference. This allows a simple assembly of the carrier ring since it can be arranged on the carrier element at any point.
[0073] The transmission unit 11 and the first reception unit 12 D are aligned against one another along the transmission axis sx which runs through the carrier element 21 . The test radiation emitted along the transmission axis sx is reflected at the wire ropes 21 A, 21 B and is reflected at an acute angle a with a large radiation portion within a solid angle, the main axis of which forms the reflection axis rx. The angle a, which typically lies in the region of +/−60°, is preferably optimized on the basis of trials and can change depending on the configuration of the test device and of the carrier element 21 .
[0074] FIG. 3 schematically shows a further exemplary embodiment of a test device 1 by means of which a flat carrier element 21 is tested, the latter having a sheath 215 in which, for example, four wire ropes 21 A, 21 B, 21 C, 21 D are integrated. The sheath 215 , which has a rectangular cross section, protects the integrated wire ropes 21 A, 21 B, 21 C, 21 D from influences of the surroundings and therefore lengthens the service life thereof until the replacement state of wear. Here, the number of integrated wire ropes is selected depending on the load to be carried.
[0075] The carrier element 21 is arranged between a reception unit 120 and the transmission unit 11 . Here, the carrier element 21 is arranged such that the transmission unit 11 emitting electromagnetic test radiation irradiates or illuminates a narrow side of the carrier element 21 . As in the previous examples, the reception unit 120 is connected to the calculation unit 13 . In the arrangement of the carrier element 21 shown in FIG. 3 , damage which occurs on one of the two wider sides of the carrier element 21 can predominantly be identified.
[0076] The described defects can also occur in a carrier element 21 of this type, as sketched out in FIG. 3 . An interruption of a strand 211 has occurred in the integrated wire rope 21 B and it subsequently penetrated the sheath 215 and is visible from the outside. Damage to the sheath 215 has occurred at the same time. By means of an optical test of the carrier element 21 by means of the reception unit 120 it is possible to identify this error. In one embodiment, the reception unit 120 is a digital camera, which stores individual digital images or a sequence of digital images with a predetermined resolution.
[0077] The reception unit 120 therefore captures electromagnetic radiation, in the visible wavelength region, which is reflected at the carrier element 21 . This electromagnetic radiation can be daylight in one exemplary embodiment if it is sufficiently bright in the elevator shaft 6 . If this is not the case, an arbitrary light source, for example illumination provided in the elevator shaft 6 , can serve all transmission unit 11 . However, provision is preferably made for a separate light source 11 which illuminates the scanned part of the carrier element 21 in optimum fashion. Hence the reception unit 120 captures directly incident transmission radiation 8 T and reflection radiation 8 R, reflected on the surface of the carrier element 21 , and supplies corresponding image data to the calculation unit 13 . By evaluating the image data it is possible automatically to identify visually identifiable defects, such as broken open and outwardly emerging wires 211 and damage 2151 to the sheath 215 , as illustrated on the screen of the calculation unit 13 .
[0078] FIG. 4 schematically shows a further exemplary embodiment of a test device 1 , by means of which a flat carrier element 21 is tested. Here, the carrier element 21 is arranged in front of a reception unit 120 , to be precise such that a wide side of the carrier element 21 lies opposite the reception unit 120 . The previously shown connection to the calculation unit 13 has not been shown in FIG. 4 for reasons of clarity.
[0079] Light—daylight or artificial light—is reflected on the surface of the wide side of the carrier element 21 and impinges on the reception unit 120 . The reception unit 120 , which can as described previously be a digital camera, records individual digital images or a sequence of digital images and stores these.
[0080] In the arrangement of the carrier element 21 shown in FIG. 4 , it is predominantly damage which occurs on the wide side of the carrier element 21 facing the reception unit 120 that can be identified.
[0081] If the at least one reception unit 12 D, 12 R, 120 is arranged at a relatively large distance from the carrier element 21 and subjected to movements, e.g. vibrations, this results in greater effort for image capture and image processing. FIG. 5 shows a test device 1 that can be coupled to the carrier element 21 and that can be used to avoid these disadvantages.
[0082] The exemplary embodiment of the test device 1 shown in FIG. 5 has a housing 100 with two housing parts 100 A, 100 B, which are interconnected by holders 102 . Arranged in the first housing part 100 A there is the transmission unit 11 and a first reception unit 12 R, which serves for imaging reflection patterns. A second reception unit 12 D is provided in the second housing part 1008 and it serves for imaging transmission patterns. In this example, the holders 102 simultaneously serve as bearing shafts for optional running wheels 101 , which can roll down the narrow side surfaces on both sides of the carrier element 21 . In one exemplary embodiment, which is shown in FIG. 5 , the running wheels 101 can roll down along sliding surfaces 2150 present on the carrier element 21 .
[0083] Naturally, the housing 100 A, 100 B can also be embodied such that running wheels or guide surfaces guide the carrier element 21 at the longitudinal sides thereof. Particularly if grooved surfaces of the carrier element are used, for example in the case of a V-ribbed belt, guidance by means of this grooved surface is expedient.
[0084] In another exemplary embodiment of the test device 1 , the housing 100 only has a single reception unit. Here, the reception unit is dimensioned and arranged such that it can record an image of the whole width of the carrier element 21 . The reception unit can therefore contain a single, appropriately dimensioned sensor element (sensor array) or a plurality of individual sensor elements arranged next to one another, which are then connected appropriately. The reception unit is arranged on the same side as the transmission unit 11 , which illuminates the wide side of the carrier element 21 . Reflected light is then recorded by the reception unit, analogously to as in FIG. 4 .
[0085] The shown test device 1 therefore can be displaced along the carrier element 21 or be kept stationary while the carrier element 21 moves. In any case, the at least one transmission unit 11 and the reception units 12 D and 12 R are kept at a constant distance from the carrier element 21 . This is how it is possible to make high-quality image recordings and evaluate these with minimal effort.
[0086] Test devices 1 according to the invention in the various embodiments are preferably installed in the vicinity of the drive pulley 24 and hence in a region through which the elevator car 22 does not pass and which, at the same time, allows an analysis of almost a whole length of the carrier element.
[0087] In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.
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A testing device includes a receiving unit for electromagnetic signals arranged on a carrier element to be tested to generate test data from received electromagnetic radiation. The test data are evaluated in a processing system in order to determine a deviation of the test data from a nominal state of the carrier element. The testing device is used to test a carrier element of an elevator installation on which the elevator car is suspended.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a U.S. National Stage of International Patent Application No. PCT/EP2005/053016 filed Jun. 28, 2005 which published as WO 2006/003140 on Jan. 12, 2006, and claims priority of Japanese Patent Application No. 2004-192461 filed Jun. 30, 2004.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a headbox in a paper machine which discharges paper raw material in a widened slit-form.
2. Discussion of Background Information
Paper machines for making paper include a non-concentration controlling type paper machine in which paper is manufactured by setting the fiber concentration of the pulp raw material in advance, and a concentration controlling type paper machine in which paper is manufactured by mixing high concentration pulp raw material and dilution water to control the fiber concentration.
In a non-concentration controlling type paper machine, as shown in FIG. 10( a ), which is a schematic top view of a headbox 101 , and FIG. 10( b ), which is a schematic view seen from the direction of an arrow A, illustrating the interior of the headbox 101 of FIG. 10( a ), pulp raw material is stored in a taper header 102 with the fiber concentration thereof set in advance.
The pulp raw material stored in the taper header 102 is supplied to a slice 105 via a chamber 103 and a turbulence generator 104 , and then discharged from the slice 105 as a raw material jet “gj” onto a wire (not shown).
On the other hand, in a concentration controlling type paper machine, as shown in FIG. 11( a ), which is a schematic top view of a headbox 201 , and FIG. 11( b ), which is a schematic view seen from the direction of an arrow B, illustrating the interior of the headbox 201 of FIG. 11( a ), high concentration pulp raw material is stored in a high concentration taper header 202 a , and dilution water is stored in a dilution water taper header 202 b.
The high concentration pulp raw material in the high concentration taper header 202 a and the dilution water in the dilution water taper header 202 b are mixed and conveyed to a mixing chamber 203 , whereupon the mixture is supplied to a slice 205 via a turbulence generator 204 and discharged from the slice 205 as a raw material jet “gj” onto a wire (not shown).
The pulp raw material placed on the wire in this manner is drained of moisture while being conveyed in a subsequent process, and thus formed into the end product paper.
Incidentally, ever-higher quality is being demanded for paper recently, and a particularly high standard is being demanded for the orientation of the pulp fibers of the paper, or in other words the fiber orientation, not only in western paper, but also in paperboard.
In the case of paper produced in a paper machine, for example, an average angle of no more than plus/minus 3 is typically demanded for the flow direction of the raw material jet “gj” of pulp fibers “ps” of the paper shown in FIG. 9( a ).
Hence, in a conventional first regulation method for improving fiber orientation, as shown in FIG. 10( a ), a top lip plate 107 of the headbox 101 is regulated to a Cross/Direction direction (to be referred to as C/D direction hereinafter) (the direction of the arrow “a 1 ”) in the case of a non-concentration controlling type paper machine, and likewise in the case of a concentration controlling type paper machine, as shown in FIG. 11( a ), a top lip plate 207 of the headbox 201 is regulated to the C/D direction (the direction of the arrow a 2 ), and thus the direction of the raw material jet “gj” is regulated.
In a second regulation method for a non-concentration controlling type paper machine, as shown in FIG. 10 , pipes 104 a for correcting the fiber orientation are disposed at both ends of the turbulence generator 104 , and thus the direction of the raw material jet “gj” in the C/D direction is corrected.
Likewise in a concentration controlling type paper machine, as shown in FIG. 11 , pipes 204 a for correcting the fiber orientation are disposed at both ends of the turbulence generator 204 , and hence the velocity of the raw material jet “gj” is increased or decreased, thus correcting the direction of the raw material jet “gj” in the C/D direction.
The following are disclosed as prior art documents relating to the present application.
[Patent Document 1]
Japanese Unexamined Patent Application Publication S62-162096
[Patent Document 2]
Japanese Unexamined Patent Application Publication S62-191592
[Patent Document 3]
Japanese Unexamined Patent Application Publication H06-192989
[Patent Document 4]
Japanese Unexamined Patent Application Publication H11-1884
SUMMARY OF THE INVENTION
Problems Solved by the Invention
In the first regulation method for improving the fiber orientation property, although the direction of the raw material jet “gj” is corrected by altering the shape of the top lip plates 107 , 207 , the extent of the impact of a single action is too great due to the structure of the top lip plates 107 , 207 , and hence there are limitations on localized correction of the fiber orientation.
Meanwhile, in the second regulation method, only the two end portions of the slice are corrected, which is effective when the slice width is between three and four meters, but when the slice width is great, for example up to approximately eight meters, it becomes difficult to have an effect over the entire width.
In addition, it is often impossible to respond to cases in which the fiber orientation needs to be corrected toward the centre of the slice.
The present invention has been designed in consideration of the circumstances described above, and provides a headbox for a paper machine in which correction of the fiber orientation of paper is possible over the entire width of the C/D direction, regardless of the slice width, and in which the fiber orientation in the direction of paper thickness can be corrected over the entire thickness of the paper.
Ways of Solving the Problems
A headbox for a paper machine according to the present invention discharges paper raw material onto a wire as a raw material jet from a slice which is supplied with the paper raw material, and comprises an orientation correcting arrangement for correcting the pulp fiber orientation by supplying the paper raw material, which is extracted from a taper header in which paper raw material for a main flow is stored or from a correction-only taper header in which paper raw material for correcting the pulp fiber orientation is stored, as a correction flow to a single location in a central portion of the slice or a plurality of locations on the slice via at least one flow control valve.
A headbox for a paper machine according to the present invention is also provided which discharges paper raw material onto a wire as a raw material jet from a slice which is supplied with the paper raw material, and further comprises an orientation correcting arrangement for correcting the pulp fiber orientation by supplying the paper raw material, which is extracted from a taper header in which paper raw material for a main flow is stored or from a correction-only taper header in which paper raw material for correcting the pulp fiber orientation is stored, as a correction flow to a plurality of locations on the slice, other than the two end portions thereof, via at least one flow control valve.
A headbox for a paper machine according to the present invention is also provided which pertains to the headbox for a paper machine and further comprises an orientation correcting arrangement for correcting the pulp fiber orientation by supplying paper raw material extracted from the taper header or correction-only taper header as a correction flow to the two end portions of the slice via the flow control valve.
In a headbox for a paper machine according to the present invention, which pertains to the headbox for a concentration controlling type paper machine at least one of the orientation correcting arrangement comprises a plurality of paper thickness direction correcting arrangements overlapping in the direction of paper thickness for correcting the pulp fiber orientation in the paper thickness direction by supplying a correction flow via respective flow control valves.
In a headbox for a paper machine according to the present invention, which pertains to the headbox for a paper machine, the orientation correcting arrangement uses concentration-controlled paper raw material when the correction flow flows to a location which is to become an end product in the direction of paper width.
In a headbox for a paper machine according to the present invention, which pertains to the headbox for a paper machine, the orientation correcting arrangement uses concentration-controlled paper raw material.
In a headbox for a paper machine according to the present invention, which pertains to the headbox for a paper machine, the orientation correcting arrangement comprises a flowmeter on a pipe provided with the flow control valve, and the headbox further comprises a fiber orientation sensor for measuring the pulp fiber orientation of the manufactured paper, and control arrangement for controlling the flow control valve on the basis of pulp fiber orientation data for the manufactured paper obtained by the fiber orientation sensor, and data from the flowmeter.
Effects of the Invention
As described in detail above, the headbox for a paper machine according to the present invention comprises an orientation correcting arrangement for correcting the pulp fiber orientation by supplying paper raw material as a correction flow to a single location in a central portion of the slice or a plurality of locations on the slice via at least one flow control valve, and is therefore capable of correcting the pulp fiber orientation over the entire width of the slice, even when the slice width is great.
The headbox for a paper machine according to the present invention comprises an orientation correcting arrangement for correcting the pulp fiber orientation by supplying the paper raw material, which is extracted from a taper header in which paper raw material for a main flow is stored or from a correction-only taper header in which paper raw material for correcting the pulp fiber orientation is stored, as a correction flow to a plurality of locations on the slice, other than the two end portions thereof, via at least one flow control valve, and is therefore capable of correcting the pulp fiber orientation over the entire width of the slice, even when the slice width is great.
The headbox for a paper machine according to the present invention comprises an orientation correcting arrangement for correcting the pulp fiber orientation by supplying paper raw material extracted from the taper header or correction-only taper header as a correction flow to the two end portions of the slice via the flow control valve, and is therefore capable of correcting the fiber orientation in the vicinity of the two end portions of the slice.
In the headbox for a paper machine according to the present invention, at least one arrangement of the orientation correcting arrangement comprises a plurality of paper thickness direction correcting arrangement overlapping in the direction of paper thickness for correcting the pulp fiber orientation in the paper thickness direction by supplying a correction flow via respective flow control valves, and hence the pulp fiber orientation can be corrected in the paper thickness direction from the rear surface to the front surface of the paper.
In the headbox for a paper machine according to the present invention, the orientation correcting arrangement use concentration-controlled paper raw material when the correction flow flows to a location which is to become an end product in the direction of paper width, and hence a deterioration of the paper quality caused by the correction flow is prevented, enabling a predetermined level of quality to be maintained.
In the headbox for a paper machine according to the present invention, the orientation correcting arrangement uses concentration-controlled paper raw material, and hence the paper produced by the correction flow can also be used as an end product.
The headbox for a paper machine according to the present invention comprises a control arrangement or system for controlling the flow control valve on the basis of pulp fiber orientation data for the manufactured paper obtained by the fiber orientation sensor, and data from the flowmeter, and hence automatic control of the fiber orientation of the paper can be performed, enabling laborsaving in the manufacturing operation.
The invention also provides for a headbox for a paper machine which discharges paper raw material onto a wire as a raw material jet from a slice supplied with the paper raw material, comprising an orientation correcting arrangement for correcting a pulp fiber orientation by supplying the paper raw material as a correction flow to a single location in a central portion of the slice. The paper raw material is one of extracted from a taper header in which paper raw material for a main flow is stored and extracted from a correction-only taper header in which paper raw material for correcting the pulp fiber orientation is stored.
The orientation correcting arrangement may comprises a flow control valve. The headbox may further comprise another orientation correcting arrangement for correcting the pulp fiber orientation by supplying the paper raw material as a correction flow to two end portions of the slice. The headbox may further comprise another orientation correcting arrangement for correcting the pulp fiber orientation by supplying the paper raw material as a correction flow to two end portions of the slice via flow control valves. At least one of said orientation correcting arrangements may comprise a plurality of paper thickness direction correcting arrangements overlapping in a direction of paper thickness for correcting the pulp fiber orientation in the paper thickness direction by supplying a correction flow. At least one of said orientation correcting arrangements may comprise a plurality of paper thickness direction correcting arrangements overlapping in a direction of paper thickness for correcting the pulp fiber orientation in the paper thickness direction by supplying a correction flow via flow control valves. The orientation correcting arrangement may utilize concentration-controlled paper raw material. The orientation correcting arrangement may utilizes concentration-controlled paper raw material when said correction flow flows to a location which is to become an end product in a direction of paper width. The orientation correcting arrangement may comprise a flowmeter, a pipe and a flow control valve. The headbox may further comprise a fiber orientation sensor for measuring the pulp fiber orientation and a control system for controlling said flow control valve on a basis of pulp fiber orientation data for manufactured paper obtained by said fiber orientation sensor, and data from said flowmeter. The orientation correcting arrangement may comprise a flow pipe, a flow meter, a branch header and a flow control valve.
The invention also provides for a headbox for a paper machine which discharges paper raw material onto a wire as a raw material jet from a slice supplied with the paper raw material, comprising an orientation correcting arrangement for correcting a pulp fiber orientation by supplying the paper raw material as a correction flow to a plurality of locations on the slice, other than two end portions thereof. The paper raw material is one of extracted from a taper header in which paper raw material for a main flow is stored and extracted from a correction-only taper header in which paper raw material for correcting the pulp fiber orientation is stored.
The orientation correcting arrangement may comprises a flow control valve. The headbox may further comprise another orientation correcting arrangement for correcting the pulp fiber orientation by supplying the paper raw material as a correction flow to two end portions of the slice. The headbox may further comprise another orientation correcting arrangement for correcting the pulp fiber orientation by supplying the paper raw material as a correction flow to two end portions of the slice via flow control valves. At least one of said orientation correcting arrangements may comprise a plurality of paper thickness direction correcting arrangements overlapping in a direction of paper thickness for correcting the pulp fiber orientation in the paper thickness direction by supplying a correction flow. At least one of said orientation correcting arrangements may comprise a plurality of paper thickness direction correcting arrangements overlapping in a direction of paper thickness for correcting the pulp fiber orientation in the paper thickness direction by supplying a correction flow via flow control valves. The orientation correcting arrangement may utilize concentration-controlled paper raw material. The orientation correcting arrangement may utilizes concentration-controlled paper raw material when said correction flow flows to a location which is to become an end product in a direction of paper width. The orientation correcting arrangement may comprise a flowmeter, a pipe and a flow control valve. The headbox may further comprise a fiber orientation sensor for measuring the pulp fiber orientation and a control system for controlling said flow control valve on a basis of pulp fiber orientation data for manufactured paper obtained by said fiber orientation sensor, and data from said flowmeter. The orientation correcting arrangement may comprise a flow pipe, a flow meter, a branch header and a flow control valve.
The invention also provides for a method of correcting a pulp fiber orientation in a headbox of a paper machine, wherein the method comprises supplying a paper raw material as a correction flow to a plurality of locations on a slice utilizing an orientation correcting arrangement and one of extracting the paper raw material from a taper header in which paper raw material for a main flow is stored and extracted from a correction-only taper header in which paper raw material for correcting the pulp fiber orientation is stored.
The supplying may comprise supplying the paper raw material as a correction flow to a single location in a central portion of the slice. The supplying may comprise supplying the paper raw material as a correction flow to a plurality of locations on the slice, other than two end portions thereof. The supplying may comprise supplying the paper raw material as a correction flow to two end portions thereof and to a single location in a central portion of the slice. The supplying may comprise supplying the paper raw material as a correction flow to two end portions thereof and to a plurality of locations on the slice other than the two end portions thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings of exemplary embodiments of the present invention, wherein:
FIGS. 1( a ) and ( b ) are a schematic top view of a headbox for a non-concentration controlling type paper machine of a first embodiment according to the present invention, and a schematic view seen from the direction of an arrow C, showing the interior of the headbox in FIG. 1( a );
FIGS. 2( a ) and ( b ) are a schematic top view of a headbox for a non-concentration controlling type paper machine of a second embodiment according to the present invention, and a schematic view seen from the direction of an arrow D, showing the interior of the headbox in FIG. 2( a );
FIGS. 3( a ) and ( b ) are a schematic top view of a headbox for a non-concentration controlling type paper machine of a modified example of the second embodiment according to the present invention, and a schematic view seen from the direction of an arrow E, showing the interior of the headbox in FIG. 3( a );
FIGS. 4( a ) and ( b ) are a schematic top view of a headbox for a concentration controlling type paper machine of a third embodiment according to the present invention, and a schematic view seen from the direction of an arrow F, showing the interior of the headbox in FIG. 4( a );
FIGS. 5( a ) and ( b ) are a schematic top view of a headbox for a concentration controlling type paper machine of a modified example of the third embodiment according to the present invention, and a schematic view seen from the direction of an arrow G, showing the interior of the headbox in FIG. 5( a );
FIGS. 6( a ) and ( b ) are a schematic top view of a headbox for a concentration controlling type paper machine of a fourth embodiment according to the present invention, and a schematic view seen from the direction of an arrow H, showing the interior of the headbox in FIG. 6( a );
FIGS. 7( a ) and ( b ) are a schematic top view of a headbox for a concentration controlling type paper machine of a fifth embodiment according to the present invention, and a schematic view seen from the direction of an arrow I, showing the interior of the headbox in FIG. 7( a );
FIGS. 8( a ) and ( b ) are a schematic top view of a headbox for a concentration controlling type paper machine of a sixth embodiment according to the present invention, and a schematic view seen from the direction of an arrow J, showing the interior of the headbox in FIG. 8( a );
FIGS. 9( a ) and ( b ) are a view showing an example of the disposal of pulp fibers ps in relation to the flow direction of a raw material jet of the paper manufactured by the paper machine, and an enlarged sectional view showing in detail the thickness direction of the paper;
FIGS. 10( a ) and ( b ) are a schematic top view of a headbox for a conventional non-concentration controlling type paper machine, and a schematic view seen from the direction of an arrow A, showing the interior of the headbox in FIG. 10( a ); and
FIGS. 11( a ) and ( b ) are a schematic top view of a headbox for a conventional concentration controlling type paper machine, and a schematic view seen from the direction of an arrow B, showing the interior of the headbox in FIG. 11( a ).
DETAILED DESCRIPTION OF THE INVENTION
Preferred embodiments of the present invention will be described below with reference to the attached drawings.
First Embodiment
In a headbox 1 for a non-concentration controlling type paper machine according to the first embodiment to which the present invention is applied, as shown in FIG. 1( a ), which is a schematic top view thereof, and FIG. 1( b ), which is a schematic view seen from the direction of an arrow C, illustrating the interior of the headbox 1 of FIG. 1( a ), pulp raw material of a predetermined concentration is stored in a taper header 2 for creating a main flow to become the end product paper. The pulp raw material inside the taper header 2 is conveyed to a slice 5 as a main flow through a manifold tube 3 a , a chamber 3 b , and a turbulence generator 4 .
Note that, for example, the turbulence generator 4 has a three-level pipe form in the vertical direction of the paper surface in FIG. 1( b ). The inlets on the chamber 3 b side each have a circular cross-section. The outlets on the slice 5 side have a pentagonal cross-section at the upper level and lower level, and a hexagonal cross-section at the middle level. The configuration of the turbulence generator 4 is not limited to the configuration described above.
As described above, the pulp raw material that is conveyed to the slice 5 is discharged onto a wire (not shown) as a raw material jet “gj” at a maximum velocity of approximately 2000 m/min, or a velocity between 1200 and 1300 m/min for high-quality paper, for example.
Further, correction flow pipes (an orientation correcting arrangement) h 1 , h 2 for correcting the fiber orientation are disposed at both ends of the turbulence generator 4 in the headbox 1 . The pipes h 1 , h 2 are connected to the taper header 2 , comprise flow control valves b 1 , b 2 , flowmeters r 1 , r 2 , and branch headers bh 1 , bh 2 , and are thus connected to the slice 5 .
Also in the headbox 1 , a correction flow pipe (another orientation correcting arrangement) h 3 is connected to the taper header 2 , comprises a flow control valve b 3 , a flowmeter r 3 , and a branch header bh 3 , and is disposed in the central portion of the turbulence generator 4 so as to be connected to a central portion of the slice 5 .
Correction flows of the pulp raw material are supplied to the slice 5 from the correction flow pipes h 1 , h 2 , h 3 , and discharged as the raw material jet “gj” together with the main flow that is supplied to the slice 5 .
Here, when the flow velocity of the correction flow is faster than the flow velocity of the main flow in the turbulence generator 4 , the orientation of the pulp fibers in the main flow is corrected to an orientation that moves away from the correction flow, whereas when the flow velocity of the correction flow is slower than the flow velocity of the main flow in the turbulence generator 4 , the orientation of the pulp fibers in the main flow is corrected to an orientation that approaches the correction flow side.
For example, focussing on the correction flow on the two sides of the turbulence generator 4 , when the flow velocity of the correction flow is faster than the flow velocity of the main flow in the turbulence generator 4 , the orientation of the pulp fibers in the main flow is corrected to face inside, whereas when the flow velocity of the correction flow is slower than the flow velocity of the main flow in the turbulence generator 4 , the orientation of the pulp fibers in the main flow is corrected to face outside.
Here, an example is shown in which the correction flow pipe h 3 in the central portion is provided in a single location, but a plurality of the correction flow pipes h 3 may be provided in a plurality of locations other than the two end portions.
For example, a width “m 1 ” of the slice 5 in the paper machine may be between three and four meters, or in a large paper machine, may be ten meters.
Accordingly, when the width “m 1 ” of the slice 5 is between three and four meters, the correction flow pipe h 3 may be provided in a single location in the central portion, and when the width “m 1 ” of the slice 5 is ten meters, a plurality of the correction flow pipes h 3 may be provided in a plurality of locations every three meters other than at the two end portions.
The pulp raw material placed on the wire in this manner is drained of water by natural dehydration while being conveyed, then pressed by a roll (not shown) to be further drained of water, then drained further by the application of heat and vaporization, and thus formed into paper.
According to the constitution described above, the correction flow pipes h 1 , h 2 , h 3 are provided not only on the two end portions of the turbulence generator 4 , but also in a single location in the central portion or in a plurality of locations other than the two end portions of the turbulence generator 4 , and hence by regulating the flow rate using the flow control valves on each of the correction flow pipes so as to vary the flow velocity of the pulp raw material, regulation of the pulp orientation of the paper can be performed over the entire width of the slice even in the headbox 1 which has a large slice width “m 1 ”.
Note that, as shown by the double-dash line in FIG. 1 , a correction-only taper header 2 s in which the pulp raw material for correcting the fiber orientation is stored may be provided in this headbox 1 separately to the taper header 2 such that the correction flow pipes h 1 , h 2 , h 3 are connected to the correction-only taper header 2 s rather than the taper header 2 .
According to this variation, the pressure and so on of the pulp raw material inside the correction-only taper header 2 s can be modified appropriately, freely, and independently of the taper header 2 . Hence regulation of the fiber orientation of the paper using correction pipes can be performed in a wider scope.
Second Embodiment
The second embodiment is constituted such that in the paper machine headbox according to the first embodiment, a plurality of correction flow pipes are disposed in the direction of paper thickness, and a flow control valve is attached to each pipe so that the fiber orientation can be regulated in the direction of paper thickness.
All other features are identical to the configuration of the first embodiment. Hence identical reference symbols, with the addition of ′ (a prime), are allocated to identical elements, and description is provided only for different features.
In a headbox 20 for a paper machine of the second embodiment, as shown in FIG. 2( a ), which is a schematic top view thereof, and FIG. 2( b ), which is a schematic view seen from the direction of an arrow D, illustrating the interior of the headbox of FIG. 2( a ), correction flow pipes (an orientation correcting arrangement and a paper thickness direction correcting arrangement) h 21 , h 22 , h 23 are disposed at one end of a turbulence generator 4 ′, connected to a taper header 2 ′, comprise flow control valves b 21 , b 22 , b 23 and flowmeters r 21 , r 22 , r 23 , and are thus connected to a slice 5 ′.
Correction flow pipes (an orientation correcting arrangement and a paper thickness direction correcting arrangement) h 31 , h 32 , h 33 are disposed at the other end of the turbulence generator 4 ′, connected to the taper header 2 ′, comprise flow control valves b 31 , b 32 , b 33 and flowmeters r 31 , r 32 , r 33 , and are thus connected to the slice 5 ′.
Note that, as shown by the double-dash line in FIG. 2 , a correction-only taper header 2 s ′, in which pulp raw material for correcting the fiber orientation is stored, may be provided in this headbox 20 separately to the taper header 2 ′ such that the correction flow pipes h 21 , h 22 , h 23 on one end of the turbulence generator 4 ′ are connected to the correction-only taper header 2 s ′ rather than the taper header 2 ′. The correction flow pipes h 31 , h 32 , h 33 on the other end of the turbulence generator 4 ′ are connected to the correction-only taper header 2 s ′ rather than the taper header 2 ′.
According to this configuration, the correction flow pipes for correcting the fiber orientation of the paper are disposed so as to overlap in the direction of paper thickness, and can be controlled by their respective flow control valves. Hence, by varying the flow velocity of the pulp raw material that flows through the respective pipes, the fiber orientation can be regulated to become uniform from the front surface of the paper to the rear surface of the paper.
Further, by constituting the headbox 20 such that the correction flow pipes h 21 , h 22 , h 23 and the correction flow pipes h 31 , h 32 , h 33 are connected to the correction-only taper header 2 s ′ rather than the taper header 2 ′, pressure control and so on of the correction-only taper header 2 s ′ can be performed freely and independently of the taper header 2 ′, enabling correction of the fiber orientation to be performed in a wider scope.
Next, a headbox 21 for a paper machine according to a modified example of the second embodiment will be described.
In the headbox 21 for a paper machine, as shown in FIG. 3( a ), which is a schematic top view thereof, and FIG. 3( b ), which is a schematic view seen from the direction of an arrow E, illustrating the interior of the headbox 21 of FIG. 3( a ), in addition to the correction flow pipes h 21 , h 22 , h 23 disposed at one end of the turbulence generator 4 ′ and the correction flow pipes h 31 , h 32 , h 33 disposed at the other end of the turbulence generator 4 ′, correction flow pipes (an orientation correcting arrangement and a paper thickness direction correcting arrangement) h 41 , h 42 , h 43 for correcting the fiber orientation are disposed in a central portion of the turbulence generator 4 ′, connected to the taper header 2 ′, comprise flow control valves b 41 , b 42 , b 43 and flowmeters r 41 , r 42 , r 43 , and are thus connected to a central portion of the slice 5 ′.
Note that, as shown by the double-dash line in FIG. 3 , the central portion correction flow pipes h 41 , h 42 , h 43 may be connected to the correction-only taper header 2 s ′ rather than the taper header 2 ′.
Further, an example is shown in which the fiber orientation correction flow pipes h 41 , h 42 , h 43 in the central portion of the turbulence generator 4 ′ are disposed in a single location, but the pipes may be disposed in a plurality of locations other than the two end portions.
According to this configuration, the correction flow pipes h 41 , h 42 , h 43 are disposed in the central portion of the turbulence generator 4 ′, and the flow rates thereof are regulated by the respective flow control valves b 41 , b 42 , b 43 . Hence the fiber orientation can be regulated to become uniform from the front surface of the paper to the rear surface of the paper in the central portion of the slice 5 ′.
Note that by disposing the correction flow pipes not only in a single location in the central portion of the turbulence generator 4 ′, but also in a plurality of locations other than the two end portions of the turbulence generator 4 ′, regulation can be performed in a wider region of the width of the slice 5 ′.
Further, by connecting the correction flow pipes h 41 , h 42 , h 43 in a single location in the central portion or the correction flow pipes in a plurality of locations to the correction-only taper header 2 s ′, the correction-only taper header 2 s ′ can be controlled freely and independently of the taper header 2 ′, enabling correction of the fiber orientation in a wider scope.
Third Embodiment
The third embodiment differs from the headboxes for a non-concentration controlling type paper machine of the first and second embodiments in that it is applied to a headbox 30 for a concentration controlling type paper machine.
In the headbox 30 for a concentration controlling type paper machine, as shown in FIG. 4( a ), which is a schematic top view thereof, and FIG. 4( b ), which is a schematic view seen from the direction of an arrow F in FIG. 4( a ), high concentration pulp raw material is stored in a high concentration taper header 32 a , and dilution water is stored in a dilution water taper header 32 b.
The high concentration taper header 32 a is connected to a mixing chamber 33 b via a module jet mixing chamber 33 ab , and the dilution water taper header 32 b is connected to the mixing chamber 33 b via a module jet bulb 33 aa.
The mixing chamber 33 b is connected to a slice 35 via a turbulence generator 34 , whereby the high concentration pulp raw material inside the high concentration taper header 32 a and the dilution water inside the dilution water taper header 32 b are supplied to the slice 35 as a main flow.
In this headbox 30 for a paper machine, correction flow pipes (an orientation correcting arrangement) h 5 , h 6 are disposed at both ends of the turbulence generator 34 , connected to the high concentration taper header 32 a , comprise flow control valves b 5 , b 6 , flowmeters r 5 , r 6 , and branch headers bh 5 , bh 6 , and are thus connected to the slice 35 .
The correction flow pipe h 5 further comprises a flow control valve kb 5 so as to be connected to the dilution water taper header 32 b , and the correction flow pipe h 6 further comprises a flow control valve kb 6 so as to be connected to the dilution water taper header 32 b.
Thus high concentration pulp raw material and dilution water flow through the correction flow pipes h 5 , h 6 to the slice 35 .
By way of the configuration described above, the high concentration pulp raw material and dilution water transmitted from the high concentration taper header 32 a and dilution water taper header 32 b through the module jet mixing chamber 33 ab or the module jet bulb 33 aa , the mixing chamber 33 b , the turbulence generator 34 , the correction flow pipes h 5 , h 6 , and so on are discharged as a raw material jet gj onto a wire (not shown).
Here, the correction flow flows from the correction flow pipes h 5 , h 6 to the slice 5 1 , and hence when the flow velocity of the correction flow is faster than the flow velocity of the main flow in the turbulence generator 4 2 , the orientation of the pulp fibers in the main flow is corrected to an orientation that moves away from the correction flow.
On the other hand, when the flow velocity of the correction flow is slower than the flow velocity of the main flow in the turbulence generator 34 , the orientation of the pulp fibers in the main flow is corrected to an orientation that approaches the correction flow side.
The pulp raw material placed on the wire in this manner is drained of water by natural dehydration while being conveyed, then pressed by a roll (not shown) to be further drained of water, then drained further by the application of heat and vaporization, and thus formed into paper.
Here, as shown in FIG. 9( b ), which is an enlarged sectional view of a sheet of paper “p” in the direction of thickness, when the high concentration pulp raw material and dilution water are mixed such that there is a large amount of high concentration pulp raw material and little dilution water, the basis weight increases (td 1 , td 2 in FIG. 9( b )) and the paper becomes thicker, whereas when there is little high concentration pulp raw material and a large amount of dilution water, the basis weight decreases (“ts 1 ” in FIG. 9( b )) and the paper becomes thinner.
Incidentally, extraction of the raw material in the orientation correction flow pipes h 5 , h 6 may be set to the high concentration taper header 32 a alone such that only high concentration pulp raw material is extracted.
According to the configuration described above, a correction flow at the two end portions is present in addition to the main flow on the inside of the slice 35 , and hence the fiber orientation of the pulp fibers can be corrected to an inside or outside orientation by varying the flow velocity of the correction flow.
Further, by making the correction flow through the correction flow pipes h 5 , h 6 a mixture of high concentration pulp raw material and dilution water, the correction flow approaches the entire width of the raw material jet “gj” from the slice 35 , and can be used as the paper of the end product.
Further, as shown by the double-dash line in FIG. 4 , the headbox 30 may also comprise a high concentration taper header for the orientation correction flow only (a correction-only taper header) 32 a 1 and a dilution water taper header for the orientation correction flow only (a correction-only taper header) 32 b 1 , whereby the orientation correction flow pipes h 5 , h 6 are connected only to the correction-only high concentration taper header 32 a 1 and the correction-only dilution water taper header 32 b 1 in order to extract high concentration pulp raw material and dilution water.
According to this configuration, control and so on of the high concentration taper header 32 a 1 for the orientation correction flow only and the dilution water taper header 32 b 1 for the orientation correction flow only can be performed freely and independently of the main flow high concentration taper header 32 a and dilution water taper header 32 b , and hence regulation of the correction flow can be performed in a wider scope.
FIG. 5 shows a modified example of the third embodiment, comprising an orientation correction flow pipe h 7 in the center of the turbulence generator 34 in addition to the orientation correction flow pipes h 5 , h 6 .
Note that FIG. 5( a ) shows a schematic top view of a modified example of the headbox 30 for a concentration controlling type paper machine, and FIG. 5( b ) shows a schematic view seen from the direction of an arrow G in FIG. 5( a ).
More specifically, the correction flow pipe (an orientation correcting arrangement) h 7 is disposed in a central portion of the turbulence generator 34 , connected to the high concentration taper header 32 a , comprises a flow control valve b 7 , a flowmeter r 7 , and a branch header bh 7 , and is thus connected to a central portion of the slice 35 .
The correction flow pipe h 7 further comprises a flow control valve kb 7 so as to be connected to the dilution water taper header 32 b.
A plurality of the correction flow pipes h 7 may be provided in a plurality of locations, other than the two end portions of the turbulence generator 34 , in addition to the correction flow pipe h 7 provided in a single location in the central portion of the turbulence generator 34 .
Further, as shown by the double-dash line in FIG. 5 , the headbox 30 may further comprise the high concentration taper header 32 a 1 for the orientation correction flow only and the dilution water taper header 32 b 1 for the orientation correction flow only, such that the orientation correction flow pipe h 7 is connected only to the correction-only high concentration taper header 32 a 1 and the correction-only dilution water taper header 32 b 1 in order to extract high concentration pulp raw material and dilution water.
According to this configuration, correction of the fiber orientation may be performed in a single location in the central portion of the slice 35 , or in a plurality of locations other than the two end portions, and hence correction of the fiber orientation can be performed over the entire width of the slice 35 even when the width of the slice 35 is great.
Fourth Embodiment
The fourth embodiment is constituted such that in the paper machine headbox according to the third embodiment, correction flow pipes are disposed in a plurality in the direction of paper thickness, and are each capable of correction control.
All other features are identical to the configuration of the third embodiment. Hence identical reference symbols, with the addition of ′ (a dash), are allocated to identical elements, and description is provided only for different features.
In a headbox 41 for a paper machine of the fourth embodiment, as shown in FIG. 6( a ), which is a schematic top view thereof, and FIG. 6( b ), which is a schematic view seen from the direction of an arrow H, illustrating the interior of the headbox 41 of FIG. 6( a ), correction flow pipes (an orientation correcting arrangement and a paper thickness direction correcting arrangement) h 81 , h 82 , h 83 are disposed at one end of a turbulence generator 34 ′, connected to a high concentration taper header 32 a ′, comprise flow control valves b 81 , b 82 , b 83 and flowmeters r 81 , r 82 , r 83 , and are thus connected to a slice 35 ′.
Correction flow pipes (an orientation correcting arrangement and a paper thickness direction correcting arrangement) h 91 , h 92 , h 93 are disposed at the other end of the turbulence generator 34 ′, connected to the high concentration taper header 32 a ′, comprise flow control valves b 91 , b 92 , b 93 and flowmeters r 91 , r 92 , r 93 , and are thus connected to the slice 35 ′.
Note that, as shown by the double-dash line in FIG. 6 , a high concentration-only taper header (correction-only taper header) 32 a 1 ′ to which pulp raw material is supplied to correct the fiber orientation is provided in this headbox 41 separately to the high concentration taper header 32 a′.
Further, the correction flow pipes h 81 , h 82 , h 83 on one end of the turbulence generator 34 ′ may be connected to the high concentration-only taper header 32 a 1 ′ rather than the taper header 32 a ′, and the correction flow pipes h 91 , h 92 , h 93 on the other end of the turbulence generator 34 ′ may be connected to the high concentration-only taper header 32 a 1 ′ rather than the high concentration taper header 32 a′.
According to this constitution, the correction flow pipes h 81 , h 82 , h 83 and h 91 , h 92 , h 93 for correcting the fiber orientation of the paper are disposed so as to overlap in the direction of paper thickness, and hence the fiber orientation can be corrected to become uniform over the front surface of the paper and the rear surface of the paper by regulating the flow rate of the high concentration pulp raw material that flows through the respective pipes using the respective flow control valves.
Further, by constituting the headbox 41 such that the correction flow pipes h 81 , h 82 , h 83 and the correction flow pipes h 91 , h 92 , h 93 are connected to the high concentration-only taper header 32 a 1 ′ rather than the high concentration taper header 32 a ′, control of the high concentration-only taper header 32 a 1 ′ can be performed freely and independently of the high concentration taper header 32 a ′, enabling correction of the fiber orientation to be performed in a wider scope.
Fifth Embodiment
The fifth embodiment is constituted such that in the paper machine headbox according to the fourth embodiment, correction flow pipes are connected to a high concentration taper header and a dilution water taper header.
All other features are identical to the constitution of the third and fourth embodiments. Hence identical reference symbols, with the addition of ′ (a dash), are allocated to identical elements, and description is provided only for different features.
In a headbox 51 for a paper machine of the fifth embodiment, as shown in FIG. 7( a ), which is a schematic top view thereof, and FIG. 7( b ), which is a schematic view seen from the direction of an arrow I, illustrating the interior of the headbox 51 of FIG. 7( a ), correction flow pipes (an orientation correcting arrangement and a paper thickness direction correcting arrangement) h 101 , h 102 , h 103 are disposed at one end of the turbulence generator 34 ′, connected to the high concentration taper header 32 a ′, comprise flow control valves b 101 , b 102 , b 103 and flowmeters r 101 , r 102 , r 103 , and are thus connected to the slice 35 ′.
The correction flow pipes h 101 , h 102 , h 103 further comprise flow control valves kb 101 , kb 102 , kb 103 respectively so as to be connected to a dilution water taper header 32 b′.
Meanwhile, correction flow pipes (an orientation correcting arrangement and a paper thickness direction correcting arrangement) h 111 , h 112 , h 113 are disposed at the other end of the turbulence generator 34 ′, connected to the high concentration taper header 32 a ′, comprise flow control valves b 111 , b 112 , b 113 and flowmeters r 111 , r 112 , r 113 , and are thus connected to the slice 35 ′.
The correction flow pipes h 111 , h 112 , h 113 further comprise flow control valves kb 111 , kb 112 , kb 113 respectively so as to be connected to the dilution water taper header 32 b′.
According to the constitution described above, the plurality of correction flows overlapping in the direction of paper thickness are disposed at the two end portions of the slice 35 ′ in addition to the main flow on the inside of the slice 35 ′, and hence the fiber orientation of the pulp fibers can be corrected from the rear surface to the front surface of the paper by regulating the respective flow rates of each correction flow using the flow control valves.
Moreover, the correction flows produced in the correction flow pipes h 101 , h 102 , h 103 and the correction flow pipes h 111 , h 112 , h 113 are flows comprising a mixture of high concentration pulp raw material and dilution water, and hence the correction flow approaches the entire width of the raw material jet “gj” from the slice 35 ′, and can therefore be used as the paper end product.
Note that, as shown by the double-dash line in FIG. 7 , the high concentration taper header 32 a 1 ′ for the orientation correction flow only and the dilution water taper header 32 b 1 ′ for the orientation correction flow only (correction-only taper header) may be provided separately, whereby the orientation correction flow pipes h 101 , h 102 , h 103 and the correction flow pipes hill, h 112 , h 113 are connected only to the correction-only high concentration taper header 32 a 1 ′ and the correction-only dilution water taper header 32 b 1 ′ in order to extract high concentration pulp raw material and dilution water.
According to this configuration, control of the high concentration taper header 32 a 1 ′ for the orientation correction flow only and the dilution water taper header 32 b 1 ′ for the orientation correction flow only can be performed freely and independently of the main flow high concentration taper header 32 a ′ and dilution water taper header 32 b ′, and hence regulation of the fiber orientation by way of the correction flows can be performed in a wider scope.
Sixth Embodiment
The sixth embodiment is constituted such that further fiber orientation correction flow pipes are added to a central portion of the turbulence generator 34 ′ in the paper machine headbox 51 of the fifth embodiment.
All other features are identical to the features of the third and fifth embodiments. Hence identical reference symbols, with the addition of ′ (a dash), are allocated to identical elements to those of the third embodiment, and description is provided only for different features.
In a headbox 61 for a paper machine of the sixth embodiment, as shown in FIG. 8( a ), which is a schematic top view thereof, and FIG. 8( b ), which is a schematic view seen from the direction of an arrow J, illustrating the interior of the headbox 61 of FIG. 8( a ), fiber orientation correction flow pipes (an orientation correcting arrangement) h 121 , h 122 , h 123 are disposed in a central portion of the turbulence generator 34 ′, connected to the taper header 32 a ′, comprise flow control valves b 121 , b 122 , b 123 and flowmeters r 121 , r 122 , r 123 , and are thus connected to the slice 35 ′.
The correction flow pipes h 121 , h 122 , h 123 further comprise flow control valves kb 121 , kb 122 , kb 123 respectively so as to be connected to the dilution water taper header 32 b′.
Here, the correction flow pipes h 121 , h 122 , h 123 in the central portion of the turbulence generator 34 ′ may be provided not only in a single location, but in a plurality of locations other than the two end portions.
According to the configuration described above, the correction flow pipes h 121 , h 122 , h 123 are provided in a single location in the central portion or also in a plurality of locations other than the two end portions, and hence correction of the fiber orientation of the paper can be performed over the entire width, even in the headbox 1 having a large slice width “m 1 ”, by regulating the respective flow rates of the correction flow pipes using the flow control valves so as to vary the flow velocity of the pulp raw material.
Furthermore, the plurality of controllable correction flows overlapping in the direction of paper thickness are disposed at the two end portions and a single location in the central portion or a plurality of locations in addition to the main flow on the inside of the slice 35 ′, and hence the fiber orientation of the pulp fibers can be corrected from the rear surface to the front surface of the paper over the entire width of the slice 35 ′ by varying the respective flow velocities of each correction flow.
As shown by the double-dash line in FIG. 8 , the high concentration taper header 32 a 1 ′ for the orientation correction flow only and the dilution water taper header 32 b 1 ′ for the orientation correction flow only are provided separately.
Moreover, the orientation correction flow pipes h 121 , h 122 , h 123 may be connected only to the correction-only high concentration taper header 32 a 1 ′ and the correction-only dilution water taper header 32 b 1 ′ in order to extract high concentration pulp raw material and dilution water.
According to this configuration, control of the high concentration taper header 32 a 1 ′ for the orientation correction flow only and the dilution water taper header 32 b 1 ′ for the orientation correction flow only can be performed freely and independently of the main flow high concentration taper header 32 a ′ and dilution water taper header 32 b ′, and hence regulation using the correction flows can be performed in a wider scope.
Incidentally, in the first through sixth embodiments, a fiber orientation sensor is provided for measuring the fiber orientation by causing probes for measuring propagation velocity to contact the manufactured paper appropriately in set regions, releasing ultrasonic waves, and measuring the propagation velocity of the ultrasonic waves.
Alternatively, a fiber orientation sensor is provided for measuring the fiber orientation of the manufactured paper from the reflectance of light which is emitted onto certain regions of the manufactured paper.
By connecting the fiber orientation sensor and the flow control valves and flowmeters of the correction flow pipes to the control system online, open/close control of the flow control valves can be performed automatically on the basis of fiber orientation data obtained by the fiber orientation sensor, data from the flowmeters of the correction flow pipes, and so on, and automatic control can also be performed to maintain the fiber orientation of the paper at a predetermined value.
According to this configuration, a laborsaving paper machine is obtained.
According to the present invention exemplified in the first through sixth embodiments, by correcting the fiber orientation of the paper uniformly over the entire slice width and from the rear surface to the front surface of the paper, extremely high-quality paper can be obtained as an end product and for post-processing such as printing or finishing of the paper.
Moreover, an improvement in operational efficiency can be achieved.
INDUSTRIAL APPLICABILITY
The present invention can be used effectively as a headbox for a paper-making machine, and as a headbox for machines having a similar constitution.
DESCRIPTION OF REFERENCE SYMBOLS
1 , 20 , 21 , 30 , 31 , 41 , 51 , 61 headbox
2 , 2 ′, 32 a , 32 a ′ taper header
5 , 5 ′, 35 , 35 ′ slice
2 s , 2 s ′, 32 a 1 , 32 b 1 , 32 a 1 ′, 32 b 1 ′ correction-only taper header
b 1 , b 2 , b 3 , b 21 , b 22 , b 23 , b 31 , b 32 ,
b 33 , b 41 , b 42 , b 43 , b 5 , b 6 , kb 5 , kb 6 ,
b 7 , b 81 , b 82 , b 83 , b 91 , b 92 , b 93 ,
b 101 , b 102 , b 103 , b 111 , b 112 , b 113 ,
kb 101 , kb 102 , kb 103 , kb 111 , kb 112 ,
kb 113 , b 121 , b 122 , b 123 , kb 121 ,
kb 122 , kb 123 flow control valve
gi raw material jet
h 1 , h 2 , h 21 , h 22 , h 23 , h 31 , h 32 , h 33 ,
h 5 , h 6 , h 81 , h 82 , h 83 , h 91 , h 92 , h 93 ,
h 3 , h 41 , h 42 , h 43 , h 7 , h 121 , h 122 , h 123 correction flow pipe (an orientation correcting arrangement)
h 101 , h 102 , h 103 , h 111 , h 112 , h 113 correction flow pipe (another orientation correcting arrangement)
h 21 , h 22 , h 23 , h 31 , h 32 , h 33 , h 41 , h 42 ,
h 43 , h 81 , h 82 , h 83 , h 91 , h 92 , h 93 ,
h 101 , h 102 , h 103 , h 111 , h 112 , h 113 ,
h 121 , h 122 , h 123 correction flow pipe (paper thickness direction correcting arrangement)
r 1 , r 2 , r 3 , r 21 , r 22 , r 23 , r 31 , r 32 , r 33 ,
r 41 , r 42 , r 43 , r 5 , r 6 , r 7 , r 81 , r 82 , r 83 ,
r 91 , r 92 , r 93 , r 101 , r 102 , r 103 , r 111 ,
r 112 , r 113 , r 121 , r 122 , r 123 flowmeter
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Headbox for a paper machine which discharges paper raw material onto a wire as a raw material jet from a slice which is supplied with the paper raw material. The headbox includes an orientation correcting arrangement for correcting a pulp fiber orientation by supplying the paper raw material as a correction flow to a single location in either a central portion of the slice or a plurality of locations other than end portions thereof. The paper raw material is one of extracted from a taper header in which paper raw material for a main flow is stored and extracted from a correction-only taper header in which paper raw material for correcting the pulp fiber orientation is stored. This abstract is not intended to define the invention disclosed in the specification, nor intended to limit the scope of the invention in any way.
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BACKGROUND OF THE INVENTION
The invention relates to a control device operatively associated with a needle-bearing bar in a quilting machine. Such a device can be used in either quilting machines having a single needle-bearing bar or in quilting machines having a plurality of needle-bearing bars.
In the conventional quilting machines, the control device of the needle-bearing bar has driving means inserted between a main control shaft of the machine and the needle-bearing bar. These driving means are suitable to convert, via cam means, the rotatory motion of the main shaft into a reciprocating movement of the needle-bearing bar. Such conventional driving means forms a non-disengageable connection between the main shaft and the needle-bearing bar and does not permit a temporaneous stopping of the needle-bearing bar and, consequently, of the stitching operation. When the quilting machine is in operation, the needle-bearing bar is constantly in movement, and accomplishment of discontinuous quiltings, in order to manufacture quilted articles having stitched patterns with pattern-free zones intervening therebetween, is not readily possible. In order to obtain quiltings of the foregoing type, it has been necessary with the known machines to stop the entire combination of parts forming the driving means of the needle-bearing bar to cause thereafter the article being quilted to advance a predetermined length, and finally to restore the working of the combination of parts forming the driving means of the needle bearing bar. Obviously, such operations must be repeated whenever a non-stitched zone has to be prepared. This makes the working of the quilting machine extremely difficult and complex and, consequently, also the electric equipment provided for actuating, in timed coordination, the various operations. Machines of this type generally use, for the preparation of discontinuous stitchings, a self-braking motor which, whenever a stitch-free zone has to be prepared, must lock the main shaft of the machine and enable a secondary control device for moving the article which must advance without being stitched. The working complexity of the conventional machines results in the impossibility of increasing the production rate beyond a given limit; consequently, the output is necessarily limited. As a result, the manufactured articles are expensive. There should be also considered the possible frequent drawbacks which can occur, such as e.g. article tearing caused by the article advancement, if the needle-bearing bar is not at the top dead center, i.e. the needles are not in raised position with respect to the article.
SUMMARY OF THE INVENTION
It is the principal object of the present invention to provide in an apparatus for driving at least one needle-bearing bar of a quilting machine, a control device of the needle-bearing bar in a quilting machine which overcomes the above-mentioned drawbacks and allows discontinuous quilting, the stitched zones having non-stitched zones intervening therebetween, without requiring that the main motor of the machine or of the main shaft be stopped.
The control device of a needle-bearing bar according to the present invention is characterized in that it has means for disengaging a reciprocating means from the needle-bearing bar.
The main advantage afforded by the control device of the present invention resides in that the device makes it possible to obtain discontinuous stitches without stopping the machine members, thus permitting either a continuous or an intermittent quilting without stopping the machine.
A further advantage of the control device of the present invention is that, during the preparation of a non-stitched zone, the advancement of the fabric takes place with the needle-bearing bar at the top dead center, thus avoiding tearing of the fabric.
A further advantage of the control device of the present invention is that the disengaging means are operable even at maximum quilting speed, without requiring any temporaneous slowing down which would result in a decrease of the number of quilted articles produced.
A further advantage is the continuity in production and consequently the decrease of the ultimate costs of the articles obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and further advantages, objects and features of the control device according to the present invention are to become more apparent from the following detailed description given by way of non-limiting examples with reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view showing a first embodiment of a control device according to the present invention, engaged with a needle-bearing bar at top dead center;
FIG. 2 is a perspective view showing the control device of FIG. 1, engaged with the needle-bearing bar at bottom dead center;
FIG. 3 is a perspective view showing the control device of FIGS. 1 and 2 when disengaged from the needle-bearing bar; and
FIG. 4 is a perspective view showing a second embodiment of control device, which can be used in practicing the invention, engaged with a needle-bearing bar at top dead center.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With specific reference to FIGS. 1-3, the control device of a needle-bearing bar includes a connecting rod in the form of a reciprocable rod 1 actuated, via a cam 2, by a main driving motor 3 of a quilting machine. The cam 2 has a circular plate 4 keyed on a shaft 5 which is rotated by the driving motor 3 via a reduction gear assembly 6. The circular plate 4 is rotatable within a collar 7, the rod 1 being fixed to the upper end of the collar 7. The rod 1 is fixed to the upper end of the collar 7 in a manner known per se, as is at present customary in conventional quilting machines. A first electromagnet 8 is fixed to the reciprocable rod 1 midway along its length in cooperation relationship with a second electromagnet 9 movable axially along the rod 1. The second electromagnet 9 is provided at its upper end with a cylindrical projection 10 connected, in any conventional manner, to a projection 11 provided at the end of an arm 12 keyed at its opposite end to a countershaft 13 having the purpose of transmitting the reciprocating motion to a number of mechanisms (only one being illustrated in FIGS. 1-3) connected to at least one needle-bearing bar 15. Each of these mechanisms includes a rod 16 pivoted at one of its ends to an arm 14 and at its opposite end pivoted to a sleeve 17 fastened on a shaft 18 connected rigidly at its lower end to the needle-bearing bar 15 via a bracket 19. The shaft 18 is slidable within a guide 20 fastened to the frame of the quilting machine in such a way as to assure that its movement, and consequently the movement of the needle-bearing bar 15, is always vertical. Between the sleeve 17 and the guide 20, spring 21 is provided for controlling the lifting of the needle-bearing bar 15 when the control device is disabled, as will become more apparent from the description below of the operation of the control device of the present invention.
With specific reference to FIG. 4, there is now described a further embodiment of the control device of the present invention in which the disengaging means are of the pneumatic type. In this case, a reciprocating rod 1 acts as a piston slidable within a cylinder 22 fastened at one end thereof to a projection 11 of an arm 12. As to the remaining parts, this further embodiment is identical to the previously described embodiment illustrated in FIGS. 1-3. In FIG. 4, like elements are designated by the same reference numerals.
The operation of the control device of FIGS. 1-3 is as set out below. After the quilting machine has been set so that it can operate normally, i.e. after the article to be quilted has been inserted and all of the inspections to check the various devices of actuation and stitching have been carried out, the quilting machine is started. If the leading portion of the article must be quilted, the electromagnets 8 and 9 have to be energized so that, remaining attracted to each other, they maintain the connection between the rod 1 and the countershaft 13 in such a way that the needle bearing bar 15 can accomplish its normal stitching movement.
When a non-stitched portion must be realized, i.e. the movement of the needle-bearing bar 15 has to be stopped, it is sufficient to de-energize the electromagnets 8 and 9 so as to disengage the rod 1 from the mechanism which otherwise keeps it connected to the needle-bearing bar 15. When the electromagnets 8 and 9 are de-energized, they detach from each other. The electromagnet 8 follows the movement of the rod 1, because it is fixed thereto, while the electromagnet 9 stops at a final position which, no matter at what time the de-energization takes place, corresponds to the top dead center of the needle-bearing bar 15.
It is a feature of the control device according to the present invention that the de-energization of the electromagnets 8 and 9 can take place at any moment, even at a different moment from that in which the needle-bearing bar 15 is at its top dead center. In fact, even if the de-energization is effected at a moment in which the needles are inserted within the article to be quilted, the movement of of the rod 1 is such as to cause, in any case, the upward motion of the needle-bearing bar 15 because the second electromagnet 9 and all the mechanical members connected thereto are pushed to an upward position where they stop, through action of the spring 21. Subsequently, the first electromagnet 8 descends again detaching from the second electromagnet 9. All of the control members of the machine are in motion. The electromagnets 8 and 9 are subsequently energized when stitching must be started again.
It is suitable that the position of the rod 1 corresponding to the top dead center of the needle-bearing bar 15 be such that the first electromagnet 8 is very close to second electromagnet 9, so as to bring about easily a further attraction to each other.
In case the leading zone of the article need not to be stitched, it is sufficient to start the machine with the electromagnets 8 amd 9 in de-energized condition, causing them to become energized when the stitching must be started, In order to control the subsequent energizations and de-energizations of electromagnets 8 and 9, a conventional electronic control device can be provided. This control device can be timed, thus making the operation of the quilting machine automatic.
The foregoing disclosures relating to the case in which the disengaging means is of electromagnetic type can be easily applied to the case in which the disengaging means is of pneumatic type, as is shown in FIG. 4. When the quilting machine has to effect the stitching of the article, it is sufficient to keep a preestablished pressure within the chamber of the cylinder 22 so as to block the position of the piston, i.e. the rod 1. This can be easily obtained by introducing a fluid under pressure into the cylinder 22. When the machine must provide a non-stitched zone, the delivery of fluid under pressure into the cylinder 22 is discontinued, and the pressure therein reduced by putting it in communication with the outer environment, thus disengaging the rod 1, which then moves freely within the cylinder 22. This latter stops at a final position corresponding to the top dead center of the needle-bearing bar 15. Also for this further embodiment, it is possible to provide a control device for the subsequent introductions of fluid and the attendant interruptions, which can be timed, thus making fully automatic the operation of the machine.
It is further to be understood that various changes and/or modifications can be made to the control devices of this invention, without departing from the spirit and scope thereof, its scope being defined by the appended claims.
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At least one needle-bearing bar of a quilting machine is connected to a reciprocable shaft, a control device is operatively arranged selectively to engage and to disengage the needle-bearing bar from the shaft. The control device includes either two electromagnetic or a pneumatically operated cylinder. A timer can be provided to effect energization of the electromagnets or fluid delivery to and venting of the cylinder.
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BACKGROUND
1. Field of the Invention
The present invention relates generally to Power over Ethernet (PoE) and, more particularly, to a system and method for multiple PoE power supply management.
2. Introduction
The IEEE 802.3af and 802.3at PoE specifications provide a framework for delivery of power from power sourcing equipment (PSE) to a powered device (PD) over Ethernet cabling. Various types of PDs exist, including voice over IP (VoIP) phones, wireless LAN access points, network cameras, computing devices, etc.
In the PoE process, a valid device detection is first performed. This detection process identifies whether or not it is connected to a valid device to ensure that power is not applied to non-PoE capable devices. After a valid PD is discovered, the PSE can optionally perform a power classification. In 802.3af, the power classification process can be used to classify a PD into various pre-defined power levels (i.e., 4.0 W, 7.0 W, and 15.4 W).
In more advanced power classification schemes, a dynamic power management process can be used to generate a power request and priority for a PD based on current or anticipated power needs. As the total PSE power budget is typically limited as compared to the total power demand of the set of PDs, the dynamic power management process would consider the competing power needs of the various PDs.
The goal of the PSE management task is to provide stable output power to the various PDs. In a conventional PSE design, multiple power supplies can be used. A benefit of such a multiple power supply design is the elimination of a single point of failure. What is needed, however, is a mechanism for managing the allocation of power to a plurality of PDs based on the relative status of the multiple power supplies.
SUMMARY
A system and/or method for multiple PoE power supply management, substantially as shown in and/or described in connection with at least one of the figures, as set forth more completely in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 illustrates an embodiment of a PoE system.
FIG. 2 illustrates an embodiment of a microcontroller that receives power supply status signals.
FIG. 3 illustrates an embodiment of PSE controllers that receive power supply status signals.
FIG. 4 illustrates a flowchart of a management process in a PoE system having multiple power supplies.
FIG. 5 illustrates an embodiment of a mechanism that generates power supply status signals.
FIG. 6 illustrates another embodiment of PSE controllers that receive power supply status signals.
DETAILED DESCRIPTION
Various embodiments of the invention are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the invention.
FIG. 1 illustrates an embodiment of a power over Ethernet (PoE) system. As illustrated, the PoE system includes power sourcing equipment (PSE) 120 that transmits power to powered device (PD) 140 . Power delivered by the PSE to the PD is provided through the application of a voltage across the center taps of transformers that are coupled to a transmit (TX) pair and a receive (RX) pair of wires carried within an Ethernet cable. In general, the TX/RX pair can be found in, but not limited to structured cabling. The two TX and RX pairs enable data communication between Ethernet PHYs 110 and 130 in accordance with 10BASE-T, 100BASE-TX, 1000BASE-T, 10GBASE-T and/or any other layer 2 PHY technology.
As is further illustrated in FIG. 1 , PD 140 includes PoE module 142 . PoE module 142 includes the electronics that would enable PD 140 to communicate with PSE 120 in accordance with a PoE standard such as IEEE 802.3af, 802.3at, legacy PoE transmission, or any other type of PoE transmission. PD 140 also includes pulse width modulation (PWM) DC:DC controller 144 that controls power FET 146 , which in turn provides constant power to load 150 .
In the example of the IEEE 802.3af standard, PSE 120 can deliver up to 15.4 W of power to a plurality of PDs (only one PD is shown in FIG. 1 for simplicity). In the IEEE 802.at draft specification, on the other hand, a PSE may be able to deliver up to 30 W of power to a PD over 2-pairs. Other proprietary solutions can potentially deliver even higher levels of power to a PD. In general, high power solutions are often limited by the limitations of the cabling.
In one embodiment, multiple power supplies PS 0 , PS 1 , PS 2 , . . . PSN can be used to provide power to the PoE system. In one implementation, this set of power supplies is connected to all of the PSEs. In another implementation, each PSE is connected to an identifiable subset of the power supplies. Consider, for example, a PoE system that supports 48 ports using 12 quad controller PSEs. In this example, PSE 1 can be coupled to power supplies PS 0 , PS 1 , PS 2 , PSE 2 can be coupled to power supplies PS 0 , PS 3 , PS 4 , and PSE 3 can be coupled to power supplies PS 4 , PS 5 , PS 6 . In general, any combination of power supplies to a given PSE can be used.
One of the responsibilities of the PSEs is to manage the power that is supplied to the various supported PDs based on the status of the multiple connected power supplies. In the example of FIG. 1 , PSE 120 is shown as being coupled to three power supplies PS 0 , PS 1 , PS 2 . If PS 0 , PS 1 , and PS 2 are all up, then the maximum amount of power is available to PSE 120 . Assume at that point, that PSE 120 has enough power for four PDs (PD 1 , PD 2 , PD 3 , PD 4 ) at respective power levels PL 1 , PL 2 , PL 3 , PL 4 . If power supply PS 1 fails, an adjustment of the power allocation amongst PD 1 , PD 2 , PD 3 , and PD 4 may be required. This process would consider the power priorities for PD 1 , PD 2 , PD 3 , and PD 4 along with the power priorities for any other PDs that are supported by a PSE coupled to power supply PS 1 . For example, if only a second PSE (supporting PD 5 , PD 6 , PD 7 , and PD 8 at power levels PL 5 , PL 6 , PL 7 , and PL 8 ) is coupled to PS 1 , then the power management process would consider the power priorities of PD 1 -PD 8 . The lowest priority PDs having a total power level equivalent to the reduction in power would then be cut off from receiving any more power.
FIG. 2 illustrates an embodiment of a PoE system that enables management of multiple power supplies. As illustrated, the PoE system includes PSE controllers 1 -N. Each PSE controller supports a set of PDs. In this configuration, PSE controllers 1 -N are each coupled to bus 210 (e.g., I2C), which is coupled to microcontroller 220 . Here, microcontroller can operate as a master device, while PSE controllers 1 -N can operate as slave devices. Microcontroller 220 is coupled to a host device through opto 230 , which provides an isolation boundary.
As illustrated, microcontroller 220 receives power supply status signals PSS 0 , PSS 1 , PSS 2 , which each provide power supply status information for a given power supply. In this example, it is assumed that only three power supplies PS 0 , PS 1 , PS 2 are used for the PoE system. In various examples, the power supply signals can represent power supply outputs, “power good” signals, or the like.
When power supply status signals PSS 0 , PSS 1 , PSS 2 indicate that power supplies PS 0 , PS 1 , PS 2 are up and running, PSE controllers 1 -N can be configured to provide power to a first set of PDs. If power supply PS 1 fails, an indication of such a failure would be reflected by power supply signal PSS 1 . At that point, a reallocation of power amongst the plurality of supported PDs would occur. Implementation of this determined reallocation would then be implemented by microcontroller 220 in the reprogramming of various PSE controllers to account for the new power budget. A disadvantage of such a technique is the significant time required for the reprogramming of the PSE controllers. During such a reconfiguration time, disruption in PoE service can occur.
FIG. 3 illustrates an embodiment of the present invention that enables disconnection of ports without reprogramming of the PSE controllers. In this embodiment, each of PSE controllers 1 -N have an integrated microcontroller, thereby obviating the need for an external microcontroller. As such, one of the PSE controllers (e.g., PSE controller 1 ) can operate as a master device, while the remaining PSE controllers ( 2 -N) can operate as slave devices. Communication between PSE controllers 1 -N is facilitated by bus 310 .
In the configuration of FIG. 3 , each of PSE controllers 1 -N is designed to receive power supply status signals PSS 0 , PSS 1 , PSS 2 , which relate to the status of power supplies PS 0 , PS 1 , PS 2 . In operation, power supply status signals PSS 0 , PSS 1 , PSS 2 function as an enable signal for internal pre-configured registers (or software function), which when configured as unmasked will disconnect the specified port(s) for the active combination. In one embodiment applied to quad PSE controllers, each PSS 0 , PSS 1 , PSS 2 combination would be associated with a 4-bit mask, wherein each bit is associated with an individual PD port. Each PSE controller would have its own 4-bit mask that would apply for the four associated ports.
In the current example, the power supply status signals have the following combinations where a “0” indicates that a power supply is down and a “1” indicates that a power supply is up.
PSS0
PSS1
PSS2
0
0
1
0
1
0
0
1
1
1
0
0
1
0
1
1
1
0
1
1
1
Each of these PSS 0 , PSS 1 , PSS 2 combinations trigger pre-configured registers in each PSE controller that take into account port priorities (e.g., 0 - 3 ). In general, higher priority ports are powered up first to use up an available power budget and lower priority ports are disconnected first to accommodate an oversubscribed power budget. In the configuration process, the bit masks for each PSS 0 , PSS 1 , PSS 2 combination are created by identifying the ports that should be powered for a given power PSE budget as dictated by the available power supplies.
In one embodiment, the ports are examined for the highest priority level (e.g., 3) from the lowest to the highest numbered port (e.g., port 0 to port 47 ). This examination would then continue at the next highest priority level (e.g., 2) from the lowest to the highest numbered port. The process would continue until the lowest priority level is reached and all ports are examined. In this process, the sequentially identified ports from highest to lowest priority are identified until the power budget dictated by the combination of available power supplies is reached. At that power supply combination, each identified port that can be powered is associated with a masked bit for the serving PSE controller, while each remaining ports that cannot be powered is associated with an unmasked bit for the serving PSE controller. The end result at that power supply combination is a bit mask for each PSE controller that identifies which ports are powered and which ports are not powered. The configuration process would be repeated for each power supply combination to produce bit masks for each PSE controller at every power supply combination.
In the current example, the configuration process is based on priority levels. As would be appreciated, the configuration process can be based on any priority or other derating information that would be applicable to the power management process.
The end result of the configuration process is a set of pre-configured bit masks for each PSE controller that would be individually selectable based on the power supply combination indicated by the power supply status signals. In one embodiment, these pre-configured bit masks can be implemented as pre-configured registers (or software function) for use by the PSE controllers. To illustrate the use of such bit masks, a brief description of the transition between example combinations is provided below.
Combination ( 111 ) indicates that all three power supplies PS 0 , PS 1 , PS 2 are up and running and PSE controllers 1 -N allocate power according to the bit masks associated with combination ( 111 ). If PS 2 fails, then combination ( 111 ) goes to combination ( 110 ). The global power management modules within the PSE controllers would then access the bit masks associated with combination ( 110 ) and power down the additional ports having an unmasked bit. In one embodiment, the global power management modules are implemented in firmware within the PSE controllers.
For example, assume that PSE controller 1 has a 4-bit mask for combination ( 111 ) of 1110 and a 4-bit mask for combination ( 110 ) of 1010 . Here, a “1” is a masked bit, and a “0” is an unmasked bit. The 4-bit mask 1110 for combination ( 111 ) would indicate that when power supplies PS 0 , PS 1 , PS 2 are all up, ports 0 - 2 would be powered and port 3 would not be powered. The 4-bit mask 1010 for combination ( 110 ), on the other hand, would indicate that when power supply PS 2 fails, ports 0 and 2 would be powered and ports 1 and 3 would not be powered. In the transition from combinations ( 111 ) to combination ( 110 ), the global power management module in PSE controller 1 would determine that port 1 in addition to port 3 would not be powered.
As noted, combination ( 110 ) indicates that power supplies 0 and 1 are up and running. If power supply 0 fails, then combination ( 110 ) would transition to combination ( 010 ). Assume that PSE controller 1 has a 4-bit mask of 1010 for combination ( 010 ). In this example, the global power management modules within PSE controller 1 would then access the bit mask associated with combination ( 010 ). In this example, the 4-bit mask for combination ( 110 ) is the same as the 4-bit mask for combination ( 010 ). The global power management module in PSE controller 1 would therefore know that no changes to the powering of the ports served by PSE controller 1 would be required. As such, the impact of the transition between combination ( 110 ) to combination ( 010 ) would be felt by ports served by one or more of the remaining PSE controllers.
For example, assume that PSE controller 2 has a 4-bit mask of 1xxx for combination ( 110 ) and a 4-bit mask of 0xxx for combination ( 010 ). In the transition from combination ( 110 ) to combination ( 010 ), the impact would be felt by port 0 of PSE controller 2 . Here, port 0 would be powered down based on an identification of an unmasked bit at the first position of the 4-bit mask 0xxx for combination ( 010 ).
If at some point, PS 0 comes back on line, then combination ( 010 ) goes back to combination ( 110 ). In the above example, the global power management module within PSE controller 2 would then access the 4-bit mask associated with combination ( 110 ) and power up port 0 based on an identification of a masked bit at the first position of the 4-bit mask 1xxx.
As this example illustrates, the changes in combination based on the change in status of the power supplies can lead to rapid connection/disconnection of ports for each of the PSE controllers. This rapid connection/disconnection of ports is facilitated by the receipt of power supply status signals directly by each PSE controller. Upon detection of changes in state of a power supply, the individual PSE controllers can then connect/disconnect ports through the guidance of pre-configured combination logic within the PSE controllers. Response time to changes in power supply state is therefore improved as reprogramming of the PSE controllers would not be required. With the principles of the present invention, response time to changes in power supply status can occur in approximately 1 μs.
To further illustrate the power supply management process of the present invention reference is now made to the flowchart of FIG. 4 . As illustrated, the process begins at step 402 where power supply status signals are received at a PSE controller. As noted above, the power supply status signals are received directly by each PSE controller. This is in contrast to conventional systems that receive the power supply status signals at a single external microcontroller.
Based on the receipt of a set of power supply status signals, the PSE controller would then access a bit mask associated with the combination indicated by the power supply status signals. At step 404 , the PSE controller would then configure the ports (i.e., powered or not powered) based on the logic presented by the pre-configured bit mask that is accessed.
The process then proceeds to step 406 , where it is determined whether a change has occurred in the combination reflected by the received power supply status signals. If it is determined at step 406 , that a change in combination has occurred, then the pre-configured bit mask associated with the new combination is accessed. At step 408 , the ports are then configured in accordance with the new bit mask. Here, it should be noted that the new bit mask may be identical to the bit mask of the previous combination. In this case, the combination logic would not produce any changes in the powered/non-powered configuration of the ports. If, on the other hand, the new bit mask is different than the bit mask of the previous combination, then the PSE controller would change the powered/non-powered status of at least one of the ports. In general, the process of FIG. 4 would continue through the detection of various combination changes as indicated by the power supply status signals. Throughout this process, reprogramming of the PSE controllers would not be required.
In the example embodiments described above, the power supply status signals are associated with a single power supply. For example PSS 1 can be associated with the status of PS 1 . In one embodiment, the power supply status signals are not associated directly with the status of a particular power supply. FIG. 5 illustrates an example of such an embodiment that is applied to a system having eight power supplies PS 1 -PS 8 . In the illustrated example, the status of the eight power supplies PS 0 -PS 7 are provided as inputs to logic block 510 . In various embodiments, logic block 510 can be embodied as a complex programmable logic device (CPLD), field programmable gate array (FPGA), or the like. In general, logic block 510 is operable to convert the status indications of power supplies PS 0 -PS 7 into power supply status signals PSS 0 , PSS 1 , PSS 2 . Power supply status signals PSS 0 , PSS 1 , PSS 2 would then be provided as inputs to each of PSE controllers 1 -N. In one example, logic block 510 would be designed to indicate how many of the eight power supplies PS 0 -PS 7 are available through the logic level of the three power supply status signals PSS 0 , PSS 1 , PSS 2 . For example, power supply status signals PSS 0 , PSS 1 , PSS 2 can have values 0, 1, 1, respectively, indicating that three out of eight power supplies are operational.
In one embodiment, the various PSE controllers need not receive the same set of power supply status signals. FIG. 6 illustrates such an example embodiment. As illustrated, PSE controller 1 receives power supply status signals PSS 0 , PSS 1 , PSS 2 , PSE controller 2 receives power supply status signals PSS 0 , PSS 3 , PSS 4 , and PSE controller 3 receives power supply status signals PSS 0 , PSS 5 , PSS 6 . In this configuration, the port configurations for PSE controller 1 would be dependent on power supplies PS 0 , PS 1 , PS 2 , the port configurations for PSE controller 2 would be dependent on power supplies PS 0 , PS 3 , PS 4 , and the port configuration for PSE controllers 2 would be dependent on power supplies PS 0 , PS 5 , PS 6 . In general, each PSE controller can have ports whose powered/non-powered status is dependent on the status of a particular set of power supplies. Example of such customization include the sharing of a particular power supply by ports on different PSE controllers, the exclusive use of a particular power supply by ports on a particular PSE controller, the use of redundant power supplies by ports on one or more PSE controllers, etc.
It should be noted that the use of multiple power supply management can achieve the powering down of lower priority ports in less than 1 microsecond, which therefore saves the PoE system from shutting down due to increased port current or dropping voltage levels.
These and other aspects of the present invention will become apparent to those skilled in the art by a review of the preceding detailed description. Although a number of salient features of the present invention have been described above, the invention is capable of other embodiments and of being practiced and carried out in various ways that would be apparent to one of ordinary skill in the art after reading the disclosed invention, therefore the above description should not be considered to be exclusive of these other embodiments. Also, it is to be understood that the phraseology and terminology employed herein are for the purposes of description and should not be regarded as limiting.
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A system and method for multiple power over Ethernet (PoE) power supply management. Power supply status signals indicative of an operating condition of a plurality of PoE power supplies are provided to a plurality of power sourcing equipment (PSE) controller chips. Pre-configured combination logic within each of the PSE controller chips converts an indicated operational state of the plurality of PoE power supplies into a powering decision for each of the Ethernet ports served by the PSE controller chip within one microsecond.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to and the benefit of U.S. patent application Ser. No. 14/618,989, filed Feb. 10, 2015, which claims priority to U.S. Provisional Application No. 61/937,683, filed Feb. 10, 2014, each of which is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The invention relates to optical transmitters in general, and particularly to an optical driver for a Gigabit/second transmitter.
BACKGROUND OF THE INVENTION
Optical interconnects offer promising solutions to data transmission bottlenecks in supercomputers and in data-centers as well as other applications. Adopting higher channel data rates can greatly reduce the complexity in optical communication systems and/or further improve interconnect capacity and density.
The most important requirement on the driver amplifier is the output voltage swing. The state-of-the-art driver amplifier in CMOS/BiCMOS can output 3 Vpp at 40 Gb/s, consuming 1.35 W DC power. See for example, C. Knochenhauer, J. Scheytt, and F. Ellinger, “A Compact, Low-Power 40-GBit/s Modulator Driver With 6-V Differential Output Swing in 0.25 um SiGe BiCMOS,” Solid-State Circuits, IEEE Journal of, vol. 46, no. 5, pp. 1137-1146, 2011.
At higher data rates it is difficult to maintain or improve the available drive voltage without substantial advances in the fabrication process. This trend is at odds with the increasingly higher drive voltage required by modulators at higher speed.
There is a need for improved drivers for use in optical data handling systems.
SUMMARY OF THE INVENTION
According to one aspect, the invention features a distributed traveling wave modulator. The distributed traveling wave modulator comprises a differential optical input for receiving an optical input carrier signal and a differential optical output for providing a modulated optical carrier signal; a plurality N of optical phase-shifters connected in series connection as N sequential modulators between the differential optical input and the differential optical output, where N is an integer equal to or greater than 2; a plurality N of driver amplifier stages, each having a respective differential driver amplifier input and a differential driver amplifier output; N−1 delay/relay stages, each having a respective differential delay/relay input and a differential delay/relay output; a first of the plurality N of driver amplifier stages having its input connected to a differential electrical data input; each of the first N−1 of the plurality N of driver amplifier stages having its output connected to a respective input of a successive one of the N−1 delay/relay stages; each of the N−1 delay/relay stages having its respective differential delay/relay output connected to the differential driver amplifier input of a successive one of the last N−1 of the plurality N of driver amplifier stages; and each of the plurality N of driver amplifier stages having a differential signal output connected to a respective one of the N sequential modulators; wherein each driver amplifier stage includes only a single type of transistor to enable high-speed operation.
According to another aspect, the invention relates to a method of modulating an optical signal, comprising the steps of: receiving the optical signal to be modulated at an optical input port; applying a plurality N of sequential optical phase shifts to the optical signal by operation of a plurality N of fixed-length optical phase-shifters connected in series connection as N sequential modulators, where N is greater than or equal to 2, each of the N−1 phase shifts after the first of the N phase shifts delayed by a time calculated to apply each of the N−1 phase shifts after the first of the N phase shifts at a respective time when the optical signal passes a respective one of the N−1 sequential modulators after the first modulator, and providing a modulated optical signal at an optical output port.
The foregoing and other objects, aspects, features, and advantages of the invention will become more apparent from the following description and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and features of the invention can be better understood with reference to the drawings described below, and the claims. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the drawings, like numerals are used to indicate like parts throughout the various views.
FIG. 1A is a block diagram of a typical optical transmitter and receiver of the prior art.
FIG. 1B is a graph that illustrates the power scaling versus data rate for prior art silicon traveling-wave modulators.
FIG. 2A is a circuit block diagram of a distributed traveling-wave Mach-Zehnder (TWMZ) modulator driver that operates according to principles of the invention.
FIG. 2B is a schematic circuit diagram of a driver amplifier stage of the distributed traveling-wave Mach-Zehnder modulator driver of FIG. 2A .
FIG. 2C is a schematic circuit diagram of a delay/relay stage of the distributed traveling-wave Mach-Zehnder modulator driver of FIG. 2A .
FIG. 2D is an image of a chip that embodies the distributed traveling-wave Mach-Zehnder modulator driver of FIG. 2A . The chip has a width of 1 mm and a length of 2.9 mm. DC bias is provided by the structure at the right side of the chip.
FIG. 3A is a graph that illustrates the results of a distributed TWMZ driver post-layout simulation showing 100 Gb/s eye-diagrams at the driver outputs.
FIG. 3B is a graph that illustrates the results of a distributed TWMZ driver post-layout simulation showing 100 Gb/s eye-diagrams after the Si TWMZ. The differential output is 2 Vpp at 25Ω impedance; data is shifted by 13 picoseconds (ps) between each output stage.
DETAILED DESCRIPTION
As illustrated in FIG. 1A , the analog front-end in a typical prior art optical transceiver includes a modulator driver and a transimpedance amplifier that serve as interfaces between a high-speed optical channel and lower speed digital electronics. Data is provided to the MUX and is modulated onto a laser carrier in an optical fiber using the driver and the modulator. The modulated carrier travels down the fiber. At a receiver, a photodetector samples the optical carrier and a transimpedance amplifier and DEMUX provide an electrical output signal that represents the data provided to the MUX.
FIG. 1B shows the expected voltage requirement vs. data rate. As shown in FIG. 1B , the required drive voltage for the prior art modulator at 100 Gb/s is >6 Vpp (on each swing-end output), which is far from a practical voltage in existing CMOS/BiCMOS technology.
We describe systems and methods to provide ultra-high channel rate (40 to 100 Gb/s) optical transmitters in silicon-based electronics and photonics technology.
We have described another design of a traveling wave modulator in Ran Ding, Yang Liu, Qi Li, Yisu Yang, Yangjin Ma, Kishore Padmaraju, Andy Eu-Jin Lim, Guo-Qiang Lo, Keren Bergman, Tom Baehr-Jones, and Michael Hochberg, “Design and characterization of a 30-GHz bandwidth low-power silicon traveling-wave modulator,” Optics Communications (available online Feb. 7, 2014).
In various embodiments of the present invention, the following assumptions are made: Cpn is 230 fF/mm, Rpn is 5.5 Ω-mm, Vπ Lπ is 2.0 V-cm, device bandwidth is 70% data rate, a differential-drive geometry is used, and an equivalent of Vπ/3 swing generate acceptable optical modulation amplitude. As an example, we describe a distributed TWMZ driver that can be fabricated in a 130-nm SiGe BiCMOS process in order to bridge the gap between the increasingly higher drive-voltage required by modulators and limited available driver output voltage swing from electronics at higher data rates.
FIG. 2A is a circuit block diagram of a distributed traveling-wave Mach-Zehnder (TWMZ) modulator driver that operates according to principles of the invention. An optical input waveguide 220 receives an optical signal that is to be modulated, and splits the signal in two, one portion of the signal passing through wave shifters 210 , 212 , 214 and 216 , and the other portion of the signal passing through wave shifters 210 ′, 212 ′, 214 ′ and 216 ′. In a preferred embodiment, the optical signal is split into two portions having equal intensities. In one embodiment, the wave shifter pairs ( 210 , 210 ′), ( 212 , 212 ′), ( 214 , 214 ′), and ( 216 , 216 ′), are Mach-Zehnder interferometers with fixed optical lengths to minimize power consumption and increase speed. The optical signals are recombined and exit the modulator at optical port 240 . In some embodiments, the drive circuitry which will now be described is attached to the chip using flip-chip bump bonding, illustrated by bonding interface 230 .
As shown in the circuit block diagram in FIG. 2A , the driver amplifier takes 400 mVpp input signals at each of the differential inputs In+ and In−, and delays and amplifies the signals to four pairs of differential outputs with 13 ps delay between each output stage. Each output swings 1 Vpp single-ended (2 Vpp differential) on a 25Ω impedance. The output is intentionally configured to be open-collector to offer the flexibility to drive both 25Ω and 50Ω impedance TWMZ sections (without and with near-end termination, respectively). The termination resistors are not illustrated in the schematic shown in FIG. 2B . They could be introduced during the packaging step or they could be monolithically integrated on the modulator side. The open-collector nature of the proposed driver enables the TWMZ sections to be designed to have different impedance, increasing the size of the optimization space and the number of possible configurations.
In the preferred embodiment of FIG. 2A , there are illustrated a plurality of N of optical phase shifter pairs, where N=4. In other embodiments, one can use a different number N of optical phase shifter pairs, so long as N is greater than or equal to 2. In the embodiment shown, the distributed traveling-wave Mach-Zehnder (TWMZ) modulator driver has four driver amplifier stages 250 (illustrated in greater detail in FIG. 2B ) and three delay/relay stages 260 (illustrated in greater detail in FIG. 2C ).
In other embodiments, one can use other kinds of optical phase shifters in place of the TWMZ, so long as the number of optical phase shifters is greater than or equal to 2.
FIG. 2B and FIG. 2C are circuit diagrams that illustrate preferred embodiments of the driver amplifier stages 250 and the delay/relay stages 260 of FIG. 2A , respectively. The driver stage 250 , shown in FIG. 2B , starts with a pair of emitter followers 252 a and 252 b equipped with termination resistors for efficient coupling to the data source or to the previous stage of the driver. The received signal is then amplified using a differential pair 254 a and 254 b , and subsequently buffered again using emitter followers 256 a and 256 b . Finally, the signal is split and applied to two open collector cascode output drivers 258 a and 258 b , one driving the TWMZ segment, and one 259 a and 259 b amplifying the signal for the following stage of the driver. Each modulator includes a driver amplifier stage 250 , which includes only a single type of transistor to enable high-speed operation. The preferred type is NPN bipolar transistor; however other possible transistors include a PNP, a MOSFET (NFET or PFET, either one) or even a HEMT or a pHEMT.
In one embodiment, the integration interface between silicon TWMZ sections and the driver circuits is expected to be flip-chip bump-bonding. A 40 fF parasitic capacitance is assumed for each signal connection. The optical delay of each TWMZ section plus optical waveguide wiring matches the delay between the amplifier stages so that the modulations constructively add. As an additional step to improve the performance, we have incorporated pre-amplification in the driver output to extend the length of TWMZ sections that can be driven at 100 Gb/s by about 40%. The driver pre-amplifier stage 254 a and 254 b is shown in FIG. 2B immediately after the input emitter follower stage 252 a and 252 b . Without the pre-amplifier 254 a and 254 b the overall driver 250 would not be able to have the gain-bandwidth product required to achieve the target 100 Gb/s data rate, especially when driving a longer TWMZ section.
The example circuit described above consumes 1.5 W power overall. The DC bias structures illustrated on the right of the chip ( FIG. 2D ) control the on and off states of each main driver stage individually, which is a useful feature for testing before integration. The bias voltages Vtb and Vtb_main of the driver section 250 shown in FIG. 2B are generated separately in the DC Bias structures shown in FIG. 2D . Each of the driver sections 250 can then be enabled or disabled by turning the corresponding bias voltages on and off. This increases the flexibility of the driver 250 , allowing integration with different types of TWMZs. For example, if the TWMZ has only three sections, the fourth section of the driver (the one providing outputs Out4+ and Out4− in FIG. 2D ) can be shut down, reducing the overall power dissipation. The feature can also be useful in other scenarios. For example, if optical modulation resulting from the action of fewer stages of the driver is found to be adequate, the redundant stages can be shut down. In addition, slight variation in the biasing voltages of individual stages can be used to optimize delays, gains and the overall performance of the driver-TWMZ system.
In the embodiment shown in FIG. 2D the chip or substrate is silicon. In other embodiments, the substrate can be fabricated from a semiconductor, which may be different from a silicon or silicon-on-insulator wafer.
Post-layout simulations at 100 Gb/s is shown in FIG. 3A and FIG. 3B . The TWMZ sections are modeled using an equivalent circuit model. Bump-bonding parasitics are taken into account. As one can see, similar electrical eye quality is maintained in each stage output and this is achieved by scaling the transmission lines and device sizes in each stage. The eye-diagrams at the end of the TWMZ ( FIG. 3B ) provide a conservative estimation of the optical eye-diagrams.
In the driving scheme used in the embodiment of FIG. 2A through FIG. 2D , the overall drive voltage requirement is linearly lowered by accumulating modulation from four sections of TWMZ of 750 μm length, achieving an overall modulator length of 3 mm, which is similar to a 40 Gb/s device illustrated in FIG. 1B . The present device provides a practical solution for a 100 Gb/s optical transmitter.
In operation, an optical wave (or an optical signal) to be modulated is expected to be received at an input port such as 220 , subjected to a succession of N modulations performed by successive ones of a plurality N a plurality N of optical phase-shifters connected in series connection as N sequential modulators, where N is greater than or equal to 2, each of the N−1 phase shifts after the first of the N phase shifts delayed by a time calculated to apply each of the N−1 phase shifts after the first of the N phase shifts at a respective time when the optical signal passes a respective one of the N−1 sequential modulators after the first modulator, and providing a modulated optical signal at an optical output port, such as port 240 .
The apparatus described above can be used for performing such optical modulation as just described.
Definitions
Unless otherwise explicitly recited herein, any reference to an electronic signal or an electromagnetic signal (or their equivalents) is to be understood as referring to a non-volatile electronic signal or a non-volatile electromagnetic signal.
Theoretical Discussion
Although the theoretical description given herein is thought to be correct, the operation of the devices described and claimed herein does not depend upon the accuracy or validity of the theoretical description. That is, later theoretical developments that may explain the observed results on a basis different from the theory presented herein will not detract from the inventions described herein.
Any patent, patent application, patent application publication, journal article, book, published paper, or other publicly available material identified in the specification is hereby incorporated by reference herein in its entirety. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material explicitly set forth herein is only incorporated to the extent that no conflict arises between that incorporated material and the present disclosure material. In the event of a conflict, the conflict is to be resolved in favor of the present disclosure as the preferred disclosure.
While the present invention has been particularly shown and described with reference to the preferred mode as illustrated in the drawing, it will be understood by one skilled in the art that various changes in detail may be affected therein without departing from the spirit and scope of the invention as defined by the claims.
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A distributed traveling-wave Mach-Zehnder modulator driver having a plurality of modulation stages that operate cooperatively (in-phase) to provide a signal suitable for use in a 100 Gb/s optical fiber transmitter at power levels that are compatible with conventional semiconductor devices and conventional semiconductor processing is described.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a mine cooling power recovery system delivering a cold water or ice slurry for cooling mines, e.g. a gold mine and diamond mine and pumping a warm water or mud slurry produced in the mines up to the ground surface.
2. Description of the Related Art
Prior-art mine cooling processes have failed to clearly disclose a changeover between means for delivering a cold water from the ground surface to an underground mine and lifting a warm water produced in the mine up to the ground surface and means for lifting a mud slurry up to the ground surface. In addition, one prior-art mine cooling process employs a manometer with a contact for controlling opening and shutting operations of valves of a mine cooling system.
For example, South African patent No. 82/0078 is related with such mine cooling processes.
The prior-art mine cooling processes have failed to take into account a pumping up of the mud slurry produced when the cold water is scattered in the mine. Thus, a high-pressure pump for pumping the mud slurry out of the underground mine up to the ground surface and an associated high-pressure pipeline must be provided together with the mine cooling power recovery system.
In addition, the prior-art mine cooling processes employ a manometer with a contact for controlling opening and shutting operations of shut-off valves and of equalizing valves connected to opposite ends of a pressure changeover feed chamber. The prior-art mine cooling processes have failed to take into account a service life of the mine cooling power recovery system.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a mine cooling power recovery system which reduces an equipment cost and a power cost in pumping up a mud slurry and increases the reliability of equipment.
In order to achieve the object of reducing the equipment cost, a low-pressure slurry pump for charging the mud slurry produced in a mine into a pressure changeover feed chamber is arranged in parallel to a warm water charging low-pressure pump and each of outlets of these pumps has a changeover valve so that a single power recovery system pumps up both the mud slurry and the warm water out of the mine.
A monitoring sensor for sensing an interface between the mud slurry and the warm water is provided on the ground surface in order to allow changeover valves to open to a huge ore-waste heap during a transportation of the mud slurry and to open to a warm water tank during a transportation of the warm water and to prevent the warm water from entering the huge ore-waste heap and the mud slurry from entering the warm water tank.
A pig charger is provided in order to eliminate a scale deposited on the inner surface of a pipeline which has delivered the mud slurry.
A durable service life noncontact sensor and a timer are used in order to achieve the object of increasing the reliability of a valve operation control apparatus.
A mud slurry sedimentation tank is provided on the ground surface in order to reduce a mine excavation cost.
In order to achieve the object of reducing a power cost in pumping up the mud slurry or warm water, a low-pressure pump for charging the warm water into a refrigerator is provided on the ground surface so that the head of warm water is used to recover a power.
When the warm water or mud slurry is transported, the changeover valves provided respectively at the outlets of the warm water charging low-pressure pump and the low-pressure slurry pump, and the changeover valve provided at the outlet of the ground surface of a pipeline of the mine cooling power recovery system are charged over so that the operation of the mine cooling power recovery system can be continued.
A fluid density variation monitoring sensor provided near the outlet of the ground surface of the pipeline senses the interface between the mud slurry and warm water and timely controls the changeover valves provided at the outlet of the ground surface of the pipeline so that the warm water is prevented from entering the huge ore-waste heap and the mud slurry is prevented from entering the warm water tank.
Passing a pig having an outer diameter essentially equal to the bore diameter of a transportation pipeline through the transportation pipeline which has transported the mud slurry can eliminate a scale deposited on the inner surfaces of pipes of the transportation pipeline.
In addition, since a timer and noncontact sensor having a durability equal to or more than 10 7 cycles are employed in a valve opening and closing operation control device, the service lives of the timer and noncontact sensor are prominently longer than that of the prior-art manometer with the contact (having a 10 4 -cycle service life).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a mine cooling power recovery system of a first embodiment of the present invention;
FIG. 2 is a diagram of control time schedules of the valves;
FIG. 3 is a block diagram of a mine cooling power recovery system of a second embodiment of the present invention;
FIG. 4 is a block diagram of a mine cooling power recovery system of a third embodiment of the present invention; and
FIG. 5 is a block diagram of a mine cooling power recovery system of a fourth embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1 a warm water tank T1 is installed on the ground surface, with a warm water pump P1 delivering a warm water out of the warm water tank T1 through a refrigerator HE into an underground mine. The warm water passing through the refrigerator HE changes to a cold water which is delivered through a high-pressure pipeline extending from the ground surface to the mine and through a valve A1 provided in the mine to a pressure changeover feed chamber CH1. When the cold water is delivered to the feed chamber CH1, a valve C1 is open and valves B1 and D1 and equalizing valves HA1 and HD1 are closed.
When the cold water has filled the feed chamber CH1, the valves A1 and C1 are closed. Then, the valve HD1 is opened to change the pressure within the feed chamber CH1 from a high pressure to a low pressure and then is closed.
Then, the valves B1 and D1 are opened and a low-pressure warm water pump P2 delivers a warm water from a warm water tank T2 through a changeover valve V1, a low-pressure pipeline 3 and the valve B1 to the feed chamber CH1 to fill the feed chamber CH1 with the warm water. During this time, the warm water urges the cold water out of the feed chamber CH1 through the valve D1. The cold water is fed to a working face or working place L through a low-pressure pipeline 4.
Then, when the warm water has filled the feed chamber CH1, the valves B1 and D1 are closed. Then, the valve HA1 is opened to change the pressure within the feed chamber CH1 over from a low pressure to a high pressure and then is closed.
Then, the valves A1 and C1 are opened to allow the cold water to be delivered from the ground surface to the feed chamber CH1 as described above. During this time, the warm water is urged out of the feed chamber CH through the valve C1 and is pumped up into the warm water tank T1 through a high-pressure pipeline 2 and a changeover valve V3.
The cold water which has passed through a low-pressure pipeline 4 is scattered over the working face or working place L and eliminates heat from heat loads of e.g. the atmosphere, machines and a head way) of the working face L, so that the cold water is changed into the warm water.
Thus, the scattered cold water dissolves a clay content of a head way rock wall to become a warm mud slurry. The warm mud slurry is separated into a mud content and a warm water content in a slurry sedimentation tank T3 and only a warm water of supernatant is delivered to the warm water tank T2. The low-pressure warm water pump P2 delivers the warm water of supernatant to feed chambers CH in the manner as described above.
The low-pressure slurry pump P3 changes the mud slurry which has sedimented in the sedimentation tank T3 into the feed chamber CH1 through the changeover valve V2 and through the low-pressure pipeline 3 and the valve B1 as in the case of the warm water. During this time, the changeover valve V1 is closed and the low-pressure warm water pump P2 is stopped.
Thus, the operation principle by which the cold water urges the low-pressure mud slurry which has filled the feed chamber CH1 into the high pressure pipeline 2 is the same as the operation principle of pumping up the warm water as described above.
FIG. 2 illustrates a method of controlling the valves connected to opposite ends of each of the feed chambers CH. Proximity switches detect open and closed positions of the valves and timers produce opening and closing timing signals for the valves. Thus, the first embodiment of the present invention has a greatly increased reliability than the prior-art technique in which a pressure switch (i.e. manometer with a contact) controls valves in response to a pressure within each of the feed chambers CH.
As described above, the first embodiment of FIG. 1 employs the power recovery pump (e.g. a hydrohoist) installed in the underground mine, which pump can utilize a potential energy of the cold water descending from the ground surface for pumping the warm water and mud slurry from the underground mine up to the ground surface, so that the mud slurry pump is not required to generate a high pressure and a decrease of the operating pressure of the mud slurry pump can reduce an initial cost, maintenance cost and demand power of the mud slurry pump.
In addition, the high-pressure piping for pumping the warm water up from the underground mine to the ground surface can also serve as the mud slurry transportation piping, so that an initial cost of the high-pressure piping, e.g. material cost, civil engineering work cost and installation cost and a maintenance cost of the high-pressure pipeline can be reduced.
In addition, since the durable noncontact sensors and timers control the opening and closing operations of the valves connected to the opposite ends of each of the feed chambers, the reliability of the mine cooling power recovery system of the first embodiment is increased.
The mud slurry which has been delivered to the ground surface must be discharged through the changeover valve V4 to a huge ore-waste heap M but must not enter the warm water tank T1, because a refrigerator HE will be damaged by the mud slurry if the mud slurry is delivered to the warm water tank T1 and then the warm water pump P1 delivers the mud slurry out of the warm water tank T1 to the refrigerator HE.
The slurry pump P3 delivers the mud slurry out of the slurry sedimentation tank T3 through the high-pressure pipeline 2 and changeover valve V4 to the huge ore-waste heap M as in the first embodiment of FIG. 1. After a predetermined amount of the mud slurry is delivered, the changeover valve V2 is closed and the operation of the slurry pump P3 is stopped. Then, the warm water pump P2 is operated and the changeover valve V1 is opened, so that the warm water is pumped out of the warm water tank T2 through the low-pressure pipeline 3 up to the surface. Thus, when the operation of the mine cooling power recovery system is changed over from a slurry transportation mode to a warm water transportation mode, the changeover valve V4 provided at the ground surface is turned off and concurrently the changeover valve V3 provided at the ground surface is turned on to allow the warm water to enter the warm water tank T1. If the mud slurry enters the warm water tank T1, the mud slurry produces damages of an abrasion, clogging and/or reduction in a heat exchanger effectiveness of the refrigerator HE. Thus, the changeover timings of the changeover valves V3 and V4 must be adequately controlled so that the mu-d slurry will not enter the warm water tank T1. As shown in FIG. 3, in accordance with the second embodiment of the present invention, a sensor S 1 (e.g. a densitometer or photosensor) which is provided at an outlet of the ground surface of the high-pressure pipeline 2 and which detects an interface between the mud slurry and warm water in order to automatically control the changeover timings of the changeover valves V3 and V4.
As described above, the provision of the sensor S 1 for detecting the interface between the mud slurry and warm water provides a control system by which the mud slurry will not enter the refrigerator HE when the operation of the mine cooling power recovery system of the second embodiment is changed over from the mud slurry transportation mode to the warm water transportation mode.
In order to prevent the mud slurry from sticking on a pipe inner surface when the mud slurry passes through the pipelines from contaminating the warm water and from demanding the refrigerator HE during the warm water transportation mode, as shown in FIG. 4, a pig charger f charges a pig into the low-pressure pipeline 3 and the warm water discharged by the warm water pump P2 moves the pig. The pig has a diameter slightly smaller than the bore diameter of each of the pipelines and can scrape the mud slurry from the inner surface of each of the pipelines. When the pig approaches the outlet of the ground surface of the high-pressure pipeline 2, a pig sensor S 2 detects the pig and outputs signals to the changeover valves V 3 and V 4 so that the changeover valve V4 is turned off and concurrently the changeover valve V3 is turned on after the pig passes through the changeover valve V4 to the huge ore-waste heap M.
As described above, in the embodiment of FIG. 4 the pig charge f can eliminate a sticking of the mud slurry the inner surface of each of the pipelines which have transported the mud slurry.
The embodiment of FIG. 5 differs from the other embodiments in that the slurry sedimentation tank T3 is installed on the ground surface. Thus, a need for an excavation space for an underground slurry sedimentation tank is eliminated and a single pipeline serves as both of a warm water transportation system and a mud slurry transportation system so that simplify the mine cooling power recovery system of the present invention is simplified.
The present invention is also applicable to a system in which the low-pressure pipelines 3 and 4 are connected to each other through e.g. an air conditioning heat load and in which the warm water is pumped up to the ground surface, in addition to the above-described embodiments.
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A mine cooling power recovery system wherein a low-pressure slurry pump for charging the mud slurry produced in a mine into a pressure changeover feed chamber is arranged in parallel to a warm water charging low-pressure pump and each of outlets of the two pumps has a changeover valve so that a single power recovery system pumps up both the mud slurry and a warm water out of the mine. A slurry sedimentation tank may be provided on the ground surface.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application claims the priority of Korean Patent Application No. 10-2005-121985, filed on Dec. 12, 2005, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a wavelength tracking apparatus and method in a wavelength-division multiplexed (WDM)-passive optical network (PON), and more particularly, to a reliable WDM-PON system by aligning wavelengths of an optical source in the central office, a pass band of multiplexer/demultiplexer in the central office, and an optical source in the subscriber terminal, with respect to a pass band of the multiplexer/demultiplexer in the remote node, which varies according to ambient temperature.
[0004] 2. Description of the Related Art
[0005] A digital subscriber line (DSL) technique that uses a unshielded twisted pair (UTP) and a cable modem termination system (CMTS) technique that uses a hybrid fiber coaxial (HFC), which have been currently used, are not expected to guarantee a bandwidth and service quality enough to provide subscribers with a convergence service of voice, data, and broadcasting which will be widely popularized in a few years. To solve this problem, a great deal of research has been conducted all over the world to develop a fiber-to-the home (FTTH) technique that connects the subscriber's home to the network via an optical fiber.
[0006] In a wavelength-division multiplexed (WDM)-passive optical network (PON), since communications are established between a central office and each subscriber by using a wavelength allocated to the subscriber, it is possible to provide a variety of independent communication services to each subscriber while guaranteeing quality of service and security. Also, unlike time division multiplexing (TDM), the WDM-PON assigns each wavelength to an individual subscriber who may use an optical source with low output power and a receiver with a narrow bandwidth.
[0007] However, the WDM-PON employs optical sources corresponding to subscribers, each optical source having a unique wavelength, thus increasing installation costs, and is substantially difficult to be competitive in cost over the TDM based passive optical network accordingly. Thus, development of a low-cost optical source for the WDM-PON is critically important. Also, in terms of equipment management, preparing a stock of optical sources having different wavelengths for respective subscribers against mechanical and functional troubles may be too heavy a burden for a service provider. Therefore, it is very important to design a WDM-PON that can provide subscribers with the ONT (optical Network Terminal) of one kind with wavelength-independent optical source.
[0008] For reliable management of the WDM-PON, it is important to monitor wavelengths of optical sources against aging of the componets or temperature changes, and optical fiber cut, and to align wavelengths of the multiplexer/demultiplexer whose pass band change according to ambient temperature.
[0009] In particular, it is very important to align wavelengths of optical sources and the multiplexer/demultiplexer in the central office, and an optical source of a subscriber terminal (ONT) with respect to a pass band of the multiplexer/demultiplexer in the remote node (RN) whose pass bands vary on ambient temperature changes.
[0010] For easy repair and management of the WDM-PON, electric current is not supplied to a remote node. However, in this case, the temperature of the optical multiplexer/demultiplexer in the remote node may change from −40° C. to 80° C., and particularly, to a maximum of 120° C., according to ambient temperature.
[0011] Accordingly, misalignment of wavelengths of the WDM multiplexers/demultiplexers (WMD) of the central office (CO) and the remote node (RN), and wavelengths of the WDM multiplexer/demultiplexer (WMD) in the remote node and each of optical sources of ONTs, may cause not only optical loss in the optical channels but also performance degradation due to crosstalk occurring between optical channels.
[0012] To solve these problems, a wavelength tracking method has been introduced to equalize a wavelength of an optical source for downward transmission with a passband of WMD, which varies upon ambient temperature change.
[0013] Also, a method has been introduced to equalize a passband of WMD in the RN with that of WMD in the CO for a WDM-PON that uses a spectrum-sliced optical source. However, these methods do not disclose alignment of the wavelength of an optical source, a pass band of WMD in CO, a pass band of WMD in RN, and an optical source in ONT. These methods are not applicable to a WDM-PON that uses a general single-mode optical source.
SUMMARY OF THE INVENTION
[0014] The present invention provides a system and method for aligning wavelengths of an optical source and an optical multiplexer/demultiplexer of a central base station, an optical multiplexer/demultiplexer of a remote node, and an optical source of a subscriber terminal together in a wavelength-division multiplexing (WDM)-passive optical network (PON) that uses a single-mode optical source.
[0015] According to an aspect of the present invention, there is provided an apparatus for tracking a wavelength in a passive optical subscriber network in which a central base station and at least one subscriber terminal are connected via a remote node, the apparatus comprising a first wavelength aligning unit multiplexing and aligning wavelengths of optical signals from a plurality of single-mode optical sources of the central base station; a second wavelength aligning unit multiplexing and aligning wavelengths of optical signals transmitted to the remote node from a plurality of single-mode optical sources of the subscriber terminal; and a third wavelength aligning unit being included in the central base station, and demultiplexing and aligning wavelengths of optical signals from the second wavelength aligning unit.
[0016] According to another aspect of the present invention, there is provided a method of tracking a wavelength in a passive optical subscriber network in which a central base station and at least one subscriber terminal are connected via a remote node, the method comprising a first wavelength aligning operation in which wavelengths of optical signals from a plurality of single-mode optical sources of the central base station are multiplexed and aligned; a second wavelength aligning operation in which the remote node multiplexes and aligns wavelengths of optical signals from a plurality of single-mode optical sources of the subscriber terminal; and
a third wavelength aligning operation in which the central base station demultiplexes and aligns the optical signals being demultiplexed and aligned in the second wavelength aligning operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above and other aspects and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:
[0019] FIG. 1 is a block diagram of a wavelength-division multiplexing (WDM)-passive optical network (PON) system that uses a single-mode optical source;
[0020] FIG. 2 is a block diagram of a wavelength tracking apparatus included in a WDM-PON system according to an embodiment of the present invention;
[0021] FIG. 3 is a block diagram of a bi-directional WDM-PON that uses a single optical fiber line;
[0022] FIG. 4 is a block diagram of a WDM-PON illustrated in FIG. 3 which uses a wavelength tracking apparatus, according to an embodiment of the present invention;
[0023] FIG. 5 is a flowchart illustrating operations of controlling the temperatures of thermoelectric coolers and power monitors of the wavelength tracking apparatus shown in FIG. 4 , according to an embodiment of the present invention;
[0024] FIG. 6 illustrates graphs respectively showing variations in the optical power level and wavelength of an optical upstream signal received at a central base station when the temperature of a remote node changes, in the wavelength tracking apparatus illustrated in FIG. 2 , according to an embodiment of the present invention;
[0025] FIG. 7 illustrates graphs respectively showing variations in the optical power level and wavelength of an optical downstream signal received at a subscriber terminal when the temperature of a remote node changes, in the wavelength tracking apparatus of FIG. 2 , according to an embodiment of the present invention;
[0026] FIG. 8 is a flowchart illustrating a method of aligning a wavelength of an optical source of a central base station with respect to that of a multiplexer/demultiplexer of a central base station according to an embodiment of the present invention;
[0027] FIG. 9 is a flowchart illustrating a method. of aligning a wavelength of a passband of a multiplexer/demultiplexer of a remote node with respect to that of an optical source of a subscriber terminal according to an embodiment of the present invention; and
[0028] FIG. 10 is a flowchart illustrating a method of aligning a wavelength of a passband of a demultiplexer of a central base station with respect to that of a passband of a multiplexer of a remote node according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. Throughout the drawings, whenever the same element reappears in a subsequent drawing, it is denoted by the same reference numeral.
[0030] FIG. 1 is a block diagram of a general wavelength-division multiplexed (WDM)-passive optical network (PON) system that uses a single-mode optical source. Referring to FIG. 1 , the system includes a central base station 110 , an optical fiber 120 for a downstream signal, an optical fiber 121 for an upstream signal, a remote node 130 , an optical fiber 140 for a downstream signal, an optical fiber 141 for an upstream signal, and N subscriber terminals 150 .
[0031] The central base station 110 includes an array of N individual or integrated single-mode optical sources 111 (a DFB-LD, etc.), an array of individual or integrated optical receivers 113 , an optical multiplexer 114 , and an optical demultiplexer 115 .
[0032] The single-mode optical sources 111 output a unique wavelength for one subscriber terminal 150 . Thus, N-optical sources build up N wavelengths, for the N subscriber terminals 150 , i.e., downstream signals D i (i=1 to N). The array of the optical receivers 113 may be constructed with PIN-PDs orAPDs, and receive upstream signals U i from the N subscriber terminal 150 (i=1 to N). The optical multiplexer 114 multiplexes signals from the N single-mode optical sources 111 and delivers the multiplexing result to the optical fiber 120 .
[0033] N thermoelectric coolers 112 are respectively connected to the N single-mode optical sources 111 so as to control wavelengths of the N single-mode optical sources 111 .
[0034] The remote node 130 also includes an optical multiplexer 131 and an optical demultiplexer 132 . The optical demultiplexer 131 distributes the downstream signals D i to the N subscriber terminals 150 via the optical fiber 140 according to a wavelength.
[0035] Each of the Nsubscriber terminals 150 includes a single-mode optical source 151 and an optical receiver 153 . Like in the central base station 110 , N thermoelectric coolers 152 are respectively connected to the N single-mode optical sources 151 to control wavelengths of the N single-mode optical sources 151 . The N optical receivers 153 respectively receive the downstream signals D i , and the N single-mode optical sources 151 respectively modulate the received downstream signals D i , into the upstream signals U i and transmit the upstream signals U i to the central base station 110 .
[0036] The lights modulated into the upstream signals U i are multiplexed by the optical multiplexer 132 of the remote node 130 via the optical fiber 141 , and the multiplexed lights are supplied to the central base station 110 via the optical fiber 121 . The supplied multiplexed lights are demultiplexed via the optical demultiplexer 115 according to a wavelength, and supplied to the optical receivers 113 .
[0037] The optical receiver 113 finally receives the upstream signal U N . However, a change in a passband of the optical demultiplexer 131 and the optical demultiplexer 132 due to a change in the ambient temperature of the remote node 130 may cause not only loss in optical channels of the upstream and downstream signals but also performance degradation due to a crosstalk among the wavelength channels.
[0038] FIG. 2 is a block diagram of a wavelength tracking apparatus for use in a WDM-PON system according to an embodiment of the present invention. Referring to FIG. 2 , in order to maintain the system performance even when a passband of an optical demultiplexer 131 and an optical multiplexer 132 of a remote node 130 of FIG. 1 change, power monitors 210 , 211 , and 250 and partial reflectors 212 and 230 according to an embodiment of the present invention are installed into a central base station 110 , the remote node 130 , and subscriber terminals 150 .
[0039] The installed power monitors 210 , 211 , and 250 and partial reflectors 212 and 230 equalize a wavelength of an optical multiplexer 114 of the central base station 110 with those of optical sources 111 of the central base station 110 , a wavelength of an optical multiplexer 132 of the remote node 130 with those of subscriber optical sources 151 , and wavelengths of an optical multiplexer 114 and an optical demultiplexer 115 of the central base station 110 with those of the optical demultiplexer 131 and the optical multiplexer 132 of the remote node 130 .
[0040] Thus, even if wavelengths of passbands of the optical multiplexer 131 and the optical demultiplexer 132 are changed due to a change in the temperature of the remote node 130 , optical downstream signals from the central base station 110 are transmitted to the subscriber terminals 150 and optical upstream signals from the subscriber terminals 150 are transmitted to the central base station 110 without optical loss.
[0041] Aligning wavelengths of the optical multiplexer 114 and the optical sources 111 of the central base station 110 , lights emitted from the optical sources 111 pass through the optical multiplexer 114 , and some portion of the power of the lights are reflected from the partial reflector 212 and the other portion pass through the partial reflector 212 for transmission of the downstream signals.
[0042] The lights reflected from the partial reflector 212 pass through the optical multiplexer 114 again, and some portion of the reflected power of the lights are feeded into the power monitors 210 via optical couplers 117 , respectively.
[0043] Each of the power monitors 210 controls a thermoelectric cooler 112 connected to the corresponding optical source 111 to maximize the power of the received light. In particular, since the lights reflected from the partial reflector 212 pass through the optical multiplexer 114 twice, the lights are significantly affected by a change in a passband of the optical multiplexer 114 , and thus can be efficiently used for wavelength tracking.
[0044] Aligning wavelengths of the optical multiplexer 132 of the remote node 130 with those of the optical sources 151 , lights emitted from the optical sources 151 pass through the optical multiplexer 132 via the optical fiber 141 , and some portion of the optica; power of the passing lights are reflected from the partial reflector 230 and the other portion of the power pass through the partial reflector 230 for transmission of upstream signals.
[0045] The reflected power of the lights pass through the optical multiplexer 132 and the optical fiber 141 and travel into the power monitors 250 via optical couplers 155 , respectively. Then, each of the power monitors 250 controls the thermoelectric cooler 152 connected to the corresponding optical source 151 to maximize the power level of the received light.
[0046] Lastly, the output power of upstream signals received at the central base station 110 are used in order to align wavelengths of the optical multiplexer 114 and the optical demultiplexer 115 of the central base station 110 with those of the optical multiplexer 131 and the optical demultiplexer 132 of the remote node 130 . Specifically, upstream signals from the subscriber terminals 150 sequentially pass through the remote node 130 , the optical fiber 121 , and the demultiplexer 115 of the central base station 110 , and are finally supplied to the optical receivers 113 . Some of the upstream signals are supplied to the power monitor 211 via an optical coupler 118 before the optical receiver 113 . The power monitor 211 maximizes the power level of the received light by controlling a thermoelectric cooler 115 - 2 of the demultiplexer 115 .
[0047] FIG. 3 is a block diagram of a bi-directional WDM-PON system that uses a channel of an optical fiber. In the bidirectional WDM-POM system of FIG. 3 , an optical fiber via which optical downstream signals and optical upstream signals are transmitted, is a single optical fiber 120 for economical efficiency.
[0048] Referring to FIG. 3 , an array of N single-mode optical sources 111 modulate lights having N unique wavelengths into downstream signals D i (i=1 through N) to be transmitted to N subscriber terminals 150 . An array of optical receivers 113 may be constructed with PIN-PDs or APDs, and receives upstream signals U i (i=1 to N) from subscriber terminals 150 . An optical demultiplexer/multiplexer 114 multiplexes the N single-mode optical sources 111 and outputs the multiplexed to the optical fiber 120 .
[0049] Also, thermoelectric coolers 112 are respectively connected to the single-mode optical sources 111 to control wavelengths of the single-mode optical sources 111 .
[0050] A remote node 130 includes an optical multiplexer/demultiplexer 131 that respectively distributes the downstream signals D i to the subscriber terminals 150 via the optical fiber 140 according to a wavelength. The optical demultiplexer/multiplexer 114 of the central base station 110 and the optical demultiplexer/multiplexer 131 of the remote node 130 are respectively constructed as single AWGs, each acting as an optical multiplexer or an optical demultiplexer according to the direction of an optical signal. In this type of use, the key of optical demultiplexer/multiplexer 114 or 131 is the passing wavelength periodicity of AWG.
[0051] Each of the subscriber terminals 150 includes single-mode optical source 151 and an optical receiver 153 . Like in the central base station 110 , a thermoelectric cooler 152 is connected to the single-mode optical source 151 to control a wavelength of the single-mode optical source 151 . The optical receivers 153 respectively receive the downstream signals D i , and the single-mode optical sources 151 respectively modulate the received optical signals D i into the upstream signals U i and transmit them to the central base station 110 .
[0052] The upstream signals U i are multiplexed by the optical multiplexer 131 of the remote node 130 via an optical fiber 140 , and the multiplexed lights are input to the central base station 110 via the optical fiber 120 . The input multiplexed lights are demultiplexed by the optical demultiplexer 114 according to a wavelength and the demultiplexed lights are input to the optical receivers 113 , respectively. Then, the nth optical receiver 113 finally receives the upstream signal U N .
[0053] Compared to the WDM-PON system of FIG. 1 , the bidirectional WDM-PON system of FIG. 3 that uses a single optical fiber further includes a WDM filter 116 in the central base station 110 and a WDM filter 154 in the subscriber terminals 150 in order to separate the optical upstream signals from the optical downstream signals.
[0054] FIG. 4 is a block diagram of a WDM-PON system, illustrated in FIG. 3 , which uses a wavelength tracking apparatus, according to an embodiment of the present invention. Referring to FIG. 4 , in order to maintain the system performance even when a passband of an optical multiplexer/demultiplexer 131 of a remote node 130 changes, power monitors 210 , 211 , and 250 and partial reflectors 212 and 230 according to an embodiment of the present invention are installed into a central base station 110 , the remote node 130 , and subscriber terminals 150 .
[0055] The installed power monitors 210 , 211 , and 250 and partial reflectors 212 and 230 align wavelengths of an optical multiplexer/demultiplexer 114 of the central base station 110 with those of optical sources 111 of the central base station 110 , wavelengths of the optical multiplexer/demultiplexer 131 of the remote node 130 with those of subscriber optical sources 151 , and wavelengths of the optical multiplexer/demultiplexer 114 with those of the optical multiplexer/demultiplexer 131 of the remote node 130 .
[0056] Thus, even if the wavelengths of passbands of the optical multiplexer/demultiplexer 131 of the remote node 130 are changed due to a change in the temperature of the remote node 130 , optical downstream signals from the central base station 110 are transmitted to the subscriber terminals 150 and optical upstream signals from the subscriber terminals 150 are transmitted to the central base station 110 without optical loss.
[0057] Specifically, in order to equalize the wavelengths of the optical multiplexer/demultiplexer 114 and the optical sources 111 of the central base station 110 , lights emitted from the optical sources 111 pass through the optical multiplexer/demultiplexer 114 , and some portion of the optical power of the lights are reflected from the partial reflector 212 and the other portion of the optical power pass through the partial reflector 212 for transmission of the downstream signals.
[0058] The lights reflected from the partial reflector 212 pass through the optical multiplexer 114 again, and some portion of the power of the reflected lights travel into the power monitors 210 via optical couplers 117 , respectively.
[0059] Each of the power monitors 210 maximizes the power level of the received light by controlling a thermoelectric cooler 112 connected to the corresponding optical source 111 . In particular, since the lights reflected from the partial reflector 212 pass through the optical multiplexer 114 twice, the lights are significantly affected by a change in a passband of the optical multiplexer 114 , and thus can be efficiently used for wavelength tracking.
[0060] Similarly, in order to equalize wavelengths of the optical multiplexer 131 of the remote node 130 with those of the optical sources 151 , lights emitted from the optical sources 151 pass through the optical multiplexer 131 via an optical fiber 140 , and some portion of the optical power of the passing lights are reflected from the partial reflector 230 and the other portion of the power pass through the partial reflector 230 for transmission of upstream signals.
[0061] The reflected lights pass through the optical multiplexer 131 and the optical fiber 140 again and travel into the power monitors 250 via optical couplers 155 , respectively. Then, each of the power monitors 250 controls the thermoelectric cooler 152 connected to the corresponding optical source 151 to maximize the power level of the received light.
[0062] Lastly, in order to equalize the wavelengths of the optical multiplexer/demultiplexer 114 of the central base station 110 with those of the optical multiplexer/demultiplexer 131 of the remote node 130 , upstream signals supplied to the central base station 110 are used. Specifically, the upstream signals from the subscriber terminals 150 sequentially pass through the remote node 130 , the optical fiber 120 , and the demultiplexer 114 , and are finally the optical receivers 113 via the optical demultiplexer 114 . Some of the upstream signals are supplied to the power monitor 211 via an optical coupler 118 before the optical receiver 113 . The power monitor 211 controls a thermoelectric cooler 115 - 1 of the demultiplexer 114 to maximize the power level of the received light.
[0063] FIG. 5 is a flowchart illustrating operations of controlling the power monitors 210 , 211 , and 250 and the temperatures of the thermoelectric coolers 112 , 115 , and 152 of the wavelength tracking apparatus shown in FIG. 4 , according to an embodiment of the present invention. Referring to FIG. 5 , the power level of an optical signal P 0 is measured ( 510 ), and the changed optical power level of an optical signal P 1 is measured ( 530 ) after increasing or reducing the temperature by ΔT ( 520 ).
[0064] Next, it is determined whether the power level of the optical signal P 1 is equal to or greater than that of the optical signal P 0 , i.e., P 1 ≧P 0 ( 540 ). If P 1 ≧P 0 , the changed temperature is maintained ( 541 ), and then, the level of an optical signal P 2 is measured ( 542 ).
[0065] Similarly, it is determined whether P 2 ≧P 1 . If P 2 ≧P 1 , the changed temperature is maintained.
[0066] However, if P 1 <P 0 , the increased temperature is reduced or the reduced temperature is increased ( 543 ). In this way, it is possible to control the thermoelectric coolers 112 , 115 , and 152 so that the level of an optical signal can be maximized.
[0067] FIG. 6 illustrates graphs respectively showing variations in the optical power level and wavelength of an optical upstream signal received from the central base station 110 when the temperature of the remote node 130 changes, in the wavelength tracking apparatus illustrated in FIG. 2 , according to an embodiment of the present invention. The graph (a) of FIG. 6 shows a variation in the optical power level of the optical upstream signal received at the central base station 110 as the temperature of the remote node 130 changes. The graph (b) of FIG. 6 shows a variation in the wavelength of the optical upstream signal received at the central base station 110 as the temperature of the remote node 130 changes.
[0068] To measure the performance of the wavelength tracking apparatus, the temperature of the remote node 130 was periodically changed by about 30° C. at a rate of 0.88° C./min. As a result, a variation in the optical power level of the optical upstream signal received was just 0.25 dB or less when the temperature of the remote node 130 was changed by 30° C. The result shows that the optical upstream signal tracks down a variation in the wavelength of a passband of the optical multiplexer 132 of the remote node 130 .
[0069] FIG. 7 illustrates graphs respectively showing variations in the optical power level and wavelength of an optical downstream signal received from one of the subscriber terminals 150 when the temperature of the remote node 130 changes, in the wavelength tracking apparatus of FIG. 2 , according to an embodiment of the present invention. The graph (a) of FIG. 6 shows a variation in the optical power level of the optical downstream signal received at the subscriber terminal 150 as the temperature of the remote node 130 changes. The graph (b) of FIG. 6 shows a variation in the wavelength of the optical downstream signal received at the subscriber terminal 0 as the temperature of the remote node 130 changes.
[0070] To measure the performance of a wavelength tracking method according to an embodiment of the present invention, the temperature of the remote node 130 was periodically changed by about 30° C. at a rate of 0.88° C./min. As a result, a variation in the optical power level of the optical downstream signal received was just 0.7 dB or less when the temperature of the remote node 130 was changed by 30° C. The graph shows that the optical downstream signal tracks down a variation in the wavelength of a passband of the optical multiplexer 131 of the remote node 130 .
[0071] FIG. 8 is a flowchart illustrating a method of aligning a wavelength of to those of a plurality of single-mode optical sources of a central base station with respect to that of a multiplexer of a central base station according to an embodiment of the present invention. Referring to FIG. 8 , optical signals from the single-mode optical sources of the central base station are multiplexed by the multiplexer/demultiplexer of the central base station and transmitted downward to the subscriber terminals (S 800 ).
[0072] Next, some portion of the optical power of the multiplexed optical signals are reflected from a partial reflector and returned to the optical sources, and the other portion of the multiplexed optical signals are transmitted downward to the subscriber terminals (S 810 ).
[0073] Some portion of the optical power of the optical signals that are reflected from the partial reflector, pass through the multiplexer, and then are returned are extracted by optical couplers (S 820 ).
[0074] Next, a power monitor controls a thermoelectric cooler connected to each of the optical sources to maximize the optical power level of the optical signals extracted by the optical coupler, thereby aligning the wavelengths of the single-mode optical sources of the central base station with respect to the wavelengths of the multiplexer/demultiplexer (S 830 ).
[0075] FIG. 9 is a flowchart illustrating a method of aligning wavelengths of passbands of a multiplexer/demultiplexer of a remote node with respect to those of a plurality of single-mode optical sources of subscriber terminals according to an embodiment of the present invention. Referring to FIG. 9 , signals from the single-mode optical sources of the subscriber terminals are multiplexed by the multiplexer of the remote node and then transmitted upward to the central base station (S 900 ).
[0076] Next, some portion of the optical power of the multiplexed optical signals are reflected from a partial reflector and returned to the optical sources of the subscriber terminals, and the other portion of the optical signals are transmitted upward to the central base station (S 910 ).
[0077] Next, some portion of the optical power of the optical signals that are reflected from the partial reflector, pass through the multiplexer, and then are returned are extracted by optical couplers (S 920 ).
[0078] Then, a power monitor controls a thermoelectric cooler connected to each of the optical sources so that the optical power level of the optical signals extracted by the optical coupler can be maximized, thereby aligning the wavelengths of the single-mode optical sources of the subscriber terminal with respect to those of the multiplexer of the remote node (S 930 ).
[0079] FIG. 10 is a flowchart illustrating a method of aligning a wavelength of passbands of a demultiplexer of a central base station with respect to that of passbands of a multiplexer of a remote node according to an embodiment of the present invention. First, optical signals that are multiplexed by the multiplexer of the remote node and transmitted upward are demultiplexed by the demultiplexer of the central base station (S 1000 ).
[0080] Next, some portion of the optical power of the demultiplexed optical signals are extracted by optical couplers (S 1010 ).
[0081] Next, a power monitor controls a thermoelectric cooler connected to the demultiplexer to maximize the optical power level of the optical signals extracted by the optical coupler, thereby aligning the wavelength of the multiplexer of the remote node with respect to that of the demultiplexer of the central base station (S 1030 ).
[0082] As described above, the present invention provides an apparatus and method for efficiently tracking a wavelength in a general WDM-PON system that uses a single-mode optical source. According to the present invention, even if the temperature of a remote node changes, the optical power levels of an optical upstream signal received at a central base station and an optical downstream signal received at a subscriber terminal can be maintained at 1 dB or less. Even if power is not supplied to a remote node, the optical downstream signal can be stably transmitted to the subscriber terminal and the optical upstream signal can be stably transmitted to the central base station, thereby increasing the reliability of the WDM-PON system.
[0083] Also, it is possible to minimize optical loss in a channel caused by a change in the temperature of a remote node and the performance degradation of the system due to crosstalk among the optical channels.
[0084] In a wavelength tracking apparatus according to the present invention, a signal reflected from a partial reflector passes through a multiplexer/demultiplexer twice to be adjusted according to a change in the wavelength of a passband of the multiplexer/demultiplexer, and thus can be effectively utilized for wavelength tracking.
[0085] The wavelength tracking apparatus according to the present invention also equalizes a wavelength of an optical source of a central base station with that of an optical multiplexer of the central base station, a wavelength of an optical multiplexer of a remote node with that of a subscriber optical source, and a wavelength of an optical multiplexer/demultiplexer of the central base station with that of an optical multiplexer/demultiplexer of the remote node, thereby monitoring a cut occurrence of the optical fiber and increasing the reliability of the network.
[0086] While this invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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Provided are an apparatus and method for tracking a wavelength in a passive optical subscriber network in which a central base station and at least one subscriber terminal are connected via a remote node. The apparatus includes a first wavelength aligning unit multiplexing and aligning wavelengths of optical signals from a plurality of single-mode optical sources of the central base station; a second wavelength aligning unit multiplexing and aligning wavelengths of optical signals transmitted to the remote node from a plurality of single-mode optical sources of the subscriber terminal; and a third wavelength aligning unit demultiplexing and aligning wavelengths of optical signals from the second wavelength aligning unit, the third wavelength aligning unit being included in the central base station. Accordingly, when the wavelengths of passbands of a multiplexer/demultiplexer (MUX/DEMUX) of a remote station change due to a change in the ambient temperature, wavelength tracking is performed by making aligned the wavelengths of optical sources of a central base station, a multiplexer/demultiplexer, and subscriber terminals, thereby minimizing optical channel loss and enabling reliable management of WDM-PON.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. application Ser. No. 08/468,225, filed on Jun. 6, 1995, now U.S. Pat. No. 5,779,268, by Bradley W. Smith, Kirk H. Rasmussen, and Brian T. Snyder.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a base of a housing of a driver side gas generator or inflator for a vehicle safety system, and more particularly, to a base of which a majority of the features are stamped from a thin sheet of material.
2. Description of the Related Art
Gas generators or inflators which use combustible solid fuel gas generant compositions for the inflation of inflatable crash protection or air bag restraint systems are known in the prior art.
One type of inflator, such as a driver side inflator apparatus, comprises a housing made of an upper shell or diffuser and a bottom shell or base. A plurality of concentric cylinders are formed in the diffuser. The cylinders together with the base form various chambers in the housing, an outer diffuser chamber, an inner ignitor chamber and a middle combustion chamber.
In operation, a crash sensor sends an electrical signal to an initiator or squib. The squib fires into the ignitor chamber and ruptures a container, which holds an ignitor material, commonly a mixture of boron and potassium nitrate. The ignitor material burns with a very hot flame and ignites solid fuel gas generant pellets contained in the combustion chamber. The pellets release a nitrogen gas, which travels through the diffuser chamber and into a protective air bag for protecting occupants of the vehicle.
Due to the enormous mechanical and thermal stresses produced, gas generators must be made from strong materials. U.S. Pat. No. 4,547,342, assigned to the assignee of the present invention, the disclosure of which is herein incorporated by reference, discloses a two-piece light weight aluminum inflator housing strong enough to withstand the associated stresses. Specifically, the inflator includes an aluminum diffuser shell and base shell, which are impact forged, heat treated and then finally machined to produce an inflator having the desired strength and shape.
Using an impact forging process for forming a part is well known in the art. During the impact forging process, the material to be processed, e.g. the slug, is placed into a die. The stroke of the die press causes the punch to force the material through openings between the punch and the die, or into cavities in the punch or die.
A disadvantage with the prior art impact forging process, is that a forged housing base requires excessive machining to form the base in its desired final shape. FIG. 1 illustrates a base 10' which has been formed by the impact forging process. The as forged part is shown by dashed line and the final shape of the part is indicated by the solid line. As shown, numerous areas of the forged base must be machined after the formation of the part. This significantly increases manufacturing cost and time.
U.S. Pat. No. 4,530,516, assigned to the assignee of the present invention and herein incorporated by reference, discloses an inflator housing including a housing structure comprising a stamped diffuser and base. Both the base and diffuser are significantly simpler in design than the other prior art inflator housing components. The base does not include weld lands, a squib pocket or an attachment flange. Also, the diffuser does not include concentric cylinders forming separate chambers. Due to the simplicity of the diffuser and base, extra parts, such as a cap, which holds the base and diffuser together, are required. This also significantly increases manufacturing time and cost.
Another disadvantage with the prior art stamped base is that the diffuser and base are electron-beam welded together, which is complex and time consuming. Electron beam welding is a well known process which involves fusion by local melting produced by bombardment of a high velocity stream of electrons.
Therefore, in order to continue to decrease manufacturing time and cost, it is desirable to produce a driver side inflator base, which can be manufactured simply and quickly.
SUMMARY OF THE INVENTION
It is an object of the present invention to overcome the deficiencies of the prior art by providing a driver inflator base having a shape which is substantially formed from stamping a thin sheet of material, with only minor machining necessary to form the final part.
Another object of the invention is to provide a stamping process through which the majority of the base features can be stamped. Thus, excessive machining after forming the part is not necessary.
The process of the present invention is designed to reduce the overall inflator cost, while maintaining the processing capability and quality of current bases.
Still another object of the invention is to provide a base which can be assembled without the necessity of complex welding procedures. Costs of the base parts would be significantly reduced, because parts made from stamping are typically less expensive than forged or machined parts. This is due in part to the lack of material waste, for example, 85% of the metal blank is used.
The present invention overcomes the above-noted deficiencies of the prior art by providing a stamped base which includes a central axis and a plurality of stamped concentric rings extending upwardly from a bottom of the base and spaced from the central axis. An interface attachment flange is provided for mounting to the module, and a squib pocket extending about the central axis of the base is capable of holding a squib of the gas inflator. The concentric rings, attachment flange and squib pocket are formed during the stamping of the base. Thus, only minor machining is necessary to complete the base.
The present invention also provides a method for stamping a base from a thin blank of material. The blank is positioned between a first set of dies and a squib pocket, for accommodating a squib of the gas inflator, is stamped about a central axis of the blank. Next, the blank is positioned between a second set of dies and an outer ring is stamped from the blank. The outer ring extends upwardly from the blank and is concentric with the central axis. The blank is then positioned between a third set of dies and a plurality of rings are stamped from the blank. The plurality of rings also extend upwardly from the base, spaced concentrically about the central axis and inwardly of the outer ring. Finally, the blank is positioned between another set of dies and the attachment flange is stamped. The attachment flange, provided for mounting the inflator, is located outwardly of the outer ring.
Other features and advantages of the present invention will become apparent from the following description of the invention, which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a prior art impact forged housing base.
FIG. 2 is a cross-sectional view of a stamped base blank according to the present invention, taken along Line I--I of FIG. 3.
FIG. 3 is a top view of the stamped base blank of FIG. 2.
FIG. 4 illustrates a step in the process of stamping the base according to the present invention.
FIGS. 5A-5D are cross-sectional views of the blank at various stages during stamping.
FIG. 6 is a cross-sectional view of the stamped base blank of the present invention, indicating the areas which must be machined.
FIG. 7 is a cross-sectional view of the completed stamped base, taken along Line II--II of FIG. 10.
FIG. 8 is an enlarged detail of FIG. 7.
FIG. 9 is an enlarged detail of the squib pocket of FIG. 7.
FIG. 10 is a top view of the stamped base of FIG. 7.
FIG. 11 is a partial cross-sectional view of a gas inflator incorporating the stamped base of the present invention.
FIG. 12 is an enlarged cross-sectional view of the stamped base of the present invention with a universal connector engaged within the squib pocket of the base.
FIG. 13 is a cross-sectional view of the squib clamp of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 2 and 3, the present invention relates to a base 10 for a driver side inflator housing, which is stamped from a relatively thin sheet of material, such as aluminum. Preferably, the blank and the finished stamped part each have a thickness of about 0.125 in., and more preferably of 0.100 in. However, different material thicknesses can be used as desired.
The finish stamped base blank can be configured as shown in FIGS. 2 and 3. The base 10 includes a central axis 12, a squib pocket 13 formed about axis 12, an interface attachment flange 15, and a plurality of upwardly extending rings 16, 18, 20 spaced concentrically about axis 12. Squib pocket 13, after being machined, is capable of retaining a squib 50, which will be discussed in detail further herein.
As shown in FIGS. 6, 7 and 10, the module interface attachment flange 15, which is provided for mounting the inflator to the airbag module (not shown), includes a plurality of apertures 24 spaced circumferentially thereabout. Apertures 24 provide the capability to inertia weld the base 10 to a diffuser 14, which will be described further herein. An upper wall 27 (FIG. 2) of squib pocket 13 will eventually include a hole 22, as shown in FIG. 10, for receiving the squib 50.
The base 10 of the present invention is produced by a stamping process. A plurality of different operations are preformed at different stations with the process continuing through a set of progressive die until the final stamped shape (shown in FIG. 2) is produced.
FIG. 4 illustrates a representative step in the stamping process. Initially, raw stock, shown in FIG. 4 as a round blank of material 30, most likely aluminum, travels to a first station and is positioned between two dies 32, 34, where a pre-draw of the center squib pocket 13 is preformed. Each and every punch die 32 is configured on its contact face 33 to produce the desired features or deformations at that particular step in the stamping process. It should be understood that variations of the above steps are contemplated, depending on the desired final shape of the part.
Referring to FIGS. 5A-5D, formation of the base at the various stamping stages will be described. Blank 30 travels to a second station where the squib pocket 13 is finish drawn, as shown in FIG. 5A. At a third set of dies, outer ring 20, is formed, as shown in FIG. 5B. Following this step, inner rings 16 and 18 are stamped at the next station of dies, (see FIG. 5C). Next, the perpendicular walls at the periphery of the base, leading to flange 15 are raised, as shown in FIG. 5D. In the sixth step, the base is finished formed, i.e., the base is drawn to its final stamped configuration, as shown in FIG. 2.
Referring to FIG. 6, the part is completed by pre-piercing the hole 22 in the squib pocket's upper wall 27. In the last steps in the stamping process, hole 22 is pierced to its final size, a chamfer 37 is formed at an edge of hole 22, and apertures 24 are blanked in the flange 15. Only minor machining at valley 36 and relief 40, which will be described further herein, is necessary to produce the finished base. Thus, a majority of the base features are stamped, limiting the need for extensive finish machining. Through this process approximately 85% of the metal blank is used, significantly reducing waste.
As described above, only minor machining, shown by the dotted areas in FIG. 6, is necessary to finish the stamped base as shown in FIG. 7. As shown in detail in FIG. 8, a small area is removed from the base to form valley 36. Valley 36 can be approximately 0.235 in. in height and after machining a typical wall thickness, indicated by numeral 35, may be, for example, 0.058 in. This machining on the periphery 36 is done so that the weld curl 66, shown in FIG. 11, can have room to move away from the diffuser 14. The valley 36 is removed in a high capacity lathe type operation. The base 10 is chucked into the lathe and the material is removed with a cutting tool.
Machining of the squib pocket 13 will be described with reference to FIGS. 6-10. The edge of hole 22 is coined to form chamfer 37. As will be described herein, chamfer 37 corresponds with a lower conical surface 51 of squib 50, shown in FIG. 11, when the squib is mounted in the inflator. Additionally, a conical seal washer (not shown) is located between chamfer 37 and surface 51 to provide a hermetic seal between the two parts. Chamfer 37 is coined by smashing the material into the desired shape, without moving the material to another location. Therefore, the material in the coined area, i.e. chamfer 37, becomes more dense.
A significant amount of material is removed from the walls 26 of squib pocket 13 at relief 40, and shoulder 38 and notch 39 are formed. As shown in FIG. 12, squib pocket 13 is formed with notch 39 and shoulder 38 to accommodate a connector assembly 80. Connector 80 is pushed into pocket 13 after the squib 50 has been installed and the inflator welded. Connector 80 is the link to the electronics of the car used to fire the air bag inflator. Connector 80 includes an engaging rim 82 which engages notch 39 to retain the connector within the inflator during the life of the inflator. Relief 40 is formed by chucking base 10 in a lathe and cutting the material. The material is removed from relief 40 from a side of the base opposite the side from which the material of valley 36 is removed.
Referring again to FIG. 11, a cross-section of the two structural components comprising the housing of the inflator, namely upper shell or diffuser 14 and base 10 is shown. Diffuser 14 and base 10 are joined by three concentric inertia welds 54, 56 and 58, which will be discussed further herein. Diffuser 14 includes three different chambers, an innermost ignition chamber 44, a middle combustion chamber 46 and an outer diffuser chamber 48.
Ignition chamber 44 is designed to receive an ignitor charge assembly (not shown), as is customary. Extending into ignition chamber 44 is an initiator or squib 50. Squib 50, as shown, has conically shaped lower surface 51, which follows chamfer 37 of squib pocket 13 and an upper conical surface 52 that extends above central portion 12 of pocket 13. Squib 50 can be a conventional electric squib having a pair of energizing electric terminals 53, adapted for a plug-in connection to an external crash sensor means (not shown).
Combustion chamber 46 may be a conventional combustion chamber adapted to contain pellets of a gas generant composition (not shown). Also, outer diffuser chamber 48 can contain a conventional deflector ring or filter (not shown). See U.S. Pat. No.4,547,342.
To provide a more stable retention of the squib 50 in base 10, a retainer 70 is provided. As shown in FIG. 13, retainer 70 includes an upper rim 72, a mid cylinder 74 and a flared bottom flange 76.
Referring once again to FIG. 11, rim 72 of the clamp overlaps and engages the upper conical surface 52 of squib 50 and the mid cylinder 74 engages the outer surface of walls 26 of squib pocket 13. Bottom flange 76 of retainer 70 is flared to mate with the curve formed between wall 26 and ring 16 of base 10.
Retainer 70 is press fit over the squib pocket and locks in place near the weld land. Once retainer 70 is pressed into place, the weld curl formed during the welding process will cover the bottom flange 76, holding the retainer securely in place.
Retainer 70 is also formed by stamping. The retainer is stamped from a thin piece of material, such as aluminum, in a manner similar to the base of the present invention. Thus, each step and progressive die set will add another feature to the retainer until the part is complete. It should be noted that various other configurations of the squib pocket, which would otherwise allow the squib to be pressed, staked or otherwise held in place during the lifetime of the inflator, are contemplated. Also, a squib pocket configuration which would eliminate the need for retainer 70 is possible. In that instance, a different type of squib and a deeper draw of the squib pocket may be necessary.
As shown in FIGS. 2, 7 and 11, the concentric interface regions of base 10, which meet with the walls of chambers 44, 46 and 48, comprise short concentric-like rings 16, 18, and 20. During the formation of the inertia welds 54, 56 and 58, weld curls indicated at 62, 64 and 66, respectively, form around the ends of the walls of chambers 44, 46 and 48.
The inertia welds 54, 56 and 58 are preformed simultaneously in a single inertia welding step. The diffuser 42 and base 10 are welded in a wholly loaded condition, i.e. the squib, ignitor material, gas pellets etc., are loaded within the diffuser assembly.
As fully set forth in U.S. Pat. Nos. 4,561,675 and 5,104,466, assigned to the assignee of the present invention, and herein incorporated by reference, in the inertia welding operation, the base 16 is rotated beneath the loaded diffuser 14 by a power driven clutch means (not shown) to a speed, for example, 3000 r.p.m. Upon reaching such a speed, the clutch is activated to disconnect the power source and the freely spinning base 10 is raised upwardly to bring concentric rings 16, 18 and 20 into contact with the lower ends of the walls of the respective chambers 44, 46 and 48. The resulting friction stops the spinning of the base 10 in a fraction of a second, but raises the temperature of each of the areas of contact sufficiently to cause consolidation of the metal of the diffuser and base in such areas. Pressure is maintained between the diffuser and base for a short time, for example, one to two seconds, to allow the welds 54, 56 and 58 to solidify.
Weld curls 62, 64 and 66 are a natural result of the inertia welding process. When the two parts are pressed together at the same time the part or parts are spinning, as described above, a certain amount of material curls off the weld lands, i.e. rings 16, 18 and 20, and results in a welded part with weld curls 62,64 and 66 around the area where the parts are engaged. The process described above contemplates the use of a vertical welder. However, the same procedure can be accomplished in a horizontal configuration.
Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.
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A driver side inflator base for a vehicle safety system which is stamped from a thin sheet of aluminum. The base includes a central axis, a plurality of stamped concentric rings extending upwardly from a bottom of the base and spaced from the central axis. An interface attachment flange is provided for mounting the inflator, and a squib pocket extending about the central axis of the base is capable of holding a squib of the gas inflator. The concentric rings, attachment flange and squib pocket are all formed during the stamping of the base; thus, excessive machining is not required. Only minor machining is necessary to complete the base. The base of the present invention is designed to reduce the overall inflator cost, while maintaining the processing capability and quality of current bases.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Non-Provisional patent application Ser. No. 11/674,309 filed on Feb. 13, 2007.
FIELD OF THE INVENTION
[0002] The present invention relates to systems for filtering contaminate such as paint sludge and oil from a solution.
BACKGROUND OF THE INVENTION
[0003] During the manufacture of painted parts, such as automotive body parts industrial wastes are produced. By-products such as paint sludge particles and oils are produced and require proper disposal. Systems for concentrating, filtering and removing paint sludge particles and oils from mixtures derived from industrial solutions are necessary to meet environmental standards.
[0004] A common technique for capturing paint overspray/airborne paint particulate produced when operating a paint spray booth is to capture the particulate in a waterfall backdrop within the spray booth. The resulting water-and-particulate fluid mixture is then channeled into a suitable system in which the paint particulate is substantially removed from the water. The filtered water is thereafter advantageously recirculated back to the spray booth's waterfall backdrop to capture more airborne paint particulate.
[0005] A similar pre-treatment process is used prior to spray painting the part in order to remove oil residue that can be on the surface of the parts either from transport or from the cutting and pressing processes. Similar to the paint process described above, the mixture of oil and solution also needs to be treated. This particular process involves treating or washing the part with a solution to remove the oil residue. The solution with the oil residue is collected and channeled in a manner similar to the painting process described above.
[0006] The paint sludge and oil filtration systems discussed above often require large amounts of solution to be filtered. This in turn requires larger pumps and a larger or greater number of filters if necessary, to be used. Thus it is desirable to design systems that concentrate the contaminate (i.e., paint sludge or oil residue) in order to eliminate filtering and separating large volumes.
[0007] Another problem that can occur is during system shutdowns back pressure in the recycling lines cause mixtures of solution and contaminate to backup into the contaminate tank; it is desirable to have a system that will continue to filter and remove the contaminate in the areas where the backup can occur in order to reduce the energy consumption of the pumps in the system.
[0008] Another issue that can be encountered is that existing systems often lack the ability to adapt to drastic changes in fluid levels in the various tanks or account for foam and other coagulated particles floating on the surface of the solution which can give false readings as to the actual fluid levels in the tanks.
[0009] It is desirable to develop improved systems that separate the paint sludge more effectively. Thus it is desirable to develop systems that can adapt or account for such conditions.
SUMMARY OF THE INVENTION
[0010] The present invention relates to a system for consolidating and removing contaminate such as paint sludge from a fluid mixture. The system includes a contaminate tank that receives a supply of fluid mixture containing contaminate. A weir is positioned on the surface of the contaminate tank for mechanically separating and removing the contaminate from the surface of the fluid mixture collected in the contaminate tank. A consolidation tank is connected through a series of conduits to the contaminate tank and receives contaminate collected by the weir. The consolidation tank further includes a surface scraper for collecting contaminate proximate to the surface of the consolidation tank and moving the contaminate to a chute. A micro-aeration inlet is connected to the consolidation tank and inputs contaminate from the contaminate tank to the consolidation tank.
[0011] A dissolved gas flotation arrangement having a fluid mixture source, a gas source and an aeration pump creates a dissolved gas mixture from the fluid mixture and gas received from the fluid mixture source is provided. The dissolved gas mixture is input to the consolidation tank through the micro-aeration inlet. A contaminate chute arrangement is connected to the consolidation tank and receives contaminate removed by the surface scraper. The system further includes a pump screen dividing the contaminate tank into a first section where the fluid mixture enters and a second section where a portion of the fluid mixture exits the contamination tank. Additionally, one or more booth pumps are contained in the second section of the contaminate tank for removing a portion of the fluid mixture.
[0012] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0014] FIG. 1 is a schematic view of a first embodiment of the invention;
[0015] FIG. 2 is a schematic view of a second embodiment of the invention;
[0016] FIG. 3 is a schematic view of a third embodiment of the invention;
[0017] FIG. 4 is a schematic view of a fourth embodiment of the invention;
[0018] FIG. 5 a is an overhead plan view of the floating weir;
[0019] FIG. 5 b is a perspective view of the suction box of the weir;
[0020] FIG. 5 c is a cross-sectional side plan view of the floating weir;
[0021] FIG. 6 is a schematic view of a fifth embodiment of the invention;
[0022] FIG. 7 is a schematic view of a conveyorized dryer;
[0023] FIG. 8 is a schematic diagram of a self-dump hopper;
[0024] FIG. 9 is a schematic diagram of a centrifuge dryer; and
[0025] FIG. 10 is a schematic diagram of a dissolved gas flotation arrangement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0027] Referring to FIG. 1 a schematic diagram of a system 10 for consolidating and removing contaminate from a fluid mixture. The fluid mixture containing contaminate such as paint sludge particles or oils contained in a solution, such as water or a hydrophobic wash solution which together form a fluid mixture. The fluid mixture is obtained from the waterfall of a paint spray booth and/or a catch basin for spray painting or washing automotive parts. The waterfall and catch basin is channeled through an inlet pipe 12 or spray header that empties into a contaminate tank 14 .
[0028] The contaminate tank 14 in this particular embodiment is quite large and can hold approximately 5,000 to 150,000 gallons. However, it is possible to a contaminate tank 14 of virtually any size to be used if needed. Within the contaminate tank 14 a stationary weir 16 is positioned to operably align with the surface of the fluid mixture contained in the contaminate tank 14 . The stationary weir 16 has a hinged door 18 that is connected to a float that opens and closes to allow the fluid mixture to enter the stationary weir 16 . When used in a paint sludge removal application the fine particles of paint will float on the surface of the fluid mixture in the contaminate tank 14 and be trapped or gathered by the stationary weir 16 which has the hinged door 18 located adjacent the surface of the fluid mixture.
[0029] The contaminate tank 14 is divided by one or more pump screens 20 so that the contaminate tank has a first section 22 and a second section 24 . The pump screens 20 aid in keeping some of larger particles of paint or booth debris from crossing from the first section 22 into the second section 24 . In the second section 24 is one or more booth pumps 26 which function to recycle or supply solution back to the manufacturing processes. One example is where the booth pumps 26 will pump solution back to the waterfalls in the paint spray booths. Thus it is important to prevent large particles of paint from building up within the second section 24 .
[0030] Despite the fact that the pump screens 20 remove the paint sludge on the surface of the fluid mixture in the second section 24 in order to block the passage of larger paint particles, smaller particles can still pass and enter the booth pumps 26 . This is not usually a problem except when the booth pumps 26 are shutdown the booth pumps 26 and their pipes will drain back into the contaminate tank 14 . As a result some of the finer paint particles that made it past the pump screens 20 may accumulate on the surface of the second section 24 . Thus it is desirable during the shutdown period to prevent damage or overheating of the booth pumps 26 by removing the accumulated paint sludge in the second section 24 . In order to resolve this problem a floating weir 28 is positioned in the second section 24 . The floating weir 24 will operate to remove paint sludge in the second section.
[0031] The floating weir 28 is a free floating weir box that has a hose 30 connecting to the weir box for removing the paint sludge that is collected. The stationary weir and the floating weir 28 both are connected to a vacuum pump assembly 32 that facilitates the removal of the paint sludge and solution that becomes trapped by the stationary weir 16 and floating weir 28 .
[0032] The vacuum pump assembly 32 moves the paint sludge to a consolidation tank 34 where the fluid mixture is more concentrated with paint sludge. The paint sludge will float to the surface of the consolidation tank because the specific gravity of the paint sludge is less than the specific gravity of the solution. At the top of the consolidation tank 34 is a scraper assembly 36 that has a moveable scraper that moves along the surface of the consolidation tank 34 . The scraper assembly 36 pushes the paint sludge into a contaminate chute 38 that empties the paint sludge material into a drying bag 40 . In the drying bag wet paint sludge is gathered.
[0033] The drying bag 40 is porous and allows the solution to drip away from the paint sludge into a drip pan 42 where it can be removed or re-introduced back to the contaminate tank 14 . Once the drying bag 40 has become full it can be removed and the dried paint sludge material can be disposed of. The drying bag 40 can also be contained in a canister 44 that can be heated to facilitate the evaporation or drying process of the paint sludge material. The consolidation tank 34 also has several drains 46 that allow the solution that has been separated from the paint sludge to be re-introduced back to the contaminate tank 14 so that it may ultimately be recycled through the booth pumps 26 back to the paint spray booth.
[0034] Referring now to FIG. 2 an alternate system is shown. Like reference numerals will be used to indicate structures similar to those shown in FIG. 1 . A system 100 shown in FIG. 2 is similar to the system shown in FIG. 1 . The main difference is that this particular system does not have a stationary weir, but instead has a floating weir 102 within the first section 22 of the contaminate tank 14 . The second section 24 of the contaminate tank does not have a weir box within and only has a single booth pump 26 . The type of system shown in FIG. 2 would be for a smaller type of operation wherein a lower volume of fluid mixture such as 200-2000 gallons would need to be filtered. However, it is possible to a contaminate tank 14 of virtually any size to be used if needed.
[0035] The type of system depicted in FIG. 2 provides more level control as well as eliminating the problem of pump cavitation. In paint sludge recovery applications the surface of the contaminate tank 14 can become covered with foam or coagulated paint sludge. This can cause existing paint sludge recovery systems to misread the true fluid levels in the contaminate tank 14 . For example some systems employ a sonic sensor to determine the fluid level. Foam or coagulated paint sludge can give a false reading indicated that the liquid levels in the tank are significantly higher than the true liquid level. The floating weir of the present invention solves this problem because it is always on the surface of the liquid in the contaminate tank 14 . This eliminates any issues of not having enough liquid to supply to the system which can result in cavitation of the pump. Additionally this type of system would allow for the easier re-location or if a user anticipates moving the system to various locations in order to find the “best” location within their facilities. Also this type of system is smaller and would reduce the overall installation costs that would normally be incurred for larger systems.
[0036] Referring now to FIG. 3 wherein like reference numerals are used to indicate similar structures that were indicated in FIGS. 1 and 2 . A system 200 is depicted as having a first floating weir 202 positioned in the first section 22 of the contaminate tank 14 . A second floating weir 204 is positioned in the second section 24 of the contaminate tank 14 . The contaminate tank 14 in this type of application could be between 200 and 10,000 gallons. However, it is possible to a contaminate tank 14 of virtually any size to be used if needed.
[0037] This application shown in FIG. 3 wherein two floating weirs are used is advantageous in systems where there are plants that do not have a central waste treatment system and a large centralized system would not be practical. In large systems as well as other smaller types of systems the systems will be shut down so that the spray booths can be cleaned. During the cleaning process the liquid level in the contaminate tank 14 will rise due to liquid being added from the cleaning process. The only way the liquid level in the contaminate tank 14 returns to normal is for evaporation to occur. In the meantime the system will run with liquid levels that are above the normal operating levels. The use of floating weirs solves this problem because the weir is always as on the surface of the liquid in the contaminate tank 14 . Thus the floating weirs are always at normal operating levels.
[0038] Referring now to FIG. 4 a schematic embodiment of an oil skimmer system 300 is generally shown. In this particular embodiment a contaminate tank 302 receives a fluid mixture of solution and oils from an auto part treatment booth. Prior to spray paint, auto parts the parts must be washed and treated in order to remove any oil residues that are present on the surface of the part, otherwise the oil residue can cause bubbling or peeling of the paint. The oil residue is often applied during transport in order to prevent the part from rusting or becoming scratched. Secondly oil residues can also sometimes be present as a result of the cutting and pressing processes used to create the part. A solution is used to wash the part to remove the residue from the part surface. This solution is collected in the contaminate tank 302 where the oil can be separated from the solution and the solution can be recycled back to the treatment booth.
[0039] Within the contaminate tank 302 is a floating weir 304 that floats on the surface and skims the oil residue away from a majority of the fluid mixture. Connected to the floating weir 304 is a vacuum hose 306 that leads to a strainer 308 wherein unwanted solid particles are removed prior to filtration. The solid particles can be metal shavings from the cutting and manufacturing process and their removal is important because they can clog or damage the filtration system. After passing through the strainer 308 the oil residue and solution mixture passes through a pump 310 which supplies the suction to the floating weir 304 . The pump 310 in one embodiment can be a diaphragm pump; however, it is possible for virtually any style of pump to be used as long as the pump does not emulsify the solution. The solution is then passed to an oil/water hydrocyclone unit 312 which have one or more filtration columns that separate the oil residue from the solution. After filtration the waste oil progresses to a decant tank where it is further concentrated, collected and separated. The solution that has been separated by the hydrocyclones 314 is removed and re-introduced through a solution outlet 318 back to the contaminate tank 312 wherein a booth pump (not shown) can draw fluid from the contaminate tank 314 and introduce it to the spray headers or educators for agitation at the surface of the part to be washed.
[0040] Referring now to FIGS. 5 a - 5 c a floating weir 400 identical to those shown in the embodiments depicted in FIG. 1-4 is shown in greater detail. The floating weir 400 has a suction box 402 that collects the contaminate (e.g., paint sludge or oils) from the tank that it is position within. The suction box 402 has four hinged doors 404 that each have a float member 406 attached to the back side of each hinged door 404 for controlling the opening and closing of the door. The float members 406 float on the surface of the liquid contained within the suction box 402 in order to control the position of the hinged door 404 . This in turn controls the ingress of fluid from the tank into the suction box 402 . When the fluid levels in the suction box 402 are low the hinged door 404 will be more open and when the fluid levels in the suction box 402 are high the hinged door 404 will be more closed.
[0041] The suction box 402 has an outlet 408 that connects to a vacuum hose for providing suction to the suction box 402 . A lifting eyelet 410 is positioned at the top of the suction box 402 for removing the floating weir 400 from the tank that the floating weir is placed within. The suction box 402 has four flotation canisters 412 which can be filled with air for giving the floating weir 400 buoyancy. Alternatively the flotation canisters 412 can be filled with some other substance that is sufficient to provide buoyancy to the floating weir 400 on the surface of a tank full of fluid.
[0042] The flotation canisters 412 are connected to the suction box 402 by one or more adjustment bands 414 that wrap around each of the flotation canisters and connect through one or more eyelets 416 formed on the exterior surface of the suction box 402 . The suction box 402 is adjustable along the height of the vertical axis Y-Y of the flotation canisters 412 by placing the bands 414 and suction box 402 at a different height.
[0043] Referring now to FIG. 6 , an alternate system using a dissolved gas flotation arrangement is shown. Like reference numerals will be used to indicate structures similar to those shown in FIG. 1 . A system 500 is shown as having a consolidation tank 501 that has then modified to include a dissolved gas flotation arrangement 502 . While the present invention describes a consolidation tank 501 and dissolved gas flotation arrangement 502 used in combination with a system having only a stationary weir 16 in the contaminate tank 14 , it is within the scope of this invention for the alternate embodiment to be used in combination with one or more stationary weirs, or a combination of flotation and stationary weirs as set forth of the other embodiments in FIGS. 1-5 . The use of the consolidation tank 501 in combination with the dissolved gas flotation arrangement 502 injects gas bubbles into the consolidation tank 501 that will further contribute to the separation of the contaminate from the fluid mixture within the consolidation tank 501 . It has been found that introducing dissolved gas will increase the efficiency of the consolidation tank 501 by causing the contaminate particles (e.g. paint sludge to float at the surface of the consolidation tank for removal by the scraper assembly 36 ). As the scraper assembly 36 removes the contaminate, it is deposited into the contaminate chute 38 where it is then introduced to a contaminate treatment device 504 .
[0044] FIG. 10 is a schematic diagram of the dissolved gas flotation arrangement 502 which has a tank wall coupling 506 that serves as a fluid mixture source for the dissolved gas flotation arrangement 502 . Referring to FIGS. 6 and 10 , the tank wall coupling 506 is connected through the wall of the consolidation tank 501 . The consolidation tank 501 further includes a separator plate 508 that extends vertically through a portion of the consolidation tank and is open near the bottom of the tank to allow fluid mixture that has separated from the solid contaminates to pass under the separator plate. This ensures that the fluid mixture located between the wall of the consolidation tank and the separator plate 508 is generally clean and free of any paint sludge materials. Therefore, the fluid mixture received through the tank wall coupling 506 is generally free of any solid paint sludge material.
[0045] The dissolved gas flotation arrangement 502 further includes a gas source 508 , which in the present embodiment of the invention is an atmospheric air flow meter with a check valve or solenoid valve that controls the flow of air from the atmosphere into the arrangement 502 . While the gas source 508 is described as being a connection to atmosphere, it is possible to use other types of gas sources such a compressed air source or other types of compressed gases. The dissolved gas flotation arrangement 502 further includes an aeration pump 510 that combines and pressurizes the gas and fluid mixture. Operation of the aeration pump 510 creates a vacuum upstream as fluid is drawn in from the tank wall coupling 506 . The vacuum is measured using a first vacuum gauge 512 . The amount of vacuum created is also indicative of the amount of air being brought in thorough the gas source 508 because of the suction created by the aeration pump 510 . The pressure being output from the aeration pump 510 can be measured by a second pressure gauge 514 .
[0046] After the gas and fluid mixture has been combined it is collectively referred to as the dissolve gas, which is then passed through a diaphragm valve 516 onto a connection 518 that is placed within the stream of a micro-aeration inlet 520 that feeds to the consolidation tank 501 .
[0047] The micro-aeration inlet 520 receives fluid mixture containing contaminate from the stationary weir 516 . In other embodiments, the micro-aeration inlet 520 will receive contaminate and fluid mixture from the floating weirs or the combination of the various weirs discussed in the embodiments shown in FIGS. 1-5 .
[0048] The valve 516 can be any type of suitable one-way valve capable of allowing pressurized gas to pass through the valve to the micro-aeration inlet 520 , but preventing the back-up of fluid through the valve 516 . The present embodiment used a diaphragm valve. However, it is within the scope of this invention for other types of valves to be implemented.
[0049] The connection 518 is any suitable nozzle or outlet for placing the dissolved gas into the stream of fluid flowing trough the micro-aeration inlet 520 . The present invention contemplates the use of compression tubing; however, it is possible for any other suitable tubing to be utilized.
[0050] The aeration pump 510 described in the present invention is contemplated as being an impeller style pump. However, it is within the scope of this invention for any other suitable pump for combining and pressurizing the gas and fluid mixture to be used. For example, other types of pumps such as gerotor or vane pumps could be utilized and are within the scope of this invention.
[0051] In another alternate aspect of the invention, the dissolved gas flotation arrangement 502 further includes additional aeration ports 503 that input dissolved gas mixture directly into different locations within the consolidation tank 501 . This enhances the distribution of dissolved gas in the consolidation tank 501 .
[0052] In another alternate aspect of the present invention, it is optional to provide a chemical injection port 505 for injecting chemicals into the micro-aeration inlet 520 . Chemicals injected are any suitable chemicals, such as polymers, that promote the coagulation and flotation of the paint sludge on the surface of the consolidator 501 . The chemicals can be injected through their own independent injection port 505 or they can be injected into the arrangement 502 prior to the aeration pump 510 .
[0053] Referring now to FIGS. 7-9 , various contaminate treatment devices are shown. These contaminate treatment devices can be placed at the end of the chute 38 in FIG. 6 where the contaminate treatment device 504 is located. Alternatively, the contaminate treatment device 504 can be a drying bag 40 as shown in FIG. 1 . Additionally, the drying bag 40 , shown in FIGS. 1-3 , can be interchanged with one of the contaminate treatment devices shown in FIGS. 7-9 . FIG. 7 depicts a conveyorized dryer 522 for receiving contaminate from the chute 38 and moving the contaminate along the conveyor while being dried and ultimately deposited into a container 524 . FIG. 8 depicts a self-dump hopper 526 that receives contaminate from the chute 38 . The self-dump hopper 526 allows for the manual removal of the contaminate to a location where the contaminate can be dumped for storage. FIG. 9 depicts a centrifuge dryer 528 where contaminate enters an opening 530 of the centrifuge and fluid mixture is separated from a first outlet 532 and solid contaminate is removed from a second outlet 534 . While all the above embodiments of the invention discuss specific contaminate treatment desires, it is within the scope of this invention to use virtually any other type of device that dries the contaminate and stores it for removal.
[0054] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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A system for consolidating and removing contaminate such as paint sludge or oils from a fluid mixture. A contaminate tank receives a supply of the fluid mixture containing contaminate from a source such as a manufacturing line where overspray of paints or cleaning solutions containing washed away oils are collected. A free floating weir floats on the surface of the contaminate tank and mechanically separates and removes contaminate from a surface of the contaminate tank and concentrates the contaminate in a consolidation tank. In the consolidation tanks the contaminate is further separated and collected for disposal.
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BACKGROUND
[0001] The present invention relates generally to a set of card games used for various social games. More particularly, the invention relates to a set of card games that contribute to learning arithmetic.
[0002] Conventional playing cards are well known as game cards each having a standard design. These playing cards comprise four suits of cards having the successive figures 1 to 13. Although there are some well known games in which the winner thereof is determined to identify a specific card or a specific combination of numbers, no arithmetic knowledge is needed.
[0003] Numerous advances have been made in recent years, as does U.S. Pat. No. 5,242,171, in providing card games that help players learn aspects of arithmetic. Said aspects of arithmetic include the multiplication tables, divisors, multiples and the four rules of arithmetic. Hence, there is continuous need for more exciting, challenging and entertaining card games.
[0004] It is thus a prime object of the invention to propose card games that contribute players to learn and understand the various aspects of arithmetic.
SUMMARY OF THE PRESENT INVENTION
[0005] A card game of one or more rounds intended for learning and understanding numbers and different aspects of arithmetic comprising of numerical cards, each indicating a number between M and N and game rules, defining an arithmetic correlation procedure between at least two cards in accordance with the arithmetic properties. Said card game include the following steps: shuffling the cards then pre-defining the arithmetic correlation between at least two cards. The participants, optionally, take at least one card in every turn, providing each participant in his turn with the ability to identify a correlation according to arithmetic properties between at least two cards in the game and optionally discarding at least one card to the player's advantage. The winning participant of the round is declared after correlating all the cards according to the arithmetic correlation defined in the game.
[0006] Each participant is provided with an initial number of cards, creating a draw pile from remaining cards and an initial discard pile of cards faced up to reveal its content. In every turn the participant is optionally provided with at least one additional card from the draw pile and can discard a card or a series of cards having correlation in accordance with the arithmetic correlation procedure defined in the game.
[0007] In every turn the participant is optionally provided with at least one card from the draw pile or the discard pile and must discard one card to the discard pile according to his choice, wherein the user collects series of cards having correlation, in accordance with the arithmetic correlation procedure defined in the game.
[0008] Each round of the game involves scoring each participant in the game according to the game rules, in order to set a session of rounds.
[0009] The arithmetic correlation is any of the following ones: common digit appearing at the same decimal place, successive numbers, parity property common sum of the cards' digits, a common difference of the cards' digits, a common factor within the multiplication table, wherein the numerical cards indicate numbers within the multiplication table all having at least one pair of factors, a predetermined sum of the cards' numbers, a predetermined difference between the cards' numbers or the cards are cubes.
[0010] A definite selected number of cards are placed face-down not revealing their content as a scattered drawpile, wherein in every turn the participant draws any two cards, so that the participant discards the two cards from the game to his advantage if the defined arithmetic correlation between the two cards is obtained, and returns the two cards face-down otherwise.
[0011] The numerical cards include differentiating symbols indicating arithmetic properties or rules corresponding with arithmetic properties from the list of: a prime number, a square number, a single-digit number, and a number which is a multiple of 11. Further implemented in a computer network enabling an individual participant to play with a plurality of players over the network.
[0012] The numerical cards further include a sign which indicates the card's reading direction, said sign is any one of the following: a hat, grass, the sky or a roof.
[0013] At the start, one of the scattered cards is randomly taken out of the game and kept unrevealed, the winner thereof is determined to identify the missing card.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The present invention discloses a set of card games used in eight novel implementations for various social games. The proposed implementations contribute players in learning and understanding various aspects of arithmetic, such as the decimal system, the multiplication table, divisors and multiples. Moreover, said implementations also bridge the gap between identification of numbers by name and by appearance. The common mathematical denominator of the different implementations according to the present invention involves a correlation procedure between the values of the different numerical game cards. Said procedure provides the player with essential steps required in learning the recognition of numbers and their mathematical properties.
[0015] The proposed invention is intended for 2 or more players containing a deck of cards indicating numbers between M and N (e.g. the numbers from 1 to 100 or the numbers from 10 to 99). Aside from the numerical cards, the deck of cards according to the present invention contains “free” wild cards.
[0016] The numerical game cards attached may include unique markings in order to assist players in identifying special cards during the game. Said markings indicate whether the numerical card is a square number, a prime number, a single-digit number, a twin-digit number (i.e. a multiple of 11), or none of the above.
[0000] A green number at each corner of the card indicates a square number, e.g. 1, 4, 9, etc.
A red number at each corner of the card indicates a prime number, e.g. 2, 3, 5, etc.
A blue number at each corner of the card indicates the rest of the numbers, e.g. 6, 8, etc.
The symbol means the next player has to draw three additional cards from the draw pile, and appears only on single-digit numbers, i.e. 1, 2, 3, . . . , 9.
The symbol indicates the possibility of discarding multiple cards in a single turn, and appears only on twin-digit numbers, i.e. multiples of 11: 11, 22, 33, . . . , 99. The symbol “?” indicates a “free” wild card (joker), provided in order to enable the player to freely determine its number amongst the game cards and use it according to the rules of the game. Including these four cards (all or in part) is optional in all the games.
The symbol indicates the number “100”, can be used as a special card, and gives the player the possibility to choose between using it to force the other players to draw three additional cards from the draw pile or to protect himself from drawing three additional cards after a single-digit number is discarded by a previous player.
The symbol “X” indicates a number appearing in the multiplication table of the integers 1 through 10 (used mainly for sorting out the cards for the fourth embodiment).
[0017] The first embodiment according to the present invention is a card game intended for 2 or more players containing 100 cards indicating all the consecutive numbers from 1 to 100. Familiarity with the digits 0 to 9 is a prerequisite in this game. The object of each player in the game is to get rid of all his cards.
[0000] The cards are shuffled properly and each player is dealt 7 cards. The remaining cards are placed face down as a draw pile. The top card of the draw pile is turned over and placed face up by its side as the opening card of a discard pile. If the draw pile is used up during the game, only the top card of the discard pile is left in place whereas the rest of the discard pile is reshuffled and turned over for a new face down draw pile. The proposed game according to the first embodiment involves basic rules as follows:
1. Each player in his turn is allowed to discard one of his cards upon the top card of the discard pile, so that at least one digit of said cards is common. For example, upon the card “23” the player may place any card with the digit 2 and/or the digit 3, e.g. “27”, “35”, “3”, etc. 2. A single-digit number can be discarded upon any other single-digit card. For example, upon the card “3” the player may discard “1” or “7” etc. 3. A player who does not discard a card loses his turn and has to draw an additional card from the draw pile.
The game ends when one of the players is left with no cards, and is declared winner of the game.
A session of games is set by recording the score of each player in every game: the winner in every game scores 0 points, while each remaining player scores points according to the number of cards remaining in his hand. If the remaining players decide to continue the game, the player finishing second scores 2 points, the third scores 3 points, etc. The player scoring the lowest total of points at the end of the session is declared the winner.
[0021] The second embodiment according to the present invention is a card game intended for 2 or more players containing 100 cards indicating all the consecutive numbers from 1 to 100. Including “free” cards in the game is optional. Familiarity with the digits 0 to 9 is a prerequisite in this game. The object of each player in the game is to get rid of all his cards.
[0000] The cards' are shuffled properly and each player is dealt 7 cards. The remaining cards are placed face down as a draw pile. The top card of the draw pile is turned over and placed face up by its side as the opening card of a discard pile. If the draw pile is used up during the game, only the top card of the discard pile is left in place whereas the rest of the discard pile is reshuffled and turned over for a new face down draw pile. The proposed game according to the second embodiment involves basic rules as follows:
1. Each player in his turn is allowed to discard one of his cards upon the top card of the discard pile, so that at least one digit of said cards is common. For example, upon the card “23” the player may discard any card with the digit 2 and/or the digit 3, e.g. “27”, “35”, “3”, etc. 2. A single-digit number can be discarded upon any other single-digit card. For example, upon the card “3” the player may discard “1” or “7” etc. 3. A player who does not discard a card loses his turn and has to draw an additional card from the draw pile. 4. A player discarding a single-digit card obliges the following player to discard a single-digit card as well, and so on. A player who does not comply (i.e. does not discard a single-digit card in response), loses his turn and has to draw three additional cards from the draw pile as a penalty. The next player is not obliged to respond to this single-digit card which is still the top card of the discard pile, and is free to continue the game according to rules 1-3. 5. A player discarding a twin-digit card (i.e. a multiple of 11) is allowed to keep his turn and discard upon it all his cards having this digit, without any order priority. For example, a player discarding “55” (upon any existing card with the digit 5) may keep his turn and discard all his cards containing the digit 5 (e.g. “5”, “35”, “57”, etc) by the order of his choice. If the last discarded card is a single-digit card he obliges the following player to act according to rule 4. 6. The number of a “free” card (may only be in the range of 1 through 99) is determined and declared at the time of discard, provided it complies with the rules of the game. Using this card wisely increases the chance of winning. For example, a player discarding a “free” card upon “23” can only choose numbers containing the digits 2 and/or 3; if he declares its number as “33” he may keep his turn and discard all his cards containing the digit 3. Inclusion of any number of “free” cards in the game is optional. 7. At the beginning of every game the players can decide how to use the “100” card during the game: as a regular card (containing the digits 0 and 1) or as a special card. If the players decided to use it as a special card, the player holding it can in his turn use the card in one of two options:
According to the first option, the player may reveal the “100” card, and oblige all other players (according to the order of play) to draw three additional cards from the draw pile. Then the player places the card at the bottom of the discard pile and continues to play the game as usual (i.e. resumes his turn). According to the second option, the player loses his turn by revealing the “100” card and placing it beside him as an immunity from the obligation of discarding single-digit cards, i.e. from now on until the end of this game he does not have to draw three additional cards as a penalty after discard of a single-digit card by the previous player. For example, if a player revealed the “100” as an immunity card in one of his earlier turns and has to respond to a “7” discarded by the previous player, he is not obliged to discard a single-digit card, and is free to continue the game according to rules 1-3. Note: this immunity from the “7” is valid only if the “100” card was revealed in one of the earlier turns.
The game ends when one of the players is left with no cards, and is declared winner of the game.
A session of games is set by recording the score of each player in every game: the winner in every game scores 0 points, while each remaining player scores points according to the number of cards remaining in his hand. If the remaining players decide to continue the game, the player finishing second scores 2 points, the third scores 3 points, etc. The player scoring the lowest total of points at the end of the session is declared the winner.
[0031] The third embodiment according to the present invention is a card game intended for 2 or more players containing 100 cards indicating all the consecutive numbers from 1 to 100. Including “free” cards in the game is optional. Familiarity with the digits 0 to 9 and the ability to perform addition of two digits is a prerequisite in this game. Preferably, the players should be able to distinguish the tens-digit from the ones-digit and be familiar with the numbers 1 through 100 as well. The object of each player in the game is to get rid of all his cards.
[0000] The cards are shuffled properly and each player is dealt 7 cards. The remaining cards are placed face down as a draw pile. The top card of the draw pile is turned over and placed face up by its side as the opening card of a discard pile. If the draw pile is used up during the game, only the top card of the discard pile is left in place whereas the rest of the discard pile is reshuffled and turned over for a new face down draw pile. The proposed game according to the third embodiment involves basic rules as follows:
1. Each player in his turn is allowed to discard up to three sequential cards upon the top card of the discard pile, so that the number on each discarded card matches the previous card by a common ones-digit or a common tens-digit or a common sum of digits. For example, upon the card “23” the player may discard any card having a 2 as its tens-digit (e.g. “20”, “21”, etc.), or having a 3 as its ones-digit (e.g. “3”, “13”, etc.), or having a sum of digits adding up to (2+3) 5 (e.g. “5”, “14”, etc.). Therefore, upon the card “23” he may discard “27” (common tens-digit is 2), and may keep his turn and discard the card “57” (common ones-digit is 7) and “66” upon the “57” (common sum of digits adding up to 12), i.e. discard the sequence “27”>>“57”>>“66” 2. A single-digit number can be discarded upon any other single-digit card. For example, upon the card “3” the player may discard “1” or “7” etc. 3. A player who does not discard a card loses his turn and has to draw an additional card from the draw pile. 4. A player ending his turn by discarding a single-digit card (i.e. only if the single-digit card is the last card or the sole card a player is discarding) obliges the following player to discard only a single-digit card as well, and so on. A player who does not comply (i.e. does not discard a single-digit card in response), loses his turn and has to draw three additional cards from the draw pile as a penalty. The next player is not obliged to respond to this single-digit card which is still the top card of the discard pile, and is free to continue the game according to rules 1-3. 5. A player discarding a twin-digit card is allowed to keep his turn and discard upon it all his cards having this digit, without any order priority. For example, a player discarding “66” (even if this is his third sequential card, like in the sequence “27”>>“57”>>“66” illustrated in rule 1) may keep his turn and discard all his cards containing the digit 6 (e.g. “6”, “36”, “61”, etc) by the order of his choice. 6. The number of a “free” card (may only be in the range of 1 through 99) is determined and declared at the time of discard, provided it complies with the rules of the game. Using this card wisely increases the chance of winning. For example, a player discarding a “free” card upon “23” can only choose numbers having a 2 as its tens-digit, or having a 3 as its ones-digit, or having a sum of digits adding up to 5; if he declares its number as “33” he may keep his turn and discard all his cards containing the digit 3, and if the last discarded card is a “3” he obliges the following player to act according to rule 4. Inclusion of any number of “free” cards in the game is optional. 7. At the beginning of every game the players can decide if and how to use the “100” card during the game (i.e. inclusion of this card in the game is optional): as a regular card (having a ones-digit=0 and a sum of digits=1) or as a special card. If the players decided to use it as a special card, the player holding it can in his turn use the card in one of two options:
According to the first option, the player may reveal the “100” card, and oblige all other players (according to the order of play) to draw three additional cards from the draw pile. Then the player places the card at the bottom of the discard pile and continues to play the game as usual (i.e. resumes his turn). According to the second option, the player loses his turn by revealing the “100” card and placing it beside him as an immunity from the obligation of discarding single-digit cards, i.e. from now on until the end of this game he does not have to draw three additional cards as a penalty after discard of a single-digit card by the previous player. For example, if a player revealed the “100” as an immunity card in one of his earlier turns and has to respond to a “7” discarded by the previous player, he is not obliged to discard a single-digit card, and is free to continue the game according to rules 1-3. Note: this immunity from the “7” is valid only if the “100” card was revealed in one of the earlier turns.
The game ends when one of the players is left with no cards, and is declared winner of the game.
A session of games is set by recording the score of each player in every game: the winner in every game scores 0 points, while each remaining player scores points according to the number of cards remaining in his hand. If the remaining players decide to continue the game, the player finishing second scores 2 points, the third scores 3 points, etc. The player scoring the lowest total of points at the end of the session is declared the winner.
[0041] The fourth embodiment according to the present invention is a card game intended for 2 or more players containing all 42 cards marked by X (i.e. numbers appearing in the multiplication table of the integers 1 through 10). For a game with more than 4 players a double deck (i.e. including 42×2=84 cards) is preferred. Including “free” cards in the game is optional. Familiarity with the multiplication table is a prerequisite in this game. The object of each player in the game is to get rid of all his cards.
[0000] The cards are shuffled properly and each player is dealt 7 cards (only 5 cards are dealt in a game with 4 players or more using only a single deck). The remaining cards are placed face down as a draw pile. The top card of the draw pile is turned over and placed face up by its side as the opening card of a discard pile. If the draw pile is used up during the game, only the top card of the discard pile is left in place whereas the rest of the discard pile is reshuffled and turned over for a new face down draw pile. The proposed game according to the fourth embodiment involves basic rules as follows:
1. In this game every number is defined only as a product of two multiplying factors according to the multiplication table (of the integers 1 through 10). For example, a player discarding “35” has to declare “5 times 7”, and a player discarding “24” can declare “4 times 6” or “3 times 8”. 2. Each player in his turn is allowed to discard one of his cards upon the top card of the discard pile, so that one declared multiplying factor (only within the multiplication table!) of said cards is common. For example, upon the card “12” which was discarded by the previous player by declaring “2 times 6”, the following player may discard any card with a multiplying factor 2 (i.e. cards “2”, “4”, . . . , “20”) or a multiplying factor 6 (i.e. cards “6”, “12”, . . . , “60”). He may discard “24” by declaring “4 times 6” (common declared multiplying factor is 6), but can not declare “3 times 8” (no common declared multiplying factor). The next player may discard any card with a multiplying factor 4 or 6 (e.g. discard “28” by declaring “4 times 7”—common declared multiplying factor is 4), and so on. 3. A player who does not discard a card loses his turn and has to draw an additional card from the draw pile. 4. A player discarding a square number card (all marked by a green number at each corner of the card) compels the following player to lose his turn and draw an additional card from the draw pile. In a game with 4 players or more using only a single deck, this player only loses his turn. However, the next player does not lose his turn and is free to continue playing the game according to rules 1-3. For example, upon the card “28” which was discarded by declaring “4 times 7”, a player may discard the card “36” by declaring “4 times 9” (the common declared multiplying factor is 4). Although the “36” (which is a square number) was not discarded by declaring “6 times 6”, the following player loses his turn and has to draw an additional card from the draw pile. The next player is free to continue the game by discarding any card having a multiplying factor 4 or 9, and so on. 5. The number of a “free” card (may only be within the multiplication table) is determined and declared at the time of discard, provided it complies with the rules of the game. Using this card wisely increases the chance of winning. For example, a player discarding a “free” card upon the card “36”, which was discarded by declaring “4 times 9”, may declare its number as “4” and discard it by declaring “4 times 1” (the common declared multiplying factor is 4), thus compelling the following player to lose his turn and to draw an additional card from the draw pile (because “4” is a square number). Inclusion of any number of “free” cards in the game is optional.
The game ends when one of the players is left with no cards, and is declared winner of the game.
A session of games is set by recording the score of each player in every game: the winner in every game scores 0 points, while each remaining player scores points according to the number of cards remaining in his hand. If the remaining players decide to continue the game, the player finishing second scores 2 points, the third scores 3 points, etc. The player scoring the lowest total of points at the end of the session is declared the winner.
[0047] The fifth embodiment according to the present invention is a card game intended for 2 or more players containing 99 cards indicating all the consecutive numbers from 1 to 99. Including “free” cards in the game is optional. Familiarity with the digits 0 to 9 is a prerequisite in this game. Preferably the players should be able to distinguish the tens-digit from the ones-digit and be familiar with the term prime number, as well. The object of each player in the game is to arrange all his cards in sets.
[0000] The cards are shuffled properly and each player is dealt 7 cards. The remaining cards are placed face down as a draw pile. The top card of the draw pile is turned over and placed face up by its side as the opening card of a discard pile. If the draw pile is used up during the game, only the top card of the discard pile is left in place whereas the rest of the discard pile is reshuffled and turned over for a new face down draw pile. The proposed game according to the fifth embodiment involves basic rules as follows:
1. Each player begins his turn by drawing the top card from the draw pile or from the discard pile optionally replacing it with one of his cards, and ends his turn by discarding one of his 8 cards to the discard pile for the next player. 2. By using his cards the player creates one or more sets in the following manner:
a. Each set must include a “key” card, which has to be a prime number (all marked by a red number at each corner of the card). b. Each set includes at least two additional cards (i.e. at least 3 cards in each set) that correspond to the “key” card by a common tens-digit or a common ones-digit. For example, a player holding the card “23” as a “key” card will try to collect additional cards having a 2 as its tens-digit (i.e. “20”, “21” . . . “29”) and cards having a 3 as its ones-digit (i.e. “3”, “13” . . . “93”). c. If the “key” card is a single-digit number (i.e. “2”, “3”, “5” or “7”) the other cards in the set will be other single-digit numbers and other cards with a common ones-digit. For example, a player holding the card “2” will try to collect other single-digit cards (i.e. “1”, “3”, “4” . . . “9”) and cards having a 2 as its ones-digit (i.e. “12”, “22” . . . “92”). d. A “free” card may replace any number in the game (may only be in the range of 1 through 99), including a “key” card.
3. In the advanced version of the game (intended for up to 4 players) “free” cards are excluded, each player is dealt 14 cards and has to arrange all his cards in up to 3 sets only.
The game ends when one of the players manages to arrange all his cards in sets according to the rules of the game, and is declared winner of the game. He reveals his 7 cards arranged in sets and discards the eighth card upon the discard pile. For example, a player may arrange all his cards in one set, including the key card “23” and the additional cards “22”, “25”, “28”, “29”, “13”, “63”, or in two sets, including a first key card “23” with additional cards “22”, “13”, “63” and a second key card “59” with additional cards “50”, “29”.
A session of games is set by recording the score of each player in every game: the winner in every game scores 0 points, while each remaining player scores points according to the number of “key” cards (plus “free” cards, if included) remaining in his hand. If the remaining players decide to continue the game, the player finishing second scores 2 points, the third scores 3 points, etc. The player scoring the lowest total of points at the end of the session is declared the winner.
[0055] The sixth embodiment according to the present invention is a card game intended for 2 or more players containing cards indicating all the consecutive numbers from 1 to an even number N decided by the players. Including 2 or 4 “free” cards in the game is optional. Familiarity with all the numbers included in the game and the ability to distinguish between odd and even numbers and/or to perform addition and/or subtraction of two of these numbers is a prerequisite in this game. The object of each player in the game is to collect the largest number of cards.
[0000] The proposed game according to the sixth embodiment involves basic rules as follows:
1. Before starting the game, the players have to decide on the number of cards included. Note: since the level of difficulty rises considerably as the number of cards increases, it is recommended to use only up to 20 cards (i.e. cards 1 through 20) in the first games, thus recognizing its virtues and avoiding mistakes. 2. The cards included in the game (for example, 1 through 40) are shuffled properly and arranged face down in rows (e.g. five rows of eight cards each). 3. Before every game the players have to choose one out of three card pairing options:
According to the first option, the sum of each pair of cards must equal N+1. For example, if the players decided to play with the cards 1 through 40 (i.e. they defined that N equals 40), the sum of every pair must equal 41 (e.g. “1”&“40”, “18”&“23”, “34”&“7”, etc.). According to the second option, the difference of each pair of cards must equal N/2. For example, if the players decided to play with the cards 1 through 40, the positive difference of every pair must equal 20 (e.g. “1”&“21”, “18”&“38”, “34”&“14”, etc.). According to the third option, the cards in each pair must include two consecutive numbers, so that always the even number is greater than the odd number. For example, if the players decided to play with the cards 1 through 40, possible pairs are “1”&“2”, “18”&“17”, “34”&“33”, etc. Note: the players need to avoid the major pitfall of pairing consecutive numbers in which the odd number is greater than the even number.
4. Each player in his turn is allowed to turn over two cards, thus revealing their face value and location. After exposing the first card, the player has to declare which second card he needs to reveal in order to get a suitable pair. For example, if the players decided to play with the cards 1 through 40 and chose pairing by sum (i.e. sum of every pair equals 41), then a player exposing the card “23” declares he needs to reveal “18” in order to complete the pair. If the player succeeded in revealing a suitable pair, he places the cards face up beside him, and is allowed to keep his turn, and so on. If he did not succeed, he verifies that all other players saw the face values of the two cards and turns them face down without changing their original location. 5. Every two “free” cards are a suitable pair in all the games.
The game ends when all the cards have been collected as pairs. The player who collected the largest number of cards is declared winner of the game.
A session of games is set by recording the score (i.e. number of cards collected) of each player in every game. The player scoring the highest total of points at the end of the session is declared the winner.
[0064] The seventh embodiment according to the present invention is a card game intended for 2 or more players containing 100 cards indicating all the consecutive numbers from 1 to 100. Including “free” cards in the game is optional. Familiarity with the digits 0 to 9 is a prerequisite in this game. Preferably, the players should be able to distinguish the tens-digits from the ones-digit and be familiar with the numbers 1 through 100 as well. The object of each player in the game is to arrange all his cards in sets.
[0000] The cards are shuffled properly and each player is dealt 14 cards. The remaining cards are placed face down as a draw pile. The top card of the draw pile is turned over and placed face up by its side as the opening card of a discard pile. If the draw pile is used up during the game, only the top card of the discard pile is left in place whereas the rest of the discard pile is reshuffled and turned over for a new face down draw pile.
The proposed game according to the seventh embodiment involves basic rules as follows:
1. Each player begins his turn by drawing the top card from the draw pile or from the discard pile optionally replacing it with one of his cards, and ends his turn by discarding one of his 15 cards to the discard pile for the next player. 2. By using his cards the player creates sets in the following manner:
a. Each set must include at least 4 cards. b. All the cards in a set must have a common tens-digit or a common ones-digit or contain only single-digit numbers. c. A “free” card may replace any number in the game (may only be in the range of 1 through 100).
The game ends when one of the players manages to arrange all his cards in sets according to the rules of the game, and is declared winner of the game. He reveals his 14 cards arranged in sets and discards the fifteenth card upon the discard pile. For example, a player may arrange all his cards in the following three sets: “4”, “34”, “54”, “84” and “20”, “23”, “25”, “26”, “29” and “43”, “5”, “6”, “8”, “9”.
A session of games is set by recording the score of each player in every game: the winner in every game scores 0 points, while each remaining player scores points according to the number of his cards not arranged in sets (plus “free” cards, if included). If the remaining players decide to continue the game, the player finishing second scores 2 points, the third scores 3 points, etc. The player scoring the lowest total of points at the end of the session is declared the winner.
[0070] The eighth embodiment according to the present invention is a card game intended for 2-4 players containing 100 cards indicating all the consecutive numbers from 1 to 100. Including “free” cards in the game is optional. Familiarity with the digits 0 to 9 is a prerequisite in this game. Preferably, the players should be able to distinguish the tens-digits from the ones-digit and be familiar with the numbers 1 through 100 as well. The object of each player in the game is to get rid of all his cards by arranging them in sets on the playing table.
[0000] The cards are shuffled properly and each player is dealt 14 cards. The remaining cards are placed face down as a draw pile.
[0071] The proposed game according to the eighth embodiment involves basic rules as follows:
1. Each player in his turn has to draw an additional card from the draw pile. 2. By using the cards, the players create sets in the following manner:
a. Each set must include 4 or 5 cards only. b. All the cards in a set must have a common tens-digit or a common ones-digit or contain only single-digit numbers. Possible sets may be, for example “4”, “34”, “54”, “84”, or “20”, “23”, “25”, “28”, “29” or “3”, “5”, “6”, “8”. c. A “free” card may replace any number in the game (may only be in the range of 1 through 100).
3. Each player has to create at least one set composed only of his own cards (termed opening set) and reveal it on the playing table in his turn. From his next turn he is allowed to discard on the playing table single or multiple cards by doing any of the following on the playing table:
a. Create and/or reveal new sets; b. Add cards to all the sets already revealed on the playing table; c. Transfer cards between existing sets; d. Cancel sets by transferring all its cards to other sets.
4. A player who cannot discard any or additional cards, passes the turn to the next player. 5. Cards already revealed in previous turns cannot be taken from the playing table. 6. A “free” card already used on the playing table can be utilized for creating another set only by canceling its original set completely, i.e. transferring all its cards to other sets on the playing table. For example, in order to isolate the “free” card by canceling the set “27, “37”, “?”, “67”, the player must transfer the card “27” to the 20's set (i.e. a set of cards having a 2 as its tens-digit), the card “37” to the 30's set, and the card “67” to the 60's set. 7. In the advanced version of the game the players can decide on any of the following adjustments:
a. Exclusion of “free” cards; b. Limiting the maximal time allotted for each turn (e.g. 2 minutes); c. Limiting the number of cards a player is allowed to discard in each single turn (e.g. up to 4 cards); d. Only a player who does not discard any card has to draw an additional card from the draw pile and loses his turn (i.e. instead of rule 1).
The game ends when one of the players is left with no cards by arranging all his cards in sets on the playing table according to the rules of the game, and is declared winner of the game.
A session of games is set by recording the score of each player in every game: the winner in every game scores 0 points, while each remaining player scores points according to the number of cards remaining in his hand (a “free” card is counted as 3 points). If the remaining players decide to continue the game, the player finishing second scores 2 points, the third scores 3 points, etc. The player scoring the lowest total of points at the end of the session is declared the winner.
[0090] The proposed embodiments according to the present invention disclose a deck of numerical cards. However, cubes indicating the numbers M to N may also be used. The proposed embodiments may be further implemented as a computer game, and therefore applied for one or more players. The game can be also implemented in a computer network (e.g. internet) enabling an individual player to play with a plurality of players over the network.
[0091] According to further modifications of the present invention, it is suggested that the game cards include a sign, thus providing a clear indication of the direction of the card. In the preferred embodiment the sign is a hat. However, grass, sky, a roof or any other illustration giving the players a clear identification of ambivalent numbers may be used.
[0092] While the above description contains many specifities, these should not be construed as limitations on the scope of the invention, but rather as exemplifications of the preferred embodiments. Those skilled in the art will envision other possible variations that are within its scope.
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A method for playing cards, the method includes: defining an arithmetic correlation between at least two cards out of multiple cards; dealing at least one card out of the multiple cards to each participant of the game; allowing each participant to arrange participant cards or to discard at least one participant card in response to an arithmetic correlation between at least one participant card and at least one other card; and repeating the stage of allowing until at least one game winner is defined.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit under 35 USC 119(e) of prior U.S. application No. 60/731,477 filed Oct. 31, 2005, the contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
This invention relates to the field content-routed networks, and in particular to a method and apparatus for converting a document from one format to another that scales in terms of speed with the throughput of a content router or a high-throughput document processing system.
BACKGROUND OF THE INVENTION
Content-based networks are described in A. Carzaniga, M. J. Rutherford, A. L. Wolf, A routing scheme for content-based networking, Department of Computer Science, University of Colorado, June 2003.
U.S. patent application Ser. No. 11/224,045, the contents of which are herein incorporated by reference, describes a methods and apparatus for highly scalable subscription matching for a content network.
FIG. 1 illustrates an exemplary content-routed network 1 . The exemplary content-routed network 1 is composed of a plurality of content-routers 2 , 3 , 4 and 5 , a plurality of publishers 6 , 7 and 13 , and a plurality of subscribers 8 , 9 , 10 , 11 , 12 , 14 , 15 and 16 .
A publisher is a computer or device that can insert content into the network. Another name commonly used in the literature is an event source or a producer. A publisher connects to a content router over a link, using a certain suite of communication protocols. For example, link 17 connects publisher 7 to content router 2 . Content takes the form of a set of documents which embodies some information to be shared among participants of a content networks. A typical suite of communication protocols used by publishers to send documents is to encapsulate them within an HTTP header and send them through a TCP/IP connection to a content router, although many other protocols may be utilized.
A subscriber is a computer or device that has expressed interest in some specific content. Another name commonly used in the literature is event displayers or consumers. A subscriber connects to a content router over a link, using similar communication protocols as the publishers. For example, link 22 connects subscriber 14 to content router 4 . FIG. 1 also illustrates an example of content from publisher 7 being injected into the content routed network 1 . Publisher 7 sends a document 25 to content router 2 . Content router 2 receives the document, and matches the contents of the document against its forwarding table. The forwarding table is comprised of a series of expressions that indicates matching conditions against the contents of received documents. For example, for documents formatted as Extensible Markup Language (XML) (refer to Extensible Markup Language (XML) 1.0 (Third Edition)”, W3C Recommendation 4 Feb. 2004, W3C (World Wide Web Consortium)) a suitable subscription syntax is XML Path Language (XPath) (refer to reference “XML Path Language (XPath) Version 1.0”, W3C Recommendation 16 Nov. 1999, W3C (Word Wide Web Consortium)).
In the field of content networks, XML is establishing itself as the language of choice for exchanging documents. Transferring documents in XML does not guarantee the interoperability between the participants of a content network. Sometime the network's participants do not share a common format or schema as is known in the art, for the documents they wish to exchange. It then becomes necessary to transform a document before delivering it to subscribers. A means for specifying these transformations and applying them becomes a requirement of a content network.
FIG. 1 exemplifies a content network 1 with transformation capability comprising content routers (CR) 2 , 3 , 4 , 5 , interconnected by links 18 , 21 , 23 and 24 . In this case the network 1 provides the usual content routing function but furthermore it also provides the document transformation capability. The network contains a set of subscriptions which will result in the forwarding of document 25 to subscribers 9 , 10 , 12 and 14 . Subscriber 9 shares the same document format as publisher 7 ; hence the network will deliver to it an unmodified copy 26 of document 25 . Subscriber 10 , connected to content router 3 by link 19 , and 12 expect the content of publisher 7 to be forwarded to it but for them to make use of the document's content, they require a conversion to a different format, specified by transformation 32 . Content router 3 is aware of the required transformation and applies it to the input document 27 producing documents 28 and 29 , which then get sent to subscriber 10 and 12 respectively. Similarly, content router 4 is aware of transformations 33 and 34 . Subscriber 14 requires two copies of document 25 : one copy to be converted as per transformation 33 and another one as per transformation 34 . After the transformations have been applied, documents 31 and 35 are sent to subscriber 14 .
As per the previous example, a content network's functionality is extended by also providing a document transformation capability. This is done by extending the entries of the content router's forwarding table to also include a reference to one or many transformations. In the above example the forwarding entries that matched input document 27 also specified that transformation 32 should be applied before issuing the document to subscribers 10 and 12 . A way of specifying transformations on XML documents is by mean of XSLT stylesheets (refer to reference “XSL Transfomations (XSLT) Version 1.0”, W3C Recommendation 16 Nov. 1999, W3C (Wold Wide Wed Consortium)).
An XSLT processor is a device which takes as input XML documents and XSLT transformations and applies the said transformations to the said input documents. There are many prior art implementations of XSLT processors. Some well known ones include SAXON and Xalan, both public domain XSLT processors. Most internet web browsers also include an XSLT processor. Another prior art XSLT processor example is described in Kuznetsov (U.S. Pat. No. 6,772,413). Kuznetsov provides a method and apparatus of computing what a given transform should be based on the description of the documents' input format and output format. The transformations are computed on the fly as new input format and output format pairs are identified. The result of the computation is machine executable code targeted for a general purpose CPU, the execution of which will transform an input document in a given format to an output document in a different format.
All prior art XSLT processor examples share a common characteristic in that they do not scale very well in terms of speed. For a content router to be able to provide a document transformation capability, it needs to be able to transform document at a speed similar to its forwarding capability. For a commercially available content router like Solace Systems' VRS/32 Value-Added Services System, this would mean a transformation capacity in the order of giga bits per second. None of the prior art architectures scale to such speed and a better approach is clearly required.
SUMMARY OF THE INVENTION
The invention herein described provides a method and apparatus for transforming documents from one format to another in a speed efficient way. In one embodiment the documents are XML documents, and the transformations are supplied by means of XSLT stylesheets.
According to an aspect of the invention there is provided a transformation module for transforming documents from one format to one or more other formats according to one or many transformation functions, comprising a memory for storing a set of allowable transformations for a document, and a dedicated processor with a plurality of pipelined stages for performing a transformation on a given document, whereby the processor can operate on several transformations in parallel.
In one embodiment the invention utilizes specially designed hardware based on silicon devices such as ASICs or FPGAs. Two key characteristics of the hardware make this invention specifically speed efficient: first; the use of parallel processing in the form of multiple transformation pipeline stages and the parallel processing of multiple transformations at the same time, and second, the use of specialized dedicated hardware highly optimized for the handling of transformation operations. This is in sharp contrast to prior art such as U.S. Pat. No. 6,772,413 which generates machine code targeted for a general purpose CPU. In accordance with the invention hardware resources are provided which can directly execute atomic transformation operations. For example an atomic operation for performing template matching of XSLT stylesheets is provided. Prior art implementations need to decompose a template matching operation into many finer grain general purpose CPU machine instructions which would then be executed sequentially.
In accordance with an embodiment of the invention many parts of a document can be operated on by the different pipeline stages and a large number of documents can be operated on in parallel. This is also in contrast to prior art implementations which process documents in steps, one step at a time and one document after another.
According to another aspect of the invention there is provided a method of transforming documents from one format to one or more other formats according to one or many transformation functions, comprising storing a set of allowable transformations for a document, and performing a transformation on a given document as a plurality of pipelined stages whereby the processor can operate on several transformations in parallel.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 shows one example of a Content-Routed Network;
FIG. 2 shows an example content router's architecture which includes a transformation module;
FIG. 3 shows the exemplary embodiment's stylesheets to control unit's tool chain;
FIG. 4 shows the exemplary embodiment's hardware pipeline stages;
FIG. 5 shows the exemplary embodiment's execution stage;
FIG. 6 details a control unit and its fields; and
FIG. 7 shows the exemplary embodiment's transformation accelerator chipset.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In an exemplary embodiment described herein, a content router routes documents formatted as Extensible Markup Language (XML) and utilizes subscriptions based on XML Path Language (XPath). The manner in which a content router forwards documents based on the content of input documents is known in the prior art as exemplified by U.S. patent application Ser. No. 11/224,045 for one example. The content router's functionality is extended to include the capability to transform documents. The transformations are written in XSL Transformations Language (XSLT). The transformations are also referred to as stylesheets in the XSLT literature.
An exemplary router architecture 70 is depicted in FIG. 2 . Note that the invention is described in the context of a content router but another suitable host application for this invention includes, but is not limited to, web servers and document publishing or processing systems. The router consists of a set of hardware modules 50 , 51 , 52 and 53 . Hardware modules communicate with each others via a shared high-speed communication bus 54 or a switching fabric. Examples of such buses include PCI-X, VME, PCI-E and RapidIO. Bus bridging devices 55 , 56 , 57 and 58 act as communication controllers between the various hardware modules. One or more Input Output modules 50 handle the physical connection of the router to other networking devices. An Input Output module typically consists of a set of Gigabit Ethernet physical interfaces 60 , 61 connected to a local area network media-access device 62 which handles the termination of the module's network protocol. The routing module 51 performs the routing functions of the router. This includes, but is not limited to: maintaining statistics on port utilization, protocol termination and computing decisions, etc. The routing module consists of a general purpose CPU 63 , connected to a memory controller 64 and a memory sub-system 65 . A router accelerator module 52 hosts a chipset 66 used for accelerating the router's forwarding decisions. Finally, a transformation module 53 is used for performing the transformations on the documents. The transformation module consists of transformation accelerator chipset 67 which communicates with the rest of the system through a bus bridging device 58 . FIG. 7 details the accelerator's chipset 255 which consists of an accelerator integrated circuit 250 , a document node memory 251 , a stylesheet memory 252 , a temporary storage memory 253 and a document string memory 254 . Suitable silicon devices for the implementation of the transformation chipset 255 include a combination of one or more of the following: FPGAs, ASICs, full custom integrated circuits 250 and memory devices 251 , 252 , 253 and 254 . The choice of devices is a trade-off between the device's part cost and the required amount of integration possible in a given device technology.
The complete description of how the router performs the forwarding function is beyond the scope of the present invention. Discussion will be limited to a description of the interaction between the transformation module 53 and the rest of the router.
Documents can be transformed at two moments during their processing by the router. First, before a forwarding decision has been taken or secondly, after a forwarding decision has been taken on the document. In both cases, the documents reside in the routing modules' memory 65 . The routing module initiates a transformation by first assigning the document to be transformed, an ingress document ID and secondly by requesting the transfer of the document to the transformation module. The later is done by copying the document from the routing module memory space to a receive buffer in the transformation accelerator, using a direct memory access (DMA), as is known in the art. The document transfer involves the routing module's bus bridging device 56 reading the document out of memory 65 by means of DMA transfers. The transformation module's bridging device 58 receives the document and writes it into the transformation receive buffer. The routing module then tells the transformation module which stylesheet to apply to the sent document by writing into command registers in the transformation's chipset. It is possible for the router to request more than one transformation on a document. The command registers' actions consist of specifying an ingress document ID and a stylesheet pointer. Also, an egress document ID is provided. The stylesheet pointer indicates the start of the data structure in the accelerator's stylesheet memory 252 that represent the stylesheet. This data structure is a sequence of control units and it will be described later. The ingress and egress document ID are used for document flow tracking purposes by the routing processor module 51 . When the transformation module 53 is done applying a stylesheet to a document, it sends the transformed document back to the routing module's memory by means of DMA transfers through the accelerator's bus bridging device 58 and from the processing module's bus bridging device 56 into its memory 65 . Note that due to the pipeline nature of the of the transformation module, it is not necessary to wait for the transformed documents to return from the accelerator before initiating another document transfer to it.
In the previous description, the stylesheets are pre-loaded in the transformation accelerator's stylesheet memory 252 . The stylesheets describe how a given transformation is performed on documents. The mechanism by which the stylesheets are downloaded to the accelerator's control unit memory 252 is now described. The stylesheets are pre-processed by the router's routing module 51 before being loaded on the transformation module 53 . The pre-processing of a stylesheet involves parsing the stylesheet, decomposing it into three static data structures. They are 1) a set of a control units, 2) a constant string table and 3) a template match information table. Controls units are atomic transformation operations that the transformation hardware can directly perform on the documents. Control units will be interpreted by various hardware resources within the transformation accelerator. The constant string table contains all the stylesheets' string constants. Finally, the template match information table is a data structure used by the template match resource 137 to compute which XSLT template to apply at a given time. The various hardware resources involved in the processing of a stylesheet will be discussed below, but first the steps required for pre-processing stylesheets will be considered.
The pre-processing of stylesheets into control units consists of three steps and is shown in FIG. 3 . First the, stylesheets are processed by a stylesheet translation tool 80 . The stylesheet translation tool 80 takes as input one XSLT stylesheet at a time (which may further include other referenced stylesheets) and generates a corresponding sequence of control units, a list of constant string table and a list of template match information table entry. The control units generated by the translation tool use symbols for the various objects that are referenced by the control units. The objects are constants, variables and control units.
The second step in the pre-processing of stylesheets is performed by the assembler tool 81 . It accepts as input a transformation consisting of control unit symbols. The control units make references to constant symbols, variable symbols and other control unit reference symbols. The output of the assembler tool is again the original transformation where the symbol references for the controls units have been resolved to their machine representation. Constant symbols are also resolved into their machine representation. Finally the output of the assembler tool is fed into the last stage of the pre-processor, the loader tool 82 .
The loader tool 82 manages the accelerator's stylesheet memory 252 . As such it knows what segments of the stylesheet memory space 252 are available for new control units, constant string and template match info entries. The loader tools 82 resolves the symbols for constant and control unit sequences. Finally, it will load the machine representation of the stylesheets into the transformation module's stylesheet memory 252 . The loader tool is also responsible for managing the de-allocation of stylesheets during the execution of the accelerator. It is possible to add and remove stylesheets from the accelerator at any given moment of its execution without impacting its operation and with minimum impact on its processing speed, provided the removed stylesheet is not in use. CPU 63 keeps track of which documents have been sent to transformation module 53 and which stylesheet(s) are in use for which document. Thus, CPU 63 can remove a stylesheet after it knows that it is not currently in use.
Now that the pre-processing of the stylesheets into control units has been described, the transformation module 53 as a whole will now described. As was previously stated, the transformation module 53 consists of a bus bridging device 58 for handling the transfer of documents back and forth between the accelerator and the routing module's memory 65 . The chipset serves as a processor implementing a set of herein described digital functions and their supporting memory functions. The partitioning of the digital functions into various IC devices is known to those skilled in the art.
The transformation accelerator chipset's functions are organised as a pipeline as illustrated in FIG. 4 . All stages of the pipeline execute in parallel; this means various documents or portions of a same document are being operated on in parallel by the various stages. Further more, some later stages of the pipeline are capable of operating on more than one document at the same time. The stages that operate on more than one document at a time are said to be operating on different contexts at a time. The pipeline stages are now described.
The documents to be transformed are handed off to the chipset by means of one or more DMA transfer fragments. The initiator of the DMA transfer is the DMA In stage 100 of the pipeline and the target of the DMA transfers is the routing module's memory 65 . The DMA transfers occur over several bus segments. Each DMA transfer a segment of the document to be transformed, from main memory 65 into a receive buffer in the DMA In stage 100 . This stage is responsible for handling the handshaking of the bus protocol between the bus bridging device 58 and the first stage of the pipeline. The bus protocol itself can be any of PCI, PCI-X, PCI-Express, Hyper Transport, other standard protocols or a proprietary one as long as the desired bus bandwidth is supported by that protocol.
The documents are read out of the DMA In stage 100 , one segment at a time, and are converted into a serial byte stream by the second stage of the pipeline; the Document Reassembler stage 101 . The Document Reassembler stage is also responsible for instructing the DMA in 100 stage of initiating the document DMA transfers upon reception of a document DMA request from the routing module 51 . The DMA requests are issued by writing into a set of Document Reassembler 101 control registers.
The next pipeline stage is responsible for parsing the documents presented to it as a stream of bytes. The parsed documents are passed along to the next pipeline stage again as a stream of bytes. In the case where a parsing error is detected while serially parsing a document, the document's byte stream is marked with an error code which will indicate to further processing stages to in turn drop the processing of the document in question. The parsing stage 102 is said to be a non-validating XML processor which means that it does not perform any validation check like adherence to an XML schema or DTD. However, a validating parser could be used in place of the non-validating parser in parsing stage 102 . The parsing stage 102 is itself divided into 7 sub-stages.
The first sub-stage of parsing detects the documents encoding and re-encodes it in Unicode. The next sub-stage processes the XML declaration if it exists. More specifically, it extracts the version, the standalone and encoding fields from the document declaration. These fields are memorized and will be used in downstream logic. The next sub-stage identifies and resolves XML characters references. (e.g. &#38, &#x3A). The next sub-stage performs a classification operation on the document's characters. The classification qualifies the characters into four mutually exclusive categories which are: 1) the characters that represent valid name characters; 2) the characters that represent valid name start characters; 3) characters which are not valid XML characters and finally; 4) all characters which do not fall in any of the previous categories. The next sub-stage identifies the start and end boundaries of various XML document constituent's boundaries. The identification result is passed along to the next parsing sub-stage by appending some qualifier bits to the stream of characters before handing it off to the next sub-stage. Table 1 summarizes the various XML constituent's boundaries identified by this sub-stage.
TABLE 1 Possible XML constituents Character Attribute Start tag boundary Empty tag boundary End tag boundary Content character Processing Instruction Name Processing Instruction Data Comment character Element Name Prefix character Default Namespace Prefix Marker Element Name LocalPart character Attribute Name Prefix character Attribute Name LocalPart character Attribute Value character Null attribute value Namespace declaration character Default Namespace declaration character Namespace delimiting character Character with no special designation
The next sub-stage performs character de-referencing and attribute normalisation. Character de-referencing and attribute normalization are common operations of any XML parser and are described in (Extensible Markup Language (XML) 1.0 (Third Edition)”, W3C Recommendation 4 Feb. 2004, W3C (World Wide Web Consortium)). The last sub-stage re-encodes the document character stream into UTF-8. The constituent's boundary information computed in the previous sub-stage is passed along to the next pipeline stage, the tag processor 103 .
The Tag processor pipeline stage 103 identifies the documents' attributes and elements which are of interest and perform some well-formedness checks on the document. The interesting elements and attributes are those that are referenced by the all accelerator stylesheets' XPath expressions. For example a stylesheet may contain an XPath expressions such as “/Invoice/*[@Total>100]”. This would be interpreted as a reference to any child of Invoice element where attribute Total is defined and is greater than 100. In this example, the element Invoice and the attribute Total are said to be of interest. The set of all elements and attributes of interest which are in use in the accelerator are organised in a look-up table data structure, which resides in the accelerator's element memory 254 . The look-up table is maintained by the loader tool 82 as part of the stylesheet management functions. The look-up table is consulted by the Tag processor every time it encounters an element name or attribute name in a document. If the element name or attribute name is present in the look-up table then a handle to it is inserted in the document's byte stream. Note that the documents' element names are first expanded with the proper namespace if one is defined. Finally, a well-formedness check is performed by this stage which involves checking that start and end tags are properly matched.
The Document Storage stage 104 is the next step in the pipeline. At this stage, the parsed documents are stored in the accelerator's document memories 251 , 254 . Memory is allocated for a document when it is stored and is de-allocated when all transformations on a document have been completed. Documents are stored in two memories: a document node memory 251 (DNM) and a document string memory 254 (DSM). The document memories can contains several documents at the same time. This characteristic enables the simultaneous processing of several documents by the various pipeline and contexts of the accelerator. The DNM 251 is used to store the structure of documents and it does so by storing tree data structures, one tree per document, that represents the various nodes of XML documents. This tree structure is similar to a DOM tree as is known in the art, except that the actual string values of the documents' nodes are stored by reference. These references point to memory locations in the DSM 254 , which contains the actual string value associated with the various documents' nodes. Another function of the Document Storage stage 104 is to accumulate the transformation requests from the host and issue them to the execution stage 105 once a document is waiting in the memories 251 , 254 . Note that the execution stage 105 operates on several documents at the same time. Each transformation request is handled by a different context. A single input document may be transformed multiple times, each of which needs its own context. While a context is executing a stylesheet on a document, it is said to be active. It is the document storage stage's responsibility to keep track of the active and non-active contexts and to dispatch the transformation requests when a context becomes non-active.
The accelerator's pipeline stages operate in parallel on many portions of the same document or many portions of different documents at the same time. The pipelining constitutes one dimension of the accelerator's parallelism. Starting at the scheduling stage another dimension of parallelism is introduced. Now, documents are being operated on by several contexts in parallel.
The portion of the hardware that executes the control units will now be described. The control units are executed in the execution stage 105 of the pipeline. The next stage of the pipeline, the output generation stage 106 , receives instructions on how to assemble the transformed documents from the execution stage. In other words, the execution of the sequence of control units representing a stylesheet will result in a stream of commands to the output generation stage 106 . The commands instruct the output generation stage on how to assemble together various constituents of what will ultimately become the transformed document.
Control units 200 shown in FIG. 6 , are made up of 3 main components: the function field 201 , the data field 202 and the result field 203 . The function 201 field specifies what transformation function should be executed. The data field 202 specifies the data on which the control unit should be operating on. The data field 202 references a subset of per execution context states which contain the actual data that will be used in the execution of the control unit. The execution of a control unit's function returns a result and a set of completion flags which are used to qualify the result. The function's returned value is saved in a specified context's state. The result field 203 contains a result location sub-field 204 which specifies what should be done with the result returned by the execution of the control unit's function. It also contains a branching sub-field 205 which when considered in conjunction with the set of completion flags will determine which control unit to execute next.
Control units provide the means for specifying the transformation operations for the stylesheet. The accelerator's parts that execute the operations are called resources. The input and output operations have a type, in the same sense that variables have a type in a structured programming language like C or Pascal. The hardware resources provide transformation primitives which operates on these data types. The various types supported by the accelerator are summarized in table 2.
TABLE 2
XSLT Data Types
Data Type
Description
NODE_INFO_TYPE
The Node Info data type contains information that is
required to access a node or perform a comparison on a
node. It contains a pointer to the node allowing
resources to index to it. It also contains a numerical
handle of the fully qualified name and a position within
the node-set if it is applicable.
STR_INFO_TYPE
The String Info type contains information that is used
to read a string from the accelerator memory.
FP_NUM_TYPE
This type contains an IEEE 754 floating point number.
BOOL_TYPE
This type contains only a single bit that indicates a
TRUE/FALSE value.
NODE_SEARCH_TYPE
The Node Search type is used when specifying the
search criteria when performing search on documents.
It is typically the data stored within control units that
request a search operation.
INT_TYPE
This type is used for representing 32-bit integers.
NODE_SET_TYPE
Contains a pointer to the head of a node-set
NODE_CONTEXT_TYPE
Contains a pointer to a node along with its position
within the node-set and the size of the node-set
CU_PTR_TYPE
Contains a pointer to a control unit.
TEMPLATE_MATCH_TYPE
This data type holds static information that is used
during template matching operations.
A block diagram of the execution stage is provided in FIG. 5 . The execution stage consists of two scheduling units: an XSLT scheduling unit 120 and an XPath scheduling unit 121 . The execution stage is capable of processing several documents in parallel, each of which executes in a context. The XPath scheduling unit 121 operates on control units derived from the stylesheets' XPath expressions while the XSLT scheduling unit 120 operates on the control units derived from the rest of the XSLT stylesheet. Each scheduling unit is surrounded by a unique set of hardware resources 137 to 140 and 145 to 149 . The resources are used to execute atomic transformation operations over the XSLT processing data types of table 2. Table 3 details the set of resources available for each scheduling units and the kind of operations handled by each of them. The operations closely map to XSLT and XPath's operations. For example the String Operation Resource 146 provides an operation CONTAIN which receives as input two STR_INFO_TYPE variables and returns a BOOL_TYPE. This resource operation maps to XPath's function contains which determine if a string is contained within another string. Certain resource operations require the use of temporary storage memory to hold the result of computations. The temporary storage memory 253 provides this facility. The temporary storage memory is itself segmented in three portions each of which is dedicated to a specific resource. The three sections and their associated resources are: 1) the variable data table which is used by the node set and variable resource, 2) the temporary string table which is used by the string operation resource and 3) the node set table which is used by the node set resource.
TABLE 3
Summary of all hardware resources and their use.
Scheduling
Resource
Unit
Description
Template Match 137
XSLT 120
Performs template matching operations on
documents. Also, issues XPath expression processing
to the XPath execution unit 121.
Node Set and Variable
XSLT 120
Provides functions for accessing the elements of a
138
node set.
Also provides functions for manipulating stylesheet's
variables. Stylesheet variables can be of any XSLT
data type.
Output Generation 140
XSLT 120
Provides the functions required for building the
constituents of the output document.
Tree Walker 145
XPath 121
Provides functions for performing searches on
documents.
String Operation 146
XPath 121
Provide various string manipulation operations.
Math Operation 148
XPath 121
Provide various math operation functions.
Node Set 149
XPath 121
Node sets are lists of document's constituents. Node
sets are built throughout the execution of a stylesheet.
This resource provides the mechanism for
manipulating node sets.
Internal 139 and 147
XSLT 120
Provides a control unit branching function as well as
and XPath
stylesheets termination functions. Note that this
121
resource is implemented in both the XSLT and XPath
execution unit.
The data flow inside a scheduling unit is now described. Each scheduling unit is composed of a control unit fetch block 133 , 141 , a dispatch block 134 , 142 , a result processing block 136 , 144 , a set of per context states 135 , 143 and a set of hardware resources 137 to 140 and 145 to 149 . The XSLT and XPath scheduling units 120 and 121 both share the same architecture for the control unit fetch 133 , the dispatcher block 134 , result processing block 136 and state variable block 135 . An execution stage 120 or 121 receives control unit requests which provide a context ID and the address of a control unit. In the case of the XSLT scheduling unit the requests come from the document storage stage. The XPath scheduling unit 121 receives its requests from the template match resource 137 . A scheduling unit processes the control unit requests in the following manner. The control unit fetch block 133 receives the control unit's address and context pair then reads the whole control unit from the control unit memory 252 and hands it off to the dispatch block 134 . A control unit 200 is ready to be dispatched to a resource for execution when there are no outstanding resource requests in progress for that context. The dispatch unit 134 decodes which resource 137 to 140 should execute the control unit's function based on the function field 201 . Also, it fetches the content of the state variable specified by the control unit data field 202 from the per context state store 135 . The dispatch unit also sends the control unit's result field 203 to the result processing unit 136 . Finally the dispatch unit hands off the control unit's function 201 and data 202 to the appropriate resource 137 to 140 for execution. The resource will execute the control unit's function and return the result to the result processing block. The result processing block does two things, it stores the function's results in the context state variable as specified by the return field and it computes which control unit to execute next based on the flags returned by the resource.
The output generation resource 140 is the interface to the next stage of the accelerator's pipeline: the output generation stage 106 . Certain transformation's control units instruct the output generation resource to issue document generation commands. There are commands for generating all the possible XML constructs as well as commands for replicating entire portions of the original document. Since the execution stage processes multiple documents at the same time, the output generation resource interleaves the commands for the generation of several documents.
The output generation stage 106 receives the document reassembly commands which tell it how to assemble the output documents. Certain portions of the output documents are given explicitly by the execution stage, for example the name or value of elements not found in the original documents. Other portions of the output document are given by reference to the constituent of the input document stored by the document storage stage 104 in the document memory 254 . Internally the documents are stored using a normalized encoding like UTF-8. It is the output generation stage's responsibility to re-encode the document in the desired output encoding. The requested encoding is specified by a transformation's control unit. The output generation stage 106 operates on as many contexts in parallel as the execution unit. This is done so as to sustain a high output document throughput.
Finally, the last stage of the accelerator pipeline is the DMA Out stage 107 . This stage receives the output documents as one stream of tuples. The tuples are composed of a document character and a context ID, so it is necessary for this stage to de-interleave the documents into as many streams as there are contexts. The DMA Out stage then assembles the document streams into DMA fragments and handles the transfer of documents into fragments to the host's memory 65 through the bus bridging devices 57 , 58 in a similar fashion as for the transfer of documents into the accelerator.
It will be appreciated that an exemplary embodiment of the invention has been described, and persons skilled in the art will appreciated that many variants are possible within the scope of the invention.
All references mentioned above are herein incorporated by reference.
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A method and apparatus for converting documents from one format to another in a speed efficient way involves a hardware module which implements several operating pipeline stages which work in parallel. The transformations are supplied and decomposed into sequences of control units. The transformation of documents consists of applying control unit sequences to input documents. The control units are themselves executed by a set of dedicated hardware resources. Furthermore the pipeline is capable of operating on more than one document at a time. Fast document transformation is a key capability of document processing systems. The use of parallel processing techniques and hardware that implements highly specialized transformation resources make this invention particularly scalable for its use in large, high speed content networks.
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BACKGROUND OF INVENTION AND DESCRIPTION OF PRIOR ART
The invention herein pertains to an apparatus for helping secure rectangularly shaped sheets of rubber roofing to the upper surface of a roof. Roofing sheets comprised of rubber materials are now used more widely for roof coverings because of the attentdant optimal life and durability. The usual approach is to place over the upper roof surface a grid-like pattern of fastening (bonding) plates, usually square-shaped members, dispersed over the upper roof surface and spaced relative to one another in a regular matrix-like pattern, generally a fixed distance apart.
The rubber roof sheets, in some applications, maybe adhered in a flush manner to the upper surfaces of such fastening plates, using a suitable adhesive. The more common practice is to disperse the fastening plates over the upper surface of the rubber roof sheets to help seal and secure the rubber roof in place over the upper roof deck.
One of the predominant problems with using conventionally structured bonding plates is that such devices do not provide an optimal sealing process in affixing and securing the rubber roof sheets to the roof deck. Frequently water leakage occurs at the point where the bonding plate is fixed to the roof deck, thus detracting substantially from the distinct advantage of using rubber roof coverings.
The subject invention is conceived to overcome such problems in the installation process using rubber roof sheets and the following objects of the subject invention are set forth accordingly.
OBJECTS
In view of the above, it is an object of the subject invention to provide an improved apparatus for affixing rubber roofing sheets to the upper surface of a roof;
Yet another object of the subject invention is to provide an improved bonding device in installing rubber roof sheets for covering roof structures;
Still another object of the subject invention is to provide an improved device for adhering and affixing rubber roof sheets to the upper surface of a roof;
Still another object of the subject invention is to provide versatile bonding plates used in roofing application;
Other and further objects of the subject invention will become apparent from a reading of the following description taken in conjunction with the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a top planar view of the bonding plate device utilizing the invention herein;
FIG. 2 is a side elevational view of the subject device;
FIG. 3 is a top perspective view of the subject device demonstrating how it is applied;
FIG. 4 is a side elevational view of the subject device demonstrating how it is affixed to fasten rubber roof sheets.
FIG. 5 is a side elevational view of a portion of the subject invention, indicating how it is affixed to a roof deck.
DESCRIPTION OF GENERAL EMBODIMENT
The invention herein is directed to an improved apparatus used for facilitating the process of affixing rectangularly shaped sheets of rubber roofing material to the upper surface of a roof, in which processes a plurality of bonding plates are used to bond the rubber roof sheets to the upper roof surface. The invention relates to an improved integrated bonding plate apparatus used as stated, wherein an adhesive material is deployed on both the upper and lower surfaces respectively of such bonding plate apparatus; and wherein such plate has integrally emeshed between its upper and lower surface both a rubber binder plate and a concentrically disposed metallic plate, the latter being centrally disposed.
DESCRIPTION OF PREFERRED EMBODIMENT
The subject invention centers on a physical apparatus for process of affixing a plurality of rubber roof sheets to the upper surface of a roof of any type of building structure. However, the preferred embodiment of the subject invention is most applicable to roof structures wherein the roof is horizontal, although it is not to be so limited. Moreover, description and application of the preferred embodiment is not to be considered as limiting the scope of the subject invention.
Turning now to the drawings, the subject invention involves an apparatus to aid in the affixing of rubber roof sheets to a roof such as roof deck 10 shown in FIGS. 3 and 4. In this respect, the roof deck 10 is a horizontal, flat structure having perimeter edges not shown. Such roof deck 10 is considered conventional in this regard, however, the subject invention can apply to a roof of any external configuration, whether rectangular, flat or other structural shape.
As a preliminary consideration in the process of affixing rubber roof sheets to roof deck 10, the first step in the process is to affix a flat layer of insulation 20 over the upper surface 25 of the roof deck, as shown in FIGS. 3 and 4. In some structural arrangements, the insulation layer is affixed underneath the undersurface 30 of the roof deck, although this latter arrangement is not shown in the drawings. The next step is to place over the insulation layer a plurality of rectangular shaped rubber roof sheets, such as sheets 40, shown in figures 3 and 4. As seen, the roofing sheets 40 are affixed in a grid-like pattern so that all sheets cover the entire roofing surface in a flush manner. Next, a plurality of bonding plates 50A, 50B . . . incorporating features of the subject invention are affixed either over or under the adjoining rubber roofsheets 40, once laid generally and preferably in a series of evely-spaced rows and columns, in regular grid-like pattern, as seen from an upper elevational view. These bonding plates 50A, 50B . . . function to secure the rubber roof sheets 40 to the upper surface of the roof deck 10 or that may underlie the rubber roof sheet.
As stated previously, it is not critical to the subject invention that the bonding plate 50A be affixed in a regular pattern, however. Particularly, in the preferred embodiment shown, the bonding plate 50A is spaced a horizontal distance from one another by several feet. These distances are considered optional and are not critical to the subject invention, however, but are described and illustrated to demonstate the matrix-like grid over which the bonding plates are dispersed.
As stated, the bonding plates 50A, 50B . . . incorporating the subject invention can be deployed by placing them over both the insulation layer 30 and the adjoining rubber roof sheets 40A, 40B . . . once such rubber roof sheets are emplaced, as seen in FIG. 2. By being so placed over the top of the rubber roof sheets 40A, 40B . . . the bonding plate covers only a portion of the rubber roof sheet, as seen in FIG. 2. Once emplaced over the top of the rubber roof sheet 40, the bonding plates 50A,50B . . . are affixed to the roof 10 by a nail 75 passing through the rubber roof sheet, as shown in FIG. 5. In an alternate arrangement, as shown in FIGS. 3 and 4, the bonding plates are placed over the insulation layer 40, and the rubber roof sheets are placed on top of the bonding plates, after they are affixed. The subject invention is equally applicable to either such described arrangement.
As shown, bonding plate 50A is constructed and comprised in part of a rectangular binder base plate member 80A preferably of square or rectangular shape and formed preferably of a pliable rubber material or other flexible material. Such base binder plate member 80A has an upper surface 90A and a lower surface 100A. This central base plate member 80A functions as the main central and support element for the bonding plate 40A. Adhered or otherwise fastened to both of the upper surface 90A and the lower surface 100A of the base binder plate 80A are doublefaced adhesive layers 110A and 120A respectively.
Affixed to the upper surface of the adhesive layer 110A is a metallic washer-like member 140 of generally circular configuration. This latter circular configuration is not essential to the subject invention, however. The circular washer member 140A has an upper surface 150A and a lower surface 160A. The lower surface of the washer plate member 140A is adhered in a flush manner against and to the upper surface of adhesive layers 110A, as shown.
Adhered conformingly and in a flush manner to the upper surface 160A of the washer plate member 140A is yet another double adhesive layer 170A, as shown in FIG. 2. Moreover, as shown in the drawings, the washer plate member 140 has a centrally disposed opening 200, which functions as the opening into which a longitudinally extending fastening device is inserted, as well as through the remaining layers parts, above described, as the bonding plate 50A, such as nail 300A, as shown in FIG. 5, to be driven into the roof deck structure 10 so as to affix the bonding plate 50A to the roof structure.
Enveloping the entire bonding plate apparatus thusly described is a removable envelope 400A, as shown, which envelope 400A is of a neutral material that envelopes both the upper and lower surface areas of bonding plate 50A, and which can be removed when the plate is to be installed. The resultant bonding plate member 50A 40A shown as being a rectangular member, is viewed from a top elevational view as shown in FIG. 1, and is essentially a multilayered sandwich-like member in which the five resultant layers of functional materials described above, are pressed together in a flush manner, layer over layer, as depicted in FIG. 2 and described above. As described, the central binder support member 80A is the main support member, with the circular washer plate 140A adding further a rigid support in the middle of the multiple layers. In the one embodiment shown, and discussed, such metallic plate 140A has a circular opening 200 in the middle thereof to receive a longitudinally extending fastening member 400 which projects in a direction perpendicular to the layered members, vertically downwardly through the roof structure so as to fasten the bonding plate 50A and the adjoining roofing sheet 40 to the roof deck 10. As shown in FIG. 2 the central base binding plate 80A is shown as being slightly larger in area as seen from a top elevational view, than the area of metallic plate 140A. It must be indicated that this area ratio between the metallic plate 140 and the central binding plate 80A is preferable, but non-critical in the constructional implementations of the subject invention.
As can be surmised, the remaining bonding plates 50B, 50C . . . are all idential in structure to bonding plate 50A, and the number of such bonding plates that are used will be directly dependent on the area of roof space to be covered.
After the bonding plate 50A is affixed to the upper surface of the roof 10 and the covering envelope 400 is removed, the upper adhesive layer 70A is exposed upwardly, and the rubber roofing sheets can be laid flush over the upper surfaces of the bonding plates 50A so as to adhere the upper surfaces of the adhesive layer 170A. This functions to adhere the rubber roof sheet to the bonding plate. Alternately, as stated, the bonding plates 50A, 50B are affixed in a flush manner to the upper surface of roof sheets 40A, 40B . . .
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The invention herein is directed to an improved apparatus used for facilitating the process of affixing rectangularly shaped sheets of rubber roofing material to the upper surface of a roof, in which process a plurality of bonding plates are used to bond the rubber roof sheets to the upper roof surface. The invention relates to an improved integrated bonding plate apparatus used as stated, wherein an adhesive material is deployed on both the upper and lower surfaces respectively of such bonding plate apparatus; and wherein such plate has integrally emeshed between the upper and lower surface both a rubber binder plate and a concentrically disposed metallic plate.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority benefit of U.S. Provisional Application Ser. No. 61/610,331 filed Mar. 13, 2012. The aforementioned provisional application is incorporated by reference in its entirety.
INCORPORATION BY REFERENCE
This application is related to U.S. application Ser. No. 13/006,316 filed Jan. 13, 2011 and U.S. application Ser. No. 13/274,763 filed Oct. 17, 2011. Each of the aforementioned applications is incorporated herein by reference in its entirety.
BACKGROUND
The present disclosure relates to improved systems and methods for hanging or suspending an object from an overhead structure. The present development will be described primarily by way of reference to a hanging apparatus for suspending a heating, ventilation, and air conditioning (“HVAC”) unit from a ceiling, ceiling joists, beams, trusses, rafters, or the like of a room or space to be heated or cooled by the HVAC unit, although it will be recognized that the apparatus herein could be adapted to hanging os suspending other objects. In certain embodiments, the system is adjustable to adjust the height at which the HVAC unit is suspended. In certain embodiments, a low profile hanger bar is employed, which may advantageously be employed in a finished space. In certain embodiments, the system is adjustable to accommodate HVAC units of different sizes.
The present system is advantageously employed with an HVAC device that is connected to a fuel source by a pipe or flexible hose. Although the HVAC devices will typically be powered by natural gas or propane, it will be recognized that the present hanging system may be uses with all manner of heating and cooling units, including without limited to HVAC models that are powered by home heating oil, waste oil, diesel fuel, steam, hot water, and electricity.
Commonly, suspended HVAC units are installed based on the orientation of the ceiling joists, beams, trusses, or rafters. Therefore, the direction of the heat or cold air is controlled only at the point of installation. Often, HVAC units are installed in a corner of a room and are only able to blow air straight ahead down the aligning wall, thereby reducing the heating or cooling efficiency of the HVAC unit. The present hanging system includes a locking swivel that allows the unit to be rotated in any desired direction. In this manner, the HVAC unit can readily be oriented to blow air out into the center of the room or area to be heated or cooled, thereby increasing the heating or cooling effectiveness of the unit installed.
A traditional method of suspending an HVAC unit, illustrated in FIG. 27 , employs the use of strut channels (e.g., UNISTRUT or the like) attached to the ceiling joists (or boards attached to or between the joists, as may be necessary to achieve a desired angular position of the HVAC unit) and threaded rods supporting the HVAC unit at its corners. When a non-swivel installation is completed, however, the HVAC unit is in a fixed position and cannot be adjusted unless it is reinstalled. This limitation can create extreme difficulty for the installer in that he may have to spend an inordinate amount of time calculating an acceptable path to best bring the fuel pipe, electrical and venting connections to this fixed position. In contrast, the present locking swivel system of this disclosure can be rotated to assist the installer with finding an optimal position for venting, fuel, and electrical connections.
In addition to this flexibility during the installation phase for both the installer and the consumer (which does not exist for the prior art strut channel/threaded rod method), the present locking swivel system in accordance with this disclosure also provides additional advantages should the installed HVAC unit require routine maintenance or service down the road. For example, HVAC units typically have one or more removable access panels or doors that provide access to the interior of the unit for servicing or repair. In the prior art strut channel/threaded rod fixed installations, if an access panel is in an inconvenient location, such as adjacent to a wall or other obstacle, future servicing and repair of the HVAC unit can be made more difficult or time consuming. In the present system, however, the bolts on the locking swivel can be removed (and the fuel line shut off and disconnected, if applicable) to permit the HVAC unit to be rotated to a desired position that allows for easier and more effective access to the unit for the service required. In this manner, the installer is provided with the full range of installation options without compromising the future serviceability of the unit. Once the servicing or maintenance is completed, the HVAC unit can be rotated back to the desired position for operation and locked back into a fixed position once again.
Although the present locking system will be described herein by way of reference to the preferred application of suspending an HVAC unit in a room, garage, basement, workshop, barn, warehouse, greenhouse, or other space to be heated or cooled, whether residential, commercial, or industrial, it will be recognized that the present system may be adapted to attach to all manner of overhead joists, beams, rafters, trusses, and other supports, whether of wood or metal (e.g., steel) construction.
In addition to hanging air conditioning and heating units, the present locking system can readily be adapted to suspend virtually any type of equipment or items, including without limitation hay, tires, or equipment in a barn or large garage setting. In addition, the locking system may be made any size as dictated by the object to be suspended. For example, the size of the locking wheel system herein may be increased to allow it to be used for larger heating elements or larger objects.
SUMMARY
In one aspect, an apparatus comprises an upper hanging member having at least one arm adapted to be attached at an upper end to an overhead structure and a horizontal portion attached to the at least one arm. A lower hanging member is adapted to attach to an object to be suspended from the overhead structure. An upper locking disk comprises a first planar body and a first pair of opposing walls projecting upward from the first planar body defining a first channel. The horizontal portion of the upper hanging member is received within the first channel. A lower locking disk comprises a second planar body and a second pair of opposing walls projecting downward from the second planar body defining a second channel. The lower hanging member is received within the second channel. A fastener extends through aligned bores in the horizontal portion of the upper hanging member, the first channel, the second channel, and the lower hanging member to provide a pivoting connection between the upper hanging member and the lower hanging member. A first plurality of spaced apart apertures is formed in the first planar body and arranged in a full or partial circular array. A second plurality of spaced apart apertures formed in the second planar body and arranged in a full or partial circular array. One or more fasteners are removably received in a selected one of the first plurality of spaced apart apertures and a selected, aligned one of the second plurality of spaced apart apertures for affixing the lower hanging member in a desired angular orientation relative to the upper hanging member.
In another aspect, a kit having component parts capable of being arranged in a disassembled or partially disassembled form and of being assembled into a hanging swivel support apparatus is provided. The kit comprises an upper hanging member having at least one arm adapted to be attached at an upper end to an overhead structure and a horizontal portion attached to the at least one arm, and a lower hanging member adapted to attach to an object to be suspended from the overhead structure. An upper locking disk comprises a first planar body and a first pair of opposing walls projecting upward from the first planar body and defining a first channel. The horizontal portion of the upper hanging member is sized to be received within the first channel. A lower locking disk comprises a second planar body and a second pair of opposing walls projecting downward from the second planar body and defining a second channel, the lower hanging member being sized to be received within the second channel. A fastener is configure to extend through aligned bores in the horizontal portion of the upper hanging member, the first channel, the second channel, and the lower hanging member to provide a pivoting connection between the upper hanging member and the lower hanging member when the hanging swivel support apparatus is assembled. A first plurality of spaced apart apertures are formed in the first planar body and arranged in a full or partial circular array and a second plurality of spaced apart apertures are formed in the second planar body and arranged in a full or partial circular array. One or more fasteners are adapted to be removably received in a selected one of the first plurality of spaced apart apertures and a selected, aligned one of the second plurality of spaced apart apertures for affixing the lower hanging member in a desired angular orientation relative to the upper hanging member when the hanging swivel support apparatus is assembled.
BRIEF DESCRIPTION OF THE DRAWINGS
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.
FIG. 1 is a front elevational view of a first embodiment of the locking swivel hanger herein, wherein the hanger bars and the U-bar are in the fully retracted position.
FIG. 2 is an enlarged perspective view of the region 2 appearing in FIG. 1 .
FIG. 3 is a front elevational view of the embodiment appearing in FIG. 1 , wherein the hanger bars and the U-bar are in the fully extended position.
FIG. 4 is a top view of the embodiment appearing in FIG. 1 in the non-pivoted position.
FIG. 5 is a top view of the embodiment appearing in FIG. 1 in a pivoted position.
FIG. 6 is an assembly view of the embodiment appearing in FIG. 1 , wherein the hanger bars are shown in elevation view and wherein the swivel bar with the lower locking disk are shown in top plan view for ease of exposition.
FIG. 7 is a photographic image of one of the locking wheels herein.
FIG. 8 is an enlarged view of the locking wheel assembly in a partially rotated and locked position.
FIG. 9 is a front elevational view of a second embodiment of the locking swivel hanger herein, wherein the hanger bars and the U-bar are in the fully retracted position.
FIG. 10 is a front elevational view of the embodiment appearing in FIG. 9 , wherein the hanger bars and the U-bar are in the fully extended position.
FIG. 11 is a top view of the embodiment appearing in FIG. 9 in the non-pivoted position, showing the swivel bar carrying the unit connector arms in the fully expanded position.
FIG. 12 is a top view of the embodiment appearing in FIG. 9 in the non-pivoted position, showing the swivel bar carrying the unit connector arms in the fully retracted position.
FIG. 13 is a top view of the embodiment appearing in FIG. 9 in a pivoted position, with the swivel bar carrying the unit connector arms in the fully retracted position.
FIG. 14 is an assembly view of the embodiment appearing in FIG. 9 , wherein the hanger bars are shown in elevation view, and wherein the swivel bar with the lower locking disk and the unit connector arms are shown in top plan view.
FIG. 15 is a front elevational view of a third embodiment of the locking swivel hanger herein, illustrating the flush mount bar oriented perpendicular to the direction of the joists.
FIG. 16 is a front elevational view of the embodiment appearing in FIG. 15 , illustrating the flush mount bar oriented parallel to the direction of the joists.
FIG. 17 is a top view of the embodiment appearing in FIG. 15 , in the non-pivoted position.
FIG. 18 is a top view of the embodiment appearing in FIG. 15 , in a pivoted position.
FIG. 19 is an assembly view of the embodiment appearing in FIG. 15 , wherein the flush mount bar is shown in elevation view and wherein the swivel bar with the lower locking disk are shown in top plan view.
FIG. 20 is a photographic image of an exemplary flush mount bar herein.
FIG. 21 is a front elevational view of a fourth embodiment of the locking swivel hanger herein, illustrating the flush mount bar oriented parallel to the direction of the joists.
FIG. 22 is a front elevational view of the embodiment appearing in FIG. 21 , illustrating the flush mount bar oriented perpendicular to the direction of the joists.
FIG. 23 is a top view of the embodiment appearing in FIG. 21 in the non-pivoted position, showing the swivel bar carrying the unit connector arms in the fully retracted position.
FIG. 24 is a top view of the embodiment appearing in FIG. 21 in a pivoted position, with the swivel bar carrying the unit connector arms in the fully retracted position.
FIG. 25 is a top view of the embodiment appearing in FIG. 21 in the non-pivoted position, with the swivel bar carrying the unit connector arms in the fully extended position.
FIG. 26 is an assembly view of the embodiment appearing in FIG. 21 , wherein the flush mount bar is shown in elevation view, and wherein the swivel bar with the lower locking disk and the unit connector bars are shown in top plan view.
FIG. 27 depicts the prior art method employing strut channels and threaded rods.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals denote like or analogous components throughout the several views, FIGS. 1-5 illustrate a first embodiment locking swivel hanger unit 100 , which includes a generally U-shaped U-bar 102 having left and right vertically-extending (in the orientation shown in FIG. 1 ) portions 104 and 106 , respectively, and a generally horizontal (in the orientation shown in FIG. 1 ) portion 108 extending therebetween. The U-bar 102 is composed of square metal (preferably steel) tubing having a generally rectangular and preferably generally square cross-sectional shape and which is precut to size and fabricated to shape.
Left and right hanger arms 114 and 116 , respectively, are telescopically received within the vertical portions 104 and 106 , respectively. The left and right hanger arms 114 and 116 are formed of square or rectangular tubing formed of steel or other metal having outer dimensions sized to be slidingly received within the vertical portions 104 and 106 of the U-bar 102 . The hanger arms 114 , 116 have openings, e.g., drilled or punched openings 118 , spaced along their lengths, for example, located on centers which are between one and two inches for adjustability, although other spacings between the openings 118 are contemplated depending on the increment for adjustment. The vertical portions 104 , 106 each have one or more (two in the illustrated preferred embodiment) openings 128 adapted to receive mechanical fasteners, such as screws, bolts, pins, clevis pins, etc. The hanger arms 114 , 116 are telescopically adjusted relative to the vertical portions 104 , 106 until the openings 128 align with desired ones of the openings 118 so as to provide for different height adjustments.
FIG. 1 shows the hanger arms 114 and 116 in the fully retracted position and FIG. 3 shows the hanger arms 114 and 116 in the fully extended position. In a preferred embodiment, the height of the U-bar and hanger arms may range from approximately 19.5 inches in the fully retracted position to about 27.5 inches in the fully extended position, although it will be recognized that the unit could be adapted for any desired height range.
Although only the front surfaces of the hanger arms and the vertical portions appear in FIG. 1 , the rearward facing surfaces will likewise have the spaced apart openings 118 and the one or more openings 128 . In preferred embodiments, either or both of the vertical portions and the hanger arms will also have spaced openings on the left and right facing surfaces. In an especially preferred embodiment, the hanger arms and the U-bar are formed of square tubing, wherein the vertical portions 104 and 106 each have openings 128 on the front and rear surfaces as well as the left and right surfaces. In this manner, it is only necessary for the hanger arms to have openings 118 on two parallel surfaces.
In the illustrated embodiment of FIG. 1 , wherein the hanger arms are inserted into the respective vertical portions such that the openings 118 are oriented from front to rear as illustrated, the hanger arms may be secured to a single joist (not shown) via fasteners (e.g., screws, bolts or other threaded or mechanical fasteners) passing through the openings 118 . Alternatively, the hanger arms can be removed from the vertical portions and rotated 90 degrees as indicated by the arrows, the hanger arms 114 , 116 can be secured to parallel (e.g., adjacent) joists via fasteners passing through the openings 118 . In further embodiments, the hanger arms 104 and 106 may have spaced apart openings on all four sides allowing installation either parallel or perpendicular to the joists without the need to remove and rotate the hanger arms 90 degrees.
A pair of locking plates, comprising an upper locking plate 130 a and a lower locking plate 130 b , is disposed between the transverse portion 108 and a transverse swivel bar 150 . The locking plates 130 a , 130 b may be formed of a metal, e.g., steel, sheet or plate stock material. The swivel bar 150 may be made from the same tubular stock material as the U-bar 102 .
As best seen in FIG. 7 , an enlarged view of an exemplary locking plate 130 is illustrated. The plate includes a disc portion 132 and a pair of upstanding and facing vertical walls 134 defining a channel 136 therebetween. The walls 134 may be fabricated from a single piece of sheet or plate material and bending. The channel 136 of the upper plate 130 a is sized to removably receive the U-bar transverse portion 108 and the channel 136 of the lower plate 130 b is sized to removably receive the swivel bar 150 . In the illustrated embodiment, wherein the U-bar 102 and the swivel bar 150 are formed of the same type of tubular stock material, the upper and lower locking plates 130 a and 130 b may be of identical construction.
The plate 130 includes a plurality of opening 138 in a generally circular array. A central opening 140 is provided for receiving a pivot fastener 142 (see FIG. 8 ) such as pin, bolt, or the like.
As best seen in FIG. 8 , and with continued reference to FIGS. 1-7 , the first plate 130 a and second plate 130 b are disposed back to back, with the transverse U-bar portion 108 being received within the channel 136 of the upper plate and the swivel bar 150 being received within the channel 136 of the lower plate. The pivot fastener 142 extends through the openings 140 in the plates 130 a , 130 b , as well as through aligned openings in the transverse portion 108 and the swivel bar 150 . In this manner, the U-bar 102 and the upper plate 130 a are rotatable relative to the swivel bar 150 and the lower plate 130 b . In the illustrated embodiment, the pivot fastener 142 is a threaded bolt. In the depicted preferred embodiment, a threaded nut 144 is received on the threaded end of the bolt 142 . In the preferred embodiment, a removable pin 146 , which may be a cotter pin, R-clip, or the like, is received through a transverse bore in the end of the bolt 142 to prevent inadvertent removal of the nut 144 . In operation, the swivel bar 150 may then be rotated to any desired angular position A (see FIG. 5 ) relative to the U-bar 102 . Preferably, a sufficient number of openings are provided to allow locking the swivel bar 150 at selected increments throughout 360 degrees of rotation. When the swivel bar 150 has been rotated to the desired position, one or more (preferably two) fasteners 148 are passed through vertically aligned openings 138 on the upper and lower plates 130 a , 130 b to secure the U-bar and the swivel bar in the desired rotational position. In the depicted embodiment, the fastener is a threaded bolt 148 secured via a complimentary threaded nut 149 , although other mechanical fasteners, such as pins, clamps and so forth are also contemplated.
In the depicted embodiment, the swivel bar 150 is illustrated as being formed of generally tubular stock having a generally square cross-sectional shape and having a plurality of openings 152 there for receiving fasteners used to secure an HVAC unit or other item or device to the swivel bar 150 . In the depicted embodiment, the openings 152 are elongated to allow adjustability, as will be described in greater detail below. It will be recognized that the swivel bar 150 may be adapted for the particular units or items to be suspended.
Referring now to FIGS. 9-14 , there appears a second embodiment locking swivel hanger 200 which adds H-bar bracket members 160 for suspending an HVAC unit or other item at four points, such as 4 points at or near the corners, but otherwise, the apparatus 200 is as described above by way of reference to the apparatus 100 . Unless stated otherwise, reference numerals appearing in FIGS. 9-14 are as described above by way of reference to FIGS. 1-8 , which discussion above is equally applicable and incorporated here by reference.
The unit 200 includes the U-bar 102 , telescoping hanger arms 114 and 116 , wherein the swivel bar 150 and the upper and lower locking plates 130 a and 130 b are pivotally secured to the U-bar transverse section 108 as detailed above. Again, the hanger arms 114 and 116 are telescoping to allow the HVAC or other item to be suspended at a user-adjustable height between the fully retracted position (see FIG. 9 ) and the fully extended position (see FIG. 10 ). In addition, the swivel bar 150 may be pivoted to any desired angle A (see FIG. 13 ) as described above.
As best seen in FIGS. 11 and 12 , the H-bars 160 are secured on opposite sides of the swivel bar 150 using a mechanical fastener (e.g., a threaded fastener) 154 . The H-bars 160 may be formed of a metal (e.g., steel) tubular stock material and may be, for example, formed of the same stock material as the U-bar and/or the swivel bar. The H-bars 160 each preferably include a plurality of openings 162 along its length. The H-bars 160 are secured via the fasteners 154 passing through one of the openings 152 in the swivel bar 150 and one of the openings 162 in the H-bars 160 , preferably a centrally located one of the openings 162 . In the depiction of FIG. 11 , the H-bars 160 are secured when the fasteners 154 pass through the outer ends of outermost elongate openings 152 in the swivel bar 150 , thus illustrating the H-bar assembly in the fully extended position.
Similarly, in the depiction of FIG. 12 , the H-bars 160 are secured when the fasteners 154 pass through the inner ends of the innermost elongate openings 152 in the swivel bar 150 , thus illustrating the H-bar assembly in the fully refracted position. The exemplary dimensions for the fully retracted and expanded positions appear in FIGS. 23 (13 ⅞ inches) and 25 (20 ¾ inches), respectively, discussed below and are equally applicable here, although other dimensions are contemplated. Intermediate positions may be obtained by loosening the fasteners 154 and positioning the H-bars 160 at intermediate positions within the elongate openings 152 , thereby accommodating HVAC units or other items of various sizes.
The plurality of openings 162 are spaced along the length of the H-bars 160 and may be used to secure the HVAC unit or other item at four points, e.g., via mechanical fasteners passing through selected ones of the openings 162 and respectively aligned mounting hardware or brackets on the HVAC unit or other device to be mounted. The spacing of the openings 162 may be selected in accordance with common or conventional sizes of HVAC units to be supported and/or mounting hardware therefore.
Referring now to FIGS. 15-20 , there appears a third locking swivel embodiment 300 including the locking swivel assembly 130 a , 130 b and swivel bar 150 as detailed above, but wherein the telescoping U-bar assembly is replaced with a low profile mounting bar 170 , which is advantageous for suspending the HVAC unit or other item in a finished space, e.g., where a drywall or other finish layer 182 does not allow direct access to the overhead ceiling joists 180 . Unless stated otherwise, reference numerals appearing in FIGS. 15-20 are as described above by way of reference to FIGS. 1-14 , which discussion above is equally applicable and incorporated here by reference.
The low profile bar 170 includes left and right mounting arms 176 for attachment to an overhead surface and an offset central portion 178 containing a central opening 177 . The bar 170 may be formed out of a tubular metal (e.g., steel) stock material and may be bent to provide any desired profile, preferably 5-6 inches although any desired height between the arms 176 and the central portion 178 is contemplated.
The low profile bar 170 may be secured via fasteners passing through one or more of the openings in each of the arms 176 and into a joist, beam, or the like 180 . As shown in FIG. 15 , the bar 170 may be oriented perpendicular to the joists 180 and the openings 172 may be spaced along the lengths of the arms 176 so as to accommodate standard or conventional joist spacings. In a preferred embodiment, the inner set of openings 172 may be spaced apart approximately 24 inches on center and the outer set of openings 172 may be spaced apart approximately 32 inches on center. In addition, the openings 172 are preferably elongated to accommodate a variety of joist spacings and increase adjustability and/or to accommodate variations or tolerances in the joist spacing for applications in which the bar 170 is mounted perpendicular to the joists as shown in FIG. 15 . Exemplary dimensions for spacing of the openings 172 appear in FIG. 23 and are equally applicable here, although other dimensions are contemplated. As shown in FIG. 16 , the low profile bar 170 may also be secured in an orientation parallel to the joists 180 along a single joist.
The central portion 178 of the low profile bar 170 is received in the channel 136 of the disc 130 a . The channel 136 of the lower disc 130 b receives the swivel bar 150 . A fastener 142 passes through the central opening 177 in the center section 178 of the bar 170 , through the central openings 140 in each of the discs 130 a and 130 b , and through the central opening in the swivel bar 150 to pivotally secure the bar 170 to the swivel bar 150 . As shown in FIG. 18 , the swivel arm 150 may be pivoted relative to the low profile bar 170 to a desired angle A.
Referring now to FIGS. 22-26 , there is shown a fourth exemplary locking swivel mount embodiment 400 , which is as described above by way of reference to FIGS. 15-20 , except where the swivel bar 150 appears with the left and right H-bars 160 as described above by way of reference to FIGS. 9-14 . Unless stated otherwise, reference numerals appearing in FIGS. 22-26 are as described above by way of reference to FIGS. 1-21 , which discussion above is equally applicable and incorporated here by reference. Again, the H-bar assembly can be rotated to any desired angle A (see FIG. 24 ) and locked in position via fasteners 148 as detailed above. Likewise, the width of H-bar assembly can be adjusted between the fully expanded width appearing in FIG. 25 and the fully retracted width appearing in FIG. 23 , as described above.
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 amended claims.
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An improved hanging apparatus with a locking swivel for suspending objects from an overhead structure is provided. The apparatus may advantageously be employed to suspend a heating, ventilation, and air conditioning (“HVAC”) unit from a ceiling, ceiling joists, beams, trusses, rafters, or the like of a room or space to be heated or cooled by the HVAC unit.
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TECHNICAL FIELD
This invention relates phase locked loops and more particularly to charge pumps used in phase locked loops.
BACKGROUND OF THE INVENTION
Frequency synthesizers are used extensively in modern portable and mobile communications equipment and their performance is a key factor in interference reduction. One factor to be considered when using these devices is the battery voltage range. When designing a radio with a frequency synthesizer for use in autos or in a base station with battery backup system, the radio design most often requires the frequency synthesizer voltage supply regulation be set at 9.5 volts or lower. This is to insure the regulator stays out of saturation under all operating conditions. When this limitation is combined with the voltage saturation limits of the voltage controlled oscillator steering circuits, in the synthesizer phase locked loop, the maximum steering range of the voltage controlled oscillator (VCO) is reduced to about 8.5 volts DC or lower. This limited voltage is a problem because for better VCO performance it is desirable to increase this voltage to approximately 11 volts DC.
Normally, this is accomplished by running the phase locked loop charge pump off a higher voltage source such as a switching supply of approximately 12 volts. The problem associated with this technique is that the switching supply generates large amounts of electrical noise. Even if only microvolt spurs of electrical noise are produced, this noise is nevertheless coupled to the VCO and performance will greatly be reduced.
Therefore, the need exists for an electrical circuit which will allow steering of a charge pump current source within a phase locked loop to a higher voltage without utilizing a switching supply. Only in this way can switching noise and other electromagnetic interference (EMI) be eliminated so as not to degrade radio performance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the operation of a preferred embodiment of the invention.
FIG. 2 is a schematic diagram showing a circuit configuration showing use of a voltage boost pump network according to a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a synthesizer charge pump network 100 includes a synthesizer divider integrated circuit 101. Synthesizer divider integrated circuit 101 includes a phase detector (not shown) for producing a first control signal 103 and a second control signal 105. First control signal 103 is used to control and operate UP pump control 107 while the second control signal 105 is used to control and operate DOWN pump control 109. UP pump control 107 utilizes supply voltage V1 and is used to switch on or off the UP charge pump current source 111. UP charge pump current source 111 sources current to increase the charge on a plurality of capacitors (not shown) located in the loop filter 117. Similarly DOWN pump control 109 also utilizes supply voltage V1 and provides voltage potential to switch on or off the DOWN charge pump current source 113. DOWN charge pump current source 113 sinks current to decrease the charge on the capacitors located in loop filter 117. The UP charge pump current source 111 and the Down charge pump current source 113 charge or discharge the loop filter 117 capacitors to set voltage level of the VCO control signal line 116. This voltage is used to control the frequency of the voltage controlled oscillator (VCO) 115. VCO 115 generates a variable frequency signal at a predetermined amplitude at VCO output signal 121. The output frequency of VCO 115 is compared through feedback signal line 118 with a reference frequency 114 by synthesizer divider integrated circuit 101. This component configuration is generally referred to as a phase locked loop (PLL) where a resultant radio frequency (RF) signal is phase locked to an integer multiple of the reference frequency. The resultant phase error detected by synthesizer divider integrated circuit 101 signal is used to control the UP charge pump current source 111 or the DOWN charge pump current source 113 to adjust the voltage on VCO control signal line 116 to keep the VCO 115 at the desired frequency. For example, if the VCO drifts high in frequency the synthesizer divider integrated circuit 101 will activate DOWN charge pump current source 113 lowering the voltage on VCO control signal line 116 and bringing the frequency of VCO 115 back to a desired frequency. The VCO output signal 121 is used as a stable RF frequency injection source for driving other modules of a communications equipment.
As discussed above, in order to provide a higher voltage than an externally switched supply voltage, the present invention utilizes the narrow duty cycle of the phase locked loop. This is accomplished by inserting voltage boost network 123 between the supply voltage V2 and UP charge pump current source 111. Voltage boost network 123 acts as a storage means or charging capacitor by allowing a stored charge of a specific voltage potential to be applied to UP charge pump current source 111 during a predetermined time. The predetermined time may be when supply voltage V2 drops below a desired level. This allows a greater voltage to be applied to UP charge pump current source 111 than would normally possible with only supply voltage V2 standing alone. Hence, voltage boost network 123 eliminates the need for a switching circuit which would act to switch an external supply at a higher supply voltage to the UP charge pump current source 111.
In operation, while UP charge pump current source 111 is controlled in its on or off state by mode by UP pump control 107, the voltage boost network 123 is also synchronously controlled by UP pump control 107 in a pre-charged and dis-charge state. This has the effect of greatly increasing the voltage to UP charge pump current source 111 to a voltage which may be increased up to substantially double supply voltage V2, applied to UP charge pump current source 111, by UP pump control 107. This increase in voltage at UP charge pump current source 111 increases the performance of the phase locked loop and avoids noise problems due to switching an external above supply voltage.
Thus, a preferred method of using the charge pump network of the present invention includes the steps of supplying a first predetermined voltage i.e. network supply voltage to a voltage boost or voltage increasing network located within the synthesizer charge pump network where the voltage boost network supplies voltage to at least one of two current sources within a phase locked loop. The boost network is then controlled synchronously along with the current source to increase the voltage supplied to the current source to a second predetermined voltage above the supply voltage. This allows the boost network to improve the operating voltage range of the phase locked loop enabling it to operate in a voltage range above a network supply voltage. The step of supplying further includes charging at least one capacitor located with the voltage boost network using the network supply voltage and switching the charge within the capacitor the current source to provide a non-steady state increase of the network supply voltage to the second predetermined voltage level thereby increasing the performance of the phase locked loop.
FIG. 2 illustrates a schematic of the preferred embodiment of a synthesizer charge pump network 200 using the voltage boost network in accordance with the present invention. A synthesizer divider IC 201 includes a phase detector (not shown) which provides a plurality of control signals. A first control signal 203 is produced which is an inverted UP signal while a second control signal 205 is produced which is an inverted DOWN signal. First control signal 203 is connected to the base of transistor 207 which is an inverting buffer used to invert the first control signal 203. Thus, transistor 207 converts the inverted UP signal into a non-inverted UP signal. Resistor 209 is connected between supply voltage V1 and the base of transistor 207 and is used for limiting the current flow drawn by transistor 207. The collector of transistor 207 is connected to the base of transistor 211 which carries current to control its on/off state. A resistor 213 is connected between supply voltage V2 and the collector of transistor 207 for limiting current flow the transistor 211 and transistor 253. Transistor 217 is a PNP semiconductor device and acts as the UP charge pump current source for the phase locked loop.
The base bias of transistor 217 is set by resistor 221 and diode 223 are connected serially between the base of transistor 217 and node 225 and the connection of resistor 219 to the collector of 211. Transistor 217 is controlled by transistor 211 which operates as a control switch or stage for transistor 217. The emitter of transistor 211 is connected to ground so when switched on the bias network of 217 is active. The resistor 226 connected between node 225 and the emitter of 217, and in conjunction with the base bias, determines the current flow through transistor 217 i.e. the UP charge pump current source magnitude. Charge capacitor 227 is connected between node 225 and ground to reduce AC ripple effects on the voltage potential present at node 225.
The second control signal 205 emitted by synthesizer divider IC 201 is connected to the base of transistor 229. Transistor 229 is a switch or control stage for transistor 231. Transistor 231 is an NPN semiconductor device and acts as the DOWN charge pump current source used in the synthesizer charge pump network 200 i.e. phase locked loop. The emitter of transistor 229 is connected to ground while the collector is connected to the base of transistor 231. Resistor 233 is connected between supply voltage V1 and the base of transistor 229 and works to limit current flow drawn by transistor 229. Resistor 235 is connected between the base of transistor 231 and supply voltage V2. Diode 237 and resistor 239 are serially connected between the base of transistor 231 and ground and along with resistor 235 sets the active state base bias of transistor 231. Resistor 241 is connected between the emitter of transistor 231 and ground, and in conjunction with the base bias of transistor 231 sets the current of transistor 231 i.e. the DOWN charge pump current source magnitude.
The collectors of transistor 217 and transistor 231 are connected at node 243 and work to either inject or drain current from a loop filter circuit shown by resistor 247, capacitor 249 and capacitor 251. The charge of the stored within the filter determines the voltage sent to the voltage controlled oscillator 245. The loop filter acts to attenuate unwanted AC signals from causing spurious emissions by modulation of the voltage controlled oscillator 245 at a predetermined frequency. It should be evident to those skilled in the art that voltage controlled oscillator 245 provides a stable RF signal at VCO output frequency 244 determined by the value of the control voltage provided on VCO control signal line 243. The frequency of VCO 245 is constantly compared and adjusted by means of feedback signal line 246 to be an integer multiple of the reference frequency provided at reference frequency input 202. In order to increase the supply voltage potential above that of supply voltage V2, the preferred embodiment of the invention includes a voltage boost pump network for increasing the voltage at node 225 without using an external voltage supply. Transistor 253 acts to switch a charging voltage, generated by supply voltage V2, through diode 259 to charge capacitor 257 to a predetermined voltage of about one diode voltage drop below V2. In operation, when transistor 217 is on and base current is present through transistor 211, transistor 253 is on which allows charge capacitor 257 to be charged to supply voltage V2 less the diode drop (approximately 0.7 volts) by the connection to V2 through diode 259. When transistor 217 is then turned off using transistor 211, transistor 253 is switched off and the voltage present within charge capacitor 257 is discharged. The series connection of resistor 255, charge capacitor 257 and diode 261 provide a path to charge capacitor 227 at node 225. Thus, the voltage present at node 225 when transistor 253 is switched off is approximately equal to the voltage within charge capacitor 257 plus the voltage present at supply voltage V2. Therefore, when charge capacitor 257 is charged, the voltage potential therein may be used as a pre-charge to increase or boost the maximum voltage on charge capacitor 227 to 2(V2)-2(Vd) where V2 is supply voltage V2 and Vd is the voltage drop across diode 259 and diode 261 at approximately 0.7 volts DC.
Moreover, this increase in voltage has the effect of increasing the maximum steering range of the synthesizer charge pump network 200 without switching external voltages i.e. those other than supply voltage V2 to transistor 217. Therefore, this reduces EMI which would be present with the switching circuits associated with the prior art to eliminate EMI problems and increase efficiency of the charge pump used in the phase locked loop.
While the preferred embodiments of the invention have been illustrated and described, it will be clear that the invention is not so limited. Numerous modifications, changes, variations, substitutions and equivalents will occur to those skilled in the art without departing from the spirit and scope of the present invention as defined by the appended claims.
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An apparatus and method of increasing the voltage of a charge pump (111) used in a synthesizer charge pump network (100). The invention enables a voltage boost network (123) to be connected to a charge pump (111) and utilizes a capacitor which is charged and discharged synchronously with the charge pump to allow the charge pump (111) to effectively operate at a higher voltage than ordinary supply (V2). The invention allows the synthesizer charge pump network (100) to be operated in a low voltage condition without providing switching of external voltages greater than supply thereby eliminating EMI and increasing operating efficiency.
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STATUS OF RELATED APPLICATIONS
This is a continuation of application Ser. No. 329,974 filed Dec. 11, 1981, now abandoned, which was a continuation-in-part of application Ser. No. 235,259 filed Feb. 17,1981, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a method and reagents for determining ligands in biological fluids such as serum, plasma, spinal fluid, amnionic fluid and urine. In particular, the present invention relates to a fluorescence polarization immunoassay procedure and to tracers employed as reagents in such procedures. The fluorescence polarization immunoassay procedure of the present invention combines the specificity of an immunoassay with the speed and convenience of fluorescence polarization techniques to provide a means for determining the amount of a specific ligand present in a sample.
Competitive binding immunoassays for measuring ligands are based on the competition between a ligand in a test sample and a labeled reagent, referred to as a tracer, for a limited number of receptor binding sites on antibodies specific to the ligand and tracer. The concentration of ligand in the sample determines the amount of tracer that will specifically bind to an antibody. The amount of tracer-antibody conjugate produced may be quantitively measured and is inversely proportional to the quantity of ligand in the test sample.
In general, fluorescence polarization techniques are based on the principle that a fluorescent labeled compound when excited by linearly polarized light will emit fluorescence having a degree of polarization inversely related to its rate of rotation. Therefore, when a molecule such as a tracer-antibody conjugate having a fluorescent label is excited with linearly polarized light, the emitted light remains highly polarized because the fluorophore is constrained from rotating between the time light is absorbed and emitted. When a "free" tracer compound (i.e., unbound to an antibody) is excited by linearly polarized light, its rotation is much faster than the corresponding tracer-antibody conjugate and the molecules are more randomly oriented, therefore, the emitted light is depolarized. Thus, fluorescence polarization provides a quantitive means for measuring the amount of tracer-antibody conjugate produced in a competitive binding immunoassay.
Various fluorescent labeled compounds are known in the art. U.S. Pat. No. 3, 998,943 describes the preparation of a fluorescently labeled insulin derivative using fluorescein isothiocyanate (FITC) as the fluorescent label and a fluorescently labeled morphine derivative using 4-aminofluorescein hydrochloride as the fluorescent label. Carboxyfluorescein has also been used for analytical determinations. R. F. Chen, Anal. Lett., 10, 787 (1977) describes the use of carboxyfluorescein to indicate the activity of phospholipase. However, carboxyfluorescein is not conjugated according to the present invention. It is encapsulated in lecithin liposomes, and it will fluoresce only when released by the hydrolysis of lecithin.
SUMMARY OF THE INVENTION
The present invention encompasses a method for determining ligands in a sample comprising intermixing with said sample a biologically acceptable salt of a tracer of the formula: ##STR1## wherein R is a ligand-analog having a single reactive primary or secondary amino group which is attached to the carbonyl carbon of the carboxyfluorescein wherein said ligand-analog has at least one common epitope with said ligand so as to be specifically reconizable by a common antibody;
and an antibody capable of specifically recognizing said ligand and said tracer; and then determining the amount of tracer antibody conjugate by fluorescence polarization techniques as a measure of the concentration of said ligand in the sample.
The invention further relates to certain novel tracers and biologically acceptable salts thereof, which are useful in reagents in the above-described method. The methods and tracers of the present invention are particularly useful in quantitatively monitoring therapeutic drug concentrations in serum and plasma.
DETAILED DESCRIPTION OF THE INVENTION
The term "ligand" as used herein refers to a molecule,in particular a low molecular weight hapten having a single reactive amino group, to which a receptor, normally an antibody, can be obtained or formed. Such haptens are protein-free bodies, generally of low molecular weight that do not induce antibody formation when injected into an animal, but are reactive to antibodies. Antibodies to hapten are generally raised by first conjugating the haptens to a protein and injecting the conjugate product into an animal. The resulting antibodies are isolated by conventional antibody isolation techniques.
Ligands determinable by the method of the present invention vary over a wide molecular weight range. Although high molecular weight ligands may be determined, for best results, it is generally preferable to employ the methods of the present invention to determine ligands of low molecular weight, generally in a range of 50 to 4000. It is more preferred to determine ligands having a molecular weight in a range of 100 to 2000.
The novel tracers of the present invention include compounds of formula (I) wherein the ligand-analog represented by R include radicals having a molecular weight within a range of 50 to 4000. The preferred novel tracers include compounds of formula (I) wherein the ligand-analogs represented by R include radicals having a molecular weight within a range of 100 to 2000.
Representative of ligands having a single reactive amino group determinable by the methods of the present invention include steriods such as esterone, estradoil, cortisol, testoestrone, progesterone, chenodeoxycholic acid, digoxin, cholic acid, digitoxin, deoxycholic acid, lithocholic acids and the ester and amide derivatives thereof; vitamins such as B-12, folic acid; thyroxine, triiodothyronine, histamine, serotonin, prostaglandins such as PGE, PGF, PGA; antiasthmatic drugs such as theophylline, antineoplastic drugs such as doxorubicin and methotrexate antiarrhythmic drugs such as disopyramide, lidocaine, procainamide, propranolol, quinidine, N-acetyl-procainamide; anticonvulsant drugs such as phenobarbital, phenytoin, primidone, valproic acid, carbamazepine and ethosuximide; antibiotics such as penicillins, cephalosporins and vancomycin; antiarthritic drugs such as salicylate; antidepressant drugs including tricyclics such as nortriptyline, amitriptyline, imipramine and desipramine; and the like as well as the metabolites thereof. Additional ligands that may be determined by the methods of the present invention include drugs of abuse such as morphine, heroin, hydromorphone, oxymorphone, metapon, codeine, hydrocodone, dihydrocodeine, dihydrohydroxy, codeinone, pholcodine, dextromethorphan, phenazocine and deonin and their metabolites.
The tracers of the present invention generally exist in an equilibrium between their acid and ionized states, and in the ionized state are effective in the method of the present invention. Therefore, the present invention comprises the tracers in either the acid or ionized state and for convenience, the tracers of thc present invention are structurally represented herein in their acid form. When the tracers of the present invention are present in their ionized state, the tracers exist in the form of biologically acceptable salts. As used herein, the term "biologically acceptable salts" refers to salts such as sodium, potassium, ammonium and the like which will enable the tracers of the present invention to exist in their ionized state when employed in the method of the present invention. Generally, the tracers of the present invention exist in solution as salts, the specific salt results from the buffer employed, i.e., in the presence of a sodium phosphate buffer, the tracers of the present invention will generally exist in their ionized state as a sodium salt.
The tracers of the present invention comprise a ligand-analog represented by R linked to a carboxyfluorescein moiety of the formula: ##STR2##
The term ligand-analog as used herein refers to a mono or polyvalent radical a substantial proportion of which has the same spatial and polar organization as the ligand to define one or more determinant or epitopic sites capable fo competing with the ligand for the binding sites of a receptor. A characteristic of such ligand-analog is that it possesses sufficient structural similarity to the ligand of interest so as to be recognized by the antibody for the ligand. For the most part, the ligand analog will have the same or substantially the same structure and charge distribution (spatial and polar organization) as the ligand of interest for a significant portion of the molecular surface. Since frequently, the linking site for a hapten will be same in preparing the antigen for production of antibodies as used for linking to the ligand, the same portion of the ligand analog which provides the template for the antibody will be exposed by the ligand analog in the tracer.
In general, the class of ligand analogs represented by R are derived from the corresponding ligand by removal of a reactive hydrogen atom, i.e., a hydrogen atom bonded to a reactive amine (primary or secondary) or by the formation of an amino derivative of the ligand wherein an imino group ##STR3## replaces one or more atoms originally present in the ligand, at the site of binding to the carboxyfluorescein moiety. Illustrative of ligands which upon the removal of a reactive hydrogen may form ligand-analogs represented by R include for example, procainamide, thyroxine and quinidine. Illustrative of ligands whose amino derivatives are useful as ligand-analog include theophylline, valproic acid, phenobarbital, phenytoin, primidone, disopyramide, digoxin, chloramphenicol, salicylate, acetaminophen, carbamazepine, desipramine and nortriptyline. In addition, a ligand may be structurally modified by the addition or deletion of one or more functional groups to form a ligand-analog, while retaining the necessary epitope sites for binding to an antibody. However, such modified ligand-analogs are bonded to the carboxyfluorescein moiety through an imino group.
The tracers of the present invention are generally prepared in accordance with known techniques. For example, a compound of the formula:
R--X (III)
wherein R is above-defined and X is a reactive hydrogen; is treated with a compound of the formula: ##STR4## wherein R is hydroxy or an active ester, and wherein the carboxy group is preferably bonded to the 4 or 5 position of the benzoic acid ring; in the presence of an inert solvent to yield a compound of formula (I).
As used herein, the term "active ester" refers to a moiety which is readily "removed" from the carboxy carbon in the presence of a coupling agent. Such "active esters" of carboxyfluorescein are readily ascertained by one of ordinary skill in the art and are prepared from the reaction of carboxyfluorescein with a compound such as N-hydroxysuccinimide, 1-hydroxybenzotriazole.hydrate or p-nitrophenol in the presence of a coupling agent, such as dicyclohexylcarbodiimide and a solvent. The active esters of carboxyfluorescein thus produced are subsequently reacted with a compound of formula (III) to yield a tracer of formula (I).
If the compound of formula (III) is water soluble, the reaction mechanism proceeds by directly reacting carboxyfluorescein with a compound of formula (III) in aqueous solution in the presence of a water soluble carbodiimide, such as 1-ethyl-3-(3'-dimethylaminopropyl)carbodiimide hydrochloride, as a coupling agent.
The temperature at which the process for preparing the tracers of this invention proceeds is not critical. The temperature should be one which is sufficient so as to initiate and maintain the reaction. Generally, for convenience and economy, room temperature is sufficient. In preparing the tracers of the present invention, the ratio of reactants is not narrowly critical. For each mole of a compound of formula (II), one should employ one mole of a compound of formula (III) to obtain a reasonable yield. It is preferred to employ an excess of compound of formula (III) for ease of reaction and recovery of the reaction products.
For ease in handling and recovery of product, the process for preparing the tracers of the present invention is conducted in the presence of an inert solvent. Suitable inert solvents include those solvents which do not react with the starting materials and are sufficient to dissolve the starting materials, and include for example water (if the compound of formula (III) is water soluble), dimethylformamide, dimethylsulfoxide and the like. If the compound of formula (III) is a reactive amine salt, a suitable base is added to the reaction mixture to form the free base of the reactive amine. Suitable bases include for example, triethylamine. The reaction products of formula (I) are generally purified using either thin-layer or column chromatography prior to application in the methods of the present invention.
In accordance with the method of the present invention, a sample containing the ligand to be determined is intermixed with a biologically acceptable salt of a tracer of formula (I) and an antibody specific for the ligand and tracer. The ligand present in the sample and the tracer compete for limiting antibody sites resulting in the formation of ligand-antibody and tracer-antibody complexes. By maintaining constant the concentration of tracer and antibody, the ratio of ligand-antibody complex to tracer-antibody complex that is formed is directly proportional to the amount of ligand present in the sample. Therefore, upon exciting the mixture with polarized light and measuring the polarization of the fluorescence emitted by a tracer and a tracer-antibody complex, one is able to quantitatively determine the amount of ligand in the sample.
In theory, the fluorescence polarization of a tracer not complexed to an antibody is low, approaching zero. Upon complexing with a specific antibody, the tracer-antibody complex thus formed assumes the rotation of the antibody molecule which is slower than that of the relatively small tracer molecule, thereby increasing the polarization observed. Therefore, when a ligand competes with the tracer for antibody sites, the observed polarization of fluorescence of the tracer-antibody complex becomes a value somewhere between that of the tracer and tracer-antibody complex. If a sample contains a high concentration of the ligand, the observed polarization value is closer to that of the free ligand, i.e., low. If the test sample contains a low concentration of the ligand, the polarization value is closer to that of the bound ligand, i.e., high. By sequentially exciting the reaction mixture of an immunoassay with vertically and then horizontally polarized light and analyzing only the vertical component of the emitted light, the polarization of fluorescence in the reaction mix may be accurately determined. The precise relationship between polarization and concentration of the ligand to be determined is established by measuring the polarization values of calibrators with known concentrations. The concentration of the ligand can be extrapolated from a standard curve prepared in this manner.
The pH at which the method of the present invention is practiced must be sufficient to allow the tracers of formula (I) to exist in their ionized state. The pH may range from about 3 to 12, more usually in the range of from about 5 to 10, most preferably from about 6 to 9. Various buffers may be used to achieve and maintain the pH during the assay procedure. Representative buffers include borate, phosphate, carbonate, tris, barbital and the like. The particular buffer employed is not critical to the present invention, but in an individual assay, a specific buffer may be preferred in view of the antibody employed and ligand to be determined. The cation portion of the buffer will generally determine the cation portion of the tracer salt in solution.
The methods of the present invention are practiced at moderate temperatures and preferably at a constant temperature. The temperature will normally range from about 0° to 50° C. more usually from about 15° to 40° C.
The concentration of ligand which may be assayed will generally vary from about 10 -2 to 10 -13 M, more usually from about 10 -4 to 10 -10 M. Higher concentrations of ligand may be assayed upon dilution of the original sample.
In addition to the concentration range of ligand of interest, considerations such as whether the assay is qualitative, semiquantitative or quantitative, the equipment employed, and the characteristics of the tracer and antibody will normally determine the concentration of the tracer and antibody to be employed. While the concentration of ligand in the sample will determine the range of concentration of the other reagents, i.e., tracer and antibody, normally to optimize the sensitivity of the assay, individual reagent concentrations will be determined empirically. Concentrations of the tracer and antibody are readily ascertained by one of ordinary skill in the art.
As previously mentioned the preferred tracers of the present inention are prepared from 5-carboxyfluorescein or 4-carboxyfluorescein or mixtures thereof and are represented by the formulas: ##STR5##
The following illustrative, nonlimiting examples will serve to further demonstrate to those skilled in the art the manner in which specific tracers within the scope of the is invention may be prepared. The symbol [CF] appearing in the structural formulas illustrating the compounds prepared in the following examples, represents a moiety of the formula: ##STR6## wherein the carbonyl carbon is attached to the 4 or 5 position in the above formula in view of the fact that a mixture of 4- and 5-carboxyfluorescein is employed as starting material.
EXAMPLE I
Meta- or para- aminophenobarbital (5 mg) and carboxyfluorescein (5 mg) were dissolved in 0.5 ml of pyridine. To the mixture was added N,N'-dichohexylcarbodiimide (15 mg). The reaction proceeded for two hours at room temperature, after which time the reaction product was purified twice employing silica gel thin-layer chromatography using a chloroform:methanol (2:1) mixture as developing solvent to yield an aminophenobarbital-carboxyfluorescein conjugate of the formula: ##STR7##
EXAMPLE II
A solution containing sodium hydroxide (1.0 g), phenytoin (2.5 g) and 2-bromomethylamine hydrobromide (2.0 g) in 100 ml of 100% ethanol was refluxed for two hours and then evaporated to dryness under reduced pressure. The residue was suspended in 50 ml of water and the pH was adjusted to pH 11 by the addition of 6N sodium hydroxide to dissolve any unreacted phenytoin. The remaining precipitate, 2-β-aminoethylphenytoin, was filtered, rinsed thoroughly with water and dried.
An active ester of carboxyfluorescein was prepared by dissolving N-hydroxysuccinimide (5 mg), carboxyfluorescein (7.5 mg) and N,N'-dicyclohexylcarbodiimide (20 mg) in 0.5 ml of pyridine. The reaction was allowed to proceed for two hours at room temperature after which time 2-β-aminoethylphenytoin (10 mg) was dissolved in the reaction mixture. The resulting mixture was allowed to react overnight in the dark at room temperature and the reaction product was purified twice employing silica gel thin-layer chromatography using a chloroform:methanol (3:1) mixture as developing solvent yield a 2-β-aminoethylphenytoin-carboxyfluorescein conjugate of the formula: ##STR8##
EXAMPLE III
A solution containing 2-carboxymethylphenytoin (620 mg), N-hydroxysuccinimide (248 mg) and N,N'-dicyclohexylcarbodiimide (453 mg) in 6 ml of dry dimethylsulfoxide was allowed to stand at room temperature overnight. The mixture was filtered and 0.7 ml of 95% hydrozine was added to 4.5 ml of the filtrate. After four hours at room temperature, 40 ml of water and 0.5 ml of 10% sodium hydroxide were added to the reaction mixture. The precipitate, 2-carboxymethylphenytoin hydrazide, was filtered, rinsed with water, dried and used without further purification.
N,N'-dicyclohexylcarbodiimide (15 mg) was added to a solution of 2-carboxymethylphenytoin hydrazide (5 mg) and carboxyfluorescein (5 mg) in 0.5 ml of pyridine. The reaction was allowed to proceed for two hours at room temperature, and the reaction product was then purified twice employing silica gel thin-layer chromatography using a chloroform:acetone (1:1) mixture as developing solvent to yield a 2-carboxymethylphenytoin hydrazide-carboxyfluorescein conjugate of the formula: ##STR9##
EXAMPLE IV
N,N'-dicyclohexylcarbodiimide (15 mg) was added to a solution of 8-β-aminoethyltheophylline (5 mg) and carboxyfluorescein (5 mg) in 0.5 ml of pyridine. The reaction was allowed to proceed for two hours at room temperature and the reaction product was purified twice employing silica gel thin-layer chromatography using a thin chloroform:methanol (2:1) mixture as developing solvent to yield an 8-β-amino ethyltheophylline-carboxyfluorescein conjugate of the formula: ##STR10##
EXAMPLE V
The procedure of Example IV was employed utilizing β-aminomethyltheophylline in lieu of 8-8-aminoethylthoephylline to yield an 8-aminomethylthoephylline-carboxyfluorescein conjugate of the formula: ##STR11##
EXAMPLE VI
δ-Valerolactam (7.5 g) was dissolved in 60 ml of dry tetrahydrofuran, under a dry nitrogen atmosphere and n-butyllithium (1.6 M, 90 ml) in hexane were added dropwise to the reaction flask and chilled in a dry ice-acetone bath. Upon completion of the addition of n-butyllithium, the reaction mixture was stirred at room temperature for one hour, refluxed for thirty minutes, and cooled to room temperature under dry nitorgen atmosphere. 1-Bromoethane (8.0 g) was slowly added to the reaction flask while the flask was chilled in an ice bath. The resulting mixture was then stirred for sixteen hours at room temperature after which time 100 ml of water was slowly added. The resulting mixture was stirred at room temperature for thirty minutes and the organic layer separated. The aqueous layer was extracted with 50 ml of diethyl ether and the organic layers were combined and dried over sodium sulfate. The solvent was evaporated to give a dark oil, which crystallized on standing. The crystalline residue was recrystallized from petroleum ether to yield 3.8 g of a residue. The residue (2.8 g) was refluxed in 25 ml of 6N hydrochlorid acid for six hours. The water was evaporated from the mixture to yield a dark, thick oil--2-ethyl-5-aminopentanoic acid--which was used without further purification.
An active ester of carboxyfluorescein was prepared by dissolving N-hydroxysuccinimide (5 mg), carboxyfluorescein (7.5 mg) and N,N'-dicyclohexylcarbodiimide (20 mg) in 0.5 ml of pyridine. The reaction was allowed to proceed for two hours at room temperature, after which time 2-ethyl-5-aminopentanoic acid (20 mg) was dissolved in the reaction mixture. The resulting mixture was allowed to react overnight in the dark at room temperature and the reaction product was purified twice employing silica gel thin-layer chromatography using a chloroform:methanol (3:1) mixture as developing solvent to yield a 2-ethyl-5-aminopentanoic acid-carboxyfluorescein conjugate of the formula: ##STR12##
EXAMPLE VII
An active ester of carboxyfluorescein was prepared by dissolving N-hydroxysuccinimide (5 mg), carboxyfluorescein (7 5 mg) and N,N'-dicyclohexylcarbodiimide (20 mg) in 0.5 ml of pyridine. The reaction was allowed to proceed for two hours at room temperature, after which time 5-(γ-aminopropylidene)-5H -dibenzo[a,d]-10,11-dihydrocycloheptene (20 mg) was dissolved in the reaction mixture. The resulting mixture was allowed to react overnight in the dark at room temperature and the reaction product was purified twice employing silica gel thin-layer chromatography using a chloroform:methanol (3:1) mixture as developing solvent to yield a 5-(γ-aminopropylidene)-5H-dibenzo[a,d]-10,11-dihydrocycloheptene-carboxyfluorescein conjugate of the formula: ##STR13##
EXAMPLE VIII
A solution containing desipramine hydrochloride (1.33 g) and chloroacetyl chloride (0.8 g) in 25 ml of chloroform was refluxed for two hours. The chloroform was evaporated and the residue was dissolved in 25 ml of acetone. Sodium iodide (0.75 g) was added to the acetone solution, and the solution was refluxed for thirty minutes. The solution was filtered and the precipitated salt was rinsed with acetone. The acetone filtrate was evaporated and the residue was taken up in 20 ml of methanol. Concentrated ammonium hydroxide (20 ml) was added to the methanol solution and the resulting solution was refluxed for one hour. The reaction mixture was extracted three times with 25 ml of chloroform and combined extracts were dried over sodium sulfate, filtered and evaporated to yield N-aminoacetyldesipramine which was used without further purification.
N-aminoacetyldesipramine (5 mg) and carboxyfluorescein (5 mg) were dissolved in 0.5 ml of pyridine. To the mixture was added N,N'-diclohexylcarbodiimide (15 mg). The reaction proceeded for two hours at room temperature, after which time the reaction product was purified twice employing silica gel thin-layer chromatography using a chloroform:acetone (1:1) mixture as developing solving to yield a N-aminoacetyldesipramine-carboxyfluorescein conjugate of the formula: ##STR14##
EXAMPLE IX
A solution containing N-hydroxysuccinimide (5 mg), carboxyfluorescein (7.5 mg) and N,N'-dicyclohexylcarbodiimide (20 mg) in 1 ml of pyridine was allowed to react at room temperature for four hours. An active ester of carboxyfluorescein was precipitated by adding 10 ml of diethylether to the reaction mixture. The precipitate was filtered, rinsed well with diethylether and redissolved in 0.5 ml of dimethylsulfoxide. L-thyroxine (10 mg) was then added to the solution and the reaction was allowed to proceed for two hours at room temperature after which time the reaction product was purified twice employing silica gel thin-layer chromatography using a chloroform:methancl (3:1) mixture as developing solvent to yield a L-thyroxinecarboxyfluorescein conjugate of the formula: ##STR15##
EXAMPLE X
A solution containing ammonium acetate (0.89 g), 3-oxodigoxigenin (389 mg) and sodium cyanoborohydride (63 mg) in 5 ml of methanol was stirred at room temperature for 48 hours. The solution was adjusted to pH 1 by the addition of concentrated hydrochloric acid and evaporated to dryness under reduced pressure. The residue was taken up in 10 ml of water and extracted three times with 10 ml of chloroform. The aqueous layer was adjusted to pH 11 by using solid potassium hydroxide. The resulting solution was extracted five times with 10 ml of methylene chloride. The organic layers were combined, dried and then evaporated to dryness under reduced pressure to yield 3-amino-3-deoxydigoxigenin which was used without further purification.
An active ester of carboxyfluorescein was prepared by dissolving N-hydroxysuccinimide (5 mg), carboxyfluorescein (7.5 mg) and N,N'-dicyclohexylcarbodiimide (20 mg) in 0.5 ml of pyridine. The reaction was allowed to proceed for two hours at room temperature, after which time a 3-amino-deoxydigoxigenin-carboxyfluorescein conjugate of the formula was isolated: ##STR16##
The following tracers were also prepared in accordance with the procedures previously described:
EXAMPLE XI--O-Aminoacetyl-propranolol-carboxyfluorescein conjugate ##STR17##
EXAMPLE XII--2-Propyl-5-aminopentanoic acid-carboxyfluorescein conjugate ##STR18##
EXAMPLE XIII--2-Butyl-5-aminopentanoic acid-carboxyfluorescein conjugate ##STR19##
EXAMPLE XIV--Aminoprimidone-carboxyfluorescein conjugate ##STR20##
EXAMPLE XV--1-(4'-nitrophenyl)-1-hydroxy-2-amino-3-hydroxypropanecarboxyfluorescein conjugate ##STR21##
EXAMPLE XVI--p-aminophenol-carboxyfluorescein conjugate ##STR22##
EXAMPLE XVII--N-(2-aminoethyl)-ethosuximidecarboxyfluorescein conjugate ##STR23##
EXAMPLE XVIII--N'-desethyl-N-acetyl-procainamidecarboxyfluorescein conjugate ##STR24##
EXAMPLE XIX--N'-desethyl-N'-aminoacetyl-N-acetyl-procainamide-carboxyfluorescein conjugate ##STR25##
EXAMPLE XX--1-amino-2-phenyl-2-(2'-pyridyl)-4-(diisopropylamino)-butanecarboxyfluorescein conjugate ##STR26##
EXAMPLE XXI--3,3',5-Triiodo-L-thyroninecarboxyfluorescein conjugate ##STR27##
EXAMPLE XXII--3,3',5,5'-tetraiodo-D-thyroninecarboxyfluorescein conjugate ##STR28##
EXAMPLE XXIII--N-aminoacetyl-iminodibenzyl carboxyfluorescein conjugate ##STR29##
EXAMPLE XXIV--Carbhydrazinoimino-dibenzyl carboxyfluorescein conjugate ##STR30##
EXAMPLE XXV--Dibenzosuberonehydrazone fluorescein conjugate ##STR31##
EXAMPLE XXVI--5-amino-10,11-dihydro-5H-dibenzo-[a,d]-cycloheptene ##STR32##
As previously mentioned, the tracers of the present invention are effective reagents for use in fluorescence polarization immunoassays. The following Examples illustrate the suitablility of tracers of the present invention in immunoassays employing fluorescence polarization techniques. Such assays are conducted in accordance with the following general procedure:
(1) A measured volume of standard or test serum is delivered into a test tube and diluted with buffer;
(2) A known concentration of a tracer of the present invention optionally containing a surfactant is then added to each tube;
(3) A known concentration of antisera is added to the tubes;
(4) The reaction mixture is incubated at room temperature; and
(5) The amount of tracer bound to antibody is measured by fluorescence polarization techniques as a measure of the amount of ligang in the sample.
EXAMPLE XXVII--Phenytion assay
(A) Materials required:
(1) BGG buffer consisting of 0.1 M sodium phosphate, pH 7.5, containing bovine gammaglobulin, 0.01% and sodium azide, 0.01%.
(2) Tracer, consisting of 2-β-aminoethyl phenytoincarboxyfluorescein at a concentration of approximately 105 nM in BGG buffer with 5% sodium cholate added.
(3) Antiserum, consisting of antiserum raised against phenytion diluted appropriately in BGG buffer containing 0.005% benzalkonium chloride.
(4) Samples of human serum or other biological fluid containing phenytoin.
(5) Cuvettes, 10×75 mm glass culture tubes us as cuvettes.
(6) Fluorometer capable of measuring fluorescence polarization with a precision of ±0.001 units.
(B) Assay Method:
(1) A small volume of sample (0.366 microliters) is placed in each cuvette by pipetting 15 μl of sample and diluting with 600 μl BGG buffer in a dilution vessel. Next, 15 μl of diluted sample is pipetted into the cuvette followed by 600 μl BGG buffer.
(2) Tracer is added by pipetting 40 μl tracer and 1000 μl BGG buffer into the cuvette.
(3) Antiserum is added to start the reaction by pipetting 40 μl antiserum into the cuvette followed by 1000 μl BGG buffer.
(4) The contents of all cuvettes are well mixed and allowed to incubate for 15 minutes at ambient temperature.
(5) The fluorescence polarization is read on a fluorometer and a standard curve constructed to determine unknowns.
(C) The results of a series of serum standards containing phenytoin at concentrations between 0 and 40 μg/ml are presented below. Each concentration was assayed in duplicate and averaged.
______________________________________Concentration ofPhenytoin (μg/ml) Polarization______________________________________0 0.2222.5 0.1965.0 0.17810.0 0.15420.0 0.13240.0 0.110______________________________________
The polarization of fluorescence is seen to decrease in a regular manner as the phenytoin concentration increases, allowing construction of a standard curve. Unknown specimens treated in an identical manner can be quantitated by reference to the standard curve, thereby illustrating the utility of 2-β-aminoethyl phenytoin-carboxyfluorescein for the measurement of phenytoin.
EXAMPLE XXVIII--Phenobarbital assay
(A) Materials required:
(1) BGG buffer (see Phenytoin)
(2) Tracer, consisting of aminophenobarbital carboxyfluorescein at a concentration of approximately 110 nM in tris HCl buffer, pH 7.5, containing 0.01% sodium azide, 0.01% bovine gamma globulin, and 0.125% sodium dodecyl sulfate.
(3) Antiserum, consiting of antiserum against phenobarbital diluted appropriately in BGG buffer containing 0.005% benzalkonium chloride.
(4) Samples of human serum or other biological fluid containing phenobarbital.
(5) Cuvettes (see Phenytoin)
(6) Fluorometer (see Phenytoin)
(B) Assay Protocol:
(1) A small volume of sample (0.196 microliter) is placed in the cuvette by pipetting 10 μl of sample and diluting with 500 μl BGG buffer in a dilution vessel. Next, 10 μl of diluted sample is pipetted into the cuvette followed by 500 μl BGG buffer.
(2) Tracer is added by pipetting 40 μl of tracer and 1000 μl BGG buffer into each cuvette.
(3) Antiserum is added to start the reaction by pipetting 40 μl antiserum followed by 1000 μl BGG buffer.
(4) The contents of all cuvettes are mixed well and allowed to incubate for 15 minutes at ambient temperature.
(5) The fluorescence polarization is read on a fluorometer and a standard curve constructed to determine unknowns.
(C) The results of a series of serum standards containing phenobarbital at concentrations between 0 and 80 μg/ml are presented below. Each concentration was assayed in duplicate and the values averaged.
______________________________________Concentration ofPhenobarbital (μl) Polarization______________________________________0 0.2505.0 0.23110.0 0.19620.0 0.15040.0 0.10480.0 0.077______________________________________
(The polarization of fluorescence is seen to decrease in a regular manner as the phenobarbital concentration increases, allowing construction of a standard curve. Unknown specimens treated in an identical manner can be quantitated by references to the standard curve thereby illustrating the utility of aminophenobarbital-carboxyfluorescein for the measurement of phenobarbital.
EXAMPLE XXIX--Theophylline assay
(A) Materials required:
(1) Tracer, consisting of 2 nM of 8-aminoethyl theophylline-carboxyfluorescein in BGG buffer (see Phentoin assay) containing 0.01% sodium dodecyl sulfate.
(2) Antiserum, consisting of antiserum raised against theophylline diluted appropriately in BGG buffer.
(3) Samples of human serum or other biological fluid containing theophylline.
(4) Cuvettes, (see Phenytoin assay)
(5) Fluorometer, (see Phenytoin assay)
(B) Assay protocol:
(1) Place 1.0 ml tracer in all cuvettes.
(2) Add 2.0 μl sample to all cuvettes.
(3) Add 1.0 ml antiserum to all cuvettes.
(4) Mix well and incubate 15 minutes at ambient temperature.
(5) Read the fluorescence polarization on a fluorometer and construct a standard curve.
(C) The results of a series of serum standards containing theophylline at concentrations between 0 and 40 μg/ml are presented. Each concentration was assayed in duplicate and the average is presented.
______________________________________Concentration ofTheophylline (μg/ml) Polarization______________________________________0 0.1582.5 0.1185 0.10510 0.09120 0.07640 0.063______________________________________
The polarization of fluorescence is seen to decrease in a regular manner as the theophylline concentration increases, allowing construction of a standard curve. Unknown specimens treated in an identical manner can be quantitated by reference to the standard curbe thereby illustrating the utility of 8-aminoethyltheophylline-carboxyfluorescein for the measurement of the theophylline.
EXAMPLE XXX--Digoxin assay
(A) Materials required:
(1) BGG buffer consisting of 0.1M sodium phosphate, pH 7.5, containing bovine gammaglobulin, 0.01% and sodium azide, 0.01%.
(2) Tracer, consisting of digoxin carboxyfluorescein at a concentration of approximately 2 nM in BGG buffer.
(3) Antiserum, consisting of rabbit antiserum raised against digoxin diluted appropriately in BGG buffer.
(4) Samples of human serum or other biological fluid containing phenytoin.
(5) Precipitation reagent--5% trichloroacetic acid in water.
(6) Cuvettes, 10×75 mm glass culture tubes used as cuvettes,
(7) Fluorometer capable of measuring fluorescence polarization with a precision of ±0.001 units.
(B) Assay protocol:
(1) To 100 μl of 5% trichloroacetic acid in a test tube is added 100 μl of a standard or unknown sample. The tubes containing the sample are capped and vortexed.
(2) The tubes containing standard or sample in trichloroacetic acid are centrifuged.
(3) To a test tube 1.8 ml of BGG buffer and 25 μl of antisera at 35° C. is added 150 μl of the trichloroacetic supernatant solution.
(4) The test tubes containing antisera and supernatant is incubated for 6 minutes at 35° C., at which time the fluorescence polarization of the tubes are measured. This measurement is the background fluorescence polarization of the standard or unknown.
(5) Ten minutes after the addition of supernatant to antisera, 25 μl of the tracer is added to the test tube.
(6) Six minutes after the addition of tracer, the fluorescence polarization of the standards and sample tubes are measured and the previously measured background fluorescence polarization is substracted to yield the fluorescence polarization of the antibody-tracer complete that had formed.
(7) The results of a series of serum standards containing digoxin at concentrations between 0 and 5 ng/ml are presented below. Four samples at each concentration were assayed and averaged.
______________________________________Digoxin Concentration (ng/ml) Polarization______________________________________0 0.1420.5 0.1341.0 0.1232.0 0.1063.0 0.0925.0 0.070______________________________________
The polarization of fluorescence is seen to decrease in a regular manner as the digoxin concentration increases, allowing construction of a standard curve. Unknown specimens treated in an identical manner can be quantitated by reference to the standard curve, thereby illustrating the utility of digoxin carboxyfluorescein for the measurement of digoxin.
The following table summarizes the various fluorescence polarization assays that have been carried out in accordance with the above-described procedures employing tracers prepared in the preceeding examples. The tracers employed are identical by Example number and the specific ligand(s) determined are indicated.
______________________________________Example No. Ligand(s)______________________________________I PhenobarbitalII PhenytoinIII PhenytoinIV TheophyllineV TheophyllineVI Valproic acidVII Nortriptyline; AmitriptylineVIII Imipramine; DesipramineIX ThyroxineX DigoxinXI PropranololXII Valproic acidXIII Valproic acidXIV PrimidoneXV ChloramphenicolXVI AcetaminophenXVII EthosuximideXVIII N--acetylprocainamideXIX N--acetylprocainamideXX DisopyramideXXI TriiodothyronineXXII ThyroxineXXIII Imipramine; DesipramineXXIV Imipramine; DesipramineXXV Nortriptyline; AmitriptylineXXVI Nortriptyline; Amitriptyline______________________________________
As evident from the above results, the tracers of the present invention are effective reagents in fluorescence polarization immunoassays. In addition to the properties mentioned above, the tracers of the present invention possess a high degree of thermal stability, a high degree of bound polarization, high quantum yields and are realitively easy to produce and purify.
Although this invention has been described with respect to specific modifications, the details thereof are not to be construed as limitations, for it will be apparent that various equivalents, changes and modifications may be resorted to without departing from the spirit and scope thereof and it is understood that such equivalent embodiments are intended to be included therein.
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This disclosure relates to a method and reagents for determining ligands in biological fluids such as serum, plasma, spinal fluid, amnionic fluid and urine. In particular, this disclosure relates to a fluorescence polarization immunoassay procedure and to a novel class of tracer compounds employed as reagents in such procedures. The procedure disclosed combines the specificity of an immunoassay with the speed and convenience of fluorescence polarization techniques to provide a means for determining the amount of a specific ligand present in a sample.
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This is a Division of application Ser. No. 569,029 filed Apr. 17, 1975.
BACKGROUND OF THE INVENTION
The general process for modifying iron, and in particular producing nodular cast iron, (i.e., cast iron comprising nodular or spheroidal graphitic inclusions) comprises in its broadest aspect supplying to molten grey iron a relatively minor amount of magnesium (based on the weight of the cast iron to be treated). Such magnesium additions preferentially lowers the sulfur and oxygen content of molten cast iron compositions, and, if sufficient magnesium is added, such treatment has the effect of producing spheroidal graphite rather than a flake graphite form.
Considerable problems have been associated with the introduction of elemental magnesium to a bath or exposed stream of molten iron. Ladle additions of magnesium to a molten iron bath have been largely avoided because the comparatively low boiling point of magnesium and its high degree of reactivity with oxygen and low density (relative to the density of the molten cast iron) causes substantial and expensive magnesium losses resulting from flash off at the surface of the molten bath. The loss is usually indicated by a violent pyrotechnic display and is accompanied by a violent reaction causing splashing of molten iron; this latter factor, along with the pyrotechnic display, constitute a serious threat to the welfare of personnel and equipment, especially in commericial operations wherein the amount of iron to be treated and the amount of magnesium metal required is generally great.
Efforts to reduce pyrotechnics and splashing have usually comprised adding the nodularizing agent to an enclosed treating ladle or enclosed reservoir stationed in the mold and through which the metal must ultimately flow. A modification to the ladle addition approach has used a tubular device to introduce solid addition agents, such as magnesium, below the surface of the molten metal; the magnesium is added in the form of a fine grain suspension in a gaseous carrier. Similar to this approach is the sub-surface injection of a mixture of powdered carbon and elemental magnesium, or the use of a tiltable reaction ladle with magnesium stored in one region thereof and caused to react under a certain vapor pressure. A commercial ladle approach, is the dropping of powdered additives of magnesium through a chute that enters a conical cavity in a stream of molten iron flowing through an aperture in the bottom of a storage chamber for molten metal; this is commonly referred to as the T-nock process. There is a vast number of other published arrangements for introducing magnesium during the pouring of molten iron into a ladle or while it is in the ladle.
In all of the above enclosed pouring ladle approaches, the results are unsatisfactory because of essentially three problems, the most important of which is that the metal must be superheated to accommodate the considerable loss in heat from reladling and pouring. The superheat destroys growth sites and thus requires post inoculation to improve the distribution of the graphite nodules; inoculation has never achieved totally satisfactory homogeneity and magnesium recovery is relatively low leading to high costs.
The other two problems comprise dross build-up in the pouring vessel and the fading of the reacted magnesium before solidification. Dross on the ladle refractories create magnesium reaction products (sulfides, oxides); this can lead to excessive pouring unit downtime as a result of inductor channel clogging, loss of vessel volume, and pouring orifice restrictions. Magnesium and post inoculant fade are time dependent phenomenon. In general, the iron must be poured within 15 minutes of the time of treatment. If this cannot be done and if corrective actions are not taken, low nodularity of carbidic castings are likely to result.
Thus the prior art has turned to treating the molten iron after it leaves the mechanical pouring unit or ladle. One general approach to this post treatment is that which treats the molten metal as it flows through the casting mold or just prior to its entrance into the mold cavity. A notable example of stream treatment employs a reaction chamber embedded in the sand mold, thus forming a part of the runner system. A charge of magnesium bearing material is added to the reaction chamber in advance of pouring. Nodularization is accomplished by the reaction of this magnesium bearing material with the molten metal flowing through the reaction chamber. Several disadvantages are associated with this process including increased casting inspection, the ratio of the poured weight of metal to the cleaned weight of metal increases, there must be closer metal-lurgical control, an investment in unique runner and gating systems, and usually a closely sized magnesium ferrosilicon alloy is required since the molten metal has a difficult time in flowing around each magnesium particle. As to the increased casting inspection, this becomes a significant disadvantage. Each mold is treated individually. The conventional method of checking each treated quantity of metal for nodularizing content and for chill is impractical. A fail safe method of adding the magnesium alloy and of checking the produced castings has yet to be developed to make this approach successful.
Earlier attempts at stream treatment used a filter element placed at the mouth of this mold gating system; the filter had a predetermined porous magnesium matrix through which the molten iron was poured. Alternatively, a consumable pouring sprue containing sponge iron impregnated with magnesium, both of which were reacted at a predetermined rate of consumption. In still another approach, an exposed stream was poured into a mold and an exposed stream of magnesium additive was projected against the stream for mixing and chemical reaction. These earlier attempts at stream treatment were, of course, unsatisfactory because they did not provide a controlled rate of solution; this is a function of alloy form and composition, treatment temperature, system heat, type and time of exposure to iron (the solvent) and oxygen available.
Whether the commercial practice has been stream treatment or ladle treatment, it has been carried out in batches; typically, up to several tons of molten iron is nodularized in a treating or holding ladle, then reladled into several pouring ladles, and then finally poured into a mold with post inoculating agents added to the pouring stream during transfer from treating ladle to the pouring ladle.
SUMMARY OF THE INVENTION
The primary object of this invention is to provide an improved method and apparatus, as well as the resulting product, for treating and manufacturing nodular cast iron, all characterized by better process control, lessened quality efforts (as judged by the uniformity of the resulting product) and lower material costs.
Another object of this invention is to provide a method and apparatus for nodularizing cast iron which is relatively independent of time variations for treating the molten iron.
Still another object is to provide a method of modifying cast iron which utilizes a constant predetermined pour rate and facilitates automatic continuous pouring requiring little or no operator control.
Particular features pursuant to the above objects comprise: (a) the use of an inclined trough having the aperture of an outlet controllable to selectively develop a pool of molten iron without interrupting flow therethrough, a modifying agent is injected into the pool and/or stream to provide turbulant flow and mixing as a result of the chemical reaction and time dwell therein; (b) the pool is built-up and dissipated in stages to provide for an initial quick fill and a trailing flushing flow; (c) the modifying agent may include a post-inoculant or a desulphurizing material, such as magnesium ferrosilicon, effective to carry out a significant desulphurization simultaneous with nodularization; (d) the superheat temperature of the treated molten stream is considerably lower (about 100°-150° F.) than prior art methods; (e) the refractory chamber is effective to reduce gaseous emissions from the nodularization treatment significantly, thereby minimizing the need for special anti-pollution equipment; (f) since the stream treating equipment is small and exterior to the mold, it can be changed to treat a variety of different sized streams at different rates and back-to-back by merely changing either the reaction chamber or changing the pouring cup and exit openings, such choice depending on the design of the particular system; (g) the treated stream is directed immediately to a mold cavity and preferably a plurality of flasks containing a number of mold cavities, at a constant time factor; and (h) the resulting cast product is characterized by a unique absence of carbides and dross, and has a nodule distribution count of at least 400 per square millimeter in a 1/2 inch section.
SUMMARY OF THE DRAWINGS
FIG. 1 is a perspective view of an apparatus embodying the principality of this invention for stream treating molten iron;
FIGS. 2 and 3 are each substantially sectional views taken, respectively, along lines 2--2 and 3--3 of FIG. 1;
FIG. 4 is a composite of views depicting steps in the control of a pool of molten iron within a reaction chamber through which the stream flows;
FIG. 5 is a graphical illustration of the preferred range of carbon and silicon useful to characterize base iron as the starting material for this invention; and
FIGS. 6 and 7 are microphotographs, respectively 100x and 50x of the solidification structure of castings resulting from the practice of this invention.
DETAILED DESCRIPTION
Apparatus
Turning first to FIGS. 1-3, there is depicted an apparatus which is particularly effective in carrying out the method of this invention and which contains novel structural features for stream treatment of molten iron. The apparatus 10 comprises means 11 defining an inclined flow course of refractory elements to conduct and define a stream of molten iron. The course consists of a receiving cup or basin 12 and a conduit 13; the cup has tapered interior walls 12a arranged to receive a predetermined continuous input or discrete charge of molten iron 25. The cup has an outlet opening 16 located at the lower most region which also serves as the inlet to adjoining structure; the size of opening 16 may effectively determine the maximum flow rate through the course but more predominantly the controlled outlet aperture of treating chamber will serve this function, as will be described. In place of the receiving cup, another conduit may be substituted to receive the iron. In any event, the inclined flow course is capable of delivering a stream of iron along a path at a predetermined flow rate influenced principally by gravity; the flow rate is changeable by primarily changing the size of opening 17 which may entail substituting a different cup 12 having a different sized opening 16 and/or adjusting the incline of the adjoining structure.
A refractory lined receptable 14 is interposed in said flow course and has a closed interior reaction or expansion chamber 15; the receptacle has an open side abutting cup 12 in a sealing manner and utilizes opening 16 as an inlet. The receptacle 14 has an outlet 17 connecting with said conduit 13 and provides for egress of molten iron. Interior side walls 14a and 14b of the receptacle are inclined with respect to a central bifurcating plane; the walls 14a and 14b ; form a trough 18 substantially along the entire length of said receptacle and have bottom 18a of the trough inclined at an angle 19 with respect to a horizontal plane.
An apparatus means 20 is arranged atop the receptacle 14 for injecting a predetermined and continuous supply of modifying agent 53 into the chamber 15 of said receptacle by way of a conduit 22 extending through an opening 21 in the receptacle roof. Means 20 may be comprised of any suitable control apparatus, such as a vibrator 27 supported on structure 28 and effective to deliver a predetermined quantity of particulate material, preferably in the form of sized pellets, from a bin containing a supply 23 of said pellets.
The outlet 17 is controllable by means 30, which may take the form of a slidable gate operable by a suitable mechanical or electronic element 31. There must be at least one aperture control for either of said inlet or outlet (17 or 18). By adjusting the position of said gate relative to the opening 17, a pool 32 of molten iron may be built-up or dissipated in said chamber 15. The apertures of openings 16 and 17 are preferably designed to be of generally equal area and thus, when unobstructed, a maximum fast flow with a minimum diameter stream can be expected through chamber 15. By traversing the gate across opening 17, a differential between said apertures may be established promoting the development of said pool and in effect daming a portion of the flow therethrough.
The function of the slidable gate is twofold; (a) it must contact the stream surface to prevent the modification agent from floating out of the reaction chamber, (b) restrain the stream flow to increase residing time in the chamber. It is conceivable that if a series of gates are arranged to skim and control flow in a highly elongated chamber, the need for a pool becomes less critical.
An optical control 35 is employed to regulate the operation of injector means 20; control 35 has an optical sensor 36 aimed along a sensing path 37 to detect the presence of molten iron in said cup 12 at about a station 38. Station 38 should be adjacent the upper portion of said cup and remote from the trough 18. The control 35 is connected and arranged to electrically activate or deactivate vibrator 27 which in turn establishes the introduction of the modifying agent. When or if the charge of molten metal recedes below the station 38, the control 35, of course, deactivates the vibrator 27 and thereby stops any further injection of the modifying agent. Thus, the terminal portion of said flow residing between said receptable 14 and station 38 will not receive direct injection of the modifying agent but will be chemically reacted by virtue of mixing with the residual iron in the flow course or in the pool 32.
The reacted molten metal is immediately directed by means 48 from conduit 13 to a plurality of molding flasks (42, 43, 44) each containing a molding cavity (45, 46, 47) for solidifying the casting. No special runner or gating system 49 is required in the molding set-up and the entire apparatus may be operated by automatic pouring equipment (not shown). Highly controlled and automated operation is not possible on a continuous basis with apparatus or methods known to the art and yet achieve the cost savings and quality castings of this invention.
Method
A preferred method aspect of this invention is as follows:
(a) A charge of base iron, having a chemistry equivalent to grey cast iron, is heated to a temperature in the range of 2500°-2700° F. Ductile or grey iron of one type considered pertinent to the present method can best be defined as that having carbon and silicon within the shaded area of the graph of FIG. 5. This type of composition of grey iron should have essentially between 3.5% and 3.7% by weight, total carbon and between 2.0 and 2.75 silicon (but as much as 3.0%). Variable end limits between these ranges, depicted by lines 61 and 62, are best defined by lines 60 and 63. Line 60 is the result of the equation where total carbon plus 1/3 silicon equals 4.55; line 63 is the result of the equation where total carbon plus 1/7 silicon is equal to 3.9. However, certain iron types may be used which have a chemistry employing a greater silicon content; thus, the problems noted on the graph of FIG. 5 are only for the iron type there selected.
(b) An inclined flow course is provided; an inclined trough is interposed in the flow course having an inlet and an outlet for the trough disposed at the lower most apex of the trough and interconnecting with the flow course. The course is enclosed and particularly the trough is enclosed so that any gaseous emissions are trapped eliminating need for special anti-pollution equipment. For example, magnesium vapor will be released and will quickly condense on the tapered walls of the trough. The inlet and outlet can be arranged to have equal areas or apertures, one of which is controllable in size by way of a slidable gate thereacross; more preferably, the outlet can be sized somewhat smaller. As shown in FIG. 3, it has been deemed preferable to control the aperture of the outlet to provide a differential between the amount of flow making an ingress as compared to the flow making an egress from the trough. The length of the trough for the preferred embodiment should be about 30 inches, and the volume of the trough (defined by inclined side walls) should provide for expansion of the molten iron when reacted with a modifying agent. Such volume can be about one-third cubic foot. To insure a proper flow rate of the molten iron through said trough, it is inclined at an angle 19 which preferably is about 5°with respect to a horizontal plane. This incline, of course, is designed with the molten iron flow under no back pressure other than that which is produced by the column of molten iron in the receiving cup 12. If additional back pressure is provided, the incline and flow rate can be adjusted accordingly. In addition, a non-oxidizing atmosphere is preferably maintained within the flow course to prevent any unwanted oxidation of the molten iron.
(c) A stream of molten ductile iron is established and passed along said incline course and through said trough; the stream is controlled to have a flow rate of typically about 10 lbs. of molten iron per second which conforms to manufacturing reality, although a more preferable flow rate would be about 5 lbs. per second.
(d) As the molten grey iron passes through said trough, a modifying agent, preferably in the form of magnesium ferrosilicon operative as a nodularizing agent, is injected at a predetermined rate onto the stream for reaction therewith. A vibrating mechanism which may be used when the agent is in a particulate or lump form; the agent 53 will be urged to spill onto and through a feeding conduit 22 for deposit at a location on the stream in the upper region of the trough. For magnesium ferrosilicon, it is added at a rate and in an amount to achieve approximately 0.04-0.55% magnesium in the final casting; 0.0004-0.0006 lbs. (0.18-0.25 grams) of magnesium is dissolved for each pound of molten iron. Magnesium, being the critical modifying agent, can be introduced in other forms such as by a solid magnesium rod advanced so that the tip thereof progressively contacts the molten stream, or the magnesium may be added in the form of pure vapor. When the magnesium in particulate compound form, it is important that the lump size not be too great so as to prevent a graduated and controlled feed and should not be too small as to prevent good reaction with the molten stream; the minimum size should not be less than 750 microns.
(e) One of the main features of this invention is the flexibility of adjusting the injection rate of the modifying agent so as to match the flow rate of the stream passing through the reaction chamber of the trough and to adjust the pouring rate to fill the mold cavities at a required interval. Accordingly, the flow through said trough or reaction chamber is adjusted to provide a stage build-up and dissipating of a pool therein of sufficient quantity to provide for turbulency and thorough mixing of the modifying agent. Improved dissolvement of the agent in the molten iron is established so that at least 90% of the magnesium is recovered in the casting.
Referring to FIG. 4, the initial stage (a) permits the molten iron supplied to the receiving cup 12 from a heating ladle or furnace 51 to flow through the chamber 15 at a fast rate with no pool build-up; gate 30 is raised so that the inlet and outlet 17 apertures being maintained at generally equal size. The injection means 20 is triggered to introduce the modifying agent 53 simultaneous with the introduction of molten iron 50 to the receiving cup as sensed by the photoelectric means 35. Accordingly, the nodularizing agent, in the form of magnesium ferrosilicon pellets will be released to contact the earliest portions of the stream. However, since there is fast flow and little dwell time within the trough, total nodularization or reaction of the modifying agent and the iron will not take place in the trough. Nonetheless, the iron must migrate through the runner and gating system before reaching the mold cavity; in so doing it has been predetermined that the initial flow of the stream will totally react outside the trough but prior to entry into the mold cavity. (b) As soon as the gate 30 can be progressively lowered to restrict the outlet 17, a pool 32 of molten iron is established in the trough which should have a sufficient depth to allow thorough reaction and turbulency 54 of the molten iron therein. This may preferably be at least 3 times the normal dimension of the stream flow. The top surface 40 of the molten pool will be built-up to such an extent that it may reach to the roof of the enclosed chamber. The entire surface of the pool will not be calm and smooth during the injecting phase of treatment since the contact of the magnesium therewith will result in immediate pyrotechnics and reactions rendering the evolution of gases 52. (c) In this stage, the gate 30 is progressively raised to cause the pool to dissipate even though further molten iron is maintained in the reception cup and even though the modifying agent is continued to be injected. The same reactions and evolution of gases, of course, continue to take place with slightly less mixing due to the receeding pool. However, this stage is arranged so that it will be close to the trailing end of the charge or stream even though the surface 56 of the charge is still above the sensor 35. The pool is caused to dissipate as quickly as possible. (d) Finally, in this stage, the pool has been fully dissipated; the inlet and outlet are maintained at identical apertures or at their full uncovered aperture thereby causing a rapid flow 59 straight through the trough. This occurs almost simultaneous with the receeding of the molten iron in the reception cup below that at which the optical eye is trained, causing the injection of the modifying agent to be stopped. Thus, the trailing end of the stream flows through the trough without contact by additional injection of the modifying agent. However, since the very trailing end of the stream will fundamentally be solidified in the gating system of the mold arrangement, the unreacted or poorly reacted iron will be discarded. The rapid flow in this stage is important since it allows for flushing of the trough carrying away any impurities or slag that are retained on the surface of the pool, such impurities solidifying in the runner or gating system.
(f) The reacted stream is directed into a plurality of flasks (42, 43, 44) each containing preferably a tree-like arrangement of numerous castings interconnected by runner and gating systems in each mold. The plurality of flasks are arranged as close as possible to the reaction chamber or trough so that the dwell time, once the magnesium has reacted with the ductile iron, is limited to less that 5 seconds. The actual flow rate into each of the molds, of course, will be variable to some degree as dictated by the type of runner and gating system and the number of molds utilized. Nonetheless, this invention permits unprecedented, quick control of reaction and casting. If the dwell time between reaction and solidification is excessive, the nodularizing effect of magnesium will diminish causing a substantial nodule degeneraton in the eventual casting.
Unprecedented cost reductions result from this continuous nodularization method for cast iron. With older techniques of nodularizing in a pouring ladle, several disadvantages resulted. Superheating was required which lead to a reduction in the number of growth sites for subsequent nodularization; post inoculation was thereby required to improve the distribution and homogeneity of the nodular cast iron, all of this resulting in higher costs. When the prior art turned to reacting magnesium in an enclosed chamber within the mold itself, a very important disadvantage resulted. There was complete lack of control or monitoring of the unviewable chamber; operators could never be quite confident that every portion of the iron charge was nodularized. Operators thus used excessive amounts of nodularizing agent to provide a margin of safety and this again, of course, resulted in additional cost increases. The elimination of any baghouse or emission control equipment is an important advantage of the instant system. The need for special runners or gating is eliminated, such as that required in a system where the reaction chamber is enclosed in the molding flask.
The present inventive method is preferably operated with a low sulfur content in the iron charge (0.01%-0.015%). However, this system is uniquely adaptable to desulfurization, to a limited degree, in the reaction chamber. Accordingly, additional desulfurizing agents may be added along with the magnesium to obtain a sulfur content of less than 0.01%. The ability to desulfurize in a local reaction chamber, immediately upstream of the mold, is unknown to the art and can lead to further significant cast reduction in the total iron treating method.
Samples
Initial experimental research tests demonstrated the importance of the control of the molten flow through an inclined trough and the importance of the pool volume with respect to obtaining a full nodularizing action in stream treatment.
In a first research sample, the trough was arranged to have no pool build-up during treatment; the flow through the inlet and outlet of the trough was relatively rapid. Starting materials comprised for 42 lbs. of pig iron, 7 lbs. of pure iron, 500 grams of ferrosilicon, 160 grams of ferro manganese and 210 grams of magnesium ferrosilicon (Mg was 6% of additive). The pour temperature was 2650° F. and a nitrogen atmosphere was contained in the reaction chamber. Vibrator action was maintained for four seconds during the pour. The castings showed very good nodularization when analyzed at the middle of the pour (taken from the outlet of the chamber). However, when analyzed at initial stage of the pour, the nodularity was very poor due to inadequate reaction.
In a second research sample, the treating system was arranged to fill a plurality of molds, carried on a long cart, rolled under the outlet of the reaction chamber. Again, there was no pool build-up during stream treatment. The starting materials for the treatment included 58.2 lbs. of pig iron, 10 lbs. of pure iron, 714 grams of ferrosilicon, 228 grams of ferro manganese, and 300 grams of magnesium ferrosilicon (Mg was 6% of additive). The vibrator was operated over a 7 second interval which provided for more adequate addition of the modifying agents. The first mold poured showed poor nodularity due to inadequate magnesium reaction, there being no build-up of a pool in the trough of the treating chamber. The second casting in the second flask showed fair to good nodularity but exhibited an inserve chill. The last casting showed excellent nodularity.
A third research sample was arranged to provide a shallow pool in the treating chamber. Starting materials were similar to that in the second sample. The pour temperature was 2680° F., there was no nitrogen contained in the reaction chamber, and pouring time took 10 seconds. The castings showed only 30% nodularity, indicating that some of the reaction between the magnesium and iron took place outside the treating chamber. Part of the problem of this particular sample arose from the inadequate location of an optical power cell to begin and stop the addition of the modifying agent.
A fourth research sample was made with starting materials similar to that in the second sample except that the magnesium ferrosilicon was adjusted to provide 5% magnesium and about 0.5 Ce in the additions. Pouring temperature was 2660° F. and the pouring time took 16 seconds. A significant and deep pool was built-up in the treating trough. The nodularity of the casting was excellent and nearly 100%. The optical power cell was aimed at a different location to insure that the injection of the modifying agent was more appropriately timed with the flow of iron through the trough; the trailing portion of the stream through the trough was not accompanied by simultaneous injection causing residual reaction of the magnesium in the pool to complete a nodularizing reaction for the trailing portion.
Product
Utilizing the stream treatment development taught herein, a new product is created having a solidification structure as illustrated in FIGS. 6 and 7. The casting microstructure is characterized by a nodular distribution at a count of at least 400 per square millimeter for a 1/2 inch section, the nodules can be and are predominately of the type I shape (spherical) by at least 90%, and there is a high degree of homogeneity. There is a definite and observable absence of dross or slag in the microstructure and a definite absence of carbides. The chemistry of the casting accompanying such microstructure consists essentially of about 3.5 carbon, 2 1/2% silicon, the ratio between carbon and silicon being about 7:5 the sulfur content being less than 0.01%, about 0.6 Mn, and the remainder being substantially iron. The magnesium content of the nodularized cast iron is about 0.004.
A zoned casting can be made from a single pour according to this invention. This if facilitated by the ability to control the stream treatment of the molten iron so that a predetermined portion may be nodularized and a predetermined portion not nodularized. Accordingly, a casting may be provided whcih has a specific volume, such as a head or a hub of a casting, containing nodularized cast iron with the remaining volume of the casting being of ductile or grey cast iron depending on the application and design.
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A method and apparatus for producing modified grey iron, and particularly nodular cast iron, is disclosed. The apparatus comprises refractory elements including an inclined flow course for continuous reception of molten grey iron, a V-shaped inclined receptacle interposed in said course into which a predetermined supply of modifying agent, such as magnesium, is injected to react with said iron, and means for controlling the egress of iron from the receptacle in order to sequentially stage the build-up and dissipation of a pool of iron in said receptacle facilitating chemical reactions and thorough mixing for attaining and improving the homogeneity of the modified iron elements. The product and composition uniquely is characterized by about 3.5 carbon, by weight, 2.5% silicon, 0.2-0.9Mn sulfur no greater than 0.015%, the remainder being essentially iron; the composition is devoid of carbide and dross or slag and has a graphite nodule count of at least 400 per square millimeter in a 1/2 inch section.
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FIELD OF THE INVENTION
This invention relates to a screw rotor for fluid handling devices such as compressors, blowers, expanders, liquid transmission pumps, and the like. More specifically, the present invention is directed to a screw rotor comprising male and female rotors, which engage with each other as they rotate with the female rotor having an addendum on its threads located at the outer edge of the pitch circle.
BACKGROUND OF THE INVENTION
There exist a number of fluid handling devices employing a pair of cooperating screw rotors. Generally, these devices include a casing with a pair of operating chambers defined by two parallel bores (e.g. cylindrical bores). A male rotor and female rotor are disposed in the parallel bores, and cooperate together during operation. For example, in a compressor one bore provides a common intake port and the other bore provides a high pressure discharge port. Typically, the male and female rotors have a wrapping angle of less than 360°.
The greater part, if not all, of the lands and troughs on the male rotor lie outside the pitch circle, while the greater part, if not all, of the troughs and lands on the female rotor which engage with the aforesaid male rotor lie within the pitch circle. Generally, the male rotor will have four (4) lands, and the female rotor will have six (6) lands.
A "land" for purposes of the present invention is defined as the protruding portion of each tooth, and located between adjacent troughs. A "trough" for purposes of the present invention is defined by the concave portion located between adjacent lands.
In related screw rotor fluid handling devices, the set of rotors are driven synchronously by means of synchronized gears. In some devices, the two rotors are driven in such a way that they do not come in contact with each other (i.e. non-contact type). In other devices, one of the rotors (i.e. the male rotor) serves as a drive rotor and contacts with the other rotor (i.e.female rotor) imparting rotary torque thereto so that both rotors are rotated together.
However, in the related non-contact type fluid handling devices, the synchronized gears must operate with great precision in order to avoid direct contact between the rotors driving up the cost of manufacture.
For this reason, the majority of screw-type fluid handling devices currently in use employ a rotary scheme by which the rotors come in direct contact with each other. The tips of the lands on the female rotor extend beyond the pitch circle, forming addendum. The troughs located between adjacent teeth on the male rotor that engage with the addendum lie within the pitch circle, forming dedendum. This arrangement scheme has replaced most previous designs. The term "addendum" for purposes of the present invention refers to the tips of the lands, which extend beyond the pitch circle, and the term "dedendum" refers to the bases of the troughs between adjacent teeth located within the pitch circle.
This type of rotor arrangement is widely used in oil jet type rotor devices, however, its use is not limited to this type of application. It can also be used in oil-less type rotor devices.
These related fluid handling device encounter some problems during operation. For example, referring to the related device shown in FIG. 4, an addendum 21 is provided on a female rotor 2. This is a contact type compressor employing screw rotors of a type as disclosed in Japanese Patent Publication 56-17559. As the male and female rotors rotate together, the addendum 21 on female rotor 2 engages with and disengages from the base 11 of trough 13 of the male rotor 1. As the screw rotors rotate together, a pocket 4 initially forms between the surfaces of the teeth of both rotors and by plate 3, and then decreases in volume size as the rotors further rotate while an escape path 41 communicating with an escape chamber of pocket 4 becomes more narrow. This situation causes exit resistance in the operating fluid leaving pocket 4 resulting in the exit becoming semi-occluded. Eventually as the escape path 41 is closed down, the fluid is compressed in the pocket 4, and work required for compression of the trap fluid in the pocket 4 is wasted.
If it should happen that the fluid trapped in the pocket 4 contains an impurity such as oil from an oil jet mechanism, or operating fluid condenses within the pocket 4, not to mention the various trapped gases located in the pocket 4, significant vibration and noise can be generated when the fluid is compressed. Furthermore, as the work required for compression of trapped fluid is increased, the efficiency and reliability of the compressor will decrease substantially.
In Japanese Patent Publication 2-50319, a design is suggested whereby the addendum 21 on the female rotor 2 is provided with a curvature matching the profile of the base dedendum on the male rotor 1. However, with this rotor arrangement, a semi-occluded pocket 4 can still form as can be seen in FIG. 5, even though it is much smaller than the pocket 4 of the arrangement shown in FIG. 4. The perfect solution to one problem results in this unrelated problem in the arrangement shown in FIG. 5.
Another problem with existing related devices concerns the possibility of forming a blowhole. This situation can occur when a screw rotor device is constructed with a female rotor 2 having addendum 21 located beyond the pitch circle. Along the line of the seal between the tips of the lands on the male and female rotors and the cylindrical wall of the operating chamber, the apices of the V-shaped chambers coincide with corresponding points along the associated line on the bore of the corresponding operating chamber. Thus, different V-shaped chambers are completely sealed with respect to each other, and theoretically there are no blowholes.
However, when addendum 22 are provided on the aforementioned female rotor 2, as shown in FIG. 6, the points at which the cylindrical bores intersect cannot extend as far as the aforementioned pitch circle. Thus, a triangular ventilation hole known as a "blowhole" will be formed by one edge of point 5 of the intersection of the bores, the top of land 12 on male rotor 1, and the advancing flank of addendum 22 on female rotor 2. The term "flank" for purposes of the present invention refers to the side of either an advancing or retreating land.
To address this problem, Japanese Patent Publication 3-4757 proposes making the troughs on the female rotor 2 arcs, generated curves, or hyperbolae, while the curves of the advancing flanks which start at the bases of the troughs between teeth and end at addendum 22 would be unique curves, not arcs, whose radii would vary with the angle of the profiles. The lands on the male rotor 1 would be arcs or generated curves; the curves of the retreating flanks on the tops of the aforesaid lands would be unique curves, not arcs, whose radii would vary with the angle of the profiles. This would minimize the area of the aforementioned blowholes.
Generally, in screw rotor devices the length of the seal line varies inversely with the area of the blowholes. When the blowholes are minimized by matching the troughs on the female rotor 2 with the lands 12 on the male rotor 1 as in the related devices, it becomes extremely difficult to shorten the sealing line.
In Example 1 discussed above, the problem is addressed by having the angle γ of the tangent to the retreating flank of the trough on the female rotor 2 approach 90°. However, as can be seen in FIG. 3, this does not sufficiently shorten the sealing line.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a screw rotor configuration whose design reduces the area of blowholes more than in the existing configurations discussed above, and virtually without relationship to the length of the sealing line.
Another object of the present invention is to provide a screw rotor configuration that concerns the shape of addendum on female rotor and the shape of the dedendum on male rotor.
A further object of the present invention is to provide a screw rotor configuration in which, when the rotor configuration is employed in a compressor, the pocket 4 enclosed by the tooth surfaces of the two rotors and the surface of the chamber does not become semi-occluded, nor is the strength of female rotor diminished, nor is there a decrease in the theoretical displacement (theoretical draft, i.e., in which the aforesaid state of semi-occlusion is prevented).
The addendum of the female rotor comprises an advancing profile and a retreating profile. The advancing profile is defined by a cross section of the female rotor from the center of the crest of the addendum to the pitch circle on the advancing side relative to the direction of rotation (O 1 -J-K-L). The retreating profile is defined by a cross section of the female rotor from the center of the crest of the addendum to the pitch circle on the retreating side relative to the direction of rotation (P-Q-R-s-O 1 ).
A first embodiment according to the present invention is an improvement on the advancing profile of the addendum on the female rotor to reduce the blowhole. This improvement is characterized in that the advancing profile includes at least three (3) arcs, preferably at least three (3) arcs with centers that lie within the pitch circle of the female rotor. The three (3) arcs are defined by a number of arcuate curves (O 1 -J-K-L) smoothly connected to each other.
The designation that a portion of the rotor is referred to as an advancing profile is not meant to suggest that the rotor configuration can only be applied in compressors. This terminology was selected only so as to specify which of the two flanks on either side of the center of the crest of the addendum is being referred to. This embodiment as well as the third embodiment to be discussed below can also be applied to fluid pumps, blowers, or expanders.
In the first embodiment described above, the base portions of the dedendum of the male rotor, which correspond to the advancing profile of the addendum of the female rotor should have the shape of a generated curve matching the multiple arcuate curves.
A second embodiment of the invention according to the present invention concerns the retreating profiles of the addendum on the female rotor. The retreating profiles are shaped to prevent the occurrence of a state of semi-occlusion, which occurs in current related devices as described above, without reducing the strength of the female rotor or diminishing its theoretical displacement (i.e. theoretical draft). The second embodiment is characterized in that the retreating profile is defined by at least three (3) arcs, preferably at least three (3) arcs with centers that lie within the pitch circle. The three (3) arcs are defined by a number of arcuate curves (P-Q-R-S-O 1 ) smoothly connected to each other.
Of these several arcs, at least one (Q-R) of the arcs adjacent to the topmost arc and not extending as far as the pitch circle should have a radius substantially greater than that of the arc extending to the pitch circle (Q-P) of the female rotor.
The crest of each addendum of the female rotor includes a single arcuate curve (S-J), concentric with the shaft of the female rotor, which extends from the retreating side to the advancing side. The angle subtended by the arcuate curve is less than 4°.
As the state of semi-occlusion described above is primarily problematical in compressors, it follows that the second embodiment will be especially effective in compressors, fluid pumps and blowers.
In the second embodiment described above, a portion on each dedendum of the male rotor, which corresponds to the retreating profile on each addendum of the female rotor should have the form of a generated curve matching the several arcuate curves of the female rotor.
A third embodiment of the present invention has a rotor configuration to prevent both blowholes and the state of semi-occlusion. At a right angle to the shaft, a cross sectional profile of the addendum on the female rotor is defined by a number of arcuate curves (P-Q-R-J-K-L ) including at least five (5) arcs, and preferably the at least five (5) arcs have centers that lie within pitch circle of the female rotor.
The shape of each dedendum on the male rotor is a generated curve matching the several arcuate curves of the addendum of the female rotor.
The crest of the addendum on the female rotor are defined by a single arcuate curve (S-J), which are concentric with the shaft of female rotor 2 and extend from the retreating side to the advancing side. The angle subtended by the arcuate curve should be less than 4°.
The operation of the first embodiment of the present invention is as follows.
The blowhole illustrated in FIG. 3 will appear triangular when viewed in cross section along the A--A line in FIG. 6. If the addendum on the advancing surface of the female rotor 2 were cut parallel to its shaft and at the vertical surface passing through the point 5 at which the bores of the rotor cases intersect, curve AB would represent the edge of the cut surface. The curve BC would represent the edge if the crest of the male rotor were cut at its vertical surface. The straight line AC represents the ridge where the bores of the case intersect as viewed from a horizontal orientation. As FIG. 3 makes clear, the area of the blowhole can be reduced by causing curve AB to approach curve BC physically representing an increase degree of meshing between the male and female rotors.
In consideration of this point, we have designed this embodiment so that the advancing surface addendum on the female rotor comprise at least three (3) arcs with the result that the radius of curvature in the vicinity of point A will increase, and curve BA will be closer to curve BC. As can be seen in FIG. 3, the blowhole shown as A 1 , B 1 , C 1 has been substantially reduced in comparison to that of the rotor shown in the first example of the prior art, here labeled A 2 , B 2 , C 2 .
In this embodiment, only the advancing profile of the addendum, which has little effect on the formation of the sealing line, is prescribed. Thus, it is possible to reduce the sealing line without affecting the shape of the addendum. This results in a substantial improvement in the total efficiency relative to the cubic volume.
In this embodiment, the addendum does not assume a complicated shape whose radius varies with the variation of the angle, as was described in the second example of a prior art rotor. Rather, it merely comprises several curves. This renders it simpler to manufacture than examples of the prior art.
The operation of the second embodiment according to the present invention will now be described.
The semi-occluded pocket tends to increase in size as the cylindrical angle Θ at the top of the female rotor becomes larger, as can be noted in FIGS. 2, 4 and 5. Conversely, such a pocket will not occur at all if this angle goes to zero. However, in the prior art rotors, designers feared mechanical damage if the addendum on the female rotor lacked a crest. They therefore flattened the curve of the crest and made either side from the tip of the crest to the pitch circle of the female rotor a single arc (See Japanese Patent Publications 2-46796 and 61-8242), or a generated curve corresponding to a single arc (See Japanese Patent Publication 2-50319).
However, when each lobe consists of a single arc and one attempts to decrease the crest angle, the result obtained in the third example of a prior art rotor is unavoidable. The strength of female rotor decreases and the theoretical displacement (i.e. theoretical draft) is diminished. No solution for this failing is found in the prior art.
In this embodiment, the crest angle is stipulated to be less than 4°. To enable the two opposed rotations to occur smoothly on a large scale, in this embodiment the advancing and retreating surfaces of the female rotor include at least three (3) arcs. More specifically, at least one (Q-R) of the one or several arcs adjacent to the topmost arc and not extending as far as the pitch circle is of a significantly greater radius than the other arc (Q-P), which does extend as far as pitch circle. In this way, smooth operation can be achieved.
When the crest of the tooth on the female rotor engages with the base of the tooth on male rotor, the escape path which communicates with the escape chamber created between the tooth surfaces of the two rotors becomes larger. No semi-occluded pocket is created, and the resultant compression does not occur. The function and reliability of the screw rotor are enhanced. Because the thickness of the tooth on the addendum of the female rotor is not diminished, the operation described above can be achieved without loss of strength in female rotor, or reduction of the theoretical displacement (i.e. theoretical draft).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an enlarged transverse cross-sectional view of the essential parts of a screw rotor according to a preferred embodiment of the present invention.
FIG. 2 is an enlarged transverse cross-sectional view showing the engagement of the female rotor with the male rotor, and particularly illustrates that a state of semi-occlusion does not occur.
FIG. 3 is a functional diagram illustrating the area of the blowhole as viewed from line A--A in FIG. 6.
FIG. 4 shows the engagement of the male and female rotors in a prior art Example 1, and particularly illustrates the occurrence of a state of semi-occlusion.
FIG. 5 shows the engagement of the male and female rotors in the prior art example 2, and particularly illustrates the occurrence of a state of semi-occlusion.
FIG. 6 is an enlarged transverse cross-sectional view of the essential parts of the screw rotor in prior art example 1, and shows the occurrence of a blowhole.
DETAILED DESCRIPTION OF THE INVENTION
We shall next explain in detail, with reference to the Figures, a preferred embodiment according to the present invention. The dimensions, materials, shape and relative configuration of the components described in this embodiment are not described in detail, as this embodiment is illustrative, and is not meant to represent the complete range of this invention.
FIG. 1 illustrates a preferred embodiment of this invention. It shows a cross-sectional view at a right angle to the shaft of the screw rotor when it is used as a screw-type compressor. The male rotor 1 has four (4) lands 12 positioned symmetrically at 90° angles. Between adjacent lands 12 is defined a trough 13 whose base extends into pitch circle D pM . A portion of this base forms dedendum 11. This rotor is connected to a motor (not pictured) through a drive shaft and a series of gears so that it functions as the drive rotor, rotating in the direction shown by the arrow.
The female rotor 2 engaged by the male rotor 1, and includes six (6) lands 22 positioned symmetrically at 60° angles. Between adjacent lands 22 is a trough 23. An addendum 21 on each land 22 extends beyond the pitch circle D pF . When it receives drive torque from the male rotor 1, the female rotor 2 is driven to rotate in the direction shown by the arrow.
The profiles of the teeth on the male and female rotors will now be described in detail.
The shape of the teeth on the advancing side of addendum 21 on female rotor 2 from the crest to the base in the advancing direction is defined by profile (O 1 -J-K-L-M-O 3 ).
The segment O 1 -J is defined by an arc of the circle whose center is the center O F of the shaft, and whose radius is r F (D F ).
The segment J-K, adjacent to the crest but not extending into the pitch circle, is defined by an arc of the circle whose center O KJ is within the pitch circle D PF , and whose radius r Kj equals 0.036×CD, where CD is the distance from the center of the shaft of the rotor to the circle.
The segment K-L, extending to pitch circle D PF , is defined by an arc of the circle whose center O LK is within pitch circle D PF , and whose radius r LK equals 0.034×CD.
The segment L-M, which forms a trough extending from the pitch circle D PF , is a curve generated by the arc C-D on male rotor 1b.
The segment M-N, which extends across the center of the base of the tooth, is defined by an arc of the circle whose center O PMF is the point O PMF of intersection of the two pitch circles on the line connecting the centers of the two shafts O F and O M .
The segment O 1 -J-K-L (extending as far as pitch circle D PF ) forms the advancing profile 21a of the addendum 21.
The shape of the tooth from the base back up to the crest on the retreating side of the addendum 21 of the female rotor 2 is the profile (O 3 ˜N˜P˜Q˜R˜S˜O 1 ).
The segment N-P, which extends from the base of the tooth to pitch circle D PF , is defined by a curve generated by the arc EF of the male rotor 1a.
The segment P-Q, extending from pitch circle D PF and equivalent to the aforementioned fourth arc on addendum 21, consists of an arc whose center O PQ is a point within pitch circle D PF and whose radius r PQ equals 0.06×CD.
The segment Q-R, extending to the vicinity of the crest of the addendum 21 and equivalent to the third arc, is defined by an arc whose center O QR is a point within pitch circle D PF , and whose radius r QR equals 0.15×CD.
The segment R-S, which adjoins the arc on the crest, is defined by an arc whose center O RS is a point within the pitch circle D PF , and whose radius r RS equals 0.04×CD.
The segment O 1 -S, which forms the crest of addendum 21, is defined by an arc whose center is the center O F of the shaft of the female rotor 2 and whose radius is r F (=D F ),
The angle of the crest arc (S˜J) of the addendum 21 on the female rotor 2 (i.e., the small angle Θ formed with the center O F of the shaft) is fixed at 1.4°.
The shape of the teeth on male rotor 1 is defined by profile (O 2 ˜I˜H˜G˜F˜E˜O 3 ) on the advancing side of male rotor 1.
The segment O 2 -I of the dedendum 11 is a curve generated by the arc O 1 -S of addendum 21 on female rotor 2.
The segment I-H of the dedendum 11 is a curve generated by the arc R-S of the addendum 21 on female rotor 2.
The segment H-G of dedendum 11 is a curve generated by the arc Q-R of addendum 21 on female rotor 2.
The segment G-F of dedendum 11 is a curve generated by the arc P-Q of the addendum 21 on female rotor 2.
The segment F-E, consisting largely of the advancing flank of the land on the male rotor 1, is an arc whose center O FE lies within pitch circle D PM and whose radius r FE equals 0.297×CD.
The shape of the tooth is defined by the profile (O 3 ˜D˜C˜B˜A˜O 2 ) on the retreating side of male rotor 1.
The segment E-D, on the crest of the land of the male rotor 1, is an arc whose center O pMF is the point of intersection of the two pitch circles on the line connecting the centers of the two shafts O F and O M , and whose radius r MN equals 0.238×CD.
The segment D-C, adjacent to the aforesaid crest, is an arc whose center O CD is on the line connecting the point O PMF of the two pitch circles with point M, and whose radius r CD equals 0.02×CD.
The segment C-B forms the major part of the retreating flank of the land of male rotor 1, and includes a portion of dedendum 11. It consists of a curve generated by arc K-L on female rotor 2.
The segment B-A of dedendum 11 is defined by a curve generated by arc J-K on female rotor 2.
The segment A-O 2 , forming the apex of dedendum 11, is defined by a curve generated by arc O 1 -S on female rotor 2.
The configuration of the rotor described above allows unconstrained operation. More specifically, it results in a reduction of approximately 40% in the area of the blowhole when compared with the first example of a prior art rotor (Japanese Patent Publication 56-17559). Furthermore, the escape path which communicates with the escape chamber is substantially wider, as can be seen in FIG. 2. Thus, there is no semi-occluded pocket 4, and no useless compression. When this screw rotor is used in a compressor under identical conditions, the embodiment results in an improvement of approximately 5% in the compression efficiency over the compressor in the first example of a prior art rotor (Patent Publication 56-17559).
The profile of the retreating side of the female rotor is configured for eliminating the possibility of semi-occluded pockets between the addendum 21 of the female rotor and the dedendum 12 of the male rotor. In the preferred embodiment, the profile of the retreating side of the female rotor can be defined by a convolute having a decreasing radius when extending towards the pitch circle of the female rotor. This configuration and the matching configuration of the dedendum of the male rotor prevents the possibility of formation of semi-occluded pockets.
EFFECTS OF THE INVENTION
As was discussed above, the invention was conceived after attention was paid to the shape of the addendum on the female rotor and the dedendum on the male rotor, aspects of which that have not previously received sufficient consideration. By concentrating our efforts on the shapes of these components, we were able effectively reduce the area of the blowhole virtually without affecting the length of the sealing line.
The preferred embodiment according to the present invention concerns the use of the aforementioned rotor device as a compressor. It insures that during disengagement, the pocket enclosed by the surfaces of the teeth of the two rotors and the surface of the operating chamber does not become semi-occluded, and that the strength of the female rotor is not diminished nor the theoretical displacement (i.e. theoretical draft) reduced. Thus the aforementioned state of semi-occlusion can be prevented.
The preferred embodiment according to the present invention is able to fulfill all of the aforementioned effects. It succeeds in providing a screw rotor, which effectively improves the compression efficiency.
This invention is not limited to an oil jet-type rotor devices, but can be used in oil-less type rotors as well.
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A screw rotor for fluid handling devices configured to reduce the area of blowholes virtually without relationship to the length of the sealing line by selecting specific profile shapes of the addendum of the female rotor and the dedendum on male rotor. Further, the screw rotor configuration eliminates semi-occluded pockets forming between the addendum of the female rotor and the dedendum of the male rotor.
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FIELD OF THE INVENTION
This invention relates to resilient, thermoplastic acrylic graft rubbers. More particularly, this invention is directed to a process which results in improved handleability of such rubbers.
BACKGROUND OF THE INVENTION
Acrylic graft rubbers are compounded with hard, non-resilient methacrylate polymers to provide impact-resistant resins. During drying, storage and shipment, prior to compounding, the resilient acrylic graft rubber particles tend to stick together, and are difficult to handle. Heretofore, the resin particles were sometimes coated with particulate materials, such as silica, talc, sodium carbonate, calcium carbonate or titanium dioxide, to reduce their sticking tendency. However, use of these particulate materials has a deleterious effect on the properties of sheets or other articles made from impact-resistant resins compounded using such coated acrylic rubbers, such as decreased light transmission and embrittlement. Thus, a better means for improving the handleability, i.e., reducing the sticking tendency, of the acrylic rubber particles is desirable.
SUMMARY OF THE INVENTION
In this invention, a material whose composition is compatible with the composition of the resilient, acrylic graft rubber is coagulated onto the surface of rubber particles which have themselves been coagulated but not removed from the coagulation medium. Thus, the deleterious effect on properties caused by using the inorganic particulate materials recited above is overcome by employing the compatible material. The compatible material is a substantially non-resilient alkyl methacrylate resin.
More particularly, this invention is a method for improving the handleability of a resilient, acrylic graft rubber composed of particles having an outer layer which has a glass transition temperature greater than 25° C., consisting essentially of an alkyl methacrylate polymer and the alkyl group has 1-4 carbon atoms which method comprises mixing the acrylic graft rubber while still in its emulsion polymerization medium with a solution of an ionizable salt in which the salt is present in an amount between about 1 and 100 gm/liter in an amount such that the resulting mixture contains between about 5 and about 25 times by weight as much acrylic graft rubber as ionizable salt, and, agitating the resulting mixture at a temperature between about 30°-70° C. until the graft rubber particles coagulate, then adding to the coagulated dispersion a dispersion of an alkyl methacrylate resin prepared by emulsion polymerization which has a glass transition temperature greater than 25° C. and wherein the alkyl group has 1-4 carbon atoms in an amount sufficient to result in the presence of between about 10 and 99% by weight acrylic graft rubber in the resulting mixture based on weight of rubber and said alkyl methacrylate resin, and agitating the resulting mixture at a temperature between about 60°-120° C., followed by isolating the coagulated materials.
Surprisingly, the sticking tendency of the resilient, acrylic graft rubber is not significantly decreased by applying particles of compatible alkyl methacrylate resin to isolated particles of resilient acrylic rubber or by co-coagulating the compatible alkyl methacrylate resin with the resilient acrylic rubber particles. It is only when the compatible alkyl methacrylate resin is subsequently coagulated in the presence of previously coagulated resilient, acrylic rubber particles, that the handleability of the acrylic rubber is significantly improved.
DETAILED DESCRIPTION OF THE INVENTION
The resilient acrylic graft rubbers that can be employed herein are well known and are prepared by a multi-stage, sequential emulsion polymerization process in which the core of the particles is first produced by polymerizing a desired monomer or monomers, followed by polymerizing another set of desired monomers in the presence of the core particles to form a shell around the core. In many instances, still another set of monomers is polymerized in the presence of the core-shell particles to form another shell, while in other instances, additional sets of monomers can be likewise polymerized to ultimately form graft rubber particles having a core and multiple surrounding shells.
A common characteristic of all such resilient acrylic graft rubbers is that the outermost shell is composed of a relatively hard, non-resilient alkyl methacrylate polymer (homopolymer or copolymer), and that at least one of the inner shells or the core is composed of resilient, relatively soft acrylate copolymer to impart the resilient property to the graft rubber. Glass transition temperature is an indication of hardness or non-resiliency and the alkyl methacrylate outer shell has a glass transition temperature greater than 25° C., while the resilient acrylate copolymer has a glass transition temperature of 25° C. or less.
The relatively hard, non-resilient alkyl methacrylate outer shell is ordinarily a polymer polymerized in emulsion from a monomer mixture of about 50 to 100 weight percent (perferably 85-100%) of an alkyl methacrylate wherein the alkyl group has 1-4 carbon atoms and any remainder is styrene and/or an alkyl acrylate wherein the alkyl group has 1-4 carbon atoms. The alkyl methacrylate outer shell polymer has a glass transition temperature greater than 25° C., and preferably greater than 50° C.. Most preferably the outer shell contains at least 90% alkyl methacrylate, and is a copolymer of methyl methacrylate and ethyl acrylate. The amount of outer shell present in the graft rubber may be between about 10-30% by weight of the rubber.
Ordinarily, at least one of the inner shells or the core is a resilient, acrylate copolymer polymerized in emulsion from a monomer mixture of about 70-90 weight percent alkyl acrylate wherein the alkyl group has 1-4 carbon atoms and the remainder is a copolymerizable monomer which may be styrene, hydroxy lower alkyl acrylates and methacrylates, lower-alkyl substituted styrenes and the like. Lower alkyl is defined as alkyl of 1-4 carbon atoms. The acrylic copolymer has a glass transition temperature of 25° C. or less, and preferably 10° C. or less. The amount of the resilient copolymer in the graft rubber is sufficient to impart resiliency to the rubber, and ordinarily may be between about 45-80%, preferably 50-70% by weight of the rubber.
It is understood that the core and inner layer polymers will also contain minor amounts of graft or cross-linking monomers in order to insure adhesion between adjacent layers. It is also understood that in these resilient, acrylic graft rubbers, the core and the shell layers alternate between soft, resilient polymers and hard, non-resilient polymers, provided that the outermost shell of the rubber particles is composed of a hard, non-resilient polymer that is compatible with the resin with which the rubber is to be blended. With these requirements, it is understood that neither the compositions of the polymers in the acrylic graft rubber nor the number of layers of polymers is otherwise critical to the operation of the process of this invention. The process is useful to reduce the sticking tendency of any such acrylic graft rubber.
The resilient, impact-resistant acrylic resins can be prepared by emulsion polymerization as described in Owens, U.S. Pat. No. 3,793,402, U.S. Pat. No. 3,502,604 or U.S. Pat. No. 3,804,925.
The compatible material used in the process of this invention that is coagulated onto the surface of the resilient, acrylic graft rubber particles is an alkyl methacrylate resin (homopolymer or copolymer) prepared by emulsion polymerization wherein the alkyl group has 1-4 carbon atoms and the resin has a glass transition temperature greater than 25° C., preferably greater than 50° C. (thus it is a non-resilient polymer). This alkyl methacrylate resin can contain 50-100 percent by weight alkyl methacrylate (preferably 85-100 percent), with any remainder being an alkyl acrylate wherein the alkyl group has 1-4 carbon atoms. Preferably the compatible material is a copolymer of alkyl methacrylate and alkyl acrylate and most preferably about 95 percent by weight methyl methacrylate and 5 percent by weight ethyl acrylate.
In the process of this invention the resilient, acrylic graft rubber is first coagulated but is not isolated from its polymerization medium. Coagulation is achieved by known coagulation procedures, such as contacting the polymerization mixture containing the acrylic resin with a solution of an ionizable salt, such as magnesium sulfate or calcium acetate, and agitating the resulting mixture at about 30°-70° C. until the polymer coagulates. The amount of ionizable salt in the solution is preferably between 1 and 100 gm/liter, preferably 2.5 to 25 gm/liter. Generally, the resulting medium will contain between about 5 and about 25, preferably 10-20, times as much rubber as salt, based on weight.
Next a dispersion of the compatible alkyl methacrylate resin is added and the resulting mixture agitated at about 60°-120° C. until the compatible alkyl methacrylate polymer coagulates. The polymer content of the dispersion is not critical so long as sufficient polymer is present in the dispersion which when combined with the coagulated acrylic graft rubber results in a mixture containing between 10-99% by weight resilient acrylic rubber based on combined weight of acrylic rubber and compatible alkyl methacrylate resin. Preferably, the mixture will contain between 30 and 99% by weight resilient acrylic rubber and most preferably, 70-98% resilient acrylic rubber, based on combined weight of acrylic rubber and compatible alkyl methacrylate resin.
Pressure is not critical and both coagulations are ordinarily carried out at atmospheric pressure. Moreover the process can be batch or continuous.
The coagulated acrylic rubber particles coated with the compatible alkyl methacrylate resin are isolated from the coagulation liquor by ordinary procedures such as filtering and drying, or spray drying.
The resilient, graft acrylate rubber obtained by the process of this invention is useful in the same applications are previously known resilient, acrylic graft rubbers. Thus, the rubber is usually compounded with a hard, non-resilient methacrylate resin as described in Owens, U.S. Pat. No. 3,793,402 to obtain a resin that is molded or extruded into thermoplastic articles such as sheets, films or other articles of good mechanical strength and weatherability.
The following examples serve to illustrate the invention described hereinabove.
EXAMPLE 1
Part I--Preparation of resilient, acrylic graft rubber
A three phase resin in which 25% of its weight is hard, non-resilient methacrylate polymer, 55% is soft, resilient acrylic polymer, and 20% is hard, non-resilient methacrylate polymer was prepared by combining 15.0 parts methyl methacrylate, 9.9 parts ethyl acrylate, and 0.10 part allyl methacrylate (a graft-linker) to form a first monomer charge. The charge was emulisified in water using sodium dioctyl sulfosuccinate as the emulsifier. The monomers were polymerized using potassium persulfate as the initator to obtain a hard, non-resilient resin having a glass transition temperature greater than 25° C.
A second monomer charge was made of 43.45 parts butyl acrylate, 10.18 parts styrene, 1.1 parts allyl methacrylate (graft-linker) and 0.27 parts methacrylic acid. The charge was added to the preformed polymer emulsion obtained above and polymerized using potassium persulfate as the initiator to obtain a soft, resilient polymer layer around the core formed by the first charge and grafted thereto. The resilient polymer has a glass transition temperature of 25° C. or less.
A third monomer charge of 19 parts methyl methacrylate and 1 part ethyl acrylate was then added to the polymer emulsion obtained above and was polymerized using potassium persulfate initiator to obtain a hard, non-resilient shell around the previous prepared particles and grafted thereto, which shell had a glass transition temperature greater than 25° C. The resulting resilient acrylic graft rubber so produced comprised about 35 percent solids in the polymerization mixture.
Part II--Coagulation According to the Procedure of this Invention
16,000g of the polymerization mixture containing the resilient acrylic graft rubber produced as described above was coagulated at 45° by mixing the polymerization mixture into 75 liters of water containing 600g of Epsom salt (magnesium sulfate heptahydrate). The temperature of the resulting coagulated slurry was raised to 60° C. and 4000g of a 35% solids containing dispersion of methyl methyacrylate/ethyl acrylate copolymer (MMA/EA), prepared by emulsion polymerization of a mixture of 95 parts MMA and 5 parts EA, was added. The MMA/EA copolymer coagulated on the surface of the acrylic graft rubber particles and the resulting coated product was isolated by filtering, and was then dried at 70° C. at about 20-25 inches of mercury vacuum.
After compaction by pressing at about 1 psi to simulate storage and shipping conditions and storing at 40° C. for 96 hours the resin particles flowed freely and did not form a coherent mass.
COMPARISON A
Part I
For purposes of comparison, an acrylic graft rubber prepared as described in Part I of Example 1 was coagulated and isolated from the polymerization mixture. The rubber was compacted as in Example 1, Part II and stored at 35° C. for 67 hours. The resin exhibited poor flow properties because of the sticking tendency of the particles. This Part I shows the sticking tendency of untreated acrylic graft rubber particles.
Part II
In another comparison, an acrylic graft rubber prepared as described in Part I of Example 1 was coagulated and isolated from the polymerization mixture and then mixed with solid particles of a suspension polymerized copolymer of 95% (by weight) MMA and 5% EA.
When 95% by weight of the mixture was the acrylic rubber and 5% was the MMA/EA polymer, and the mixture was compacted as in Example 1, Part II and stored at 20° C. for 66 hours, the mixture exhibited poor flow properties because of the sticking tendency of the acrylic rubber particles.
When the amount of the MMA/EA copolymer in the mixture was increased to 40%, and the mixture was compacted as in Example 1, Part II and stored at 20° C. for 64 hours, the flow properties of the mixture were improved, but not to the point where the mixture could be stored without considerable agitation to prevent sticking.
This Part II shows that the sticking tendency of the acrylic rubber particles to form a solid mass is not substantially reduced by interspersing among the rubber particles, other hard non-sticking particles.
Part III
In another comparison, an acrylic graft rubber emulsion was prepared as described in Part I in Example 1, and diluted with water. A monomer mixture of 95% by weight MMA and 5% by weight EA was added along with a small amount of a surfactant (dioctyl ester of sulfosuccinnic acid) and polymerized in the presence of the acrylic rubber particles. The MMA and EA polymerized onto the acrylic rubber particles and increased the size of the outer shell of the acrylic rubber from 20 to 37% of the total weight of the acrylic rubber particles. The resulting rubber, after being coagulated and dried, exhibited poor flow properties and needed considerable agitation to cause flow after only 2 hours of storage after compaction as described in Example 1, Part II. This Part III shows that the sticking tendency of the acrylic rubber is not substantially reduced by increasing the thickness of the hard, non-resilient shell of the acrylic rubber particle.
Part IV
In still another comparison, an acrylic graft rubber emulsion was prepared as described in Part I of Example 1. To 15,600 gm of said emulsion was added, 24,400 gm of an emulsion containing 35% by weight of a copolymer of 95% by weight MMA and 5% by weight EA. Then the solids in the resulting emulsion were simultaneously coagulated as described in Part II of Example 1, isolated, and dried. The product exhibited poor flow properties. This Part IV shows that the sticking tendency of the acrylic rubber is not substantially reduced by co-coagulation of the rubber and a resin made of hard, non-resilient, non-sticky particles.
EXAMPLE 2
A polymerization mixture prepared as described in Part I of Example 1 was coagulated and treated with an MMA/EA dispersion as described in Part II of Example 1. The amount of the MMA/EA dispersion employed was varied to result in a coated product containing the following amounts of resilient acrylic graft rubber and MMA/EA coating (% based on weight):
Sample 1--Control (no hard resin coagulated onto the acrylic rubber)
Sample 2--% acrylic rubber 80
% MMA/EA polymer 20
Sample 3--% acrylic rubber 91
% MMA/EA polymer 9
Sample 4--% acrylic rubber 95
% MMA/EA polymer 5
Sample 5--% acrylic rubber 98
% MMA/EA polymer 2
The tack temperature of the samples was measured. Tack temperature is the temperature at which the particles begin to stick together as measured in a melting point apparatus (No. 3821, Parr Instruments Co., Inc., Moline, Ill.). Thus, unlike the tests used in Example 1 and the Comparisons, (which simulate storage conditions) the tack temperature is a measure of tackniness when the particles are not subjected to pressure caused by the presence of other particles. The tack temperatures for the samples was as follows (accuracy ±3° C.):
Sample 1--74° C.
Sample 2--103° C.
Sample 3--102° C.
Sample 4--105° C.
Sample 5--102° C.
These results are significant because the acrylic graft rubbers are ordinarily dried at temperatures of 70° C. or above. Thus, samples produced by the process of this invention (Samples 2-5) can be dried without sticking, whereas, as seen by the Table, Sample 1 would tend to stick at 74° C..
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A process which improves the handleability of resilient, acrylic graft rubber particles which comprises coagulating the rubber particles, then contacting the coagulated particles in the coagulation medium with a dispersion of a non-resilient alkyl methacrylate resin and coagulating the alkyl methacrylate resin on the surface of the rubber particles. The particles of alkyl methacrylate resin adhere to the rubber particles and prevent the normally sticky rubber particles from adhering to one another.
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RELATED APPLICATIONS
[0001] This application is related to provisional application number 60/603,073 “A System and Method for Providing a Reaction Using a Limited Reaction Surface Area” filed on Aug. 20, 2004, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention is related to the field of analyzers, and in particular, to discrete wet chemical analyzers.
[0004] 2. Statement of the Problem
[0005] FIG. 1 shows a bench top discrete analyzer for wet chemistry. In typical discrete analyzers a sample is placed in the analyzer. The analyzer draws a small amount of the sample into a sample probe and transfers it to a reaction well. Each reaction well may contain a cell where the reaction takes place. A cell is typically a small container or cup or flowcell configured to hold the sample and any reagents used in the chemical reaction. The cell may be disposable or may be reusable after reconditioning. Once the sample has been transferred to the cell, the analyzer rinses the sample probe and then draws any reagents needed for the reaction, from the reagent reservoirs, and transfers the reagent to the reaction cell. The analyzer may stir the sample and reagent, using the sample probe, to aid in the reaction. Once sufficient time has passed for the reaction to occur, the analyzer transfers the mixture to a flow cell where it will be moved into the testing area and tested for the results of the reaction. Some reactions require the sample to be pre-conditioned before a reagent is added for a reaction. For example, in the cadmium reduction method, the sample must be exposed to a cadmium source before being combined with the color forming reagents. In the cadmium reduction method, the amount of preconditioning for a given sample size is a function of the surface area of the cadmium source per volume of sample and the time of exposure to the source. In some analyzers, the sample is passed through a long thin tube or coil where the inside of the tube has been coated with cadmium. This tends to maximize the surface area of the cadmium source for the give sample size. In some analyzers, the cadmium source is placed inline with the sample probe. With the inline cadmium source every sample drawn into the sample probe passes through the cadmium source unless a switching valve is installed. The switching valve adds cost and complexity to the instrument. FIG. 2 shows a bench top discrete analyzer for wet chemistry with a cadmium coil mounted inline with the sample and reagent probe.
[0006] Putting the cadmium source inline with the sample probe has a number of disadvantages. With the cadmium source inline, every sample transferred through the sample probe passes through the cadmium source. Most discrete analyzers do more than one type of test. If the test does not need the preconditioning step, or can't tolerate being exposed to cadmium, the analyzer may not be able to run the test in the inline configuration. Another problem with the inline cadmium source is that the cadmium source may become contaminated by the transfer of a sample to the reaction well. The cadmium source may also have a limited life. Once the cadmium has been depleted, the source must be reconditioned or replaced before more testing can be performed. In the inline configuration, the analyzer can not be used for any type of testing while the cadmium source is being cleaned or reconditioned.
[0007] Therefore there is a need for a system and method for providing a better solution for preconditioning samples.
SUMMARY OF THE INVENTION
[0008] A method and apparatus for chemical analysis is disclosed that uses a sample cup insert. The insert is pre-coated with a reaction agent, enzyme, or chemical to facilitate testing of the sample. A sample fluid in the sample cup is agitated by fluid pulsing to speed the reaction or to speed a pre-conditioning step.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an isometric view of a prior art discrete bench top analyzer.
[0010] FIG. 2 is a isometric view of a prior art discrete bench top analyzer with an inline cadmium coil.
[0011] FIG. 3 is an isometric view of a sample cell.
[0012] FIG. 4 is a graph of the amount of fluid drawn into a sample probe vs. time in an example embodiment of the invention.
[0013] FIG. 5 a top view of a sample cup, in an example embodiment of the invention, showing the different locations along the stirring path where the release of the fluid back into the sample cup begins.
[0014] FIG. 6 is a drawing of an insert with a smooth or cylindrical inner surface in an example embodiment of the current invention.
[0015] FIG. 7 is an assembly drawing of a smooth inner surface cadmium insert and a sample cup in an example embodiment of the current invention.
[0016] FIG. 8 is a flow chart in an example embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] FIGS. 1-8 and the following description depict specific examples to teach those skilled in the art how to make and use the best mode of the invention. For the purpose of teaching inventive principles, some conventional aspects have been simplified or omitted. Those skilled in the art will appreciate variations from these examples that fall within the scope of the invention. Those skilled in the art will appreciate that the features described below can be combined in various ways to form multiple variations of the invention. As a result, the invention is not limited to the specific examples described below, but only by the claims and their equivalents.
[0018] When doing discrete tests in an analyzer, preconditioning the sample using an inline source has a number of disadvantages as discussed above. One way to overcome these disadvantages is to move the preconditioning source into a sample aspiration cup or cell. Unfortunately, the typical cell does not contain enough surface area for the sample volume to provide the proper preconditioning in the time needed using normal agitation methods.
[0019] FIG. 3 is an isometric view of a typical sample cell. The discrete analyzer where the cell will be used determines the height and diameter of the sample cell being used. This is typically dependent on the volume of the sample required for testing as well as the amount of the reagents needed for the reaction. The sample probe diameter and the stirring radius determine the minimum inner diameter of the sample cell used in the analyzer.
[0020] In one example embodiment of the invention, agitating the sample fluid in the sample cell is performed using two complementary techniques. The first technique is to stir the sample fluid in the sample cell using the sample probe. Stirring the sample fluid, using a circular motion, with the sample probe is well known in the arts. The second technique is to draw or suck a portion of the sample fluid, from the sample cup, back into the sample probe and then squirt or release the portion of the sample fluid from the sample probe back into the sample cup. The action of drawing the fluid from the cell into the sample probe and then squirting the fluid back into the cell can be repeated. For this application, the act of drawing the fluid from the sample cell into the sample probe and then squirting or releasing the fluid back into the sample cell will be called fluid pulsing. Fluid pulsing increase the agitation rate in the sample cup which can shorten the time required for a reaction to occur.
[0021] There are a number of variables that can be adjusted in fluid pulsing, for example the amount of fluid drawn back into the sample probe may be varied, the cycle time between fluid pulses may be varied, the rate at which the fluid is sucked up or squirted out of the sample probe may be changed, and the number of time the fluid is drawn into and then released from the sample probe may be changed. FIG. 4 is a graph of the amount of fluid drawn into a sample probe vs. time in an example embodiment of the invention. Time T 1 is the time it takes to draw a sample fluid, from a sample cup, into a sample probe. Time Ti is a function of the rate at which the sample fluid is drawn into the sample probe and the total volume (V 1 ) drawn into the sample probe. The time the fluid is retained in the sample probe before being released back into the sample cup, is time T 2 . In one example embodiment of the invention, time T 2 is set to zero to minimize the amount of time the sample fluid is no longer in contact with the sample cup. The time it takes to release or squirt the sample fluid back into the sample cup is time T 3 . The total pulse time is T 4 . The time between the end of one pulse and the start of another pulse is T 5 . The cycle time from the start of one pulse to the start of another pulse is time T 6 .
[0022] In one example embodiment of the invention, the fluid pulsing is repeated with a constant cycle time. In another example embodiment, the fluid pulsing is repeated using a variable cycle time. There are a number of different ways that the cycle time may be varied, for example changing the volume of fluid drawn into the sample probe, changing the time between pulses (T 5 ), changing the time the fluid is retained in the sample probe before being released back into the sample cup (T 2 ), or the like. In one example embodiment of the invention, the fluid drawn into the sample probe may be squirted back into the sample cup in a series of small pulses, for example the pulses that occur at times T 7 , T 8 and T 9 . In one example embodiment of the invention, the rate the fluid is released back into the sample cup is different than the rate at which the fluid is drawn into the sample probe (not shown), for example the sample fluid is drawn into the sample probe at a high rate over a short time period, and then released back into the sample cup using a slow rate over a longer period of time. In one example embodiment, 300 μL of the sample is drawn from the sample cell into the sample probe for the fluid pulsing.
[0023] The two agitation methods, stirring and fluid pulsing, may be done one after the other, at the same time, or in some combination. For example, the sample probe may first stir the sample fluid for a preset time and then do fluid pulsing while the sample probe continues stirring. In another example embodiment, the stirring and fluid pulsing may start at the same time. In one example embodiment of the invention, the sample fluid is stirred and fluid pulsed for approximately 5 seconds after the sample fluid is placed into the sample cup. The sample fluid is then left in the sample cup for approximately 15 minutes. The sample fluid is then stirred a second time for approximately 5 seconds. The sample fluid is then transferred to a reaction cuvette to continue the testing process. When the stirring and fluid pulsing occur simultaneously, the frequency or cycle time of the fluid pulsing may be adjusted such that the release of the sample fluid back into the sample cup, occurs at different locations in the sample cup. FIG. 5 is a top view of a sample cup 502 showing the different locations along stirring path 504 where the release of the fluid back into the sample cup begins. For the first pulse, the fluid is squirted out at location L 1 , the second pulse beings at location L 2 , etc.
[0024] In one example embodiment of the current invention, cadmium is used as the active surface for a reaction. The amount of cadmium present in the reaction cell or sample cell is a function of the surface area of the sample cell and the thickness of the coating. A sample cell or insert having a corrugated or ribbed inner surface coated with cadmium will have more cadmium than a cell or insert having a smooth or cylindrical inner surface. The total amount of cadmium in the sample cell is important for a number of reasons. One reason is that a cell can be disposable if the total amount of cadmium is below a threshold amount. If the total amount of cadmium is above the threshold amount, the cell must be recycled or treated as containing hazardous material. Using a cell or insert with the smooth inner surface may allow the total amount of cadmium present in the cell to fall below the threshold amount that allows the cell to be disposable. FIG. 6 is a drawing of an insert with a smooth or cylindrical inner surface. Using the agitation techniques with a sample cell having a smooth inner wall may shorten the time required for a given reaction. FIG. 7 is an assembly drawing of a sample cell using an insert with a smooth inner surface. This invention is not limited to use with sample cups having a smooth or cylindrical inner surface. Using the agitation techniques with a cell or insert having a corrugated or ribbed inner surface may shorten the required time for a pre-conditioning step or for a reaction.
[0025] In another example embodiment of the invention, the amount that the sample probe is inserted into the sample fluid, may be varied during fluid pulsing or during stirring, or during the combination of stirring and fluid pulsing. In another example embodiment of the invention, the direction that the sample probe travels while stirring, may be change, for example from a clockwise motion to a counter clockwise motion. Other stirring paths are also possible, for example a figure eight motion. In one example embodiment of the invention, when the active material for a reaction is on an insert with no bottom, the sample probe may be positioned in the center of the sample cup as the sample fluid is drawn into the sample probe. And then the sample probe may be positioned near the inner surface of the insert as the fluid is released from the sample probe back into the sample cup. In another example embodiment of the invention, when a sample cup with an active surface on the bottom of the cup is used in the reaction, the sample probe may be positioned in the center of the sample cup as the sample fluid is drawn into the sample probe. And then the sample probe may be positioned near the bottom of the cup as the fluid is released from the sample probe back into the sample cup. Other intake and outlet positions for the sample probe are possible and may be a function of the sample cup geometry, the sample probe size and shape, the speed at which the sample fluid can be drawn in and squirted out of the sample probe, the reaction type, and the like.
[0026] FIG. 8 is a flow chart of a method in an example embodiment of the current invention. At step 802 a sample fluid is placed into a sample cup. At step 804 the sample fluid is agitated in the sample cup by using fluid pulsing. At step 806 the sample fluid is optionally agitated by stirring the sample fluid with a sample probe.
[0027] Some of the active materials used in the reactions may be toxic. In one example embodiment of the invention, the cell would be configured with a cap or lid to seal the active material, contained on the cell interior or on the insert, to prevent exposure to the environment.
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A method and apparatus for chemical analysis is disclosed that uses a sample cup insert. The insert is pre-coated with a reaction agent, enzyme, or chemical to facilitate testing of the sample. A sample fluid in the sample cup is agitated by fluid pulsing to speed the reaction or to speed a pre-conditioning step.
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BACKGROUND OF THE INVENTION
The invention relates to a feeding apparatus for feeding and distributing charge material through a feeding opening onto the molten bath surface of a glass melting furnace, having a movable stand which has a charge hopper, a charging system, a pusher with pusher holder and pusher driver for the production of a pushing motion having horizontal and vertical components, and a heat shield substantially covering the feeding opening, in which at least one opening is disposed for the accommodation of the charging system and the pusher holder.
DE-OS No. 26 25 314 and DE-AS No. 29 44 349 have disclosed feeding apparatus for glass melting furnaces, which have no heat shield, but in which the pushers likewise execute a swinging movement.
In the feeding apparatus according to DE-OS No. 26 25 314, the "doghouse" is largely open at the top and above the opening or the surface of the melt there is disposed a two-substance charging apparatus for cullet and finely granular frit material, in which first the cullet is fed in by means of a chute and then the frit material is poured onto the cullet by means of a cellular wheel air lock. The free fall of the charge material raises large amounts of dust inside and out. Dust is a great hazard to the personnel and to the melting apparatus, so that heat exchangers have to be cleaned of dust deposits periodically--a task which takes days. For melting tanks with a U-shaped flame configuration this type of charging is unsuitable. In front of the doghouse there is disposed a tamping apparatus separate from the charging apparatus, by means of which the poured material is tamped into strips by a movement, consisting of horizontal and vertical components, of a pressing member with a stripping blade, forced partially below the surface of the molten glass, and pushed in strips toward the melting zone of the furnace. This, however, entails the disadvantage that the surface of the melt is raised each time. Such an oscillation of the melt surface is, however, a very undesirable manner of operation. The tamping apparatus has a stationary platform on which tracks are fastened for the longitudinal guidance of the arms holding the tamper. Since there is no heat shield, the problem of sealing off a furnace interior from the surroundings and of sealing off heat shield openings through which holding arms pass does not arise in this arrangement.
From DE-AS No. 29 44 349 it is known to shield the furnace interior and the interior of the doghouse from the feeding apparatus and the surroundings, not with a heat shield but with a kind of bipartite and very complicated coupling device. For the feeding, a sloping plate is provided which is of virtually the same width as the doghose and whose front end extending into the doghouse serves simultaneously as a pusher for the charge material. Such apparatus are also known as chute feeding machines. The pusher is moved along a parallelogram whose longest sides, however, are not parallel to the melt surface but approximately parallel to the feeding plate. The pusher can dip into the melt, therefore, only at the end of the stroke, so that no appreciable stirring action is performed in the melt. Furthermore, a chute feeding machine of this kind produces on the melt surface an undesirable, uninterrupted "carpet" of charge material. The sealing of the very wide feeding plate is, however, difficult and calls for heat-resistant woven parts of large area above the feeding plate, and likewise a heat-resistant, folding fabric apron below the feeding plate. To provide the necessary flexibility this apron has to be thin, but then it can be effective only against dust, but not against the escape of energy. The feeding plate and pusher component, however, has still another serious disadvantage in regard to the degrees of freedom of movement of the pusher: since the charge material is bulk material resting on the feeding plate under the bulk tower, any lifting of the feeding plate parallel to itself would involve a lifting of all of the bulk material. Consequently, by means of a pivoting frame the feeding plate performs a swinging movement with respect to the stationary supporting frame (platform), and it is expressly stated that the pivot axis of the said frame is to be virtually coincident with a line that lies in the area of a so-called sand seal at the bottom end of the discharge opening of the bulk tower. Therefore there is no parallel displacement of the plane of movement of the pusher.
In feeding apparatus of this kind it is important to place the charge material--a mixture as a rule--in a uniform and controllable stream onto the bath surface and distribute it thereon so that the charge material will come as quickly as possible into intimate interaction with the molten glass for the purpose of melting.
DE-GM No. 83 04 858 discloses a feeding apparatus of the kind described above, in which a heat shield is disposed between the pusher and the stand, by which the end of the charging device, a vibratory conveyor trough, extends into the glass melting furnace. More precisely, the end of the charging system enters into the so-called doghouse of the melting furnace. The heat shield serves in this case to solve the problem of reducing the action of radiant heat on the feeding apparatus, especially on its charging device, and at the same time of reducing heat losses as well as the escape of gas and dust from the furnace chamber above the molten glass surface. However, to prevent interference between the heat shield and the pusher holder, a sufficiently large opening has to be provided in the heat shield, which, however, impairs the action of the heat shield.
In the known system, a crank-type vibrating driver engaging the pusher holder sets the pusher into periodical movements in which the bottom edge of the pusher or pusher blade describes a shallow ellipsoid pattern of movement. The crank of the driver motor engages a rod which is fastened fixedly to the pusher holder in the vertical direction. The oscillating shaft of the pusher and pusher holder is mounted on the end of a rocker arm and consequently performs oscillating movements on an arc in which the center of these movements is in the front area of the stand, but not in the area of the opening in the heat shield, so that the latter opening must be of correspondingly large dimensions. On account of the complexity of the pusher movement, no reliably working sealing means can be provided at the point where the pusher passes through the heat shield, so that the effect of the heat shield is limited.
Mainly, however, in the known system the bottom edge of the pusher or pusher blade does not move precisely parallel to the bath surface on account of the above-described elliptical motion, so that the action of the pusher on the charge material floating on the melt surface is different according to the distance between the pusher and the end of the charging system. The charge material must, as it is known, be divided on the melt surface, by the action of the pusher, into individual "pads" of material pushing or pushed on the surface of the melt, so that the molten glass already present will act with as little hindrance as possible on all parts of the charge material.
SUMMARY OF THE INVENTION
It is therefore the aim of the invention to improve a feeding apparatus of the kind described above so that the pusher will be guided on a more suitable path of movement relative to the bath surface, and that at the same time the shielding action of the heat shield can be improved.
The solution of the stated problem is accomplished according to the invention, in the feeding apparatus described above, in that the pusher holder is mounted by means of a linear guiding system that is always aligned horizontally, and is displaceable on a movable, horizontal platform, and can be displaced relative to the latter by a horizontal driver, and that the platform is mounted for movement parallel to itself on the stand, and can be raised and lowered by a vertical driver.
The "platform" referred to does not need to be in the form of a solid plate; the term is rather to be understood in the sense of a "platform of reference" which determines the position of the pusher holder and of the driver connected therewith. In the simplest case the said platform can consist of a frame or frame members on which the drive means pertaining to the pusher are mounted.
By the measures taken according to the invention, a complete decoupling of the horizontal and vertical components of movement is achieved, and an arbitrarily controllable interplay of the horizontal and vertical components of movement can be achieved by the appropriate controlling of the individual drivers. This control can be achieved, for example by a programmable microprocessor.
By the solution according to the invention the pusher can be made to follow a path of movement that can be described as a rectangle or square, two sections of this path of movement being parallel to the surface of the bath of molten glass. The other two sections of the path of movement between them are perpendicular to the surface of the melt, so that the pusher is lowered vertically onto the surface of the molten bath and raised away from it again vertically. In this manner an extremely uniform and equal division of the material stream into so-called material "pads" which are moved along the surface of the bath by the pusher. At the same time the bottom edge of the pusher can be prevented on the one hand from plunging too deep into the molten glass, or on the other hand it can be prevented from being at too great a distance from the bath surface at the beginning and at the end of the pushing movement, so that the action of the pusher at this point is only limited.
On account of the measures taken according to the invention, the pusher holder no longer performs any tilting or rocking movements but only a precisely rectilinear and horizontal movement relative to the platform, so that in this manner the seal in the heat shield can be substantially improved.
An especially advantageous embodiment of the subject matter of the invention in this regard is characterized, according to the further invention, in that, in the heat shield, on either side of the opening for the passage of the charging system through it, two additional slot-like openings are provided for the passage through each of a shaft of the pusher holder, and that each of the vertical slots is provided with a cover plate which is movable together with the platform relative to the heat shield fastened to the stand and movable parallel to the latter, each cover plate being fitted as closely as possible around its shaft.
If this teaching is followed, neither any escape of radiant heat nor of gas or dust particles will be possible in the area of the pusher holder. Nor is such escape possible in the area of the opening for the charging device or on the outside of the charging device. The charging device is sealed against the heat shield by a sleeve. In the interior of the charging device, however, is the charging material which largely blocks the opening in question, so that the thermal radiation can be used advantageously for preheating the material. Dust particles are even largely trapped by the charge material and carried back to the melting furnace, so that their escape to the surroundings is very largely prevented. In this manner the nuisance of dust deposits on the components of the feeding apparatus that are located in back of the heat shield is drastically reduced, but particularly the cleanness of the atmosphere for the operating personnel is perceptibly improved.
It is especially advantageous if the covering plates for the openings in the heat shield are fastened on the platform and have a sliding seal cooperating with each pusher holder shaft at the point where the shaft passes through the shield.
This sliding seal serves not for the mechanical support of the pusher holder, but serves only for sealing purposes, so that its useful life is very long.
It is especially advantageous if the vertical guiding system of the platform consists of four perpendicular guiding columns which are disposed in the stand and on which the platform is guided by bearing cases. The guiding columns can be identical with the columns of the stand, but preferably they are present in addition to the columns of the stand.
Preferred in this case is the arrangement of the additional guiding columns between the bottom frame of the stand and cross members joining two columns of the stand to one another, at about half of the height of the stand.
Pneumatic and hydraulic cylinders as well as spindle drives, crank drives or cam drives can be used as means for driving the horizontal and vertical movement.
Additional advantageous developments of the subject matter of the invention will be found in the rest of the subordinate claims.
The various feature of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this specification. For a better understanding of the invention, its operating advantages and specific objects obtained by its use, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a first embodiment of a feed apparatus working in cooperation with a glass melting furnace
FIG. 2 shows a detail from FIG. 1 on a larger scale
FIG. 3 is a vertical section along line III--III of FIG. 1 with a view of the parts of the apparatus situated behind the plane of the section
FIG. 4 is a top view and a partial horizontal section along line IV--IV of FIG. 1
FIG. 5 is a view of the subject of FIG. 2 seen in the direction of the arrow V
FIG. 6 shows a second embodiment of a feeder in a partially cutaway side view similar to FIG. 1
FIG. 7 shows, on the left side of the center line, a front view of the subject of FIG. 6 seen in the direction of the arrow VII, and on the right side of the center line a vertical section through FIG. 6 directly behind the front columns of the frame; and
FIG. 8 shows, on the left side of the center line, a top view of the subject of FIG. 6, and on the right side of the center line a horizontal section through the subject of FIG. 6, along a plane in which the shafts of the pusher holder lie.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a complete feeding apparatus according to the invention working in cooperation with a glass melting furnace 2. The feeding apparatus includes a lower frame 4 provided with track wheels 3, and an upper frame 5 which is joined to the lower frame by columns 6. The frames 4 and 5 together with columns 6 form a stand 7.
In the upper frame 5 a charge hopper 8 is inserted over which is disposed a bin 50 represented by broken lines with a shutoff 50a and a spout 50b. The charge hopper 8 is in the form of a feeding hopper and is joined by a sleeve 9 to a charge feeder 10 which is in the form of a conveyor trough and provided with a vibratory driver 11. The charge feeder 10 is inclined slightly downward toward a feed opening 12 in a side wall 13 of the glass melting furnace 2. For the purpose of controlling the flow of the materials the vibratory drive 11 is continuously variable.
On the two front columns 6 facing the glass melting furnace are four beams 14 two of which are concealed from view. A heat shield 15, the details of which are shown in FIG. 4, is fastened to beam 14. On heat shield 15 there is fastened a box-like radiation guard 16 which surrounds the charge feeder 10 on that portion of its length which extends through the heat shield 15 into the interior of the glass melting furnace. Details will likewise be explained with the aid of FIG. 4.
The feeding apparatus 1 furthermore includes a pusher 17 which is fastened to the front end of a pusher holder 18 enabling it to extend into the interior of the glass melting furnace 2. The pusher holder 18 consists of two parallel and horizontally disposed shafts 18a and 18b (FIG. 4), of which only one is visible in FIGS. 1 and 2.
The pusher holder 18 is mounted by means of a horizontal linear guiding device 19 on a horizontal platform 20 and is displaceable with respect to the latter by a horizontal driver 21 which will be further explained in conjunction with FIG. 3. The linear guiding device 19 consists of two parallel rails 22 and 23 running toward the heat shield 15 of which, again, only one is visible in FIG. 1, and which are joined to the platform 20 by supports 24, in the manner shown especially in FIG. 3. Wheel holders 25 and 26 having each one pair of wheels 27 and 28 bracketing the rails 22 and 23 between them, respectively, can roll on the rails 22 and 23. On account of the cross-sectional shape which can be seen in FIG. 3, the left part of the linear guiding device forms a fixed bearing and the right part of the linear guiding device a loose bearing.
As it can be seen in the figures, the parallel rails 22 and 23 are fastened on the horizontal platform 20 and aligned parallel thereto, and the wheel holders 25 and 26 are in turn fastened to the supports 29 which are affixed to the shafts 18a and 18b of the pusher holder 18. The result is a horizontal linear guiding system for the absolutely horizontal movement, without any appreciable free play, of the pusher 17.
As it can furthermore be seen in FIG. 1, the platform 20 is mounted on the stand 7 by means of a vertical guiding device 30 and can be raised and lowered with respect to the frame by a vertical driver 31. The vertical guiding device 30 is in the form of a scissor linkage whose scissor joint 32 is movable vertically.
A number of additional details will be explained with reference to FIG. 2:
The glass melting furnace 2 is filled with a glass melt 33 which forms a molten bath surface 34 onto which the free-flowing bulk charge material 35 is placed by means of the feeder system 10. Dividing the charge material into so-called "pads" is performed in the manner shown, by means of the pusher 17. The latter is first lowered from the position 17a shown in broken lines to the position shown in solid lines, and from there it is pushed parallel to the molten bath surface 34 to the position 17b represented in broken lines, thereby shifting a portion of the charge material 35 leftward. From this horizontal end position the pusher 17 is raised to the position 17c, also represented in broken lines, and moved back from this position to position 17a. The rectangular pattern of movement is represented in detail by movement arrows. This pattern of movement is achieved by a centrally controlled cooperation of the horizontal linear guiding device 19 and of the vertical guiding device 30 without the need for the pusher holder 18 to perform any tilting or swinging movement.
The passing of the charging device 10 and the pusher holder 18 through the heat shield 15 is best understood in connection with FIGS. 4 and 5.
The heat shield 15 has an opening 15b for the passage of the charging device 10 on both sides of opening 15b two additional slots 36 and 37 whose longest axes are vertical. These slots serve to accommodate the shafts 18a and 18b of the pusher holder 18 (FIG. 5). As it can be seen especially from FIG. 4, the shafts 18a and 18b are bent at right angles at their front ends and thus lead into the pusher 17 whose bottom edge 17d is aligned with the bath surface 34. The pusher 17 is in the form of an approximately rectangular hollow body (with a beveled bottom) through which a coolant flows which is fed through shafts 18a and 18b.
Each of the two vertical slots 36 and 37 is provided with a cover plate 39 and 40, respectively, whose outlines are represented in broken lines in FIG. 5, since the cover plates are behind the heat shield 15, looking in the direction of radiation. At the same time an overlap has been selected such that the cover plates 39 and 40 block the slots 36 and 37 at least against radiation in every possible position of the pusher 17. Also the size and arrangement of the heat shield 15 are selected such that the latter, in its working position shown in FIGS. 1 and 2, covers the feed opening 12 or closes it as completely as possible. The heat shield 15 is provided with bolting ears 15a with which it is fastened to the beams 14.
The cover plates 39 and 40 have at the point at which the corresponding shafts 18a and 18b pass through them the sliding seals 41 and 42, respectively, whose outer circumferences are joined on the one hand to the corresponding cover plate and on the other hand through a bracket 43 (FIG. 1) to the platform 20. It is apparent that, by means of the slots, the cover plates 39 and 40 are adjustable both horizontally and vertically relative to the platform 20. The cover plates 39 and 40 together with platform 20 can thus be moved relative to the heat shield 15 fastened on the frame 7 and parallel to the heat shield. The sliding seals 41 and 42 are constructed so as to interfere as little as possible with the longitudinal movement of the shafts 18a and 18b.
As it appears from FIG. 4, left half, the cover plates 39 and 40 consist each of a metal base plate and an insulating covering that faces the back 15b of the heat shield 15, and slides on the metal plate on the back of the heat shield 15.
In FIG. 3 it can be seen that the pairs of wheel holders 25 and 26 situated opposite one another in pairs in a mirror-image relationship are joined together by horizontal transverse yokes 44 of which only the front one is seen in FIG. 3. The shafts 18a and 18b are at the same time joined first directly to the yokes 44 by the vertical supports 29 and thus indirectly to the trucks 25 and 26.
With respect to FIG. 3, the direction of movement of the horizontal linear guiding system 19 is perpendicular to the plane of drawing. According to FIG. 3, two parallel scissor joint systems 30a and 30b, connected together by a spacer shaft 45, pertain to the vertical guiding means 30.
It is furthermore apparent from FIGS. 4 and 5 how the box-like radiation guard 16 surrounds the end of the charging system 10 which lies in front of the heat shield 15 in the direction of radiation. Also due to the presence of the radiation guard 16 and of a sleeve 49 disposed between heat shield 15 and charging system 10, the sealing off of the furnace chamber from the space situated behind the heat shield 15 is perceptibly improved. The radiation guard 16 is fixedly joined to the heat shield 15. The bottom end of the charging system 10 (vibratory conveyor) is beveled as indicated by the bent, broken line in FIG. 2. The heat shield 15 consists of a metal plate with a covering of insulating material facing the furnace.
The side wall 13 is one of the boundary walls of a glass melting tank in which molten glasses are produced whose temperature can be between about 1200 and 1450 degrees, depending on the type of glass, and in the case of special glasses, such as borosilicate glass, for example, can be about 1600° C. and higher. The glass melting tank is externally surrounded also by a tank insulation 46 which includes a furnace anchoring 47. The glass melting tank is covered at the top by a protective roof 48.
The radiation guard 16 can be in the form of a double-walled protective tube with metal walls having spaces between them. These spaces can be provided either with thermal insulation materials or with forced air cooling and/or with water connections.
The horizontal driver 21 and vertical driver 31 are in the form of piston-and-cylinder drivers, connected to parts to be moved relative to one another.
If in FIGS. 6 and 8 parts are shown which have the same or similar function as those used in FIGS. 1 to 5, the same reference numbers are used, with the addition of the letter "a".
According to FIG. 6, the vertical system 30a for guiding the platform 20a consists of four vertical guiding columns 60 which are disposed in the stand 7a and extend between the lower frame 4a of the stand and the crosspieces 62 each joining together two columns 6a of the stand 7a. The platform 20a is guided on these columns 60 through bearing casing 61.
The vertical guiding columns 60 are at the vertical outside edges of the stand 7a, and two bearing casings 61 are guided on each column 60, being fastened at a distance apart one on each vertical projection 63 fixedly joined to the platform 20a. Between the pairs of bearing casings 61 the vertical guiding columns 60 are surrounded by protective sleeves 64, while they are covered at the ends of the bearing casing facing away from the protective sleeves by bellows 65.
On the members 66 of the platform 20a running at right angles to the glass melting furnace 2, horizontal guiding members 67 are fastened, on which vertical supports 29a for bearing the pusher holder 18a are guided by means of the additional bearing case 68.
The vertical supports 29a are joined together at their upper end by upper crossmembers 69 and at their lower ends by lower crossmembers 70 which run parallel to the guiding members 67. The lower crossmembers 70 are joined together by a transverse yoke 71 which is angled downwardly toward the furnace 2, as can easily be seen in FIGS. 7 and 8. This transverse yoke 71 is engaged by a connecting shaft 72 of a horizontal driver 21a (FIG. 8).
The members 66 of the platform 20a which are disposed perpendicular to the furnace 2 are joined together by an additional transverse yoke 73 on which the cylinder 74 of the horizontal driver 21a is fastened, so that the pusher holder 18a displaceable on the guiding members 67 can be shifted by operating the horizontal driver 21a (FIG. 8).
The transverse yoke 73, which, as seen in FIGS. 6 and 7, projects slightly below the platform 20a, is engaged by the connecting shaft 75 of the vertical driver 31a connected to the frame 7a. This is done with the interposition of an upwardly extending projection 80 mounted on the transverse yoke 73, to which is fastened a fork 81 which straddles the upper end of the connecting shaft 75 which is in the form of an eye (FIGS. 6 and 8). This connection is produced by a pin which is not further identified. As it can be seen especially in FIG. 8, the horizontal drive 21a and the vertical drive 31a are disposed on both sides of a center line M which also defines the vertical plane of symmetry of the entire feeding apparatus. By means of this lateral offset any interference of the two drives with one another is prevented.
The two lateral members 76 of the lower frame 4a of the stand 7a are joined together at a point inside of the frame by an additional crosspiece 77 to which the cylinder 78 of the vertical drive 31a is fastened through the brackets 79 which straddle fork-wise the cylinder 78 (FIGS. 6 and 7). In this manner the platform 20a can be raised and lowered vertically with respect to the frame 4a.
The horizontal shafts of the pusher holder 18a are fastened by clamping means 82 on the upper beams 69. Also the horizontal guiding members 67 which have a cylindrical cross section, are protected between the bearing casings 68 by protective sleeves 83, and beyond the bearing casings 68 by bellows 84. The horizontal members 67 are joined at their ends to the platform 20a by means of flanges 85.
With regard to the rest of the details of the apparatus, they are very largely the same as in the embodiment according to FIGS. 1 to 5. For example, here again a charge hopper 8a is suspended in the upper part of the stand 7a and is connected by a sleeve 9a to the charging device 10. The outline of the charging device 10a, which is concealed in the drawing, is indicated by broken lines.
Similarly, a heat shield 15a is fastened on brackets 14a on the stand 7a, its elongated openings 37a (FIG. 7) being covered in a similar manner by cover plates 39a such that the desired vertical movement of the pusher holder 18a is possible without exposing any part of the slots 37a.
In FIGS. 7 and 8 it can also be seen that the shafts of the pusher holder 18a are straight and terminate vertically at their extremities in the pusher 17a which is widened for this purpose. In this manner, gusset plates, not otherwise indicated, can be provided between the pusher holder 18a and the mechanically highly stressed pusher 17a. In FIG. 7 there is shown another of the connecting lines 86 for carrying cooling water for the pusher 17a.
FIG. 8 shows a number of additional details of the sliding seal 41a on the covering plate 39a. It can be seen that the covering plate 39a consists of a box-like metal casing that is open at one end and surrounds a mass of mineral fibers 39b. On the closed end of the metal casing is the above-mentioned sliding seal 41a. The heat shield 15a is also a box-like metal casing open at one end and carries within it a mass of mineral fibers 15c which projects out of the metal casing toward the furnace 2a so as to assure a sealing action. Brackets 15d are situated on opposite sides of the heat shield 15a and are bolted through slots to the cantilevers 14a on the stand 7a so that a horizontal adjustment is possible.
Only half of the upper frame 5a of the frame 7a is here shown (on the left), and the radiation guard 16a for the front end of the charging apparatus 10a is shown only partially, since the geometrical arrangements can easily be understood from FIGS. 1 and 2.
The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, it being recognized that various modifications are possible within the scope of the invention.
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Disclosed is an apparatus for feeding and distributing charge material through a feeding opening onto the molten bath surface in a glass melting furnace. On a movable stand there are disposed a charge hopper, a charging device, a pusher with a pusher holder and pusher driver and a heat shield substantially covering the feed opening, in which at least one opening is disposed for the passage therethrough of the charging device and of the pusher holder. To maintain a suitable path of movement of the pusher with simultaneous improvement of the shielding action of the heat shield, the pusher holder is mounted on a horizontal linear guiding device on a horizontal platform and is displaceable with respect to the latter by a horizontal driver. The platform is mounted on the stand by means of a vertical guiding device and can be raised and lowered on the stand by a vertical driver. Thus it is possible to uncouple the driving movements and provide a better sealing of the places at which the pusher holder passes through the heat shield.
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TECHNICAL FIELD
[0001] The application generally relates to sliding door or window assemblies, and more particularly, to a draining frame for removing moisture or other liquid that may accumulate within a sliding door or window assembly, and a system including such assembly and drainage frame.
BACKGROUND OF THE INVENTION
[0002] The ability to drain rain water or other condensation from window sills and patio doors is desired for some installations. Sliding closure assemblies may require some form of drainage to prevent rain water and condensation from entering the interior of a building around the movable panes. In the past, positioned drain holes throughout the assemblies have been provided to allow water to escape as it forms.
[0003] While numerous drainage systems have been designed to solve this problem, most such drainage systems require a hollow sill construction. These systems are not adapted to the drainage of horizontally sliding closure assemblies such as patio doors which are normally constructed with a solid sill for strength and durability. The infiltration of wind driven water may be a particular problem with patio doors for some installations because it is desirable to have a sill profile that is as low and unobtrusive as possible to facilitate passage through the door with wheelchairs and the like.
[0004] Many systems have been designed for directional drainage of water and moisture. Nevertheless, these systems have been invasive requiring intensive ground preparations. One such drainage system utilizes a collection pan mounted under a channel where the liquid is collected. The pan collects the liquid from the channel through an aperture, usually by way of gravity. Because of its lower position, the collection pan requires additional trenching work so that the collection pan can be properly fitted.
[0005] The present application provides a frame drain method and system for horizontally sliding closure assemblies such as patio doors or windows which permits the drainage of water from the interior of the closure. A system consisting of such frame and assembly allows minimally invasive techniques requiring less trenching or other work performed.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0006] In accordance with an embodiment of the present invention, an assembly is disclosed. The assembly comprises, in combination: an upright support allowing translational movement of at least one slidable closure element above a ground level; a weeping upright distal from said upright support forming a channel therebetween topping proximate said ground level; and an accumulator perpendicular to said channel and in fluid communication with said channel so that fluid received in said channel formed between said upright support and weeping upright flows to said accumulator.
[0007] In accordance with another embodiment of the present invention, an assembly is disclosed. The assembly comprises, in combination: an upright support allowing translational movement of at least one slidable closure element above a ground level; a weeping upright distal from said upright support topping proximate said ground level; wherein said weeping upright is shaped so as to form, in cooperation with said upright support, an L-shaped channel therebetween; and a drainage opening within one of said upright support, weeping upright, and L-shaped channel for removing said liquid within said channel.
[0008] In accordance with a further embodiment of the present invention, a system is disclosed. The system comprises, in combination: a slidable closure element; an upright support allowing translational movement of said slidable closure element above a ground level; a weeping upright distal from said upright support topping proximate said ground level; wherein said weeping upright is shaped so as to form, in cooperation with said upright support, an L-shaped channel therebetween; and a drainage opening within one of said upright support, weeping upright, and L-shaped channel for removing said liquid within said channel.
BRIEF DESCRIPTION OF DRAWINGS
[0009] The novel features believed to be characteristic of the application are set forth in the appended claims. In the descriptions that follow, like parts are marked throughout the specification and drawings with the same numerals, respectively. The drawing figures are not necessarily drawn to scale and certain figures can be shown in exaggerated or generalized form in the interest of clarity and conciseness. The application itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:
[0010] FIG. 1 is a top view of an exemplary window or door frame system that empties liquid into an accumulator in accordance with one aspect of the present application;
[0011] FIG. 2 is an elevated front cross sectional view thereof;
[0012] FIG. 3 is a top cross sectional view thereof;
[0013] FIG. 4 is a top perspective view of a cross section thereof;
[0014] FIG. 5 is a side view thereof;
[0015] FIG. 6 is a magnified top view of the accumulator thereof;
[0016] FIG. 7 is a magnified side perspective view thereof;
[0017] FIG. 8 is a top view of an illustrative window or door frame system having a conduit emptying from the side of its upright support in accordance with one aspect of the present application;
[0018] FIG. 9 is a side view thereof;
[0019] FIG. 10 is a top cross sectional view thereof;
[0020] FIG. 11 is a magnified side view thereof;
[0021] FIG. 12 is a bottom view of an exemplary window or door frame system that empties liquid a bottom portion in accordance with one aspect of the present application;
[0022] FIG. 13 is a side view thereof;
[0023] FIG. 14 is a closer top perspective view thereof;
[0024] FIG. 15 is an expanded view thereof;
[0025] FIG. 16 is a cross sectional view of an exemplary window or door frame system depicting sliding panels in accordance with one aspect of the present application;
[0026] FIG. 17 is a top perspective unfinished view thereof; and
[0027] FIG. 18 is a top perspective finished view thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The foregoing description is provided to enable any person skilled in the relevant art to practice the various embodiments described herein. Various modifications to these embodiments will be readily apparent to those skilled in the relevant art, and generic principles defined herein can be applied to other embodiments. Thus, the claims are not intended to be limited to the embodiments shown and described herein, but are to be accorded the full scope consistent with the language of the claims, wherein reference to an element in the singular is not intended to mean “one and only one” unless specifically stated, but rather “one or more.” All structural and functional equivalents to the elements of the various embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the relevant art are expressly incorporated herein by reference and intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims.
[0029] Turning now to the drawings, FIGS. 1-7 show an exemplary window or door frame system 100 having an accumulator 102 for collecting and removing liquid on a side portion in accordance with one aspect of the present application. For sliding door assemblies, the system 100 can be positioned in the ground such that barriers from preventing ingress or egress are reduced or completely removed. As will be shown below, the accumulator 102 reduces the excavation process for installing the system 100 and allows for quicker setup times as well. While primarily intended for use with doors and windows, the system 100 can also accommodate other types of slidable paneling.
[0030] As depicted in FIG. 1 , the system 100 can include at least one support member 104 . The support member 104 can provide a sturdy bottom for other components of the system 100 . While the support member 104 can be considered as a separate component, it should also be noted that the components described herein can be one continuous element. Attached thereto, mounting elements 112 can be used to provide additional support for the entire system 100 .
[0031] Coupled to the support member 104 can be an upright support 106 and a weeping upright 108 . As shown, the upright support 106 and the weeping upright 108 may be parallel to each other. In one embodiment, the upright support 106 can be an elongated track extending upright from the support member 104 , As shown in FIG. 2 , the upright support 106 can extend past the accumulator 102 positioned over a floor or window sill, The upright support 106 can form a slight barrier to prevent liquid from the exterior area entering into the interior area.
[0032] Continuing with FIG. 1 , a weeping channel 108 can be provided for each of the upright supports 106 . As shown, the weeping channel 108 is parallel to the upright support 106 and spaced slightly apart. The weeping channel 108 can capture liquid either dripping or running off the panels or running across the floor surface and over the top of track from the exterior area toward the interior area. For windows, the weeping channel 108 captures liquid that can come over the sill.
[0033] Depicted in FIG. 16 , the upright support 106 can be positioned such that a lip extends past the floor or window sill 1602 . The lip can prevent liquid from entering into the residence or interior. The weeping channel 108 can end at the floor or window sill 1602 or slightly below there. Through this combination, minimal barriers are imposed while still allowing the ability to collect liquid that enters within.
[0034] The upright support 106 can engage slidable panels 1604 . The panels 1604 can include windows, doors, etc. In one embodiment, the panels 1604 can incorporate wheels 1606 which can engage with the upright support 106 . In one embodiment, the upright support 106 can include a shaped top surface for smooth engagement with the wheels 1606 of the slidable panels 1604 . Those skilled in the relevant art will appreciate that other configurations for slidable panels 1604 exist such as nearly frictionless surfaces, ball bearings, etc. While the slidable panels 1604 as shown are straight, the slidable panels 1604 can contain curves and the system 100 can be modified for the curved slidable panels 1604 .
[0035] FIG. 17 is a top perspective unfinished view of the window or door frame system 100 . As shown, installation of the system 100 typically uses minimal trenching work. The unfinished floor 1702 , in one embodiment, can provide a proper surface for placing the system 100 . The panels 1604 of the system 100 described above can be in a closed or opened position. In the open position, the panels 1604 are placed into the side as shown. The panels 1604 can be extended therefrom into a closed position along the upper supports 106 .
[0036] FIG. 18 is a top perspective finished view of the window or door frame system 100 . The flooring 1602 can be placed within the system 100 such that the upright supports 106 are minimally exposed while the weeping channel 108 is at or below the finished flooring 1602 as shown.
[0037] Returning to FIG. 1 , the upright support 106 and the weeping upright 108 can form a channel 110 therebetween. The channel 110 can lie on top of the support member 104 . In one embodiment, the channel 110 can be part of the support member 104 . Alignment fasteners 114 can be coupled between each of the upright supports 106 and weeping uprights 108 . The alignment fasteners 114 can provide lateral support to the system 100 .
[0038] As further shown in FIG. 3 , the channel 110 can be used to remove liquid or other types of accumulated moisture from the system 100 . An inlet 302 feeding into an accumulator 102 can be at the end of the channel 110 . In the shown embodiment, the inlet 302 can be circular. In one embodiment, the inlet 302 can be provided in other shapes like a square. The inlet 302 can also conform to the shape of the channel 110 .
[0039] A filter (not shown) can be used so that larger debris does not enter into the channel 110 . In one embodiment, the filter can be a grate. The grate can allow liquid to flow through while preventing other fragments from entering, In one embodiment, the channel 110 can allow the debris to flow therethrough. The inlet 302 can be large enough to allow large debris to flow into the accumulator 102 where it can be later collected or passed through the accumulator 102 altogether.
[0040] As previously discussed, the channel 110 provides a flow of liquid into the accumulator 102 through the inlet 302 . In one embodiment, the channel 110 can be sloped so that the liquid is directed into the inlet 302 . The slope allows gravity to funnel the liquid through. When multiple accumulators 102 are used, as shown in FIG. 1 , the channel 110 can be slopped midway directing liquid to each end.
[0041] Generally, the accumulator 102 is covered to prevent injuries. In one embodiment, the covering for the accumulator 102 can be opened such that debris or other materials can be removed. The accumulator 102 can be perpendicular to the channels 110 . After the liquid is received from the channel 110 and into the accumulator 102 , the accumulator can divert the liquid to an outlet 202 . In one embodiment, the accumulator 102 can be sloped so that gravity forces the liquid to the outlet 202 .
[0042] FIG. 4 is a top perspective view of a cross section of the exemplary window or door frame system 100 . The alignment fasteners 114 can be coupled to the upright support 106 and weeping upright 108 . The alignment fasteners 114 can be coupled such that any fluid therein can be distributed within the channel 110 through a drainage canal 402 . Typically, the canal 402 is sloped so that liquid empties into the channel 110 . With the alignment fasteners 114 , a stronger frame system 100 can be provided.
[0043] FIG. 5 is a side view of the exemplary window or door frame system 100 . While three support members 104 are shown, one skilled in the relevant art will appreciate that fewer or more support members 104 can be interconnected together. Each of the support members 104 can include an upright support 106 and a weeping upright 108 with a channel 110 therebetween that feeds into the accumulator 102 . The cross sectional view shows the inlet 302 feeding into the accumulator 102 with the accumulator 102 funneling the liquid into the nozzle 204 . The nozzle 204 can be bent at an angle so that the liquid continuously travels out using gravity.
[0044] The weeping upright 108 , which is not load-bearing, can take a variety of shapes and is not limited to the vertical structure shown in FIGS. 1-7 . For example, and as shown in FIG. 9 , the weeping upright 106 can be shaped so as to form, in cooperation with the upright support 106 , an L-shaped channel 110 , as best seen in FIGS. 8-10 and 12 - 14 . This configuration converts channel 110 into a combination channel and accumulator, creating a drainage basin that runs the entire length of the system 100 as compared to prior designs wherein drainage is confined to a collection box mounted below the track and occupying only a small portion of the length of the track.
[0045] FIG. 6 is a magnified top view of the accumulator 102 . As shown, the inlet 302 feeds liquid into the accumulator 102 through the channel 110 . FIG. 7 is a magnified side perspective view of the accumulator 102 . In one embodiment, a hose or other type of tubing can be connected to the nozzle 204 .
[0046] FIGS. 1-7 provided numerous components for the system 100 . Known to those skilled in the relevant art, fewer or more components can be incorporated into the system 100 . In one embodiment, the system 100 can incorporate a check valve. The check valve can allow liquid to flow one-way, while preventing any liquid from coming the opposite way. The check valve can be placed within the accumulator 102 . Alternatively, the check valve can be incorporated into the nozzle 204 or other extension thereof.
[0047] In one exemplary window or door frame system 100 , liquid can be removed from the channel 110 from a side drainage opening 802 as depicted in FIGS. 8-11 . Generally described and shown in FIG. 8 , the upright support 106 and the weeping upright 108 can be held together through support members 104 . The support members 104 can then be placed on mounting elements 112 . Alignment fasteners 114 can also be used to provide lateral support for the system 100 . Those skilled in the relevant art will appreciate that similar components can be present in each of the exemplary window or door frame systems 100 .
[0048] The drainage opening 802 can be positioned within the upright support 106 . Alternatively, the drainage opening 802 is provided in the weeping upright 108 . Typically, the drainage opening 802 can positioned such that a portion of the drainage opening 802 is above a bottom of the channel 110 and another portion of the drainage opening 802 can be right at or slightly below the channel 110 as more clearly shown in FIG. 9 . By positioning the drainage opening 802 in such a way, the maximum amount of liquid can be removed from the channel 110 .
[0049] In one embodiment, the drainage opening 802 can be connected to an elbow joint 804 . While the elbow joint 804 allows the flow of liquid away from the other components of the system 100 , those skilled in the relevant art will appreciate that other types of connectors can be used and attached to the drainage opening 802 . Typically, the elbow joint 804 and the drainage opening 802 can contain threading so that the elbow joint can be fitted securely removing the possibility of leaks.
[0050] Generally, a conduit 806 can be coupled to the elbow joint 804 to further carry the liquid from the channel 110 away from the system 100 . The conduit 806 can take the form of a hose or other type of tubing. The channel 110 can be sloped such that the liquid therein is provided to the drainage opening 802 . While numerous conduits 806 are shown, one centralized conduit 806 can be used to remove the liquid.
[0051] As noted above, the weeping upright 108 can be shaped so as to form, in cooperation with upright support 106 , an L-shaped channel 110 . angled such that more liquid can flow through the channel 110 . This implementation of the weeping upright 108 can be used in the embodiments described herein. Optionally, the upright support 106 can be shaped, perhaps in similar manner, to expand the channel 110 , either in cooperation with a vertical weeping upright 108 or a shaped weeping upright 108 .
[0052] In one embodiment, the drainage opening 802 can be placed proximate the middle of the upright support 106 or the weeping upright 108 . Alternatively, the drainage opening 802 can be placed on one side. The channel 110 may be sloped so that the liquid flows towards the drainage opening 802 . While only one opening is shown in each of the upright supports 106 or weeping uprights 108 , those skilled in the relevant art will appreciate that there can be two or more drainage openings 802 placed therein.
[0053] FIG. 10 is a top cross sectional view of the exemplary window or door frame system 100 . As shown, alignment fasteners 114 can provide lateral support for the system 100 . One end of the alignment fastener 114 can connect to the upright support 106 while the other end can connect to the weeping upright 108 . The alignment fastener 114 can contain a drainage canal 402 that empties into the channel 110 .
[0054] FIG. 11 is a magnified side view of the exemplary window or door frame system 100 . The magnified view shows the threading for the elbow joint 804 into the drainage opening 802 which is within the upright support 106 . A conduit 806 can be coupled to the elbow joint 804 . The conduit 806 and the elbow joint 804 can be connected through threading known to those skilled in the relevant art.
[0055] As provided above, FIGS. 16-18 depict the window or door panels 1604 that can be placed on the upright support 106 . Those skilled in the relevant art will appreciate that the window or door panels 1604 can be implemented on the embodiment described above.
[0056] In one exemplary window or door frame system 100 , liquid can be removed through a bottom portion as depicted in FIGS. 12-15 . The upright support 106 and the weeping upright 108 can be held together through support members 104 . The support members 104 can then be placed on mounting elements 112 . Alignment fasteners 114 can also be placed for lateral support in the system 100 . Those skilled in the relevant art will appreciate that similar components can be present in each of the exemplary window or door frame systems 100 .
[0057] In the embodiment shown in FIG. 12 , the drainage opening 802 opens into the bottom of the L-shaped channel 110 through the support member 104 . While only one drainage opening 802 per support member 104 is shown, those skilled in the relevant art will appreciate that there can be two or more openings for each support member 104 . In one embodiment, the channel 110 can be sloped such that liquid therein can be funneled downwards by gravity into the drainage opening 802 .
[0058] FIG. 13 is a side view of the exemplary window or door frame system 100 . The drainage opening 802 can be coupled to an elbow joint 804 . In one embodiment, a simple connector can be used instead of the elbow joint 804 . The elbow joint 804 can then be connected to a conduit 806 . FIG. 13 illustrates that more than one conduit 806 can be used. In other embodiments, a single conduit 806 can be connected to each of the elbow joints 804 .
[0059] FIG. 14 is a closer top perspective view of the exemplary window or door frame system 100 . The upright support 106 , weeping upright 108 , and channel 110 therebetween can be coupled through an alignment faster 114 that provides additional support for the system 100 . FIG. 15 is an expanded view of the exemplary window or door frame system 100 . The threading used by the elbow joint 804 can be fitted securely into the drainage opening 802 so that leaks are prevented. The conduit 806 can be coupled thereto.
[0060] As provided above, FIGS. 16-18 depict the window or door panels 1604 that can be placed on the upright support 106 . Those skilled in the relevant art will appreciate that the window or door panels 1604 can be implemented on the embodiment described above.
[0061] The foregoing description is provided to enable any person skilled in the relevant art to practice the various embodiments described herein. Various modifications to these embodiments will be readily apparent to those skilled in the relevant art, and generic principles defined herein can be applied to other embodiments. Thus, the claims are not intended to be limited to the embodiments shown and described herein, but are to be accorded the full scope consistent with the language of the claims, wherein reference to an element in the singular is not intended to mean “one and only one” unless specifically stated, but rather “one or more.” All structural and functional equivalents to the elements of the various embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the relevant art are expressly incorporated herein by reference and intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims.
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A window or door assembly and/or system having a drain method and device that is less invasive than previous implementations. The assembly can include slidable window or door panels and an upright support allowing translational movement of the panels. Distal thereto, a weeping upright is provided. The upright support and the weeping upright can form a channel therebetween where the liquid is collected, wherein the channel in one embodiment is L-shaped. To remove liquid from the channel, an accumulator that is perpendicular to the channel can receive the fluid through an opening. Liquid can also be removed through a drainage opening within the upright support or weeping upright. An aperture along with a connector along a bottom portion of the channel can also be used to remove the liquid within the channel.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to Applicants' copending application Ser. Nos. 08/183,499 and 07/183,732, both filed Jan. 19, 1994, the disclosures of which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates generally to a combining conveyor system for assembling fabric pieces, and more particularly, to a combining conveyor system for fabric having a unique combining fixture, binding fixture and a transfer station for moving the fabric piece between each fixture.
(2) Description of the Prior Art
The manufacture of textile clothing articles such as briefs, tee-shirts and outer garments has resisted automation. This is due largely to the difficulty in accurately positioning so called "soft" materials. For example, the knitted material commonly used in briefs and tee-shirts may wrinkle, stick to one another and stretch significantly when handled.
One technique which has been somewhat successful has been the introduction of fiber optic edge detectors. Such detectors, when attached to a sewing machine and guide means can allow some automation of common sewing operations such as binding an edge of a precut fabric piece. However, such operations still require the use of a skilled operator to feed the fabric piece to the sewing machine and usually carry out only one sewing operation at a time.
Thus, there remains a need for a combining conveyor system for assembling fabric pieces for manufacturing fabric assemblies for a men's brief or the like which can be carried out completely automatically without the need for a skilled operator.
SUMMARY OF THE INVENTION
The present invention is directed to a combining conveyor system which combines a first fabric piece and a second fabric piece to form a combined fabric piece, such as a men's brief and applies binding to the fabric piece.
The apparatus includes an unique combining fixture. The combining fixture includes: a base; fabric clamping means for receiving and securing the first fabric piece, the second fabric piece, and the combined fabric piece; and a support attached to the base and supporting the fabric clamping means.
A conveyor transports the combining fixture to at least one sewing machine work station having means for operating on the first and second fabric pieces.
A transfer station removes the combining fixture from the conveyor when the operations are completed and places the fabric piece on an unique binding fixture.
The binding fixture includes: a base; a support attached to the base; and fabric engaging means mounted on the support for engaging, positioning and securing the fabric piece.
The conveyor transports the binding fixture to at least one sewing machine work station for operating on the fabric piece while the same is being held by the binding fixture.
Accordingly, one aspect of the present invention is to provide a combining and binding conveyor system for combining a first fabric piece and a second fabric piece to form a combined fabric piece and to apply a binding to an edge of the fabric piece. The system includes: (a) a combining fixture having means for holding the first fabric piece and the second fabric piece; (b) a upstream conveyor for transporting the combining fixture; (c) at least one work station having means for combining the first and second fabric pieces; (d) a binding fixture for holding the fabric piece; (e) a downstream conveyor for transporting the binding fixture; and (f) at least one work station located adjacent to the conveyor for attaching the binding to the edge of the fabric piece while the same is being held by the binding fixture.
Another aspect of the present invention is to provide a combining and binding conveyor system for combining a first fabric piece and a second fabric piece to form a combined fabric piece and to apply a binding to an edge of the fabric piece. The system includes: (a) a combining fixture having means for holding the first fabric piece and the second fabric piece; the combining fixture including: (i) a base; (ii) fabric clamping means for receiving and securing the first fabric piece; and (iii) a support attached to the base and supporting the fabric clamping means; (b) an upstream conveyor for transporting the combining fixture; (c) at least one work station having means for combining the first and second fabric pieces; (d) a binding fixture for holding the fabric piece; (e) a downstream conveyor for transporting the binding fixture; (f) at least one work station located adjacent to the conveyor for attaching the binding to the edge of the fabric piece while the same is being held by the binding fixture; and (g) a transfer station for removing the combining fixture from the upstream conveyor and for placing the fabric piece on the binding fixture on the downstream conveyor.
Another aspect of the present invention is to provide a combining and binding conveyor system for combining a first fabric piece and a second fabric piece to form a combined fabric piece and to apply a binding to an edge of the fabric piece. The system including: (a) a combining fixture having means for holding the first fabric piece and the second fabric piece; (b) a upstream conveyor for transporting the combining fixture; (c) at least one work station having means for combining the first and second fabric pieces; (d) a binding fixture for holding the fabric piece, the binding fixture including: (i) a base; (ii) a support attached to the base; and (iii) fabric engaging means mounted on the support for engaging, positioning and securing the fabric piece; (e) a downstream conveyor for transporting the binding fixture; (f) at least one work station located adjacent to the conveyor for attaching the binding to the edge of the fabric piece while the same is being held by the binding fixture; and (g) a transfer station for removing the combining fixture from the upstream conveyor and for placing the fabric piece on the binding fixture.
Still another aspect of the present invention is to provide a combining and binding conveyor system for combining a first fabric piece and a second fabric piece to form a combined fabric piece and to apply a binding to an edge of the fabric piece. The system includes: (a) a combining fixture having means for holding the first fabric piece and the second fabric piece; the combining fixture including: a base; fabric clamping means for receiving and securing the first fabric piece, wherein the fabric clamping means includes: (i) a support; (ii) a control arm clamp attached to the support; and (iii) at least one gripping arm, the second fabric piece, and the combined fabric piece formed from the first and second fabric pieces; and a support attached to the base and supporting the fabric clamping means; (b) a upstream conveyor for transporting the combining fixture; (c) at least one work station having means for combining the first and second fabric pieces; (d) a binding fixture for holding the fabric piece, the binding fixture including: a base; a support attached to the base; and fabric engaging means mounted on the support for engaging, positioning and securing the fabric piece, wherein the fabric engaging means includes: (i) clamping means attached to the support; (ii) adjustment means for adjusting the fabric piece to a plurality of horizontal and vertical positions when engaged; and (iii) actuator means for adjusting the adjustment means between the plurality of positions; (e) a downstream conveyor for transporting the binding fixture; (f) at least one work station located adjacent to the conveyor for attaching the binding to the edge of the fabric piece while the same is being held by the binding fixture; and (g) a transfer station for removing the combining fixture from the upstream conveyor and for placing the fabric piece on the binding fixture.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the combining portion of a conveyor system constructed according to the present invention;
FIG. 2 is a partially fragmented side elevational view of a combining fixture mounted on a conveyor, which forms a part of the present invention;
FIG. 3 is an end view of the combining fixture forming a part of the present invention;
FIG. 4 is a partial top view of the combining fixture forming a part of the present invention;
FIG. 5 is a side elevational view of a transfer station which forms a part of the present invention;
FIG. 6 is a perspective view of the combining fixture of the present invention with a brief, shown in dotted line form; and
FIG. 7 is a plan view of the binding portion of a conveyor system constructed according to the present invention;
FIG. 8 is a side elevational view of a binding fixture of the present invention in the ready position;
FIG. 9 is a top plan view of the binding fixture forming a part of the present invention in the ready position;
FIG. 10 is a side elevational view of the binding fixture forming a part of the present invention in the receiving position;
FIG. 11 is a side elevational view of the binding fixture of the present invention in the binding position;
FIG. 12 is a side elevational view of a transfer station which forms a part of the present invention; and
FIG. 13 is a perspective view of the binding fixture of the present invention holding a brief, shown in dotted line form.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as "forward", "rearward", "left", "right", "upwardly", "downwardly", and the like are words of convenience and are not to be construed as limiting terms.
The present invention provides for automatic handling of fabric pieces and fabrication of garments from the same. While the following description of the preferred embodiment only discloses the operation of combining two fabric pieces, it will be understood that a multiplicity and variety of operations could be performed on the fabric pieces and the resulting garment using the system of the present invention. In describing the preferred embodiment, the process for manufacturing men's briefs underwear will be discussed. However, many similar garment applications will be obvious to those skilled in the art.
Combining Portion
As best seen in FIG. 1, the combining portion of the apparatus of the present invention includes two basic sub-systems: an upstream conveyor generally denoted by the numeral 100 and a combining fixture generally denoted by the numeral 300. Also forming a part of the invention is sewing machine 200. While only this single work station is shown, the system of the present invention can easily be designed to accommodate many work stations.
Basic operation of the present invention is as follows. Fixture 300 rides along upstream conveyor 100. Work stations such as sewing machine 200 are located along the path of upstream conveyor 100. As a garment mounted on fixture 300 passes by a work station, it is operated upon. Several features are provided to facilitate the flow of the fixture and the accuracy and efficiency of the operations including lift systems 130, rotators 170, stops 120, secondary conveyors 150, and sensor means 122 and 124. It is particularly noteworthy that a plurality of fixtures can be used at once, and therefore a plurality of garments can be fabricated simultaneously.
Upstream conveyor 100 has frame 110. Mounted on frame 110 are primary belts 102 which ride on a fluorocarbon plastic surface and are driven by primary drive means 104A. These drive means may be servo-controlled or conventional motors, for example, depending on the degree of control needed for the associated operations. Fixture 300, which will be discussed more fully later, has base 302 adapted to ride on upstream conveyor 100 and is guided by frame 110. In operation, fixture 300 travels in a clockwise direction. Lift systems 130 are provided to allow fixture 300 to pass around the corners of upstream conveyor 100 without interference with frame 110.
Lift systems 130 have lift belts 134 which travel on lift rollers 136 and are driven by lift motors 136A. Lift systems 130 also have lift supports which support the aforementioned lift system components and are operatively connected to pneumatic cylinders 132A. When fixture 300 is positioned over a lift system 130, the cylinder is actuated such that the lift support raises and meets the base of fixture 300. Driven lift belts 134 engage fixture 300 and push or pull (depending on whether the lift system is located at the entrance or at the exit of the corner) fixture 300 over frame 110 and onto the adjacent primary belts 102. Position sensors 124 sense the presence of fixture 300 and can thereby provide associated software with the data necessary to determine when fixture 300 is in position to raise the lift support.
Rotator 170 operates much like lift system 130. Position sensor 124 signals the position of fixture 300. Rotator support 172 is raised by a pneumatic cylinder 172B and rotated by a pneumatic actuator 172A. Depending on the desired position of fixture 300 for the next operation, fixture 300 may be rotated 90° or 180°.
When multiple fixtures are used or where speed sensitive operations are implemented, it will be advantageous to control the speed of each fixture. Stops 120 are provided to stop a fixture when desired. Stops 120 are actuated by a pneumatic cylinder 120A in the preferred embodiment and engage stop locator 316 formed in base 302 of fixture 300. Stops 120 can then be retracted to allow fixture 300 to resume travel. Secondary conveyors 150 are provided to either speed up or slow down fixtures on various portions of upstream conveyor 100. Secondary belts 154 are driven by drive means 158 and ride on rollers 156 which are in turn mounted on secondary lift 152. A fixture traveling over a secondary lift is raised off the primary belts and as a result travels at the speed of the secondary belts. This is helpful to ensure a steady and appropriate speed at any given work station, such as a sewing machine, during operation.
Turning now to combining fixture 300, the same is shown in detail in FIGS. 2-4 and 6. Fixture 300 has base 302. Attached to base 302 is lower support 310 which supports lower platform 304 on one end. At the opposite end of the lower platform 304, upper support 312 is attached to and supported by the same. Upper support 312 supports upper platform 306 and gripping arms 360.
Bumpers 318 are mounted on base 302 to protect fixture 300 in case of collisions with other fixtures. An identification badge 320 is affixed to the bottom of base 302 to provide information about the fixture and its associated garment to a scanning device. Identification badge 320 may be a bar code or an electrically encoded tab, for example. Sensor means 122 located on upstream conveyor 100 are designed to read whatever information may be encoded on the identification badge (for example, the size of the brief on the fixture).
Lower clamp arm 330 is pivotally attached to lower platform 304 at pivot 330a and is biased against platform 304 by spring 330b. Upper clamp arm 340 is pivotally attached to upper platform 306 at pivot 340a and is biased against upper platform 306 by spring 340b.
Gripping arms 360, generally denoted, are supported by upper support 312. Gripper supports 380 are rigidly affixed to and extend outwardly from supports 312. Gripper sub-frames 378 are pivotally connected to gripper supports 380 at pivots 376 and are held in place by detent systems 377.
Pushing pivot rod 376 forward will cause detent system 377 to disengage, allowing gripper sub-frames 378 to rotate downwardly. Mounted on gripper sub-frames 378 are lower gripper arms 362 and upper gripper arms 364. Linkages 366 are connected to lower gripper arms 362 at pivots 368 and to the control rods 374 such that when rods 374 are rotated, linkages 366 draw lower gripper arms 362 downward. Guides 370 maintain the attitude of lower gripper arms 362 throughout the range of motion. Springs 370b bias lower gripper arms 362 upward against upper gripper arms 364.
Upper clamp arm 340 may be raised by applying a downward force to pivot end 340c. Similarly, lower clamp arm 330 may be raised by applying an upward force to pivot end 330c.
Fixture 300 may be used as follows to receive and secure two pieces of fabric in order to construct a garment such as a pair of men's briefs.
An external actuator engages pins 375 and pushes pivot rods 376 forward causing detent systems 377 to disengage, thereby allowing gripper sub-frames 378 to be rotated downward. After gripper sub-frames 378 are rotated, then lower and upper gripper arms 362 and 364 are separated by rotating control rod 374. Gripper arms 362 and 364 are now positioned to receive fabric hanging vertically. An external apparatus can be used to insert the fabric. Control rods 374 are then released, allowing gripper arms 362,364 to close so that now the two ends of the fabric are held by the gripper arms. The gripper sub-frames 378 are then rotated upward about pivot 376. The ends of the fabric are now held horizontally by the gripper arms, which is the preferred position for sewing and trimming operations.
Simultaneous with the opening of the gripper arms, lower clamp arms 330 and upper clamp arms 340 are raised by pressing pivot ends 330c and 340c, respectively. The front fabric panel is then inserted between upper clamp arm 340 and upper platform 306. The pivot end 340C is then released, allowing upper clamp arm 340 to pin down the front panel. Likewise, the center portion of the back panel is inserted between lower clamp arm 340 and lower platform 304 along with being inserted into the openings of gripper arms 362, 364. Pivot end 330C is then released and the back panel is secured by lower clamp arm 330 and lower platform 304.
Once mounted in the fixture as described above and shown in FIG. 6, the panels are in the preferred position. All of the critical edges of fabric are accurately located, firmly secured, and held such that they can be easily accessed and manipulated.
Transfer Station
A further benefit of fixture 300's design is that it facilitates use of a transfer station, generally denoted as 400, which forms a part of the present invention. The basic purpose of the transfer station is to remove a combined front and back panel from fixture 300 and hold the fabric such that it can be subsequently operated on in the binding fixture 600 (see below).
Transfer station 400 has a rotatable mast 402. Mast 402 is mounted by rotational pivot 406 onto base 407, which is in turn fixedly mounted onto table 409. Rotator motor 411 is operatively connected to turn mast 402. Lift assemblies, denoted generally 410, are mounted on mast 402 by braces 404. Braces 404 are vertically slidable along tracks 401 formed in mast 402.
Lift assemblies 410 have carriages 412 formed thereon. Eight clamp arms 414 depend from each of carriages 412 in four sets of opposed pairs. Each clamp arm 414 has foam backing 414A located on the surface facing its opposing clamp arm 414. Clamp arm actuator means 416 mounted on carriages 412 are operatively connected to clamp arms 412 and are designed to move the same between an open position and a closed position. In the closed position, the foam backing 414A on each clamp arm 414 is pressed against the foam backing of the opposing clamp arm 414. In the open position, the clamp arms are separated.
A pivot assembly, generally denoted 460, has platform 462, which is securely mounted on 409. Pivot point 464 is slidably mounted on platform 462 and pivotly holds base 470. Support 472 extends upwardly from base 470 and supports engagement rods 466, upper release actuator 467, lower release actuator 469, fixture latch 474 and actuator rods 468. Engagement rods 466 are designed to be inserted into the transfer engagement bushings 314 of combining fixture 300 and are adequately sturdy to lift the fixture. Actuator rods 468 are designed to engage the ends Of control rods 374 and rotate the same, such that gripper arms 362 and 364 are opened and closed. Upper and lower release actuators 467 and 469 are designed to engage the ends 340C,330C of upper and lower clamp arms 340 and 330 and fixture latch 474 to secure the fixture during rotation.
A fabric brief (combined front and back panels) is transferred from combining fixture 300 to clamp arms 414 as follows. Upstream conveyor 100 positions and raises fixture 300 in front of pivot assembly 460, as shown in FIG. 5. Pivot point 464 and base 470 slide forward so that pivot assembly 460 engages fixture 300. As pivot assembly 460 engages fixture 300, actuator rod 468 engages control rods 374 and engagement rods 466 enter transfer engagement bushings 314 and fixture latch 474 engages slot 382. Fixture 300 is then lifted to a vertical position by pivoting base 470 at pivot point 464.
Once fixture 300 is in the vertical position, retracted carriage 412 is lowered such that the clamp arms 414, which are in the open position, surround the brief. Carriage 412 then extends. Clamp arms 414 are now positioned such that each pair of opposed clamp arms has one clamp arm on the exterior circumference of the brief and one clamp arm on the interior circumference of the brief. The clamp arms are then put in the closed position by actuator means 416, so that each of the four sets of the clamp arms 414 is gripping the brief on a separate point along its circumference and fully along its length. Actuator rod 468, still engaged with control rods 374, is rotated, opening gripper arms 362 and 364 of fixture 300. Simultaneously, upper release actuator 467 is operated to press downwardly on upper pivot end 340C to raise upper clamp arm 340, and lower release actuator 469 is operated to press upwardly upon lower pivot end 330C to lower clamp arm 330. As a result of these operations, the brief which is now securely held by clamp arm 414, is released from fixture 300.
Lift assembly 410 is then raised vertically by powering brace 404 up track 401. Finally, lift assembly 410 and the brief it is holding are transferred to the opposite side of mast 402 by rotating mast 402 at rotational pivot 406. The brief can now be transferred to the binding fixture 600 for further operations or placed in a bin for shipping.
After the brief has been removed from fixture 300, fixture 300 is lowered back onto upstream conveyor 100 by reversing the lifting steps.
Binding Portion
As best seen in FIG. 7, the binding portion of the apparatus of the present invention includes two basic sub-systems: a downstream conveyor generally denoted by the numeral 500 and a binding fixture generally denoted by the numeral 600. Also forming a part of the invention is binding machine 202. While only this single work station is shown, the system of the present invention can easily be designed to accommodate many work stations.
Basic operation of the present invention is as follows. Fixture 600 rides along downstream conveyor 500. Work stations such as binding machine 202 are located along the path of downstream conveyor 500. As a garment mounted on fixture 600 passes by a work station, it is operated upon. Several features are provided to facilitate the flow of the fixture and the accuracy and efficiency of the operations including lift systems 530, rotators 570, stops 520, secondary conveyors 550, and sensor means 522 and 524. It is particularly noteworthy that a plurality of fixtures can be used at once, and therefore a plurality of garments can be fabricated simultaneously.
Downstream conveyor 500 has frame 510. Mounted on frame 510 are primary belts 502 which ride on a fluorocarbon plastic surface and are driven by primary drive means 504A. These drive means may be servo-controlled or conventional motors, for example, depending on the degree of control needed for the associated operations. Fixture 600, which will be discussed more fully later, has base 602 adapted to ride on downstream conveyor 500 and is guided by frame 510. In operation, fixture 600 travels in a clockwise direction. Lift systems 530 are provided to allow fixture 600 to pass around the corners of downstream conveyor 500 without interference with frame 510.
Lift systems 530 have lift belts 534 which travel on lift rollers 536 and are driven by lift motors 536A. Lift systems 530 also have lift supports which support the aforementioned lift system components and are operatively connected to pneumatic cylinders or motors 532A. When fixture 600 is positioned over a lift system 530, the cylinder or motor is actuated such that the lift support raises and meets the base of fixture 600. Driven lift belts 534 engage fixture 600 and push or pull (depending on whether the lift system is located at the entrance or the exit of the corner) fixture 600 over frame 510 and onto the adjacent primary belts 502. Position sensors 524 sense the presence of fixture 600 and can thereby provide associated software with the data necessary to determine when fixture 600 is in position to raise lift support 532.
Rotator 570 operates much like lift system 530. Position sensor 524 signals the position of fixture 600. Rotator support 572 is raised by a pneumatic cylinder 572B and rotated by a pneumatic actuator 572A. Depending on the desired position of fixture 600 for the next operation, fixture 600 may be rotated 90° or 180°.
When multiple fixtures are used or where speed sensitive operations are implemented, it will be advantageous to control the speed of each fixture. Stops 520 are provided to stop a fixture when desired. Stops 520 are actuated by a pneumatic cylinder 520A in the preferred embodiment and engage stop locator 612 formed in base 602 of fixture 600. Stops 520 can then be retracted to allow fixture 600 to resume travel. Secondary conveyors 550 are provided to either speed up or slow down fixtures on various portions of downstream conveyor 500.
Secondary belts 554 are driven by drive means 558 and ride on rollers 556 which are in turn mounted on secondary lift 552. A fixture traveling over a secondary lift is raised off the primary belts and as a result travels at the speed of the secondary belts. This is helpful to ensure a steady and appropriate speed at any given work station during operation, such as a binding machine.
Turning now to binding fixture 600, the same is shown in detail in FIGS. 8-11 and 13. Fixture 600 has base 602.
Stop locators 612 are formed in base 602. Platform 604 is formed on top of base 602.
Bumpers 610 are mounted on base 602 to protect fixture 600 in case of collisions with other fixtures. An identification badge 620 is affixed to the bottom of base 602 to provide information about the fixture and its associated garment to a scanning device. Identification badge 620 may be a bar code or an electrically encoded tab, for example. Sensor means 522 located on downstream conveyor 500 are designed to read whatever information has been encoded on the identification badge (for example, the size of the brief on the fixture).
Front assembly 630 and rear assembly 633 are supported by platform 604. In the preferred embodiment, front post 606 is fixedly mounted to platform 604 and rear post 608 is slidably mounted in track 683 which is formed in platform 604. Rear post 608 and rear assembly 633 may be locked in position by engaging lock teeth 685. Depressing lock release rod 684 will cause lock teeth 685 to disengage so that rear assembly 633 can be slidably readjusted. The importance of this adjustment mechanism will become apparent hereinafter.
Lower legs 654 are pivotally mounted to front and rear posts 606,608 at lower assembly pivots 650A. Lower clamp arms 650 are also pivotally mounted at lower assembly pivots 650A and are biased against lower legs 654 by springs. Lower clamp arms 650 may be pivoted away from lower legs 654 to achieve an open position by pushing lower clamp control levers 662 toward the center of platform 604. Slots 660 are formed in lower legs 654 and lower clamp arms 650 as shown.
Upper legs 656 are pivotally mounted to lower legs 654 at pivot points 670. Upper clamp arms 652 are pivotally mounted to upper legs 656 at pivot points 652A and are biased against upper legs 656 by magnets 690. Upper clamp arms 652 may be separated from upper legs 656 to achieve an open position by rotating actuator engagement slot 653.
Front and rear assemblies 630,633 are interconnected by linkages 672. In the preferred embodiment, a latch, not shown, locks the assemblies in the ready position shown in FIG. 8. Pushing release levers 666 disengages the latches. Assembly control means 674 is operatively connected to linkages 672 such that forcing the end of assembly control means 674 towards or away from the center of platform 604 will cause front and rear assemblies 630,633 to assume the positions shown in FIGS. 10 and 11. These positions will be more fully discussed hereinafter and are referred to as follows:
a. FIGS. 8 and 9 show the "ready" position,
b. FIG. 10 shows the "receiving" position,
c. FIGS. 11 and 13 show the "binding" position.
Tensioner spring assembly 686 biases the assemblies to remain in the binding position once they have been so disposed by actuating assembly control means 674.
The ready position is shown in FIGS. 8 and 9. In this position, upper clamp arms 652 are open and lower clamp arms 650 are in the closed position. Lower legs 654 are positioned at right angles to front and rear posts 606,608. Upper legs 656 are positioned at right angles to lower legs 654. Rear assembly 633 is positioned near the center of platform 604.
The receiving position is shown in FIG. 10. Upper and lower legs 654,656 are aligned and positioned vertically. Upper clamp arms 652 and lower clamp arms 650 are open. Rear assembly 633 is on the front end of platform 604.
The binding position is shown in FIGS. 11 and 13. In FIG. 13, the binding fixture is shown holding a brief (shown in dotted line form). Front assembly 630 is positioned the same as in the ready position. Rear assembly 633 is positioned somewhat rearward of platform 604 relative to its position in the ready position. The exact location will depend on the size of the brief to be held. Upper and lower legs 656,654 are aligned and positioned at approximately 45° angles to platform 604. Upper and lower clamp arms 652,650 are in the closed position.
The three positions of binding fixture 600 can best be understood in relation to the transfer station, generally denoted 400, forming a part of the present invention. In the preferred embodiment, the basic purpose of the transfer station when used to fabricate briefs is to place a garment comprising a combined front brief panel and back brief panel onto fixture 600 such that the critical edges are continuously located and accurately positioned.
As discussed above, transfer station 400 has mast 402. Mast 402 is mounted by rotational pivot 406 onto base 407, which is in turn fixedly mounted onto table 409. Rotator motor 411 is operatively connected to turn mast 402. Lift assemblies, denoted generally 410, are mounted on mast 402 by braces 404. Braces 404 are vertically slidable along track 401 formed in mast 402.
Lift assemblies 410 have carriages 412 formed thereon. Eight clamp arms 414 depend from each of carriages 412 in four sets of opposed pairs. Each clamp arm 414 has foam backing 414A located on the surface facing its opposing clamp arm 414. Clamp arm actuator means 416 mounted on carriages 412 are operatively connected to clamp arms 412 and are designed to move the same between an open position and a closed position. In the closed position, the foam backing 414A on each clamp arm 414 is pressed against the foam backing of the opposing clamp arm 414. In the open position, the clamp arms are separated.
A fabric brief (combined front and back panels) is transferred from clamp arms 414 to binding fixture 600 as follows. Note that the garment is generally tubular because the crotch seam has not yet been sewn. One end, hereinafter referred to as the top end, is basically circular. The opposite end, hereinafter referred to as the bottom end, has two arcuate cut-outs representing the leg holes of a completed brief.
Clamp arms 414 are initially positioned such that each pair of opposed clamp arms has one clamp arm on the exterior circumference of the brief and one clamp arm on the interior circumference of the brief. The clamp arms are in the closed position so that each of the four sets of the clamp arms 414 is gripping the brief on a separate point along its circumference and fully along its length, with the top end of the brief nearest the carriage and the free ends of the clamp arms extending out of the bottom end of the brief.
Lift assembly 414 is initially disposed on the side of mast 402 opposite binding downstream conveyor 500.
Lift assembly 410 and the brief it is holding are transferred to the opposite side of mast 402 by rotating mast 402 at rotational pivot 406. Lift assembly 410 is then lowered vertically by powering brace 404 down track 401.
Binding fixture 600 is initially in the ready position. When downstream conveyor 500 positions fixture 600 in front of transfer station 400, stop 520 raises and holds the fixture in place. Next, rear assembly positioning means 470 and front assembly positioning means 472 slide outwardly from support 474 and base 407, respectively, to engage fixture 600.
Rear assembly positioning means 470 engages lock release 684 and pushes rear assembly 633 along tracks 683 in the direction of mast 402. At the same time, rear assembly positioning means 470 engages release lever 666 and U-shaped slot 470A engages assembly control means 674. Simultaneously and in coordination, U-shaped slot 472A of front assembly positioning means 472 engages and pushes assembly control means 674 of front assembly 630. As assembly control means 674 are pushed forward or rearward by U-shaped slots 470A,472A, linkages 672 cause upper and lower legs 654,656 to assume the receiving position. Rear and front assembly position means 470,472 then force lower clamp control levers 662 upward causing lower clamp arms 650 to open. Clamp actuator means 476 then engage actuator engagement slots 653 of upper clamp pivots 652A and rotate the same.
Upon completion of the above steps, fixture 600 is positioned beneath carriage 412 in the receiving position. Carriage 412 is then lowered vertically down track 401 until assemblies 633,630 are flanked by two sets of clamp arms 414 on each side and the top edge of the brief, still held by clamp arms 414, is approximately level with the top ends of upper legs 656. The crotch portions of the brief (that is, the fabric strips between the leg cut-outs) are disposed between lower legs 654 and lower clamp arms 650.
Next, lower clamp control levers 662 are released by assembly positioning means 470,472 and upper clamp pivots 652A are rotated by clamp actuator means 476. As a result, the brief is captured securely by the upper and lower clamps of fixture 600. Clamp arms 414 of the transfer station are then opened and carriage 412 is raised.
Rear assembly positioning means 470 then forces rear assembly 633 of fixture 600 into the binding position via U-shaped slot 670A. Assembly positioning means 470,472 are then retracted. Fixture 600 remains in the binding position due to tensioner spring assembly 686 and latch 666.
The brief is now held such that the leg cut-outs are held straight, as shown in FIG. 13. In this position, all of the critical edges for binding are accurately located, firmly secured and held such that binding can be applied to the leg holes using a conventional binding apparatus 202. Once the binding has been applied, the brief can be removed by returning fixture 600 to a ready position, opening the upper and lower clamps, and pulling the brief out of the fixture. This may be done manually or robotically.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing disclosure. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability, but are properly in the scope of the following claims.
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A combining and binding conveyor system which combines a first fabric piece and a second fabric piece to form a combined fabric piece, such as a men's brief and applies binding to the fabric piece. The apparatus includes an unique combining fixture for receiving and securing the first fabric piece, the second fabric piece, and the combined fabric piece. A conveyor transports the combining fixture to at least one sewing machine work station having means for operating on the first and second fabric pieces. A transfer station removes the combining fixture from the conveyor when the operations are completed and places the fabric piece on an unique binding fixture for engaging, positioning and securing the fabric piece. The conveyor transports the binding fixture to at least one sewing machine work station for operating on the fabric piece while the same is being held by the binding fixture.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims all benefits accruing under 35 U.S.C. §119 from Taiwanese Patent Application No. 096127011, filed on Jul. 25, 2007 and Taiwanese Patent Application No. 097120421, filed on Jun. 2, 2008 in the Intellectual Property Office Ministry of Economic Affairs, Republic of China, the disclosures of which are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention provides a series of novel phosphor composition, particularly for use in light-emitting devices, and fabrication thereof.
DESCRIPTION OF THE RELATED PRIOR ART
[0003] The use of light-emitting diode (LED) to generating white light similar to sunlight thus generally replaces traditional white light lighting source, such as sunlight lamps, has been a main object of lighting source technical field in this century. As a comparison to traditional lighting sources, LED has advantages such as compactness, high brightness, usage life 10 times longer than traditional lighting equipments, lower cost in fabrication process and disposal treatment, and environmental friendliness. Therefore, LED has already been considered as the lighting source of next generation.
[0004] At present, the fabrication of white light LED can be divided as single-chip type and multi-chip type, wherein the multi-chip type using three kinds of LED with red, green and blue light, respectively, to generate white light. The advantage of multi-chip type LED is adjustable light color depending on different requirements. But, since it requires plural LEDs at same time, therefore, it has higher cost. Also, since materials of three kinds of LED are different, they have different drive voltages, and therefore, must design three types of circuits to control electric current. Besides, the decay rate, temperature characteristic and usage life of three types of LEDs are all different, thus it will lead to the variation of color of generated white light with time. Therefore, the product of commercial available white light LED and the trend in future will still take single-chip type as mainstream. As the fabrication method of single-chip type LED generally have three kinds as following:
[0005] (1) Combination of blue light LED with yellow light phosphor, which is using blue light LED to excite phosphor that can emit yellow light. The phosphor used is primarily a YAG phosphor with yttrium aluminum garnet structure ((Y,Gd) 3 (Al,Ga) 5 O 12 :Ce (YAG:Ce), Y. Shimizu et al. U.S. Pat. No. 5,998,925) which emits yellow light that can mix up with un-absorbed blue light to generate white light. Most of white light LED currently commercially available are fabricated in this manner. The advantages of this type of LED are can emit white light with single chip, low cost and easy to fabricate, but it has drawbacks such as low light-emitting efficiency, poor color rendering, light color varies with different output currents, and un-uniform light color, etc.
[0006] (2) Combination of blue light LED with red light and green light phosphor, which is using blue light LED to separately excite phosphors can emit red light and those can emit green light. The phosphor composition used is primarily a sulfur-containing phosphor, which emits red light and green light thus can mix up with un-absorbed blue light to generate white light. The advantages of such LED is having a spectrum with three wavelength distribution and thus have a higher color rendering, and adjustable light color and color temperature.
[0007] (3) Combination of UV-LED with red, green and blue light phosphors, which is using UV light emitted by UV-LED to excite three or more kinds of phosphors that can emit red, blue and green light individually, and mix up the three color light emitted to generate white light. The white light generated in this manner is similar to sunlight lamp, it has advantages such as high color rendering, adjustable light color and color temperature, using high-converting efficiency phosphors can improve its light-emitting efficiency, and uniform light color without variation with current changes, but it also has drawbacks such as hard to mix its powder, hard to find phosphor with high efficiency and novel chemical composition.
[0008] Wherein the phosphor, or so called fluorescence converting material (or fluorescence converting compound), can converts UV light or blue light into visible light with different wavelengths, and the color of produced light depends on the specific composition of phosphor. The phosphor may have only one phosphor composition or have two or more phosphor compositions. However, if we like to take LED as lighting source, only LED with brighter and whiter light can used in LED lamps. Therefore, the phosphor is generally coated on LED to produce white light. Each kind of phosphor under excitation of different wavelength can be converted into lights with different colors, for example, under excitation of near UV or blue light LED with wavelength of 365 nm-500 nm, phosphors can be converted into visible light. And the visible lights produced by the conversion of excited phosphor have characteristics of high luminescence intensity and high brightness.
[0009] Two colors visually feeling the same may actually composed of lights with wavelength different from each other. Based on the three primary colors, i.e., red, blue and green, visually various colors are achieved by combining the primaries at various ratios, i.e. so called principle of the three primary colors. Commission Internationale de l'Eclairage (CIE) has determined the equivalent unit for primary colors, and the luminous flux of standard white light is defined as:
[0000] r:g:b=1:4.5907:0.0601.
[0010] As equivalent unit for primary colors is determined, color combination relationship for white light Fw is:
[0000] Fw= 1[ R]+ 1[ G]+[B]
[0011] wherein R represents red light, G represents green light, and B represents blue light.
[0012] To light F with any color, color combination equation thereof is Fw=r[R]+g[G]+b[B], wherein r, g and b represents coefficients of red, blue and green, respectively, determined experimentally. Corresponding luminous flux is Fw=680(R+4.5907G+0.0601B) lumens (Im, illumination unit), wherein the ratio among r, g and b determines chromaticity (degree of color saturation), and the values determine the brightness of combined color. Relationship of three primary colors r[R], g[G] and b[B] can be expressed by matrix after normalization:
[0000]
F=X[X]+Y[Y]+Z[Z]=m{x[X]+y[Y]+z[Z]},
[0013] wherein m=X+Y+Z, and x=(X/m), y=(Y/m) and z=(Z/m). Every light-emitting wavelength corresponds to specific r, g and b values. By defining sum of r values in VIS region as X, sum of g values as Y, and sum of b values as Z, then chromaticity of light emitted from phosphor powder can be expressed by x, y coordinates system, which is named C.I.E. 1931 Standard Colorimetric System (C.I.E. Chromaticity Coordinates). As a spectrum is measured, contribution from lights of each wavelength are calculated, then exact position on chromaticity coordinates is pointed, and color of light emitted from phosphor powder is thus defined.
[0014] However, in the application of using blue light LED and yellow light phosphor to fabricate white light LED, the currently available yellow light phosphors are lack of contribution in red spectrum in color rendering and have drawbacks such as un-uniform light color and low light-emitting efficiency. In this connection, if a phosphor with improved color rendering index, high stability and lower cost can be provided and applied in the phosphor layer of white light LED, the color temperature of white light LED can be adjusted and color rendering of LED can be improved and, eventually, it can used to replace commercially available fluorescence converting materials for LED fabrication nowadays.
SUMMARY OF THE INVENTION
[0015] The present invention disclosed a yellow light phosphor with low fabrication cost, stable material and novel chemical compositions, which can be excited by blue light emitting LED or laser diode to emit yellow light and to mix with un-absorbed blue light to generate white light. The present invention also provides white light light-emitting device with high color rendering.
[0016] The present invention provides a series of phosphor with novel chemical composition, which is a Ce 3+ -doped germinate material which is completely different from that of YAG:Ce or silicate-based phosphors, expressed by the following general formula:
[0000] A m (B 1-x Ce x ) n Ge y O z
[0017] wherein A is at least one element select from Mg and Zn; B is at least one element select from the group consist of La, Y, Gd; each of m, n, y, z is the number larger than 0, providing that 2m+3n+4y=2z; x is in the range of 0<x<1, preferably 0.005≦x≦0.01, more preferably 0.01≦x≦0.10, most preferable 0.03≦x≦0.05. More specifically, said phosphor material can be expressed by the general formula Mg 3 (Y 1-x Ce x ) 2 Ge 3 O 12 , wherein x is in the range of 0.0001≦x≦0.8, preferably 0.01≦x≦0.05, more preferably x=0.03.
[0018] The phosphor can be excited by a primary radiation emitted by a light-emitting element thus emitting a secondary radiation, wherein the wavelength of the primary radiation emitted by the light-emitting element is in the range 450 nm˜500 nm, and the wavelength of the secondary radiation emitted by the excited phosphor is longer than the wavelength of the primary radiation emitted by the light-emitting element.
[0019] Specifically, the wavelength of the primary radiation emitted by said light-emitting element is preferably in the range 460 nm˜480 nm, thus the wavelength of the secondary radiation emitted by the excited phosphor is in the range 500 nm˜700 nm, with the CIE Chromaticity Coordinates (x,y) is in the range 0.40≦x≦0.60, 0.40≦y≦0.60, which is yellow in color.
[0020] Further, the wavelength of the primary radiation emitted by said light-emitting element is more preferably in the range 460 nm˜470 nm, thus the wavelength of the secondary radiation emitted by the excited phosphor is in the range 550 nm˜570 nm, with CIE Chromaticity Coordinates (x,y) is in the range 0.45≦x≦0.55, 0.45≦y≦0.55, which is yellow in color.
[0021] The present invention also provides a fabrication method of the above phosphor, comprising: stoichiometrically weighed materials (A) at least one oxide select from the group consisting of MgO and ZnO, (B) at least one oxide select from the group consisting of Y 2 O 3 , La 2 O 3 and Gd 2 O 3 , (C) CeO 2 , and (D) GeO 2 ; grounding the weighed material and mixing them well; transferring the obtained mixture into an alumina boat crucible, and carrying out the solid-state synthesis at 1200˜1400° C. with a reaction time of 4˜10 hours.
[0022] Furthermore, the present invention provides a light-emitting device, comprising a light-emitting element and a phosphor, wherein the light-emitting element emits a primary radiation with wavelength in the range 450 nm˜480 nm, and the phosphor can be excited by absorbing part of primary radiation emitted by the light-emitting element and thus emitting a secondary radiation with wavelength different from that of the primary radiation, and the phosphor can select from the above mentioned phosphor.
[0023] The light-emitting element can be a semiconductor light-emitting source, a light-emitting diode or an organic light-emitting device, and the phosphor is coated on the top or surface of the light-emitting element. The wavelength of the secondary radiation emitted by the excited phosphor is longer than that of the primary radiation emitted by the light-emitting element. Further, the light-emitting device is formed by packaging the phosphor on the top or surface of the light-emitting element, after the phosphor is excited by the primary radiation emitted by the light-emitting element, the secondary radiation emitted by the excited phosphor can combined with the un-absorbed primary radiation to generate a white light.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 shows the X-ray diffractograms of Example 1.
[0025] FIG. 2 shows the X-ray diffractograms of the samples synthesized at various synthetic temperatures obtained in a preferred embodiment.
[0026] FIG. 3 shows the fluorescence emission and excitation spectra for the said phosphors with different Ce 3+ doping concentrations in Example 1.
[0027] FIG. 4 shows the relationship between the luminous intensity and luminance for the said phosphors with different Ce 3+ doping concentrations in a preferred embodiment.
[0028] FIG. 5 shows the reflection spectrum obtained in a preferred embodiment.
[0029] FIG. 6 shows the comparison of the fluorescence emission and excitation spectra between the preferred embodiment and commercial product.
[0030] FIG. 7 shows the CIE chromaticity coordinates obtained in a preferred embodiment.
[0031] FIG. 8 shows X-ray diffractograms of Example 2.
[0032] FIG. 9 shows the fluorescence emission and excitation spectra for the said phosphors with different Ce 3+ doping concentrations in Example 2.
[0033] FIG. 10 shows the relationship between the luminous intensity and the doping concentration of Ce 3+ in Example 2.
[0034] FIG. 11 shows X-ray diffractograms of Example 3.
[0035] FIG. 12 shows the fluorescence emission and excitation spectra for the said phosphors with different Ce 3+ doping concentrations in Example 3.
[0036] FIG. 13 shows X-ray diffractograms of Example 4.
[0037] FIG. 14 shows the fluorescence emission and excitation spectra for the said phosphors with different Zn 2+ doping concentrations in Example 4.
[0038] FIG. 15 shows the relationship between the luminance and the doping concentration of Zn 2+ in Example 1˜3.
[0039] FIG. 16 shows the relationship between the luminous intensity and the doping concentration of Ce 3+ in Example 1˜3.
[0040] FIG. 17 shows the relationship between the luminance and the doping concentration of Ce 3+ in Example 1˜3.
DETAILED DESCRIPTION OF THE INVENTION
[0041] The present invention describes in detail by referring to embodiments and drawings, in order to facilitate a better understanding of the present components and characteristics thereof for those skilled in this field, hence the objects, technical contents, features, and effectiveness of the present invention are more easily to be known.
Example 1
Mg 3 (Y 1-x Ce x ) 2 Ge 3 O 12
[0042] According to the chemical composition of Mg 3 (Y 1-x Ce x ) 2 Ge 3 O 12 , stoichiometric amount of MgO, Y 2 O 3 , GeO 2 and CeO 2 are weighed, wherein x is 0.005, 0.01, 0.03, 0.05 and 0.1. The weighed materials were ground thoroughly and mixed well, the obtained mixture was transferred into alumina boat crucible and loaded into a high temperature furnace to carry out solid-state sintering at 1200˜1400° C. with a reaction time of 4˜10 hours.
[0043] The results obtained by using X-ray diffractometer (Bruker AXS D8 advance type) to confirm the purity of crystalline phase and structural analysis are shown in FIG. 1 . From the X-ray diffractograms, we have observed that no impurity was found, also proving that the phosphor synthesized by present invention is a pure substance.
[0044] Also at various synthetic temperatures, the X-ray diffraction profile of a preferred phosphor Mg 3 (Y 0.97 Ce 0.03 ) 2 Ge 3 O 12 of the present invention has been measured and the results are shown in FIG. 2 . From the X-ray diffractogram it is seen that no impurity is present, also proving that the phosphor synthesized by present invention is a pure substance.
[0045] Since the light emitting wavelength of blue light LED is between 450 nm˜500 nm, therefore a xenon lamp with the same wavelength can be used as a simulated excitation source to test the luminous properties of phosphors of the present invention.
[0046] The fluorescence emission and excitation spectra of phosphor Mg 3 (Y 1-x Ce x ) 2 Ge 3 O 12 were measured by using the Spex Fluorolog-3 spectrofluorometer (Jobin-Yvon Spex S.A., USA) equipped with 450 W xenon lamp and the results are shown in FIG. 3 . There is a broad band absorption in blue and near UV region, the wavelength of the emission band is centered at about 562 nm and the band width is about 250 nm. The emission band is attributed to the transitions 5d→ 2 F 5/2 and 5d→ 2 F 7/2 of Ce 3+ , proved that the phosphor of the present invention can be excited by blue light, and the un-absorbed blue light in combination with the yellow light emitted by the phosphor itself can combine to produce white light.
[0047] Using color analyzer (DT-100 Color Analyzer, manufactured by LAIKO Co. Ltd., Japan) in combination with the fluorescence spectrometer, we have measured the luminance and chromaticity of phosphor.
[0048] FIG. 4 shown the relationship between the luminous intensity and luminance of phosphor Mg 3 (Y 1-x Ce x 3+ ) 2 Ge 3 O 12 with various Ce 3+ doping concentrations, the left arrow (circle solid line) represents luminous intensity and right arrow (square dashed line) represents the luminance. These results indicate that when the phosphor is doped with 3 mole % of Ce 3+ , it exhibits the highest luminous intensity and luminance.
[0049] A reflection spectrum was measured by using a U-3010 UV-Vis Spectrometer (Hitachi Co., Japan) with wavelength ranging from 190 nm to 1000 nm to investigate the absorption region of the preferred phosphor Mg 3 (Y 0.97 Ce 0.03 ) 2 Ge 3 O 12 of the present invention and the host Mg 3 Y 2 Ge 3 O 12 without Ce 3+ ion doping and the results are summarized in FIG. 5 . When Ce 3+ ions are not doped in the host Mg 3 Y 2 Ge 3 O 12 , absorption only appeared in the region between 200 nm˜300 nm, but when the Ce 3+ ions are doped, a broad absorption band in blue light region between 400 nm˜500 nm can be observed. Therefore, this observation indicates that the phosphor of the present invention can absorb blue light effectively.
[0050] FIG. 6 shows the photoluminescence and excitation spectra of the preferred embodiment Mg 3 (Y 0.97 Ce 0.03 ) 2 Ge 3 O 12 and commercially available YAG:Ce (Nichia Co., Japan). As a result of comparison, the phosphor of the present invention exhibits higher excitation efficiency than that of the YAG:Ce commodity.
[0051] FIG. 7 shows the CIE chromaticity diagram of Mg 3 (Y 0.97 Ce 0.03 ) 2 Ge 3 O 12 measured under the excitation of light with wavelength of 467 nm, the experimental chromaticity coordinate is (0.506,0.465). As compared to the YAG:Ce commodity, the phosphor of the present invention is much closer to yellow light, and the color saturation is higher.
[0052] According to the above methods, phosphors doped with different concentrations of Ce 3+ are measured, the results are shown in Table 1.
Example 2
Mg 3 (Y 0.9-x Ce x La 0.1 ) 2 Ge 3 O 12
[0053] Besides adding 10 mole % of La 2 O 3 , the processing conditions are similar as those described in example 1. The results of measurements are shown in Table 1.
[0054] FIG. 8 shows the X-ray diffractograms of Mg 3 (Y 0.9-x Ce x La 0.1 ) 2 Ge 3 O 12 phosphor. From the X-ray diffractogram, we have observed that no impurity is present, also proving that the phosphor synthesized by present invention is a pure substance.
[0055] FIG. 9 shows emission and excitation spectra of Mg 3 (Y 0.9-x Ce x La 0.1 ) 2 Ge 3 O 12 phosphors.
[0056] FIG. 10 shows the luminous intensity of phosphor Mg 3 (Y 0.9-x Ce x La 0.1 ) 2 Ge 3 O 12 with various Ce 3+ doping concentrations.
Example 3
Mg 3 (Y 0.9-x Ce x Gd 0.1 ) 2 Ge 3 O 12
[0057] Besides adding 10 mole % of Gd 2 O 3 , the processing conditions are similar as those described in example 1. The results of measurements are shown in Table 1.
[0058] FIG. 11 shows the X-ray diffractograms of Mg 3 (Y 0.9-x Ce x Gd 0.1 ) 2 Ge 3 O 12 phosphors. From the X-ray diffractogram, we have observed that no impurity is present, also proving that the phosphor synthesized by present invention is a pure substance.
[0059] FIG. 12 shows emission and excitation spectra of Mg 3 (Y 0.9-x Ce x Gd 0.1 ) 2 Ge 3 O 12 phosphor.
Example 4
(Mg 1-x Zn x ) 3 (Y 0.99 Ce 0.01 )Ge 3 O 12
[0060] According to the chemical composition of (Mg 1-x Zn x ) 3 (Y 0.99 Ce 0.01 )Ge 3 O 12 , stoichiometric amounts of MgO, ZnO, Y 2 O 3 , GeO 2 and CeO 2 are weighed, wherein x is 0.01, 0.03, and 0.05. Others are prepared according to the processing conditions described in example 1. The results are shown in Table 1.
[0061] FIG. 13 shows the X-ray diffractogram of (Mg 1-x Zn x ) 3 (Y 0.99 Ce 0.01 )Ge 3 O 12 phosphors. From the X-ray diffractogram, no impurity is found, indicating that the phosphor synthesized by present invention is a pure substance.
[0062] FIG. 14 shows emission and excitation spectra of (Mg 1-x Zn x ) 3 (Y 0.99 Ce 0.01 )Ge 3 O 12 phosphors.
[0063] FIG. 15 shows the luminance of a phosphor (Mg 1-x Zn x ) 3 (Y 0.99 Ce 0.01 )Ge 3 O 12 with various Zn 2+ doping concentration.
[0000]
TABLE 1
Excitation
Emission
CIE
relative
Example
wavelength
wavelength
coordinates
luminance
No.
Phosphor
x
(nm)
(nm)
(x, y)
(cd/m2)
1
Mg 3 (Y 1-x Ce x ) 2 Ge 3 O 12
0.005
467
560
(0.497, 0.465)
26.9
0.01
467
561
(0.498, 0.465)
34.8
0.03
467
559
(0.506, 0.465)
43.9
0.05
467
560
(0.508, 0.465)
40.8
0.1
467
561
(0.509, 0.465)
34
2
Mg 3 (Y 0.9-x Ce x La 0.1 ) 2 Ge 3 O 12
0.005
467
564
(0.513, 0.458)
32.8
0.01
467
564
(0.516, 0.458)
35.5
0.03
467
565
(0.521, 0.458)
42
0.05
467
568
(0.523, 0.458)
39.3
0.1
467
569
(0.530, 0.446)
28.2
3
Mg 3 (Y 0.9-x Ce x Gd 0.1 ) 2 Ge 3 O 12
0.005
467
562
(0.502, 0.458)
25.9
0.01
467
563
(0.502, 0.458)
29.2
0.03
467
568
(0.510, 0.463)
34.9
0.05
467
568
(0.514, 0.462)
39.4
0.1
467
569
(0.517, 0.458)
33.2
4
(Mg 1-x Zn x ) 3 (Y 0.99 Ce 0.01 )Ge 3 O 12
0.01
467
558
(0.495, 0.468)
43
0.03
467
555
(0.495, 0.467)
42.7
0.05
467
555
(0.499, 0.465)
41.6
[0064] As shown by FIGS. 16 and 17 , the Ce 3+ doping novel phosphor of the present invention shows high luminous intensity and luminance. The Ce 3+ ion doping concentration is preferably 0.5˜10% by mole, more preferably 1˜10% by mole, and most preferably 3˜5% by mole.
[0065] Further, the present phosphor can be used in LED, particularly white LED. In order to achieve better color effectiveness, it can be used alone or it can be used in combination with other red or blue light phosphors for other chromogenic purposes.
[0066] A preferred embodiment of the present invention provides light-emitting device, comprising a light-emitting element which can be a semiconductor light-emitting source, i.e., LED chip, and a conductive lead connected to the LED chip. The conductive lead is supported by sheet-like electrodes which supply current to the LED to enable radiation emitting. The light-emitting device can comprise any blue light semiconductor as lighting source, the radiation emitted by which directly irradiates on the phosphor composition of the present invention to generate white light.
[0067] In a preferred embodiment of the present invention, LED can be doped with various impurities. Said LED can comprise various suitable III-V, II-VI or IV-IV semiconductor layers, and the wavelength of the radiation emitted by which preferably is 250˜500 nm. Said LED comprises at least a semiconductor layer composed of GaN, ZnSe or SiC. For example, a LED composed of a nitride represented by the general formula In i Ga j Al k N (wherein 0≦i; 0≦j; 0≦k, and i+j+k=1) emits light with wavelength in the range 250 nm˜500 nm. Use of the above LED semiconductor has been known and is useful as excitation source in the present invention. However, the excitation lighting source for the present invention is not limited to the above LED, and any kind of semiconductor with light emitting capability, including semiconductor laser lighting source, are applicable.
[0068] Generally, the mentioned LEDs are directed to inorganic ones, however, those skilled in this field can easily understand that the mentioned LEDs are replaceable by organic ones or any other radiation sources. The present phosphor is coated on said LEDs used as excitation source to generate white light. Therefore, as can be seen from the above preferred embodiments, the present phosphor is capable of emitting yellow light with excellent luminance and color saturation, in comparison to those of commercial available YAG:Ce.
[0069] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and illustrative example shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general invention concept as defined by the appended claims and their equivalents.
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The present invention provides a novel phosphor represent by the following general formula:
A m (B 1-x Ce x ) n Ge y O z wherein A is at least one element selected from Mg and Zn; B is at least one element selected from the group consisting of La, Y and Gd; each of m, n, y and z is the number larger than 0 provided that 2 m +3 n +4 y =2 z ; and x is in the range 0.0001≦x≦0.8.
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TECHNICAL FIELD
[0001] The present invention relates to a method for producing fluorine-containing alkane.
BACKGROUND ART
[0002] Fluorine-containing alkane is useful for various kinds of applications, such as a reaction intermediate, foaming agent, coolant and the like.
[0003] As an example of a known method for producing fluorine-containing alkane, fluorine-containing olefin is reduced at room temperature using a palladium catalyst (see Non Patent Literature 1 below). Another method is also reported wherein CF 3 CF═CF 2 is reduced by hydrogen through a liquid phase reaction using BaSO 4 , a palladium catalyst supported on activated carbon, etc. (see Patent Literature 1 below).
[0004] However, in order to achieve a high selectivity of the target fluorine-containing alkane in these methods, the reaction rate needs to be slowed down; therefore, it is impossible to produce fluorine-containing olefin efficiently on an industrial scale.
[0005] Patent Literature 2 below discloses a method for producing fluorinated propane, through a multistep reaction, using fluorine-containing olefin as a starting material by reacting it with hydrogen or a like reducing agent in the presence of a catalyst. A preferable embodiment of this method is such that the reaction is suppressed using only a small amount of catalyst at the initial stage of reaction and then the amount of the catalyst is gradually increased. It is said that this method achieves a high conversion rate and selectivity at a relatively high production speed.
[0006] However, in the method disclosed in Patent Literature 2, the amount of heat generated by the reaction becomes unduly large; therefore, removal of heat is necessary by a method, for example, that employs a reactor equipped with a jacket and removes heat using a refrigerant, or other means for cooling the reaction mixture, such as the use of an internal cooling coil, introduction of a diluent into the reaction mixture for additional cooling, and the like. This makes the structure of the reaction apparatus complicated. Furthermore, in order to avoid an excessive temperature rise, control of the introduction speed of the starting material compound becomes necessary, and this entails a reduction in the production efficiency of the target fluorine-containing alkane.
CITATION LIST
Patent Literature
[0000]
PTL 1: Japanese Unexamined Patent Publication No. 1996-165256
PTL 2: Japanese Unexamined Patent Publication No. 2008-162999
Non Patent Literature
[0000]
NPL 1: Izvest. Akad. Nauk S. S. S. R., Otdel. Khim. Nauk. (19060), 1412
SUMMARY OF INVENTION
Technical Problem
[0010] The present invention has been accomplished in view of the foregoing problems found in the prior art. A main object of the present invention is to provide a method for producing fluorine-containing alkane with high production efficiency in the method of using chlorine-containing fluoroalkane or fluorine-containing alkene as a starting material, and reacting it with hydrogen gas.
Solution to Problem
[0011] The present inventors conducted extensive research to achieve the above-described object. As a result, they found the following. When chlorine-containing fluoroalkane or fluorine-containing alkene is reacted with hydrogen gas to conduct a hydrogen addition reaction or a reduction reaction by hydrogen, the temperature rise during the reaction can be suppressed without reducing the conversion rate or selectivity by using a plurality of catalysts having different catalytic activities in such a manner that the first stage of the reaction is conducted under the presence of the catalyst having the lowest activity followed by multistep reactions using catalysts having sequentially higher catalytic activity in each step. As a result, the speed of introducing the starting materials can be increased and the production efficiency can be greatly improved. The present invention has been accomplished on the basis of this finding.
[0012] Specifically, the present invention provides the following method for producing fluorine-containing alkane.
[0013] Item 1. A method for producing fluorine-containing alkane comprising reacting at least one fluorine-containing compound selected from the group consisting of chlorine-containing fluoroalkanes and fluorine-containing alkenes with hydrogen gas in the presence of a catalyst,
[0014] wherein two or more types of catalysts having different catalytic activities are used, and said at least one fluorine-containing compound and hydrogen gas, which are starting materials, are sequentially contacted with the catalysts in the order of lower to higher catalytic activity.
[0015] Item 2. The method according to Item 1, which uses a reaction apparatus in which two or more reaction tubes charged with catalysts having different catalytic activities are connected in series.
[0016] Item 3. The method according to Item 1 or 2, wherein each catalyst is one containing a noble metal component supported on a carrier.
[0017] Item 4. The method according to any one of Items 1 to 3, wherein the noble metal is at least one member selected from the group consisting of Pd, Pt, Ru and Rh, and the carrier is at least one member selected from the group consisting of activated carbon, porous alumina silicate, aluminum oxide, silicon oxide, titanium oxide, zirconium oxide, zinc oxide and aluminum fluoride.
[0018] Item 5. The method according to Item 3 or 4, wherein the catalysts having different catalytic activities are those containing identical noble metal components supported on identical carriers with different supporting amounts, and the fluorine-containing compound and hydrogen gas, which are starting materials, are sequentially contacted with a catalyst containing a smaller amount of noble metal component to a catalyst containing a larger amount of noble metal component.
[0019] Item 6. The method according to any one of Items 1 to 5, wherein the chlorine-containing fluoroalkane is at least one member selected from the group consisting of:
[0020] a compound represented by Formula (1):
[0000] R 1 —CCl 2-(n+m) H n F m —CCl 2-(o+p) H o F p —CCl 3-(q+r) H q F r
[0000] wherein R 1 is a alkyl group, a hydrogen atom, a fluorine atom, or a C 1-4 fluoroalkyl group that may contain a chlorine atom(s); n, m, o and p are each individually an integer of 0 to 2; q and r are each individually an integer of 0 to 3, with the proviso that n+m≦2, o+p≦2, q+r≦3, and n+m+o+p+q+r≦6; provided that when R 1 is neither a fluoroalkyl group nor a fluorine atom, the sum of m, p and r is 1 or greater; and
[0021] a compound represented by Formula (2):
[0000] CCl 3-(a+b) H a F b —CCl 3-(c+d) H c F d
[0000] wherein a, b, c and d are each individually an integer of 0 to 3, a+b≦3, c+d≦3, b+d≧1, and a+b+c+d≦5; and
[0022] the fluorine-containing alkene is a fluorine-containing alkene represented by Formula (3):
[0000] R 3 Y 1 C═CY 2 R 4
[0000] wherein R 3 and R 4 may be the same or different and each represents a C 1-4 alkyl group, a hydrogen atom, a fluorine atom, a chlorine atom, or a C 1-4 fluoroalkyl group that may contain a chlorine atom(s); Y 1 and Y 2 may be the same or different and each represents a hydrogen atom, a fluorine atom or a chlorine atom; with the proviso that when R 3 and R 4 are neither a fluoroalkyl group nor a fluorine atom, at least one of Y 1 and Y 2 is a fluorine atom.
[0023] Item 7. The method according to any one of Items 1 to 6, wherein the chlorine-containing fluoroalkane is a compound represented by Formula (1-1): R 2 —CCl 2-(j+k) H j F k —CCl 3-(l+t) H 1 F t wherein R 2 is a C 1-3 alkyl group, a hydrogen atom, a fluorine atom, or a C 1-3 fluoroalkyl group that may contain a chlorine atom(s); j and k are each individually an integer of 0 to 2; l and t are each individually an integer of 0 to 3; j+k≦2; l+t≦3; and j+k+l+t≦4; with the proviso that when R 2 is neither a fluoroalkyl group nor a fluorine atom, the sum of k and t is 1 or greater; and
[0024] the fluorine-containing alkene is a compound represented by Formula (3-1): R 5 CY 3 ═CY 4 Y 5
[0025] wherein R 5 is a hydrogen atom, a C 1-3 alkyl group, or a C 1-3 fluoroalkyl group; Y 3 , Y 4 and Y 5 may be the same or different and each represents a hydrogen atom or a fluorine atom; with the proviso that when R 5 is not a fluoroalkyl group, at least one of Y 3 and Y 4 is a fluorine atom.
[0026] The production method of the present invention is explained in detail below.
Starting Material Compound
[0027] In the present invention, at least one fluorine-containing compound selected from the group consisting of chlorine-containing fluoroalkanes and fluorine-containing alkenes is used as a starting material.
[0028] The chlorine-containing fluoroalkanes are not particularly limited and examples thereof include a compound represented by Formula (1):
[0000] R 1 —CCl 2-(n+m) H n F m —CCl 2-(o+p) H o F p —CCl 3-(q+r) H q F r
[0000] wherein R 1 is a C 1-4 alkyl group, a hydrogen atom, a fluorine atom, or a C 1-4 fluoroalkyl group that may contain a chlorine atom(s); n, m, o and p are each individually an integer of 0 to 2; q and r are each individually an integer of 0 to 3, with the proviso that n+m≦2, o+p≦2, q+r≦3, and n+m+o+p+q+r≦6; provided that when R 1 is neither a fluoroalkyl group nor a fluorine atom, the sum of m, p and r is 1 or greater; and
[0029] a compound represented by Formula (2):
[0000] CCl 3-(a+b) H a F b —CCl 3-(c+d) H c F d
[0000] wherein a, b, c and d are each individually an integer of 0 to 3, a+b≦3, c+d≦3, b+d≧1, and a+b+c+d≦5.
[0030] Among the groups represented by R 1 in Formula (1), fluoroalkyl groups that may contain a chlorine atom(s) include linear or branched fluoroalkyl groups having about 1 to 4 carbon atoms that may contain up to 8 chlorine atoms. Specific examples of the fluoroalkyl groups include a perfluoroalkyl group and a fluoroalkyl group that contains 1 to 8 fluorine atoms. Among the groups represented by R 1 , examples of alkyl groups include a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, a sec-butyl group, a tert-butyl group and like linear or branched alkyl groups.
[0031] Among the chlorine-containing fluoroalkanes represented by the above formula, a preferable compound is as shown below.
[0000] R 2 —CCl 2-(j+k) H j F k —CCl 3-(l+t) H l F t Formula (1-1)
[0000] wherein R 2 is a C 1-3 alkyl group, a hydrogen atom, a fluorine atom, or a C 1-3 fluoroalkyl group that may contain a chlorine atom(s); j and k are each individually an integer of 0 to 2; 1 and t are individually an integer of 0 to 3; j+k≦2; 1+t≦3; and j+k+l+t≦4; with the proviso that when R 2 is neither a fluoroalkyl group nor a fluorine atom, the sum of k and t is 1 or greater.
[0032] Examples of C 1-3 alkyl groups represented by R 2 in Formula (1-1) include a methyl group, an ethyl group, a propyl group, an isopropyl group and the like. Examples of C 1-3 fluoroalkyl groups that may contain a chlorine atom(s) include the aforementioned alkyl groups having 1 to 7 fluorine atoms and 0 to 2 chlorine atoms substituted thereon.
[0033] Examples of chlorine-containing fluoroalkanes represented by Formula (1-1) include CH 3 CF 2 CH 2 Cl, CH 3 CH 2 CF 2 CH 2 Cl, CF 3 CH 2 Cl, CF 3 CHClCH 2 F, CF 2 ClCH 2 CFClCF 3 , CH 3 CFClCH 3 , CF 3 CH 2 CHClCCl 2 F, CH 3 CHFCFHCl, CF 3 CHClCHFCF 2 Cl, CClHFCH 2 F and the like.
[0034] An example of a fluorine-containing alkene includes a compound represented by the following formula:
[0000] R 3 Y 1 C═CY 2 R 4 Formula (3)
[0000] wherein R 3 and R 4 may be the same or different and each represents a C 1-4 alkyl group, a hydrogen atom, a fluorine atom, a chlorine atom, or a C 1-4 fluoroalkyl group that may contain a chlorine atom(s); be the same or different and each Y 1 and Y 2 may represents a hydrogen atom, a fluorine atom, or a chlorine atom; with the proviso that when R 3 and R 4 are neither a fluoroalkyl group nor a fluorine atom, at least one of Y 1 and Y 2 is a fluorine atom.
[0035] In Formula (3), examples of fluoroalkyl groups and alkyl groups represented by R 3 and R 4 include the same groups as those represented by R 1 . Among the compounds represented by Formula (3), a compound shown below is preferable.
[0000] R 5 CY 3 ═CY 4 Y 5 Formula (3-1)
[0000] wherein R 5 is a hydrogen atom, a C 1-3 alkyl group, or a C 1-3 fluoroalkyl group; Y 3 , Y 4 and Y 5 may be the same or different and each represents a hydrogen atom or a fluorine atom; with the proviso that when R 5 is not a fluoroalkyl group, at least one of Y 3 and Y 4 is a fluorine atom. Examples of alkyl groups and fluoroalkyl groups represented by R 5 in Formula (3-1) are the same as those represented by R 2 .
[0036] Specific examples of fluorine-containing alkenes represented by Formula (3-1) include the compounds represented by chemical formulae CF 3 CF═CF 2 , CF 3 CH═CFH, CH 3 CF 2 CF═CH 2 and the like.
Catalyst
[0037] In the present invention, the catalyst is not particularly limited and any catalysts can be used as long as they are active in an addition reaction of hydrogen gas to an alkene compound or a hydrogen substitution reaction of a chlorine-containing compound with hydrogen gas. It is particularly preferable to use a catalyst comprising a noble metal component supported on a carrier.
[0038] Examples of the noble metals usable as catalytic components include Pd, Pt, Ru and Rh. Examples of carriers include activated carbon, porous alumina silicate represented by zeolite, aluminum oxide, silicon oxide, titanium oxide, zirconium oxide, zinc oxide, aluminum fluoride, a mixture of one or more of these carrier components, a composite of one or more of these carrier components, which are structurally combined, and the like.
[0039] The amount of noble metal supported on the carrier is not limited, and, for example, preferably the amount of the noble metal supported is about 0.001 to 50% by weight, more preferably about 0.001 to 20% by weight, and particularly preferably 0.01 to 10% by weight, based on the total weight of the catalyst supporting noble metal.
[0040] The method for preparing the catalyst is not particularly limited. An example of the method for preparing a catalyst comprising a noble metal component supported on a carrier is as below. That is, activated carbon or a like carrier is immersed in a solution containing a metal salt to impregnate the carrier with the solution, if necessary, followed by neutralization, sintering or a like operation, thereby obtaining the catalyst comprising a noble metal component supported on a carrier. The amount of the noble metal supported can be suitably controlled by adjusting the impregnation method, such as the concentration of the metal salt in the metal salt solution, the impregnation time, and the like.
Method for Producing Fluorine-Containing Alkane
[0041] The method of the present invention is to produce fluorine-containing alkane using at least one fluorine-containing compound selected from the group consisting of the aforementioned chlorine-containing fluoroalkanes and fluorine-containing alkenes as starting materials and reacting the starting materials with hydrogen gas in the presence of a catalyst.
[0042] Among the chlorine-containing fluoroalkanes, when a chlorine-containing fluoroalkane represented by Formula (1): R 1 —CCl 2-(n+m) H n F m —CCl 2-(o+p) H o F p —CCl 3-(q+r) H q F r (wherein R 1 , n, m, o, p, q and r are the same as above) is used as a starting material, a fluorine-containing alkane represented by Formula: R 1 —CH 2-m F m —CH 2-p F p —CH 3-r F r (wherein R 1 , m, p and r are the same as above) can be produced by a substitution reaction of hydrogen for a chlorine atom(s). When a chlorine-containing fluoroalkane represented by Formula (2): CCl 3-(a+b) H a F b —CCl 3-(c+d) H c F d (wherein a, b, c and d are the same as above) is used as a starting material, a fluorine-containing alkane represented by Formula: CH 3-b F b —CH 3-d F d (wherein b and d are the same as above) can also be produced by the substitution reaction of hydrogen for a chlorine atom(s). For example, when a compound represented by Formula (1-1): R 2 —CCl 2-(j+k) H j F k —CCl 3-(l+t) H l F t (wherein R 2 , j, k, 1 and t are the same as above) is used as a starting material, a fluorine-containing alkane represented by Formula: R 2 —CH 2-k F k —CH 3-t F t (wherein R 2 , k and t are the same as above) can be produced by a hydrogen substitution reaction.
[0043] Among fluorine-containing alkenes, when a fluorine-containing alkene represented by Formula (3): R 3 Y 1 C═CY 2 R 4 (wherein R 3 , R 4 , Y 1 and Y 2 are the same as above) is used as a starting material, a fluorine-containing alkane represented by Formula: R 3 Y 1 CH—CHY 2 R 4 (wherein R 3 , R 4 , Y 1 and Y 2 are the same as above) can be produced by an addition reaction of hydrogen gas. For example, when a fluorine-containing alkene represented by Formula (3-1): R 5 CY 3 ═CY 4 Y 5 (wherein R 5 , Y 3 , Y 4 and Y 5 are the same as above) is used as a starting material, a fluorine-containing alkane represented by Formula: R 5 CHY 3 —CHY 4 Y 5 (wherein, R 5 , Y 3 , Y 4 and Y 5 are the same as above) can be produced.
[0044] In the method for producing fluorine-containing alkane of the present invention, the use of a plurality of catalysts having different catalytic activities is required. In this method, it is necessary to conduct a multistep reaction by contacting hydrogen gas and at least one fluorine-containing compound selected from the group consisting of chlorine-containing fluoroalkanes and fluorine-containing alkenes with a catalyst having the lowest activity in the first stage of the reaction, followed by contact thereof with a catalyst(s) in the order of lower to higher catalytic activity. By employing a multistep reaction method as described above, wherein a plurality of catalysts having different catalytic activities are used and the starting materials are contacted with a catalyst in the order of lower to higher catalytic activity, the temperature rise during the reaction can be suppressed without deteriorating the conversion rate, selectivity, and the like. This makes it possible to increase the amount of starting material supplied and to greatly improve the production efficiency of the target fluorine-containing alkane.
[0045] The catalytic activity of the catalyst varies depending on the types of catalyst metal and carrier used, and the amount of the catalyst metal supported. When identical catalyst metals and carriers are used, although there is an upper limit, there is a tendency for the catalytic activity to rise as the amount of the catalyst metal supported increases. Therefore, when catalysts comprising identical noble metal components are supported on identical carriers in different amounts, the fluorine-containing compound and hydrogen gas, which are starting materials, should be sequentially contacted with a catalyst comprising a smaller amount of noble metal component supported followed by a catalyst comprising a larger amount of noble metal component supported.
[0046] A catalyst can be made into one that has a lower catalytic activity by mixing it with an inactive substance to dilute it. An example of such an inactive substance is activated carbon, but is not limited thereto. When catalysts comprising different types of catalyst metal and/or carrier are used, by performing a preliminary experiment using the same starting material as that actually used, the intensity of the catalytic activity can be easily determined.
[0047] When a plurality of catalysts having different catalytic activities are used, the proportion of catalysts is not particularly limited and can be suitably selected, depending on the level of activity of the catalyst used, so as to suppress the heating during reaction, to prevent an excessive temperature rise, and to maintain the desirable conversion rate of the starting material and selectivity of the target product, as long as it meets the requirement that the fluorine-containing compound and hydrogen gas, which are starting materials, are made to contact with a catalyst having a smaller catalytic activity sequentially followed by that having a higher catalytic activity. For example, the proportion of the catalyst used may be such that, relative to 100 parts by weight of the catalyst having the highest activity, the total amount of other catalysts is about 50 to 400 parts by weight, and preferably about 70 to 300 parts by weight.
[0048] The structure of the reaction apparatus is not particularly limited. As an example of a usable reaction apparatus, two or more gas phase reactors are connected in series, wherein a catalyst having the lowest catalytic activity is placed in the first reactor of the reaction apparatus, and catalysts having sequentially higher catalytic activities are placed in the second and following reactors sequentially. Furthermore, it is also possible to use a single gas phase reactor, rather than a plurality of reactors, wherein a catalyst having the lowest catalytic activity is placed near the entrance and a catalyst having the highest catalytic activity is placed near the exit, so that the catalytic activities of the catalysts are sequentially arranged from low to high in the direction along which the starting material gas flows.
[0049] An example of each reactor usable in the reaction apparatus described above includes a tubular flow reactor. Examples of flow reactors include adiabatic reactors, multi-tubular reactors that are cooled using a heat transmittance medium. Preferably, the reactor is made of a material that is resistant to the corrosive action of hydrogen fluoride, such as Hastelloy, Inconel, Monel, or the like.
[0050] Because the production method of the present invention allows heating to be suppressed during the reaction, the target fluorine-containing alkane can be produced at a high production efficiency without actively performing cooling. Fluorine-containing alkane can be efficiently produced by, for example, a reaction apparatus with a simple structure such as only having cooling fins, without having to introduce a diluent into the reaction mixture as a coolant or use a complicated reaction apparatus provided with a jacket or an internal cooling coil.
[0051] The reaction temperature is not particularly limited but it must be set lower than the ignition point of hydrogen. The reaction temperature is generally about 50 to 400° C., preferably about 50 to 390° C., and more preferably about 50 to 380° C. The production method of the present invention can suppress heating during the reaction; therefore, compared to conventional methods, even in the case where the amount of starting material introduced is increased, the reaction temperature can be controlled within the above mentioned range. This allows the target fluorine-containing alkane to be produced at a high production efficiency.
[0052] The pressure during the reaction is not particularly limited and the reaction may be performed under reduced pressure, ordinary pressure, or the application of pressure. Usually, the reaction may be performed under a level of pressure that is close to atmospheric pressure (0.1 MPa).
[0053] The amount of hydrogen gas used is preferably about 1 to 10 mol, preferably about 1 to 8 mol, and more preferably about 1 to 5 mol per mole of the starting material, i.e., at least one fluorine-containing compound selected from the group consisting of chlorine-containing fluoroalkanes and fluorine-containing alkenes.
[0054] The reaction time is not particularly limited and, when a chlorine-containing fluoroalkane is used as the starting material, it is preferable that the reaction time be selected in such a manner that the contact time represented by W/Fo, i.e., the ratio of the total weight of the catalyst used in all stages of the reaction W (g) relative to the total flow rate Fo (the flow rate: cc/sec at 0° C. and 0.1 MPa) of the starting material gases (i.e., the total amount of the fluorine-containing compound and hydrogen gas) that are supplied to the reaction apparatus, is generally about 0.5 to 60 g·sec/cc, more preferably about 1 to 50 g·sec/cc, and still more preferably about 1 to 40 g·sec/cc. Furthermore, when fluorine-containing alkene is used as the starting material, the contact time represented by W/Fo is preferably about 0.5 to 30 g·sec/cc, more preferably about 0.5 to 20 g·sec/cc, and still more preferably about 0.5 to 15 g·sec/cc.
Advantageous Effects of Invention
[0055] In terms of the method for producing fluorine-containing alkane wherein chlorine-containing fluoroalkane or fluorine-containing alkene is used as a starting material and reacted with hydrogen gas, the present invention provides a method that can suppress the temperature rise during the reaction without decreasing the conversion rate and selectivity; therefore, it can significantly improve the production efficiency by increasing the introduction rate of the starting material.
DESCRIPTION OF EMBODIMENTS
[0056] The present invention is explained in further detail below with reference to the Examples.
Example 1
[0057] Using a reaction tube made of SUS having an inside diameter of 50 mm and a length of 128 cm, 530 g of a catalyst containing Pd supported on activated carbon (the amount of Pd supported: 0.1% by weight (the total amount of the carrier and Pd is defined as 100% by weight) (0.1 wt % Pd/C catalyst) was placed in the area within the range of about 10 to 70 cm from the entrance of the reaction tube and 530 g of a catalyst containing Pd supported on activated carbon (the amount of Pd supported: 0.25% by weight) (0.25 wt % Pd/C catalyst) was placed in the area within the range of about 70 to 120 cm from the entrance. The catalysts were dried at 150° C. and reduced by flowing hydrogen at 200° C. beforehand.
[0058] After heating the reaction tube described above to about 260° C. using a heater, CF 3 CF 2 CH 2 Cl (HCHC-235cb) and hydrogen were supplied therein at a rate of 945 ml/min (the flow rate at 0° C. and 0.1 MPa, the same applies to the following) and 1,920 ml/min respectively.
[0059] The exit gas from the reactor was analyzed by gas chromatography, with the result that the conversion of CF 3 CF 2 CH 2 Cl (HCFC-235cb) was 94.5% and the selectivity of CF 3 CF 2 CH 3 (HFC-245cb) was 96.9%. The maximum temperature inside the reactor was 336° C.
[0060] This method obtained the target product, i.e., CF 3 CF 2 CH 3 (HFC-245cb), at a rate of 865 ml/min (0.82 ml/min/g-cat).
Comparative Example 1
[0061] 1,059 g of catalyst containing Pd supported on activated carbon (the amount of Pd: 0.25% by weight) (0.25 wt % Pd/C catalyst) was placed in a reaction tube made of SUS having an inside diameter of 50 mm and a length of 128 cm. The catalyst was dried at 150° C. and reduced by flowing hydrogen at 200° C. beforehand.
[0062] After heating the reaction tube described above to about 260° C. using a heater, CF 3 CF 2 CH 2 Cl (HCFC-235cb) and hydrogen were supplied therein at a flow rate of 702 ml/min and 1,991 ml/min respectively.
[0063] The exit gas from the reactor was analyzed by gas chromatography, with the result that the conversion of CF 3 CF 2 CH 2 Cl (HCFC-235cb) was 95.5% and the selectivity of CF 3 CF 2 CH 3 (HFC-245cb) was 96.7%. The maximum temperature inside the reactor was 381° C.
[0064] This method obtained the target product, i.e., CF 3 CF 2 CH 3 (HFC-245cb), at a rate of 648 ml/min (0.61 ml/min/g-cat).
[0065] In Example 1 and Comparative Example 1, almost the same amounts of catalysts were used. However, in Example 1, the half amount thereof was a catalyst having low catalytic activity. Comparing the results of Example 1 to those of Comparative Example 1, the conversion rate of the starting material and the selectivity of fluorine-containing alkane were almost the same; however, the temperature rise in the reactor was suppressed in Example 1 compared to Comparative Example 1. As a result, in contrast to Comparative Example 1 wherein the introduction amount of the starting material could not be increased, the introduction amount of the starting material in Example 1 could be increased, enhancing the production amount of the target product, i.e., CF 3 CF 2 CH 3 (HFC-245eb) per unit time.
Example 2
[0066] Using a reaction tube made of SUS having an inside diameter of 25 mm and a length of 140 cm, 100 g of a catalyst containing Pd supported on activated carbon (the amount of Pd supported: 0.2% by weight) (0.2 wt % Pd/C catalyst) was placed in the area within the range of about 10 to 50 cm from the entrance of the reaction tube, 100 g of catalyst containing Pd supported on activated carbon (the amount of Pd supported: 0.3% by weight) (0.3 wt % Pd/C catalyst) was placed in the area within the range of about 50 to 90 cm from the entrance of the reaction tube, and 100 g of catalyst containing Pd supported on activated carbon (the amount of Pd supported: 0.6% by weight) (0.6 wt % Pd/C catalyst) was placed in the area within the range of about 90 to 130 cm from the entrance of the reaction tube. The catalysts were dried at 150° C. and reduced by flowing hydrogen at 200° C. beforehand.
[0067] From the entrance of the reaction tube where the 0.2 wt % Pd/C catalyst was placed, hexafluoropropene (CF 3 CF═CF 2 ) and hydrogen were flowed into the reaction apparatus described above at flow rates of 1,597 ml/min and 2,256 ml/min respectively. The internal temperature of the reaction tube when the hydrogen and hexafluoropropene were introduced was 25° C.
[0068] The exit gas from the reactor was analyzed by gas chromatography, with the result that the conversion of hexafluoropropene was 98.9% and the selectivity of CF 3 CHFCHF 2 (HFC-236ea) was 100%. The maximum temperature inside the reactor was 268° C.
[0069] This method made it possible to obtain the target product, i.e., CF 3 CHFCHF 2 (HFC-236ea), at a rate of 1,578 ml/min (5.26 ml/min/g-cat).
Comparative Example 2
[0070] 270 g of catalyst containing Pd supported on activated carbon (the amount of Pd supported: 3% by weight) (3 wt % Pd/C catalyst) was placed in a reaction tube made of SUS having an inside diameter of 25 mm and a length of 120 cm, followed by ice-cooling. The catalyst was dried at 150° C. and reduced by flowing hydrogen at 200° C. beforehand.
[0071] Into the reaction tube described above, hexafluoropropene and hydrogen were supplied at flow rates of 769 ml/min and 1,662 ml/min respectively. The internal temperature of the reaction tube when the hydrogen and hexafluoropropene were introduced was 0° C.
[0072] The exit gas from the reactor was analyzed by gas chromatography, with the result that the conversion of hexafluoropropene was 100% and the selectivity of CF 3 CHFCHF 2 (HFC-236ea) was 99.6%. The maximum temperature inside the reactor was 293° C.
[0073] This method made it possible to obtain the target product, i.e., CF 3 CHFCHF 2 (HFC-236ea), at a rate of 764 ml/min (2.83 ml/min/g-cat).
[0074] In Example 2 and Comparative Example 2 described above, reaction apparatuses having almost the same size were used and the amounts of catalyst used were also almost the same. The difference lies in that three types of catalysts having different activities were used in Example 2 but a single catalyst having high activity was used in Comparative Example 2.
[0075] Comparing the results of Example 2 to those of Comparative Example 2, the conversion rate and selectivity were almost the same level. However, in Comparative Example 2, regardless of the use of an ice-cooled reaction tube, the temperature significantly rose during the reaction; therefore, the introduction amount of the starting material could not be increased. In contrast, although no ice-cooling or like active cooling was performed, the temperature rise in the reaction tube was suppressed in Example 2. This allowed the introduction amount of the starting material to be increased, enhancing the production amount of the target product, i.e., CF 3 CHFCHF 2 (HFC-236ea) per unit of time.
Example 3
[0076] Using a reaction tube made of SUS having an inside diameter of 25 mm and a length of 140 cm, 100 g of catalyst containing Pd supported on activated carbon (the amount of Pd supported: 0.2% by weight) (0.2 wt % Pd/C catalyst) was placed in the area within the range of about 10 to 50 cm from the entrance of the reaction tube, 100 g of catalyst containing Pd supported on activated carbon (the amount of Pd supported: 0.3% by weight) (0.3 wt % Pd/C catalyst) was placed in the area within the range of about 50 to 90 cm from the entrance of the reaction tube, and 100 g of catalyst containing Pd supported on activated carbon (the amount of Pd supported: 0.6% by weight) (0.6 wt % Pd/C catalyst) was placed in the area within the range of about 90 to 130 cm from the entrance of the reaction tube. The catalysts were dried at 150° C. and reduced by flowing hydrogen at 200° C. beforehand.
[0077] The reaction tube described above was heated to 150° C. using a heater, and CF 3 CF═CHF (HFC-1225ye) and hydrogen were flowed at 1,032 ml/min and 2,515 ml/min respectively from the entrance of the reaction tube where 0.2 wt % Pd/C catalyst was placed. The internal temperature of the reaction tube was 150° C. when the hydrogen and pentafluoropropene were introduced.
[0078] The exit gas from the reactor was analyzed by gas chromatography, with the result that the conversion of CF 3 CF═CHF (HFC-1225ye) was 98.0% and the selectivity of CF 3 CHFCH 2 F (HFC-245eb) was 99.4%. The maximum temperature inside the reactor was 292° C.
[0079] This method made it possible to obtain the target product, i.e., CF 3 CHFCH 2 F (HFC-245eb), at a rate of 1,005 ml/min.
Comparative Example 3
[0080] 38 g of catalyst containing Pd supported on activated carbon (the amount of Pd supported: 3% by weight) (3 wt % Pd/C catalyst) was placed in a reaction tube made of SUS having an inside diameter of 20 mm and a length of 68 cm. The catalyst was dried at 150° C. and reduced by flowing hydrogen at 200° C. beforehand.
[0081] Into the reaction tube described above, CF 3 CF═CHF (HFC-1225ye) and hydrogen were flowed at flow rates of 267 ml/min and 1,065 ml/min respectively. The internal temperature of the reaction tube when hydrogen and pentafluoropropene were introduced was 25° C.
[0082] The exit gas from the reactor was analyzed by gas chromatography, with the result that the conversion of CF 3 CF═CHF (HFC-1225ye) was 99.5% and the selectivity of CF 3 CHFCH 2 F (HFC-245eb) was 98.9%. The maximum temperature inside the reactor was 245° C.
[0083] This method made it possible to obtain the target product, i.e., CF 3 CHFCH 2 F (HFC-245eb), at a rate of 262 ml/min.
[0084] In Example 3 and Comparative Example 3 described above, reaction apparatuses with different sizes were used. Due to the large amount of heat generated, a larger reaction apparatus could not be used in Comparative Example 3. As to the catalyst, three types of catalysts having different catalytic activities were used in Example 3, but a single catalyst having high activity was used in Comparative Example 3. As a result, because a large amount of heat was generated by the reaction, the amount of catalyst used was limited in Comparative Example 3.
[0085] Comparing the results of Example 3 to those of Comparative Example 3, they are similar in the conversion rate and selectivity, but due to the heat generated, the introduction amount of the starting material could not be increased in Comparative Example 3. In contrast, in Example 3, the temperature rise in the reaction tube was suppressed; therefore, the production amount of CF 3 CHFCHF 2 (236ea) per unit of time was increased.
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The present invention provides a method for producing a fluorine-containing alkane, which comprises reacting at least one fluorine-containing compound selected from the group consisting of chlorine-containing fluoroalkanes and fluorine-containing alkenes with hydrogen gas in the presence of catalysts, wherein two or more catalysts having different catalytic activities are used, and the fluorine-containing compound and hydrogen gas, which are starting materials, are sequentially brought into contact with the catalysts in the order of the catalyst having a lower catalytic activity followed by the catalyst having a higher catalytic activity. According to the present invention, in the method for producing a fluorine-containing alkane by using chlorine-containing fluoroalkane or fluorine-containing alkene as a starting material, and subjection it to a reduction reaction or a hydrogen addition reaction, the objective fluorine-containing alkane can be produced with high productivity.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 13/353,542, filed 19 Jan. 2012, (now allowed), which in turn is a continuation of prior U.S. application Ser. No. 13/340,080, filed Dec. 29, 2011, which is a continuation of prior U.S. application Ser. No. 12/980,510, filed Dec. 29, 2010, (now issued as U.S. Pat. No. 8,088,718), which in turn is a division of prior U.S. application Ser. No. 12/870,076, filed 27 Aug. 2010 (now issued as U.S. Pat. No. 7,902,125), which in turn is a divisional of prior U.S. application Ser. No. 11/323,031, filed 30 Dec. 2005, (now issued as U.S. Pat. No. 7,803,740), which in turn claims priority from U.S. Provisional Application Ser. No. 60/640,965, filed 30 Dec. 2004, (now expired), all of which are hereby incorporated by reference in their entirety.
This application claims the benefit of U.S. Provisional Application No. 60/640,965 filed Dec. 30, 2004.
FIELD OF THE INVENTION
The present invention relates to lightweight thermoset polymer nanocomposite particles, to processes for the manufacture of such particles, and to applications of such particles. The particles of the invention contain one or optionally more than one type of nanofiller that is intimately embedded in the polymer matrix. It is possible to use a wide range of thermoset polymers and nanofillers as the main constituents of the particles of the invention, and to produce said particles by means of a wide range of fabrication techniques. Without reducing the generality of the invention, in its currently preferred embodiments, the thermoset matrix consists of a terpolymer of styrene, ethyvinylbenzene and divinylbenzene; particulate carbon black of nanoscale dimensions is used as the nanofiller, suspension polymerization is performed in the presence of the nanofiller, and optionally post-polymerization heat treatment is performed with the particles still in the reactor fluid that remains after the suspension polymerization to further advance the curing of the matrix polymer. When executed in the manner taught by this patent, many properties of both the individual particles and packings of said particles can be improved by the practice of the invention. The particles exhibit enhanced stiffness, strength, heat resistance, and resistance to aggressive environments; as well as the improved retention of high conductivity of liquids and gases through packings of said particles in aggressive environments under high compressive loads at elevated temperatures. The thermoset polymer nanocomposite particles of the invention can be used in many applications. These applications include, but are not limited to, the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells; for example, as a proppant partial monolayer, a proppant pack, an integral component of a gravel pack completion, a ball bearing, a solid lubricant, a drilling mud constituent, and/or a cement additive.
BACKGROUND
The background of the invention can be described most clearly, and hence the invention can be taught most effectively, by subdividing this section in three subsections. The first subsection will provide some general background regarding the role of crosslinked (and especially stiff and strong thermoset) particles in the field of the invention. The second subsection will describe the prior art that has been taught in the patent literature. The third subsection will provide additional relevant background information selected from the vast scientific literature on polymer and composite materials science and chemistry, to further facilitate the teaching of the invention.
A. General Background
Crosslinked polymer (and especially stiff and strong thermoset) particles are used in many applications requiring high stiffness, high mechanical strength, high temperature resistance, and/or high resistance to aggressive environments. Crosslinked polymer particles can be prepared by reacting monomers or oligomers possessing three or more reactive chemical functionalities, as well as by reacting mixtures of monomers and/or oligomers at least one ingredient of which possesses three or more reactive chemical functionalities.
The intrinsic advantages of crosslinked polymer particles over polymer particles lacking a network consisting of covalent chemical bonds in such applications become especially obvious if an acceptable level of performance must be maintained for a prolonged period (such as many years, or in some applications even several decades) under the combined effects of mechanical deformation, heat, and/or severe environmental insults. For example, many high-performance thermoplastic polymers, which have excellent mechanical properties and which are hence used successfully under a variety of conditions, are unsuitable for applications where they must maintain their good mechanical properties for many years in the presence of heat and/or chemicals, because they consist of assemblies of individual polymer chains. Over time, the deformation of such assemblies of individual polymer chains at an elevated temperature can cause unacceptable amounts of creep, and furthermore solvents and/or aggressive chemicals present in the environment can gradually diffuse into them and degrade their performance severely (and in some cases even dissolve them). By contrast, the presence of a well-formed continuous network of covalent bonds restrains the molecules, thus helping retain an acceptable level of performance under severe use conditions over a much longer time period.
Oil and natural gas well construction activities, including drilling, completion and stimulation applications (such as proppants, gravel pack components, ball bearings, solid lubricants, drilling mud constituents, and/or cement additives), require the use of particulate materials, in most instances preferably of as nearly spherical a shape as possible. These (preferably substantially spherical) particles must generally be made from materials that have excellent mechanical properties. The mechanical properties of greatest interest in most such applications are stiffness (resistance to deformation) and strength under compressive loads, combined with sufficient “toughness” to avoid the brittle fracture of the particles into small pieces commonly known as “fines”. In addition, the particles must have excellent heat resistance in order to be able to withstand the combination of high compressive load and high temperature that normally becomes increasingly more severe as one drills deeper. In other words, particles that are intended for use deeper in a well must be able to withstand not only the higher overburden load resulting from the greater depth, but also the higher temperature that accompanies that higher overburden load as a result of the nature of geothermal gradients. Finally, these materials must be able to withstand the effects of the severe environmental insults (resulting from the presence of a variety of hydrocarbon and possibly solvent molecules as well as water, at simultaneously elevated temperatures and compressive loads) that the particles will encounter deep in an oil or natural gas well. The need for relatively lightweight high performance materials for use in these particulate components in applications related to the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells thus becomes obvious. Consequently, while such uses constitute only a small fraction of the applications of stiff and strong materials, they provide fertile territory for the development of new or improved materials and manufacturing processes for the fabrication of such materials.
We will focus much of the remaining discussion of the background of the invention on the use of particulate materials as proppants. One key measure of end use performance of proppants is the retention of high conductivity of liquids and gases through packings of the particles in aggressive environments under high compressive loads at elevated temperatures.
The use of stiff and strong solid proppants has a long history in the oil and natural gas industry. Throughout most of this history, particles made from polymeric materials (including crosslinked polymers) have been considered to be unsuitable for use by themselves as proppants. The reason for this prejudice is the perception that polymers are too deformable, as well as lacking in the ability to withstand the combination of elevated compressive loads, temperatures and aggressive environments that are commonly encountered in oil and natural gas wells. Consequently, work on proppant material development has focused mainly on sands, on ceramics, and on sands and ceramics coated by crosslinked polymers to improve some aspects of their performance. This situation has prevailed despite the fact that most polymers have densities that are much closer to that of water so that in particulate form they can be transported much more readily into a fracture by low-density fracturing or carrier fluids such as unviscosified water.
Nonetheless, the obvious practical advantages [see a review by Edgeman (2004)] of developing the ability to use lightweight particles that possess almost neutral buoyancy relative to water have stimulated a considerable amount of work over the years. However, as will be seen from the review of the prior art provided below, progress in this field of invention has been very slow as a result of the many technical challenges that exist to the successful development of cost-effective lightweight particles that possess sufficient stiffness, strength and heat resistance.
B. Prior Art
The prior art can be described most clearly, and hence the invention can be placed in the proper context most effectively, by subdividing this section into four subsections. The first subsection will describe prior art related to the development of “as-polymerized” thermoset polymer particles. The second subsection will describe prior art related to the development of thermoset polymer particles that are subjected to post-polymerization heat treatment. The third subsection will describe prior art related to the development of thermoset polymer composite particles where the particles are reinforced by conventional fillers. The fourth subsection will describe prior art related to the development of ceramic nanocomposite particles where a ceramic matrix is reinforced by nanofillers.
1. “As-Polymerized” Thermoset Polymer Particles
As discussed above, particles made from polymeric materials have historically been considered to be unsuitable for use by themselves as proppants. Consequently, their past uses in proppant materials have focused mainly on their placement as coatings on sands and ceramics, in order to improve some aspects of the performance of the sand and ceramic proppants.
Significant progress was made in the use of crosslinked polymeric particles themselves as constituents of proppant formulations in prior art taught by Rickards, et al. (U.S. Pat. Nos. 6,059,034; 6,330,916). However, these inventors still did not consider or describe the polymeric particles as proppants. Their invention only related to the use of the polymer particles in blends with particles of more conventional proppants such as sands or ceramics. They taught that the sand or ceramic particles are the proppant particles, and that the “deformable particulate material” consisting of polymer particles mainly serves to improve the fracture conductivity, reduce the generation of fines and/or reduce proppant flowback relative to the unblended sand or ceramic proppants. Thus while their invention differs significantly from the prior art in the sense that the polymer is used in particulate form rather than being used as a coating, it shares with the prior art the limitation that the polymer still serves merely as a modifier improving the performance of a sand or ceramic proppant rather than being considered for use as a proppant in its own right.
Bienvenu (U.S. Pat. No. 5,531,274) disclosed progress towards the development of lightweight proppants consisting of high-strength crosslinked polymeric particles for use in hydraulic fracturing applications. However, embodiments of this prior art, based on the use of styrene-divinylbenzene (S-DVB) copolymer beads manufactured by using conventional fabrication technology and purchased from a commercial supplier, failed to provide an acceptable balance of performance and price. They cost far more than the test standard (Jordan sand) while being outperformed by Jordan sand in terms of the liquid conductivity and liquid permeability characteristics of their packings measured according to the industry-standard API RP 61 testing procedure. [This procedure is described by the American Petroleum Institute in its publication titled “Recommended Practices for Evaluating Short Term Proppant Pack Conductivity” (first edition, Oct. 1, 1989).] The need to use a very large amount of an expensive crosslinker (50 to 80% by weight of DVB) in order to obtain reasonable performance (not too inferior to that of Jordan Sand) was a key factor in the higher cost that accompanied the lower performance.
The most advanced prior art in stiff and strong crosslinked polymer particle technologies for use in applications in oil and natural gas drilling was developed by Albright (U.S. Pat. No. 6,248,838) who taught the concept of a “rigid chain entanglement crosslinked polymer”. In summary, the reactive formulation and the processing conditions were modified to achieve “rapid rate polymerization”. While not improving the extent of covalent crosslinking relative to conventional isothermal polymerization, rapid rate polymerization results in the “trapping” of an unusually large number of physical entanglements in the polymer. These additional entanglements can result in a major improvement of many properties. For example, the liquid conductivities of packings of S-DVB copolymer beads with w DVB =0.2 synthesized via rapid rate polymerization are comparable to those that were found by Bienvenu (U.S. Pat. No. 5,531,274) for packings of conventionally produced S-DVB beads at the much higher DVB level of w DVB =0.5. Albright (U.S. Pat. No. 6,248,838) thus provided the key technical breakthrough that enabled the development of the first generation of crosslinked polymer beads possessing sufficiently attractive combinations of performance and price characteristics to result in their commercial use in their own right as solid polymeric proppants.
2. Heat-Treated Thermoset Polymer Particles
There is no prior art that relates to the development of heat-treated thermoset polymer particles for use in oil and natural gas well construction applications. One needs to look into another field of technology to find prior art of some relevance. Nishimori, et. al. (JP1992-22230) focused on the development of particles for use in liquid crystal display panels. They taught the use of post-polymerization heat treatment to increase the compressive elastic modulus of S-DVB particles at room temperature. They only claimed compositions polymerized from reactive monomer mixtures containing 20% or more by weight of DVB or other crosslinkable monomer(s) prior to the heat treatment. They stated explicitly that improvements obtained with lower weight fractions of the crosslinkable monomer(s) were insufficient and that hence such compositions were excluded from the scope of their patent.
3. Thermoset Polymer Composite Particles
This subsection will be easier to understand if it is further subdivided into two subsections. As was discussed above, the prior art on the use of polymers as components of proppant particles has focused mainly on the development of thermoset polymer coatings for rigid inorganic materials such as sand or ceramic particles. These types of heterogeneous (composite) particles will be discussed in the first subsection. Composite particles where the thermoset polymer plays a role that goes beyond that of a coating will be discused in the second subsection.
a. Thermoset Polymers as Coatings
The prior art discussed in this subsection is mainly of interest for historical reasons, as examples of the evolution of the use of thermoset polymers as components in composite proppant particles.
Underdown, et al. (U.S. Pat. No. 4,443,347) and of Glaze, et al. (U.S. Pat. No. 4,664,819) taught the coating of particles such as silica sand or glass beads with a thermoset polymer (such as a phenol-formaldehyde resin) that is cured fully (in their terminology, “pre-cured”) prior to the injection of a proppant charge consisting of such particles into a well.
An interesting alternative coating technology was taught by Graham, et al. (U.S. Pat. No. 4,585,064) who developed resin-coated particles comprising a particulate substrate, a substantially cured inner resin coating, and a heat-curable outer resin coating. According to their teaching, the outer resin coating should cure, and should thus enable the particles to form a coherent mass possessing the desired level of liquid conductivity, under the temperatures and compressive loads found in subterranean formations. However, it is not difficult to anticipate the many technical difficulties that can arise in attempting to reduce such an approach reliably and consistently to practice.
b. Thermoset Polymers as Matrix Phase Containing Dispersed Finely Divided Filler Material
McDaniel, et al. (U.S. Pat. No. 6,632,527) describes composite particles made of a binder and filler; for use in subterranean formations (for example, as proppants and as gravel pack components), in water filtration, and in artificial turf for sports fields. The filler consists of finely divided mineral particles that can be of any available composition. Fibers are also used in some embodiments as optional fillers. The sizes of the filler particles are required to fall within the range of 0.5 microns to 60 microns. The proportion of filler in the composite particle is very large (60% to 90% by volume). The binder formulation is required to include at least one member of the group consisting of inorganic binder, epoxy resin, novolac resin, resole resin, polyurethane resin, alkaline phenolic resole curable with ester, melamine resin, urea-aldehyde resin, urea-phenol-aldehyde resin, furans, synthetic rubber, and/or polyester resin. The final thermoset polymer composite particles of the required size and shape are obtained by a succession of process steps such as the mixing of a binder stream with a filler particle stream, agglomerative granulation, and the curing of granulated material streams.
4. Ceramic Nanocomposite Particles
Nguyen, et al. (U.S. 20050016726) taught the development of ceramic nanocomposite particles comprising a base material (present at roughly 50% to 90% by weight) and at least one nanoparticle material (present at roughly 0.1% to 30% by weight). Optionally, a polymeric binder, an organosilane coupling agent, and/or hollow microspheres, can also be included. The base material comprises clay, bauxite, alumina, silica, or mixtures thereof. It is stated that a suitable method for forming the composite particulates from the dry ingredients is to sinter by heating at a temperature of between roughly 1000° C. and 2000° C., which is a ceramic fabrication process. Given the types of formulation ingredients used as base materials by Nguyen, et al. (U.S. 20050016726), and furthermore the fact that even if they were to incorporate a polymeric binder in an embodiment of their invention said polymeric binder would not retain its normal chemical composition and polymer chain structure when a particulate is sintered by heating it at a temperature of between 1000° C. and about 2000° C., their composite particulates consist of the nanofiller(s) dispersed in a ceramic matrix.
C. Scientific Literature
The development of thermoset polymer nanocomposites requires the consideration of a vast and multidisciplinary range of polymer and composite materials science and chemistry challenges. It is essential to convey these challenges in the context of the fundamental scientific literature.
Bicerano (2002) provides a broad overview of polymer and composite materials science that can be used as a general reference for most aspects of the following discussion. Many additional references will also be provided below, to other publications which treat specific issues in greater detail than what could be accommodated in Bicerano (2002).
1. Selected Fundamental Aspects of the Curing of Crosslinked Polymers
It is essential, first, to review some fundamental aspects of the curing of crosslinked polymers, which are applicable to such polymers regardless of their form (particulate, coating, or bulk).
The properties of crosslinked polymers prepared by standard manufacturing processes are often limited by the fact that such processes typically result in incomplete curing. For example, in an isothermal polymerization process, as the glass transition temperature (T g ) of the growing polymer network increases, it may reach the polymerization temperature while the reaction is still in progress. If this happens, then the molecular motions slow down significantly so that further curing also slows down significantly. Incomplete curing yields a polymer network that is less densely crosslinked than the theoretical limit expected from the functionalities and relative amounts of the starting reactants. For example, a mixture of monomers might contain 80% DVB by weight as a crosslinker but the final extent of crosslinking that is attained may not be much greater than what was attained with a much smaller percentage of DVB. This situation results in lower stiffness, lower strength, lower heat resistance, and lower environmental resistance than the thermoset is capable of manifesting when it is fully cured and thus maximally crosslinked.
When the results of the first scan and the second scan of S-DVB beads containing various weight fractions of DVB (w DVB ), obtained by Differential Scanning Calorimetry (DSC), as reported by Bicerano, et al. (1996) (see FIG. 1 ) are compared, it becomes clear that the low performance and high cost of the “as purchased” S-DVB beads utilized by Bienvenu (U.S. Pat. No. 5,531,274) are related to incomplete curing. This incomplete curing results in the ineffective utilization of DVB as a crosslinker and thus in the incomplete development of the crosslinked network. In summary, Bicerano, et al. (1996), showed that the T g of typical “as-polymerized” S-DVB copolymers, as measured by the first DSC scan, increased only slowly with increasing w DVB , and furthermore that the rate of further increase of T g slowed down drastically for w DVB >0.08. By contrast, in the second DSC scan (performed on S-DVB specimens whose curing had been driven much closer to completion as a result of the temperature ramp that had been applied during the first scan), T g grew much more rapidly with w DVB over the entire range of up to w DVB =0.2458 that was studied. The more extensively cured samples resulting from the thermal history imposed by the first DSC scan can, thus, be considered to provide much closer approximations to the ideal theoretical limit of a “fully cured” polymer network.
2. Effects of Heat Treatment on Key Properties of Thermoset Polymers
a. Maximum Possible Use Temperature
As was illustrated by Bicerano, et al. (1996) for S-DVB copolymers with w DVB of up to 0.2458, enhancing the state of cure of a thermoset polymer network can increase T g very significantly relative to the T g of the “as-polymerized” material. In practice, the heat distortion temperature (HDT) is used most often as a practical indicator of the softening temperature of a polymer under load. As was shown by Takemori (1979), a systematic understanding of the HDT is possible through its direct correlation with the temperature dependences of the tensile (or equivalently, compressive) and shear elastic moduli. For amorphous polymers, the precipitous decrease of these elastic moduli as T g is approached from below renders the HDT well-defined, reproducible, and predictable. HDT is thus closely related to (and usually slightly lower than) T g for amorphous polymers, so that it can be increased significantly by increasing T g significantly.
The HDT decreases gradually with increasing magnitude of the load used in its measurement. For example, for general-purpose polystyrene (which has T g =100° C.), HDT=95° C. under a load of 0.46 MPa and HDT=85° C. under a load of 1.82 MPa are typical values. However, the compressive loads deep in an oil well or natural gas well are normally far higher than the standard loads (0.46 MPa and 1.82 MPa) used in measuring the HDT. Consequently, amorphous thermoset polymer particles can be expected to begin to deform significantly at a lower temperature than the HDT of the polymer measured under the standard high load of 1.82 MPa. This deformation will cause a decrease in the conductivities of liquids and gases through the propped fracture, and hence in the loss of effectiveness as a proppant, at a somewhat lower temperature than the HDT value of the polymer measured under the standard load of 1.82 MPa.
b. Mechanical Properties
As was discussed earlier, Nishimori, et. al. (JP1992-22230) used heat treatment to increase the compressive elastic modulus of their S-DVB particles (intended for use in liquid crystal display panels) significantly at room temperature (and hence far below T g ). Deformability under a compressive load is inversely proportional to the compressive elastic modulus. It is, therefore, important to consider whether one may also anticipate major benefits from heat treatment in terms of the reduction of the deformability of thermoset polymer particles intended for oil and natural gas drilling applications, when these particles are used in subterranean environments where the temperature is far below the T g of the particles. As explained below, the enhancement of curing via post-polymerization heat treatment is generally expected to have a smaller effect on the compressive elastic modulus (and hence on the proppant performance) of thermoset polymer particles when used in oil and natural gas drilling applications at temperatures far below their T g .
Nishimori, et. al. (JP1992-22230) used very large amounts of DVB (w DVB >>0.2). By contrast, much smaller amounts of DVB (w DVB ≦0.2) must be used for economic reasons in the “lower value” oil and natural gas drilling applications. The elastic moduli of a polymer at temperatures far below T g are determined primarily by deformations that are of a rather local nature and hence on a short length scale. Some enhancement of the crosslink density via further curing (when the network junctions created by the crosslinks are far away from each other to begin with) will hence not normally have nearly as large an effect on the elastic moduli as when the network junctions are very close to each other to begin with and then are brought even closer by the enhancement of curing via heat treatment. Consequently, while the compressive elastic modulus can be expected to increase significantly upon heat treatment when w DVB is very large, any such effect will normally be less pronounced at low values of w DVB . In summary, it can thus generally be expected that the enhancement of the compressive elastic modulus at temperatures far below T g will probably be small for the types of formulations that are most likely to be used in the synthesis of thermoset polymer particles for oil and natural gas drilling applications.
3. Effects of Nanoparticle Incorporation on Key Properties of Thermoset Polymers
a. Maximum Possible Use Temperature
As was pointed out by Takemori (1979), the addition of rigid fillers has a negligible effect on the HDT of amorphous polymers. However, nanocomposite materials and technologies had not yet been developed in 1979. It is, hence, important to consider, based on the data that have been gathered and the insights that have been obtained more recently, whether nanofillers may be expected to behave in a qualitatively different manner because of their geometric characteristics.
A review article by Aharoni (1998) considered this question and showed that three criteria must be considered. Here are the most relevant excerpts from his article: “When a combination of the following three conditions is fulfilled, then the glass transition temperature . . . may be increased relative to that of the same polymer in the absence of these three conditions . . . First, very large surface area of a rigid heterogeneous material in close contact with the amorphous phase of the polymer. Such large surface areas may be obtained by having a rigid additive material extremely finely ground, preferably to nanometer length scale. Second, strong attractive interactions should exist between the heterogeneous surfaces and the polymer. In the absence of strong attractive interactions with the heterogeneous rigid surfaces, the chain segments in the boundary layer are capable of relaxing to a state approximating the bulk polymer and the T g will be identical or very slightly higher than that of the pure bulk polymer. Third, measure of motional cooperation must exist between interchain and intrachain fragments. Unlike the effects of high modulus heterogeneous additives on the averaged modulus of the system in which they are present, the elevation of T g of the polymer matrix was repeatedly shown to require not only that the polymer itself will be a high molecular weight substance, but that the additive will be finely comminuted to generate very large polymer-heterophase interfacial surface area, and, especially important, that strong attractive interactions will exist between the polymer and the foreign additive. These interactions are generally of an ionic, hydrogen bonding, or dipolar nature and, as a rule, require that the foreign additive will have surface energy higher than or at least equal to, but never lower than, that of the amorphous polymer in which it is being incorporated.”
Almost by definition, Aharoni's first condition will be satisfied for any nanofiller that has been dispersed well in the polymer matrix. Furthermore, since a thermoset polymer contains a covalently bonded three-dimensional network structure, his third condition will also be satisfied if any thermoset polymer is used as the matrix material. However, in most systems, there will not be strong attractive interactions “generally of an ionic, hydrogen bonding, or dipolar nature” between the polymer and the nanofiller, so that the second criterion will not be satisfied. It can, therefore, be concluded that, for most combinations of polymer and nanofiller, T g will not increase significantly upon incorporation of the nanofiller so that the maximum possible use temperature will not increase significantly either. There will, however, be exceptions to this general rule. Combinations of polymer and nanofiller that manifest strong attractive interactions can be found, and for such combinations both T g and the maximum possible use temperature can increase significantly upon nanofiller incorporation.
b. Mechanical Properties
It is well-established that the incorporation of rigid fillers into a polymer matrix can produce a composite material which has significantly greater stiffness (elastic modulus) and strength (stress required to induce failure) than the base polymer. It is also well-established that rigid nanofillers can generally stiffen and strengthen a polymer matrix more effectively than conventional rigid fillers of similar composition since their geometries allow them to span (or “percolate through”) a polymer specimen at much lower volume fractions than conventional fillers. This particular advantage of nanofillers over conventional fillers is well-established and a major driving force for the vast research and development effort worldwide to develop new nanocomposite products.
FIG. 2 provides an idealized schematic illustration of the effectiveness of nanofillers in terms of their ability to “percolate through” a polymer specimen even when they are present at a low volume fraction. It is important to emphasize that FIG. 2 is of a completely generic nature. It is presented merely to facilitate the understanding of nanofiller percolation, without implying that it provides an accurate depiction of the expected behavior of any particular nanofiller in any particular polymer matrix. In practice, the techniques of electron microscopy are generally used to observe the morphologies of actual embodiments of the nanocomposite concept. Specific examples of the ability of nanofillers such as carbon black and fumed silica to “percolate” at extremely low volume fractions when dispersed in polymers are provided by Zhang, et al (2001). The vast literature and trends on the dependences of percolation thresholds and packing fractions on particle shape, aggregation, and other factors, are reviewed by Bicerano, et al. (1999).
As has also been studied extensively [for example, see Okamoto, et al. (1999)] but is less widely recognized by workers in the field, the incorporation of rigid fillers of appropriate types and dimensions in the right amount (often just a very small volume fraction) can toughen a polymer in addition to stiffening it and strengthening it. “Toughening” implies a reduction in the tendency to undergo brittle fracture. If and when it is realized for proppant particles, it is an important additional benefit since it reduces the risk of the generation of “fines” during use.
4. Technical Challenges to Nanoparticle Incorporation in Thermoset Polymers
It is important to also review the many serious technical challenges that exist to the successful incorporation of nanoparticles in thermoset polymers. Appreciation of these obstacles can help workers in the field of the invention gain a better understanding of the invention. There are three major types of potential obstacles. In general, each potential obstacle will tend to become more serious with increasing nanofiller volume fraction, so that it is usually easier to incorporate a small volume fraction of a nanofiller into a polymer than it is to incorporate a larger volume fraction. This subsection is subdivided further into the following three subsections where each type of major potential obstacle will be discussed in turn.
a. Difficulty of Dispersing Nanofiller
The most common difficulty that is encountered in preparing polymer nanocomposites involves the need to disperse the nanofiller. The specific details of the source and severity of the difficulty, and of the methods that may help overcome the difficulty, differ between types of nanofillers, polymers, and fabrication processes (for example, the “in situ” synthesis of the polymer in an aqueous or organic medium containing the nanofiller, versus the addition of the nanofiller into a molten polymer). However, some important common aspects can be identified.
Most importantly, nanofiller particles of the same kind often have strong attractive interactions with each other. As a result, they tend to “clump together”; for example, preferably into agglomerates (if the nanofiller is particulate), bundles (if the nanofiller is fibrous), or stacks (if the nanofiller is discoidal). In most systems, their attractive interactions with each other are stronger than their interactions with the molecules constituting the dispersing medium, so that their dispersion is thermodynamically disfavored and hence extremely difficult.
Even in systems where the dispersion of the nanofillers is thermodynamically favored, it is often still very difficult to achieve because of the large kinetic barriers (activation energies) that must be surmounted. Consequently, nanofillers are very rarely easy to disperse in a polymer.
b. High Dispersion Viscosity
Another difficulty with the fabrication of nanocomposites is the fact that, once the nanofiller is dispersed in the appropriate medium (for example, an aqueous or organic medium containing the nanofiller for the “in situ” synthesis of the polymer, or a molten polymer into which nanofiller is added), the viscosity of the resulting dispersion may (and often does) become very high. When this happens, it can impede the successful execution of the fabrication process steps that must follow the dispersion of the nanofiller to complete the preparation of the nanocomposite.
Dispersion rheology is a vast area of both fundamental and applied research. It dates back to the 19 th century, so that there is a vast collection of data and a good fundamental understanding of the factors controlling the viscosities of dispersions. Nonetheless, it is still at the frontiers of materials science, so that major new experimental and theoretical progress is continuing to be made. In fact, the advent of nanotechnology, and the frequent emergence of high dispersion viscosity as an obstacle to the fabrication of polymer nanocomposites, have been instrumental in advancing the state of the art in this field. Bicerano, et al. (1999) have provided a comprehensive overview which can serve as a resource for workers interested in learning more about this topic.
c. Interference with Polymerization and Network Formation
An additional potential difficulty may be encountered in systems where chemical reactions are taking place in a medium containing a nanofiller. This is the possibility that the nanofiller may have an adverse effect on the chemical reactions. As can reasonably be expected, any such adverse effects can be far more severe in systems where polymerization and network formation take place simultaneously in the presence of a nanofiller than they can in systems where preformed polymer chains are crosslinked in the presence of a nanofiller. The preparation of an S-DVB nanocomposite via suspension polymerization in a medium containing a nanofiller is an example of a process where polymerization and network formation both take place in the presence of a nanofiller. On the other hand, the vulcanization of a nanofilled rubber is a process where preformed polymer chains are crosslinked in the presence of a nanofiller.
The combined consideration of the work of Lipatov, et al. (1966, 1968), Popov, et al. (1982), and Bryk, et al. (1985, 1986, 1988) helps in providing a broad perspective into the nature of the difficulties that may arise. To summarize, the presence of a filler with a high specific surface area can disrupt both polymerization and network formation in a process such as the suspension polymerization of an S-DVB copolymer nanocomposite. These outcomes can arise from the combined effects of the adsorption of initiators on the surfaces of the nanofiller particles and the interactions of the growing polymer chains with the nanofiller surfaces. Adsorption on the nanofiller surface can affect the rate of thermal decomposition of the initiator. Interactions of the growing polymer chains with the nanofiller surfaces can result both in the reduction of the mobility of growing polymer chains and in their breakage. Very strong attractions between the initiator and the nanofiller surfaces (for example, the grafting of the initiators on the nanofiller surfaces) can potentially augment all of these detrimental effects.
Taguchi, et al. (1999) provided a fascinating example of how drastically the formulation can affect the particle morphology. They described the results obtained by adding hydrophilic fine powders [nickel (Ni) of mean particle size 0.3 microns, indium oxide (In 2 O 3 ) of mean particle size 0.03 microns, and magnetite (Fe 3 O 4 ) of mean particle size 0.1, 0.3 or 0.9 microns] to the aqueous phase during the suspension polymerization of S-DVB. These particles had such a strong affinity to the aqueous phase that they did not even go inside the S-DVB beads. Instead, they remained entirely outside the beads. Consequently, the composite particles consisted of S-DVB beads whose surfaces were uniformly covered by a coating of inorganic powder. Furthermore, these S-DVB beads rapidly became smaller with increasing amount of powder at a fixed powder particle diameter, as well as with decreasing powder particle diameter (and hence increasing number concentration of powder particles) at a given powder weight fraction.
SUMMARY OF THE INVENTION
The present invention involves a novel approach towards the practical development of stiff, strong, tough, heat resistant, and environmentally resistant ultralightweight particles, for use in the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells.
The disclosure is summarized below in three key aspects: (A) Compositions of Matter (thermoset nanocomposite particles that exhibit improved properties compared with prior art), (B) Processes (methods for manufacture of said compositions of matter), and (C) Applications (utilization of said compositions of matter in the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells).
The disclosure describes lightweight thermoset nanocomposite particles whose properties are improved relative to prior art. The particles targeted for development include, but are not limited to, terpolymers of styrene, ethyvinylbenzene and divinylbenzene; reinforced by particulate carbon black of nanoscale dimensions. The particles exhibit any one or any combination of the following properties: enhanced stiffness, strength, heat resistance, and/or resistance to aggressive environments; and/or improved retention of high conductivity of liquids and/or gases through packings of said particles when said packings are placed in potentially aggressive environments under high compressive loads at elevated temperatures.
The disclosure also describes processes that can be used to manufacture said particles. The fabrication processes targeted for development include, but are not limited to, suspension polymerization in the presence of nanofiller, and optionally post-polymerization heat treatment with said particles still in the reactor fluid that remains after the suspension polymerization to further advance the curing of the matrix polymer.
The disclosure finally describes the use of said particles in practical applications. The targeted applications include, but are not limited to, the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells; for example, as a proppant partial monolayer, a proppant pack, an integral component of a gravel pack completion, a ball bearing, a solid lubricant, a drilling mud constituent, and/or a cement additive.
A. Compositions of Matter
The compositions of matter of the present invention are thermoset polymer nanocomposite particles where one or optionally more than one type of nanofiller is intimately embedded in a polymer matrix. Any additional formulation component(s) familiar to those skilled in the art can also be used during the preparation of said particles; such as initiators, catalysts, inhibitors, dispersants, stabilizers, rheology modifiers, buffers, antioxidants, defoamers, impact modifiers, plasticizers, pigments, flame retardants, smoke retardants, or mixtures thereof. Some of the said additional component(s) may also become either partially or completely incorporated into said particles in some embodiments of the invention. However, the two required major components of said particles are a thermoset polymer matrix and at least one nanofiller. Hence this subsection will be further subdivided into three subsections. Its first subsection will teach the volume fraction of nanofiller(s) that may be used in the particles of the invention. Its second subsection will teach the types of thermoset polymers that may be used as matrix materials. Its third subsection will teach the types of nanofillers that may be incorporated.
1. Nanofiller Volume Fraction
By definition, a nanofiller possesses at least one principal axis dimension whose length is less than 0.5 microns (500 nanometers). This geometric attribute is what differentiates a nanofiller from a finely divided conventional filler, such as the fillers taught by McDaniel, et al. (U.S. Pat. No. 6,632,527) whose characteristic lengths ranged from 0.5 microns to 60 microns.
The dispersion of a nanofiller in a polymer is generally more difficult than the dispersion of a conventional filler of similar chemical composition in the same polymer. However, if dispersed properly during composite particle fabrication, nanofillers can reinforce the matrix polymer far more efficiently than conventional fillers. Consequently, while 60% to 90% by volume of filler is claimed by McDaniel, et al. (U.S. Pat. No. 6,632,527), only 0.001% to 60% by volume of nanofiller is claimed in the present invention.
Without reducing the generality of the present invention, a nanofiller volume fraction of 0.1% to 15% is used in its currently preferred embodiments.
2. Matrix Polymers
Any rigid thermoset polymer may be used as the matrix polymer of the present invention. Rigid thermoset polymers are, in general, amorphous polymers where covalent crosslinks provide a three-dimensional network. However, unlike thermoset elastomers (often referred to as “rubbers”) which also possess a three-dimensional network of covalent crosslinks, the rigid thermosets are, by definition, “stiff”. In other words, they have high elastic moduli at “room temperature” (25° C.), and often up to much higher temperatures, because their combinations of chain segment stiffness and crosslink density result in a high glass transition temperature.
Some examples of rigid thermoset polymers that can be used as matrix materials of the invention will be provided below. It is to be understood that these examples are being provided without reducing the generality of the invention, merely to facilitate the teaching of the invention.
Rigid thermoset polymers that are often used as matrix (often referred to as “binder”) materials in composites include, but are not limited to, crosslinked epoxies, epoxy vinyl esters, polyesters, phenolics, polyurethanes, and polyureas. Rigid thermoset polymers that are used less often because of their high cost despite their exceptional performance include, but are not limited to, crosslinked polyimides. These various types of polymers can, in different embodiments of the invention, be prepared by starting either from their monomers, or from oligomers that are often referred to as “prepolymers”, or from suitable mixtures of monomers and oligomers.
Many additional types of rigid thermoset polymers can also be used as matrix materials in composites, and are all within the scope of the invention. Such polymers include, but are not limited to, various families of crosslinked copolymers prepared most often by the polymerization of vinylic monomers, of vinylidene monomers, or of mixtures thereof.
The “vinyl fragment” is commonly defined as the CH 2 ═CH— fragment. So a “vinylic monomer” is a monomer of the general structure CH 2 ═CHR where R can be any one of a vast variety of molecular fragments or atoms (other than hydrogen). When a vinylic monomer CH 2 ═CHR reacts, it is incorporated into the polymer as the —CH 2 —CHR— repeat unit. Among rigid thermosets built from vinylic monomers, the crosslinked styrenics and crosslinked acrylics are especially familiar to workers in the field. Some other familiar types of vinylic monomers (among others) include the olefins, vinyl alcohols, vinyl esters, and vinyl halides.
The “vinylidene fragment” is commonly defined as the CH 2 ═CR″- fragment. So a “vinylidene monomer” is a monomer of the general structure CH 2 ═CR′R″ where R′ and R″ can each be any one of a vast variety of molecular fragments or atoms (other than hydrogen). When a vinylidene monomer CH 2 ═CR′R″ reacts, it is incorporated into a polymer as the —CH 2 —CR′R″-repeat unit. Among rigid thermosets built from vinylidene polymers, the crosslinked alkyl acrylics [such as crosslinked poly(methyl methacrylate)] are especially familiar to workers in the field. However, vinylidene monomers similar to each type of vinyl monomer (such as the styrenics, acrylates, olefins, vinyl alcohols, vinyl esters and vinyl halides, among others) can be prepared. One example of particular interest in the context of styrenic monomers is α-methyl styrene, a vinylidene-type monomer that differs from styrene (a vinyl-type monomer) by having a methyl (—CH 3 ) group serving as the R″ fragment replacing the hydrogen atom attached to the α-carbon.
Thermosets based on vinylic monomers, on vinylidene monomers, or on mixtures thereof, are typically prepared by the reaction of a mixture containing one or more non-crosslinking (difunctional) monomer and one or more crosslinking (three or higher functional) monomers. All variations in the choices of the non-crosslinking monomer(s), the crosslinking monomers(s), and their relative amounts [subject solely to the limitation that the quantity of the crosslinking monomer(s) must not be less than 1% by weight], are within the scope of the invention.
Without reducing the generality of the invention, in its currently preferred embodiments, the thermoset matrix consists of a terpolymer of styrene (non-crosslinking), ethyvinylbenzene (also non-crosslinking), and divinylbenzene (crosslinking), with the weight fraction of divinylbenzene ranging from 3% to 35% by weight of the starting monomer mixture.
3. Nanofillers
By definition, a nanofiller possesses at least one principal axis dimension whose length is less than 0.5 microns (500 nanometers). Some nanofillers possess only one principal axis dimension whose length is less than 0.5 microns. Other nanofillers possess two principal axis dimensions whose lengths are less than 0.5 microns. Yet other nanofillers possess all three principal axis dimensions whose lengths are less than 0.5 microns. Any reinforcing material possessing one nanoscale dimension, two nanoscale dimensions, or three nanoscale dimensions, can be used as the nanofiller in embodiments of the invention. Any mixture of two or more different types of such reinforcing materials can also be used as the nanofiller in embodiments of the invention.
Some examples of nanofillers that can be incorporated into the nanocomposites of the invention will be provided below. It is to be understood that these examples are being provided without reducing the generality of the invention, merely to facilitate the teaching of the invention.
Nanoscale carbon black, fumed silica and fumed alumina, such as products of these types that are currently being manufactured by the Cabot Corporation, consist of aggregates of small primary particles. See FIG. 3 for a schematic illustration of such an aggregate, and of a larger agglomerate. The aggregates may contain many very small primary particles, often arranged in a “fractal” pattern, resulting in aggregate principal axis dimensions that are also shorter than 0.5 microns. These aggregates (and not the individual primary particles that constitute them) are, in general, the smallest units of these nanofillers that are dispersed in a polymer matrix under normal fabrication conditions. The available grades of such nanofillers include variations in specific surface area, extent of branching (structure) in the aggregates, and chemical modifications intended to facilitate dispersion in different types of media (such as aqueous or organic mixtures). Some product types of such nanofillers are also provided in “fluffy” grades of lower bulk density that are easier to disperse than the base grade but less convenient to transport and store since the same weight of material occupies more volume when it is in its fluffy form. Some products grades of such nanofillers are also provided pre-dispersed in an aqueous medium.
Carbon nanotubes, carbon nanofibers, and cellulosic nanofibers constitute three other classes of nanofillers. When separated from each other by breaking up the bundles in which they are often found and then dispersed well in a polymer, they serve as fibrous reinforcing agents. In different products grades, they may have two principal axis dimensions in the nanoscale range (below 500 nanometers), or they may have all three principal axis dimensions in the nanoscale range (if they have been prepared by a process that leads to the formation of shorter nanotubes or nanofibers). Currently, carbon nanotubes constitute the most expensive nanofillers of fibrous shape. Carbon nanotubes are available in single-wall and multi-wall versions. The single-wall versions offer the highest performance, but currently do so at a much higher cost than the multi-wall versions. Nanotubes prepared from inorganic materials (such as boron nitride) are also available.
Natural and synthetic nanoclays constitute another major class of nanofiller. Nanocor and Southern Clay Products are the two leading suppliers of nanoclays at this time. When “exfoliated” (separated from each other by breaking up the stacks in which they are normally found) and dispersed well in a polymer, the nanoclays serve as discoidal (platelet-shaped) reinforcing agents. The thickness of an individual platelet is around one nanometer (0.001 microns). The lengths in the other two principal axis dimensions are much larger. They range between 100 and 500 nanometers in many product grades, thus resulting in a platelet-shaped nanofiller that has three nanoscale dimensions. They exceed 500 nanometers, and thus result in a nanofiller that has only one nanoscale dimension, in some other grades.
Many additional types of nanofillers are also available; including, but not limited to, very finely divided grades of fly ash, the polyhedral oligomeric silsesquioxanes, and clusters of different types of metals, metal alloys, and metal oxides. Since the development of nanofillers is an area that is at the frontiers of materials research and development, the future emergence of yet additional types of nanofillers that are not currently known may also be readily anticipated.
Without reducing the generality of the invention, in its currently preferred embodiments, nanoscale carbon black grades supplied by Cabot Corporation are being used as the nanofiller.
B. Processes
In most cases, the incorporation of a nanofiller into the thermoset polymer matrix will increase the compressive elastic modulus uniformly throughout the entire use temperature range (albeit usually not by exactly the same factor at each temperature), while not increasing T g significantly. The resulting nanocomposite particles will then perform better as proppants over their entire use temperature range, but without an increase in the maximum possible use temperature itself. On the other hand, if a suitable post-polymerization process step is applied to the nanocomposite particles, in many cases the curing reaction will be driven further towards completion so that T g (and hence also the maximum possible use temperature) will increase along with the increase induced by the nanofiller in the compressive elastic modulus.
Processes that may be used to enhance the degree of curing of a thermoset polymer include, but are not limited to, heat treatment (which may be combined with stirring and/or sonication to enhance its effectiveness), electron beam irradiation, and ultraviolet irradiation. We focused mainly on the use of heat treatment in order to increase the T g of the thermoset matrix polymer, to make it possible to use nanofiller incorporation and post-polymerization heat treatment as complementary methods, to improve the performance characteristics of the particles even further by combining the anticipated main benefits of each method. FIG. 4 provides an idealized schematic illustration of the benefits of implementing these methods and concepts.
The processes that may be used for the fabrication of the thermoset nanocomposite particles of the invention have at least one, and optionally two, major step(s). The required step is the formation of said particles by means of a process that allows the intimate embedment of the nanofiller in the polymer matrix. The optional step is the use of an appropriate postcuring method to advance the curing reaction of the thermoset matrix and to thus obtain a polymer network that approaches the “fully cured” limit. Consequently, this subsection will be further subdivided into two subsections, dealing with polymerization and with postcure respectively.
1. Polymerization and Network Formation in Presence of Nanofiller
Any method for the fabrication of thermoset composite particles known to those skilled in the art may be used to prepare embodiments of the thermoset nanocomposite particles of the invention. Without reducing the generality of the invention, some such methods will be discussed below to facilitate the teaching of the invention.
The most practical methods for the formation of composites containing rigid thermoset matrix polymers involve the dispersion of the filler in a liquid (aqueous or organic) medium followed by the “in situ” formation of the crosslinked polymer network around the filler. This is in contrast with the formation of thermoplastic composites where melt blending can instead also be used to mix a filler with a fully formed molten polymer. It is also in contrast with the vulcanization of a filled rubber, where preformed polymer chains are crosslinked in the presence of a filler.
The implementation of such methods in the preparation of thermoset nanocomposite particles is usually more difficult to accomplish in practice than their implementation in the preparation of composite particles containing conventional fillers. As discussed earlier, common challenges involve difficulties in dispersing the nanofiller, high nanofiller dispersion viscosity, and possible interferences of the nanofiller with polymerization and network formation. Nonetheless, these challenges can all be surmounted by making judicious choices of the formulation ingredients and their proportions, and then also determining and using the optimum processing conditions.
McDaniel, et al. (U.S. Pat. No. 6,632,527) prepared polymer composite particles with thermoset matrix formulations. Their formulations were based on at least one member of the group consisting of inorganic binder, epoxy resin, novolac resin, resole resin, polyurethane resin, alkaline phenolic resole curable with ester, melamine resin, urea-aldehyde resin, urea-phenol-aldehyde resin, furans, synthetic rubber, and/or polyester resin. They taught the incorporation of conventional filler particles, whose sizes ranged from 0.5 microns to 60 microns, at 60% to 90% by volume. Their fabrication processes differed in details depending on the specific formulation, but in general included steps involving the mixing of a binder stream with a filler particle stream, agglomerative granulation, and the curing of a granulated material stream to obtain thermoset composite particles of the required size and shape. These processes can also be used to prepare the thermoset nanocomposite particles of the present invention, where nanofillers possessing at least one principal axis dimension shorter than 0.5 microns are used at a volume fraction that does not exceed 60% and that is far smaller than 60% in the currently preferred embodiments. The processes of McDaniel, et al. (U.S. Pat. No. 6,632,527) are, hence, incorporated herein by reference.
As was discussed earlier, many additional types of thermoset polymers can also be used as the matrix materials in composites. Examples include crosslinked polymers prepared from various styrenic, acrylic or olefinic monomers (or mixtures thereof). It is more convenient to prepare particles of such thermoset polymers (as well as of their composites and nanocomposites) by using methods that can produce said particles directly in the desired (usually substantially spherical) shape during polymerization from the starting monomers. (While it is a goal of this invention to create spherical particles, it is understood that it is exceedingly difficult as well as unnecessary to obtain perfectly spherical particles. Therefore, particles with minor deviations from a perfectly spherical shape are considered perfectly spherical for the purposes of this disclosure.) Suspension (droplet) polymerization is the most powerful method available for accomplishing this objective. Two main approaches exist to suspension polymerization. The first approach is isothermal polymerization which is the conventional approach that has been practiced for many decades. The second approach is “rapid rate polymerization” as taught by Albright (U.S. Pat. No. 6,248,838) which is incorporated herein by reference. Without reducing the generality of the invention, suspension polymerization as performed via the rapid rate polymerization approach taught by Albright (U.S. Pat. No. 6,248,838) is used in the current preferred embodiments of the invention.
2. Optional Post-Polymerization Advancement of Curing and Network Formation
As was discussed earlier and illustrated in FIG. 1 with the data of Bicerano, et al. (1996), typical processes for the synthesis of thermoset polymers may result in the formation of incompletely cured networks, and may hence produce thermosets with lower glass transition temperatures and lower maximum use temperatures than is achievable with the chosen formulation of reactants. Furthermore, difficulties related to incomplete cure may sometimes be exacerbated in thermoset nanocomposites because of the possibility of interference by the nanofiller in polymerization and network formation. Consequently, the use of an optional post-polymerization process step (or a sequence of such process steps) to advance the curing of the thermoset matrix of a particle of the invention is an aspect of the invention. Suitable methods include, but are not limited to, heat treatment (also known as “annealing”), electron beam irradiation, and ultraviolet irradiation.
Post-polymerization heat treatment is a very powerful method for improving the properties and performance of S-DVB copolymers (as well as of many other types of thermoset polymers) by helping the polymer network approach its “full cure” limit. It is, in fact, the most easily implementable method for advancing the state of cure of S-DVB copolymer particles. However, it is important to recognize that another post-polymerization method (such as electron beam irradiation or ultraviolet irradiation) may be the most readily implementable one for advancing the state of cure of some other type of thermoset polymer. The use of any suitable method for advancing the curing of the thermoset polymer that is being used as the matrix of a nanocomposite of the present invention after polymerization is within the scope of the invention.
Without reducing the generality of the invention, among the suitable methods, heat treatment is used as the optional post-polymerization method to enhance the curing of the thermoset polymer matrix in the preferred embodiments of the invention. Any desired thermal history can be optionally imposed; such as, but not limited to, isothermal annealing at a fixed temperature; nonisothermal heat exposure with either a continuous or a step function temperature ramp; or any combination of continuous temperature ramps, step function temperature ramps, and/or periods of isothermal annealing at fixed temperatures. In practice, while there is great flexibility in the choice of a thermal history, it must be selected carefully to drive the curing reaction to the maximum final extent possible without inducing unacceptable levels of thermal degradation.
Any significant increase in T g by means of improved curing will translate directly into an increase of comparable magnitude in the practical softening temperature of the polymer particles under the compressive load imposed by the subterranean environment. Consequently, a significant increase of the maximum possible use temperature of the thermoset polymer particles is the most common benefit of advancing the extent of curing by heat treatment.
A practical concern during the imposition of optional heat treatment is related to the amount of material that is being subjected to heat treatment simultaneously. For example, very small amounts of material can be heat treated uniformly and effectively in vacuum; or in any inert (non-oxidizing) gaseous medium, such as, but not limited to, a helium or nitrogen “blanket”. However, heat transfer in a gaseous medium is not nearly as effective as heat transfer in an appropriately selected liquid medium. Consequently, during the optional heat treatment of large quantities of the particles of the invention (such as, but not limited to, the output of a run of a commercial-scale batch production reactor), it is usually necessary to use a liquid medium, and furthermore also to stir the particles vigorously to ensure that the heat treatment is applied as uniformly as possible. Serious quality problems may arise if heat treatment is not applied uniformly; for example, as a result of the particles that were initially near the heat source being overexposed to heat and thus damaged, while the particles that were initially far away from the heat source are not exposed to sufficient heat and are thus not sufficiently postcured.
If a gaseous or a liquid heat treatment medium is used, said medium may contain, without limitation, one or a mixture of any number of types of constituents of different molecular structure. However, in practice, said medium must be selected carefully to ensure that its molecules will not react with the crosslinked polymer particles to a sufficient extent to cause significant oxidative and/or other types of chemical degradation. In this context, it must also be kept in mind that many types of molecules which do not react with a polymer at ambient temperature may react strongly with said polymer at elevated temperatures. The most relevant example in the present context is that oxygen itself does not react with S-DVB copolymers at room temperature, while it causes severe oxidative degradation of S-DVB copolymers at elevated temperatures where there would not be much thermal degradation in its absence.
Furthermore, in considering the choice of medium for heat treatment, it is also important to keep in mind that organic molecules can swell organic polymers, potentially causing “plasticization” and thus resulting in undesirable reductions of T g and of the maximum possible use temperature. The magnitude of any such detrimental effect increases with increasing similarity between the chemical structures of the molecules in the heat treatment medium and of the polymer chains. For example, a heat transfer fluid consisting of aromatic molecules will tend to swell a styrene-divinylbenzene copolymer particle, as well as tending to swell a nanocomposite particle containing such a copolymer as its matrix. The magnitude of this detrimental effect will increase with decreasing relative amount of the crosslinking monomer (divinylbenzene) used in the formulation. For example, a styrene-divinylbenzene copolymer prepared from a formulation containing only 3% by weight of divinylbenzene will be far more susceptible to swelling in an aromatic liquid than a copolymer prepared from a formulation containing 35% divinylbenzene.
Various means known to those skilled in the art, including but not limited to the stirring and/or the sonication of an assembly of particles being subjected to heat treatment, may also be optionally used to enhance further the effectiveness of the optional heat treatment. The rate of thermal equilibration under a given thermal gradient, possibly combined with the application of any such additional means, depends on many factors. These factors include, but are not limited to, the amount of polymer particles being heat treated simultaneously, the shapes and certain key physical and transport properties of these particles, the shape of the vessel being used for heat treatment, the medium being used for heat treatment, whether external disturbances (such as stirring and/or sonication) are being used to accelerate equilibration, and the details of the heat exposure schedule. Simulations based on the solution of the heat transfer equations may hence be used optionally to optimize the heat treatment equipment and/or the heat exposure schedule.
Without reducing the generality of the invention, in its currently preferred embodiments, the thermoset nanocomposite particles are left in the reactor fluid that remains after suspension polymerization if optional heat treatment is to be used. Said reactor fluid thus serves as the heat treatment medium; and simulations based on the solution of the heat transfer equations are used to optimize the heat exposure schedule. This embodiment of the optional heat treatment works especially well (without adverse effects such as degradation and/or swelling) in enhancing the curing of the thermoset matrix polymer in the currently preferred compositions of matter of the invention. Said preferred compositions of matter consist of terpolymers of styrene, ethylvinylbenzene and divinylbenzene. Since the reactor fluid that remains after the completion of suspension polymerization is aqueous while these terpolymers are very hydrophobic, the reactor fluid serves as an excellent heat transfer medium which does not swell the particles. The use of the reactor fluid as the medium for the optional heat treatment also has the advantage of simplicity since the particles would have needed to be removed from the reactor fluid and placed in another fluid as an extra step before heat treatment if an alternative fluid had been required.
It is, however, important to reemphasize the much broader scope of the invention and the fact that the particular currently preferred embodiments summarized above constitute just a few among the vast variety of possible qualitatively different classes of embodiments. For example, if a hydrophilic thermoset polymer particle were to be developed as an alternative preferred embodiment of the invention in future work, it would obviously not be possible to subject such an embodiment to heat treatment in an aqueous slurry, and a hydrophobic heat transfer fluid would work better for its optional heat treatment.
C. Applications
The obvious practical advantages [see a review by Edgeman (2004)] of developing the ability to use lightweight particles that possess almost neutral buoyancy relative to water have stimulated a considerable amount of work over the years. However, progress in this field of invention has been very slow as a result of the many technical challenges that exist to the successful development of cost-effective lightweight particles that possess sufficient stiffness, strength and heat resistance. The present invention has resulted in the development of such stiff, strong, tough, heat resistant, and environmentally resistant ultralightweight particles; and also of cost-effective processes for the fabrication of said particles. As a result, a broad range of potential applications can be envisioned and are being pursued for the use of the thermoset polymer nanocomposite particles of the invention in the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells. Without reducing the generality of the invention, in its currently preferred embodiments, the specific applications that are already being evaluated are as a proppant partial monolayer, a proppant pack, an integral component of a gravel pack completion, a ball bearing, a solid lubricant, a drilling mud constituent, and/or a cement additive.
It is also important to note that the current selection of preferred embodiments of the invention has resulted from our focus on application opportunities in the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells. Many other applications can also be envisioned for the compositions of matter that fall within the scope of thermoset nanocomposite particles of the invention. For example, one such application is described by Nishimori, et. al. (JP1992-22230), who developed heat-treated S-DVB copolymer (but not composite) particles prepared from formulations containing very high DVB weight fractions for use in liquid crystal display panels. Alternative embodiments of the thermoset copolymer nanocomposite particles of the present invention, tailored towards the performance needs of that application and benefiting from its less restrictive cost limitations, could potentially also be used in liquid crystal display panels. Considered from this perspective, it can be seen readily that the potential applications of the particles of the invention extend far beyond their uses by the oil and natural gas industry.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
FIG. 1 shows the effects of advancing the curing reaction in a series of isothermally polymerized styrene-divinylbenzene (S-DVB) copolymers containing different DVB weight fractions via heat treatment. The results of scans of S-DVB beads containing various weight fractions of DVB (w DVB ), obtained by Differential Scanning Calorimetry (DSC), and reported by Bicerano, et al. (1996), are compared. It is seen that the T g of typical “as-polymerized” S-DVB copolymers, as measured by the first DSC scan, increased only slowly with increasing w DVB , and furthermore that the rate of further increase of T g slowed down drastically for w DVB >0.08. By contrast, in the second DSC scan (performed on S-DVB specimens whose curing had been driven much closer to completion as a result of the temperature ramp that had been applied during the first scan), T g grew much more rapidly with w DVB over the entire range of up to w DVB =0.2458 that was studied.
FIG. 2 provides an idealized, generic and schematic two-dimensional illustration of how a very small volume fraction of a nanofiller may be able to “span” and thus “bridge through” a vast amount of space, thus potentially enhancing the load bearing ability of the matrix polymer significantly at much smaller volume fractions than possible with conventional fillers.
FIG. 3 illustrates the “aggregates” in which the “primary particles” of nanofillers such as nanoscale carbon black, fumed silica and fumed alumina commonly occur. Such aggregates may contain many very small primary particles, often arranged in a “fractal” pattern, resulting in aggregate principal axis dimensions that are also shorter than 0.5 microns. These aggregates (and not the individual primary particles that constitute them) are, usually, the smallest units of such nanofillers that are dispersed in a polymer matrix under normal fabrication conditions, when the forces holding the aggregates together in the much larger “agglomerates” are overcome successfully. This illustration was reproduced from the product literature of Cabot Corporation.
FIG. 4 provides an idealized schematic illustration, in the context of the resistance of thermoset polymer particles to compression as a function of the temperature, of the most common benefits of using the methods of the present invention. In most cases, the densification of the crosslinked polymer network via post-polymerization heat treatment will have the main benefit of increasing the softening (and hence also the maximum possible use) temperature, along with improving the environmental resistance. On the other hand, in most cases, nanofiller incorporation will have the main benefits of increasing the stiffness and strength. The use of nanofiller incorporation and post-polymerization heat treatment together, as complementary methods, will thus often be able to provide all (or at least most) of these benefits simultaneously.
FIG. 5 provides a process flow diagram depicting the preparation of the example. It contains four major blocks; depicting the preparation of the aqueous phase (Block A), the preparation of the organic phase (Block B), the mixing of these two phases followed by suspension polymerization (Block C), and the further process steps used after polymerization to obtain the “as-polymerized” and “heat-treated” samples of particles (Block D).
FIG. 6 shows the variation of the temperature with time during polymerization.
FIG. 7 shows the results of the measurement of the glass transition temperatures (T g ) of the three heat-treated thermoset nanocomposite samples via differential scanning calorimetry (DSC). The samples have identical compositions. They differ only as a result of the use of different heat treatment conditions after polymerization. T g was defined as the temperature at which the curve showing the heat flow as a function of the temperature goes through its inflection point.
FIG. 8 provides a schematic illustration of the configuration of the conductivity cell.
FIG. 9 shows the measured liquid conductivity of a packing of particles of 14/16 U.S. mesh size (diameters ranging from 1.19 mm to 1.41 mm) from Sample 40m200C, at a coverage of 0.02 lb/ft 2 , under a closure stress of 4000 psi at a temperature of 190° F., as a function of time.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Because the invention will be understood better after further discussion of its currently preferred embodiments, further discussion of said embodiments will now be provided. It is understood that said discussion is being provided without reducing the generality of the invention, since persons skilled in the art can readily imagine many additional embodiments that fall within the full scope of the invention as taught in the SUMMARY OF THE INVENTION section.
A. Nature, Attributes and Applications of Currently Preferred Embodiments
The currently preferred embodiments of the invention are lightweight thermoset nanocomposite particles possessing high stiffness, strength, temperature resistance, and resistance to aggressive environments. These attributes, occurring in combination, make said particles especially suitable for use in many challenging applications in the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells. Said applications include the use of said particles as a proppant partial monolayer, a proppant pack, an integral component of a gravel pack completion, a ball bearing, a solid lubricant, a drilling mud constituent, and/or a cement additive.
B. Thermoset Polymer Matrix
1. Constituents
The thermoset matrix in said particles consists of a terpolymer of styrene (S, non-crosslinking), ethyvinylbenzene (EVB, also non-crosslinking), and divinylbenzene (DVB, crosslinking). The preference for such a terpolymer instead of a copolymer of S and DVB is a result of economic considerations. To summarize, DVB comes mixed with EVB in the standard product grades of DVB, and the cost of DVB increases rapidly with increasing purity in special grades of DVB. EVB is a non-crosslinking (difunctional) styrenic monomer. Its incorporation into the thermoset matrix does not result in any significant changes in the properties of the thermoset matrix or of nanocomposites containing said matrix, compared with the use of S as the sole non-crosslinking monomer. Consequently, it is far more cost-effective to use a standard (rather than purified) grade of DVB, thus resulting in a terpolymer where some of the repeat units originate from EVB.
2. Proportions
The amount of DVB in said terpolymer ranges from 3% to 35% by weight of the starting mixture of the three reactive monomers (S, EVB and DVB) because different applications require different maximum possible use temperatures. Even when purchased in standard product grades where it is mixed with a large weight fraction of EVB, DVB is more expensive than S. It is, hence, useful to develop different product grades where the maximum possible use temperature increases with increasing weight fraction of DVB. Customers can then purchase the grades of said particles that meet their specific application needs as cost-effectively as possible.
C. Nanofiller
1. Constituents
The Monarch™ 280 product grade of nanoscale carbon black supplied by Cabot Corporation is being used as the nanofiller in said particles. The reason is that it has a relatively low specific surface area, high structure, and a “fluffy” product form; rendering it especially easy to disperse.
2. Proportions
The use of too low a volume fraction of carbon black results in ineffective reinforcement. The use of too high a volume fraction of carbon black may result in difficulties in dispersing the nanofiller, dispersion viscosities that are too high to allow further processing with available equipment, and detrimental interference in polymerization and network formation. The amount of carbon black ranges from 0.1% to 15% by volume of said particles because different applications require different levels of reinforcement. Carbon black is more expensive than the monomers (S, EVB and DVB) currently being used in the synthesis of the thermoset matrix. It is, therefore, useful to develop different product grades where the extent of reinforcement increases with increasing volume fraction of carbon black. Customers can then purchase the grades of said particles that meet their specific application needs as cost-effectively as possible.
D. Polymerization
Suspension polymerization is performed via rapid rate polymerization, as taught by Albright (U.S. Pat. No. 6,248,838) which is incorporated herein by reference, for the fabrication of said particles. Rapid rate polymerization has the advantage, relative to conventional isothermal polymerization, of producing more physical entanglements in thermoset polymers (in addition to the covalent crosslinks). Suspension polymerization involves the preparation of an the aqueous phase and an organic phase prior to the commencement of the polymerization process. The Monarch™ 280 carbon black particles are dispersed in the organic phase prior to polymerization. The most important additional formulation component (besides the reactive monomers and the nanofiller particles) that is used during polymerization is the initiator. The initiator may consist of one type molecule or a mixture of two or more types of molecules that have the ability to function as initiators. Additional formulation components, such as catalysts, inhibitors, dispersants, stabilizers, rheology modifiers, buffers, antioxidants, defoamers, impact modifiers, plasticizers, pigments, flame retardants, smoke retardants, or mixtures thereof, may also be used when needed. Some of the additional formulation component(s) may become either partially or completely incorporated into the particles in some embodiments of the invention.
E. Attainable Particle Sizes
Suspension polymerization produces substantially spherical polymer particles. (While it is a goal of this invention to create spherical particles, it is understood that it is exceedingly difficult as well as unnecessary to obtain perfectly spherical particles. Therefore, particles with minor deviations from a perfectly spherical shape are considered perfectly spherical for the purposes of this disclosure.) Said particles can be varied in size by means of a number of mechanical and/or chemical methods that are well-known and well-practiced in the art of suspension polymerization. Particle diameters attainable by such means range from submicron values up to several millimeters. Hence said particles may be selectively manufactured over the entire range of sizes that are of present interest and/or that may be of future interest for applications in the oil and natural gas industry.
F. Optional Further Selection of Particles by Size
Optionally, after the completion of suspension polymerization, said particles can be separated into fractions having narrower diameter ranges by means of methods (such as, but not limited to, sieving techniques) that are well-known and well-practiced in the art of particle separations. Said narrower diameter ranges include, but are not limited to, nearly monodisperse distributions. Optionally, assemblies of particles possessing bimodal or other types of special distributions, as well as assemblies of particles whose diameter distributions follow statistical distributions such as gaussian or log-normal, can also be prepared.
The optional preparation of assemblies of particles having diameter distributions of interest from any given “as polymerized” assembly of particles can be performed before or after any optional heat treatment of said particles. Without reducing the generality of the invention, in the currently most preferred embodiments of the invention, any optional preparation of assemblies of particles having diameter distributions of interest from the product of a run of the pilot plant or production plant reactor is performed after the completion of any optional heat treatment of said particles.
The particle diameters of current practical interest for various uses in the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells range from 0.1 to 4 millimeters. The specific diameter distribution that would be most effective under given circumstances depends on the details of the subterranean environment in addition to depending on the type of application. The diameter distribution that would be most effective under given circumstances may be narrow or broad, monomodal or bimodal, and may also have other special features (such as following a certain statistical distribution function) depending on both the details of the subterranean environment and the type of application.
G. Optional Heat Treatment
Said particles are left in the reactor fluid that remains after suspension polymerization if optional heat treatment is to be used. Said reactor fluid thus serves as the heat treatment medium. This approach works especially well (without adverse effects such as degradation and/or swelling) in enhancing the curing of said particles where the polymer matrix consists of a terpolymer of S, EVB and DVB. Since the reactor fluid that remains after the completion of suspension polymerization is aqueous while these terpolymers are very hydrophobic, the reactor fluid serves as an excellent heat transfer medium which does not swell the particles. The use of the reactor fluid as the medium for the optional heat treatment also has the advantage of simplicity since the particles would have needed to be removed from the reactor fluid and placed in another fluid as an extra step before heat treatment if an alternative fluid had been required.
Detailed and realistic simulations based on the solution of the heat transfer equations are often used optionally to optimize the heat exposure schedule if optional heat treatment is to be used. It has been found that such simulations become increasingly useful with increasing quantity of particles that will be heat treated simultaneously. The reason is the finite rate of heat transfer. Said finite rate results in slower and more difficult equilibration with increasing quantity of particles and hence makes it especially important to be able to predict how to cure most of the particles further uniformly and sufficiently without overexposing many of the particles to heat.
EXAMPLE
The currently preferred embodiments of the invention will be understood better in the context of a specific example. It is to be understood that said example is being provided without reducing the generality of the invention. Persons skilled in the art can readily imagine many additional examples that fall within the scope of the currently preferred embodiments as taught in the DETAILED DESCRIPTION OF THE INVENTION section. Persons skilled in the art can, furthermore, also readily imagine many alternative embodiments that fall within the full scope of the invention as taught in the SUMMARY OF THE INVENTION section.
A. Summary
The thermoset matrix was prepared from a formulation containing 10% DVB by weight of the starting monomer mixture. The DVB had been purchased as a mixture where only 63% by weight consisted of DVB. The actual polymerizable monomer mixture used in preparing the thermoset matrix consisted of roughly 84.365% S, 5.635% EVB and 10% DVB by weight.
Carbon black (Monarch 280) was incorporated into the particles, at 0.5% by weight, via dispersion in the organic phase of the formulation prior to polymerization. Since the specific gravity of carbon black is roughly 1.8 while the specific gravity of the polymer is roughly 1.04, the amount of carbon black incorporated into the particles was roughly 0.29% by volume.
Suspension polymerization was performed in a pilot plant reactor, via rapid rate polymerization as taught by Albright (U.S. Pat. No. 6,248,838) which is incorporated herein by reference. In applying this method, the “dual initiator” approach, wherein two initiators with different thermal stabilities are used to help drive the reaction of DVB further towards completion, was utilized.
The required tests only require a small quantity of particles. The use of a liquid medium (such as the reactor fluid) is unnecessary for the heat treatment of a small sample. Roughly 500 grams of particles were hence removed from the slurry, washed, spread very thin on a tray, heat-treated for ten minutes at 200° C. in an oven in an inert gas environment, and submitted for testing.
The glass transition temperature of these “heat-treated” particles, and the liquid conductivity of packings thereof, were then measured by independent testing laboratories (Impact Analytical in Midland, Mich., and FracTech Laboratories in Surrey, United Kingdom, respectively).
FIG. 5 provides a process flow diagram depicting the preparation of the example. It contains four major blocks; depicting the preparation of the aqueous phase (Block A), the preparation of the organic phase (Block B), the mixing of these two phases followed by suspension polymerization (Block C), and the further process steps used after polymerization to obtain the “as-polymerized” and “heat-treated” samples of particles (Block D).
The following subsections will provide further details on the formulation, preparation and testing of this working example, to enable persons who are skilled in the art to reproduce the example.
B. Formulation
An aqueous phase and an organic phase must be prepared prior to suspension polymerization. The aqueous phase and the organic phase, which were prepared in separate beakers and then used in the suspension polymerization of the particles of this example, are described below.
1. Aqueous Phase
The aqueous phase used in the suspension polymerization of the particles of this example, as well as the procedure used to prepare said aqueous phase, are summarized in TABLE 1.
TABLE 1
The aqueous phase was prepared by adding Natrosol Plus 330 and gelatin
(Bloom strength 250) to water, heating to 65° C. to disperse
the Natrosol Plus 330 and the gelatin in the water, and then adding
sodium nitrite and sodium carbonate. Its composition is listed below.
INGREDIENT
WEIGHT (g)
%
Water
1493.04
98.55
Natrosol Plus 330 (hydroxyethylcellulose)
7.03
0.46
Gelatin (Bloom strength 250)
3.51
0.23
Sodium Nitrite (NaNO 2 )
4.39
0.29
Sodium Carbonate (Na 2 CO 3 )
7.03
0.46
Total Weight in Grams
1515.00
100.00
2. Organic Phase
The organic phase used in the suspension polymerization of the particles of this example, as well as the procedure used to prepare said organic phase, are summarized in TABLE 2. Note that the nanofiller (carbon black) was added to the organic phase in this particular example.
TABLE 2 The organic phase was prepared by placing the monomers, benzoyl peroxide (an initiator), t-amyl peroxy(2-ethylhexyl)monocarbonate (TAEC, also an initiator), Disperbyk-161 and carbon black together and agitating the resulting mixture for at least 15 minutes to disperse carbon black in the mixture. Its composition is listed below. After taking the other components of the 63% DVB mixture into account, the polymerizable monomer mixture actually consisted of roughly 84.365% S, 5.635% EVB and 10% DVB by weight. The total polymerizable monomer weight of was 1356.7 grams. The resulting thermoset nanocomposite particles thus contained [100 × 6.8/(1356.7 + 6.8)] = 0.5% by weight of carbon black. INGREDIENT WEIGHT (g) % Styrene (pure) 1144.58 82.67 Divinylbenzene (63% DVB, 215.35 15.56 98.5% polymerizable monomers) Carbon black (Monarch 280) 6.8 0.49 Benzoyl peroxide 13.567 0.98 t-Amyl peroxy(2-ethylhexyl)monocarbonate 4.07 0.29 (TAEC) Disperbyk-161 0.068 0.0049 Total Weight in Grams 1384.435 100
C. Preparation of Particles from Formulation
Once the formulation is prepared, its aqueous and organic phases are mixed, polymerization is performed, and “as-polymerized” and “heat-treated” particles are obtained, as described below.
1. Mixing
The aqueous phase was added to the reactor at 65° C. The organic phase was then introduced over roughly 5 minutes with agitation at the rate of 90 rpm. The mixture was held at 65° C. with stirring at the rate of 90 rpm for at least 15 minutes or until proper dispersion had taken place as manifested by the equilibration of the droplet size distribution.
2. Polymerization
The temperature was ramped from 65° C. to 78° C. in 10 minutes. It was then further ramped from 78° C. to 90° C. at the rate of 0.1° C. per minute in 120 minutes. It was then held at 90° C. for 90 minutes to provide most of the conversion of monomer to polymer, with benzoyl peroxide (half life of one hour at 92° C.) as the effective initiator. It was then further ramped to 115° C. in 30 minutes and held at 115° C. for 180 minutes to advance the curing with TAEC (half life of one hour at 117° C.) as the effective initiator. The particles were thus obtained in an aqueous slurry. FIG. 6 shows the variation of the temperature with time during polymerization.
3. “As-Polymerized” Particles
The aqueous slurry was cooled to 40° C. It was then poured onto a 60 mesh (250 micron) sieve to remove the aqueous reactor fluid as well as any undesirable small particles that may have formed during polymerization. The “as-polymerized” beads of larger than 250 micron diameter obtained in this manner were then washed three times with warm (40° C. to 50° C.) water
4. “Heat-Treated” Particles
Three sets of “heat-treated” particles, which were imposed to different thermal histories during the post-polymerization heat treatment, were prepared from the “as-polymerized” particles. In preparing each of these heat-treated samples, washed beads were removed from the 60 mesh sieve, spread very thin on a tray, placed in an oven under an inert gas (nitrogen) blanket, and subjected to the desired heat exposure. Sample 10m200C was prepared with isothermal annealing for 10 minutes at 200° C. Sample 40m200C was prepared with isothermal annealing for 40 minutes at 200° C. to explore the effects of extending the duration of isothermal annealing at 200° C. Sample 10m220C was prepared with isothermal annealing for 10 minutes at 220° C. to explore the effects of increasing the temperature at which isothermal annealing is performed for a duration of 10 minutes. In each case, the oven was heated to 100° C., the sample was placed in the oven and covered with a nitrogen blanket; and the temperature was then increased to its target value at a rate of 2° C. per minute, held at the target temperature for the desired length of time, and finally allowed to cool to room temperature by turning off the heat in the oven. Some particles from each sample were sent to Impact Analytical for the measurement of T g via DSC.
Particles of 14/16 U.S. mesh size were isolated from Sample 40m200C by some additional sieving. This is a very narrow size distribution, with the particle diameters ranging from 1.19 mm to 1.41 mm. This nearly monodisperse assembly of particles was sent to FracTech Laboratories for the measurement of the liquid conductivity of its packings.
D. Reference Sample
A Reference Sample was also prepared, to provide a baseline against which the data obtained for the particles of the invention can be compared.
The formulation and the fabrication process conditions used in the preparation of the Reference Sample differed from those used in the preparation of the examples of the particles of the invention in two key aspects. Firstly, carbon black was not used in the preparation of the Reference Sample. Secondly, post-polymerization heat treatment was not performed in the preparation of the Reference Sample. Consequently, while the examples of the particles of the invention consisted of a heat-treated and carbon black reinforced thermoset nanocomposite, the particles of the Reference Sample consisted of an unfilled and as-polymerized thermoset polymer that has the same composition as the thermoset matrix of the particles of the invention.
Some particles from the Reference Sample were sent to Impact Analytical for the measurement of T g via DSC. In addition, particles of 14/16 U.S. mesh size were isolated from the Reference Sample by sieving and sent to FracTech Laboratories for the measurement of the liquid conductivity of their packings.
E. Differential Scanning Calorimetry
DSC experiments (ASTM E1356-03) were carried out by using a TA Instruments Q100 DSC with nitrogen flow of 50 mL/min through the sample compartment. Roughly nine milligrams of each sample were weighed into an aluminum sample pan, the lid was crimped onto the pan, and the sample was then placed in the DSC instrument. The sample was then scanned from 5° C. to 225° C. at a rate of 10° C. per minute. The instrument calibration was checked with NIST SRM 2232 indium. Data analysis was performed by using the TA Universal Analysis V4.1 software.
DSC data for the heat-treated samples are shown in FIG. 7 . T g was defined as the temperature at which the curve for the heat flow as a function of the temperature went through its inflection point. The results are summarized in TABLE 3. It is seen that the extent of polymer curing in Sample 10m220C is comparable to that in Sample 40m200C, and that the extent of polymer curing in both of these samples has advanced significantly further than that in Sample 10m200C whose T g was only slightly higher than that of the Reference Sample.
TABLE 3 Glass transitions temperatures (T g ) of the three heat-treated samples and of the Reference Sample, in ° C. In addition to being an “as-polymerized” (rather than a heat-treated) sample, the Reference Sample also differs from the other three samples since it is an unfilled sample while the other three samples each contain 0.5% by weight carbon black. ISOTHERMAL HEAT SAMPLE TREATMENT IN NITROGEN T g (° C.) Reference None 117.17 Sample 10m200C For 10 minutes at a temperature of 200° C. 122.18 10m220C For 10 minutes at a temperature of 220° C. 131.13 40m200C For 40 minutes at a temperature of 200° C. 131.41
F. Liquid Conductivity Measurement
A fracture conductivity cell allows a particle packing to be subjected to desired combinations of compressive stress (simulating the closure stress on a fracture in a downhole environment) and elevated temperature over extended durations, while the flow of a fluid through the packing is measured. The flow capacity can be determined from differential pressure measurements. The experimental setup is illustrated in FIG. 8 .
Ohio sandstone, which has roughly a compressive elastic modulus of 4 Mpsi and a permeability of 0.1 mD, was used as a representative type of outcrop rock. Wafers of thickness 9.5 mm were machined to 0.05 mm precision and one rock was placed in the cell. The sample was split to ensure that a representative sample is achieved in terms of its particle size distribution and then weighed. The particles were placed in the cell and leveled. The top rock was then inserted. Heated steel platens were used to provide the correct temperature simulation for the test. A thermocouple inserted in the middle port of the cell wall recorded the temperature of the pack. A servo-controlled loading ram provided the closure stress. The conductivity of deoxygenated silica-saturated 2% potassium chloride (KCl) brine of pH 7 through the pack was measured.
The conductivity measurements were performed by using the following procedure:
1. A 70 mbar full range differential pressure transducer was activated by closing the bypass valve and opening the low pressure line valve. 2. When the differential pressure appeared to be stable, a tared volumetric cylinder was placed at the outlet and a stopwatch was started. 3. The output of the differential pressure transducer was fed to a data logger 5-digit resolution multimeter which logs the output every second during the measurement. 4. Fluid was collected for 5 to 10 minutes, after which time the flow rate was determined by weighing the collected effluent. The mean value of the differential pressure was retrieved from the multimeter together with the peak high and low values. If the difference between the high and low values was greater than the 5% of the mean, the data point was disregarded. 5. The temperature was recorded from the inline thermocouple at the start and at the end of the flow test period. If the temperature variation was greater than 0.5° C., the test was disregarded. The viscosity of the fluid was obtained from the measured temperature by using viscosity tables. No pressure correction is made for brine at 100 psi. The density of brine at elevated temperature was obtained from these tables. 6. At least three permeability determinations were made at each stage. The standard deviation of the determined permeabilities was required to be less than 1% of the mean value for the test sequence to be considered acceptable. 7. At the end of the permeability testing, the widths of each of the four corners of the cell were determined to 0.01 mm resolution by using vernier calipers.
The test results are summarized in TABLE 4.
TABLE 4
Measurements on packings of 14/16 U.S. mesh size of Sample 40m200C
and of the Reference Sample at a coverage of 0.02 lb/ft 2 . The
conductivity (mDft) of deoxygenated silica-saturated 2% potassium
chloride (KCl) brine of pH 7 through each sample was measured at a
temperature of 190° F. (87.8° C.) under a
compressive stress of 4000 psi (27.579 MPa).
Time
Reference Sample
Time
Sample 40m200C
(hours)
Conductivity (mDft)
(hours)
Conductivity (mDft)
27
1179
45
1329
49
1040
85
1259
72
977
109
1219
97
903
133
1199
120
820
157
1172
145
772
181
1151
168
736
205
1126
192
728
233
1110
218
715
260
720
These results are shown in FIG. 9 . They demonstrate clearly the advantage of the particles of the invention in terms of the enhanced retention of liquid conductivity under a compressive stress of 4000 psi at a temperature of 190° F.
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Use of two different methods, either each by itself or in combination, to enhance the stiffness, strength, maximum possible use temperature, and environmental resistance of thermoset polymer particles is disclosed. One method is the application of post-polymerization process steps (and especially heat treatment) to advance the curing reaction and to thus obtain a more densely crosslinked polymer network. The other method is the incorporation of nanofillers, resulting in a heterogeneous “nanocomposite” morphology. Nanofiller incorporation and post-polymerization heat treatment can also be combined to obtain the benefits of both methods simultaneously. The present invention relates to the development of thermoset nanocomposite particles. Optional further improvement of the heat resistance and environmental resistance of said particles via post-polymerization heat treatment; processes for the manufacture of said particles; and use of said particles in the construction, drilling, completion and/or fracture stimulation of oil and natural gas wells are described.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to enzyme inhibitors, and more particularly, to novel substituted biaryl oxobutyric acid compounds or derivatives thereof useful for inhibiting matrix metalloproteases.
[0003] 2. Description of the Related Art
[0004] The matrix metalloproteases (a.k.a. matrix metalloendo-proteinases or MMPs) are a family of zinc endoproteinases which include, but are not limited to, interstitial collagenase (a.k.a.. MMP-1), stromelysin (a.k.a.. proteoglycanase, transin, or MMP-3), gelatinase A (a.k.a.. 72 kDa-gelatinase or MMP-2) and gelatinase B (a.k.a.. 95 kDa-gelatinase or MMP-9). These MMPs are secreted by a variety of cells including fibroblasts and chondrocytes, along with natural proteinaceous inhibitors known as TIMPs (Tissue Inhibitor of MetalloProteinase).
[0005] All of these MMPs are capable of destroying a variety of connective tissue components of articular cartilage or basement membranes. Each MMP is secreted as an inactive proenzyme which must be cleaved in a subsequent step before it is able to exert its own proteolytic activity. In addition to the matrix destroying effect, certain of these MMPs such as MMP-3 have been implemented as the in vivo activator for other MMPs such as MMP-1 and MMP-9 (Ito, et al., Arch Biochem Biophys. 267, 211 (1988); Ogata, et al., J. Biol. Chem. 267, 3581 (1992)). Thus, a cascade of proteolytic activity can be initiated by an excess of MMP-3. It follows that specific MMP-3 inhibitors should limit the activity of other MMPs that are not directly inhibited by such inhibitors.
[0006] It has also been reported that MMP-3 can cleave and thereby inactivate the endogenous inhibitors of other proteinases such as elastase (Winyard, et al., FEBS Letts. 279, 1, 91 (1991)). Inhibitors of MMP-3 could thus influence the activity of other destructive proteinases by modifying the level of their endogenous inhibitors.
[0007] A number of diseases are thought to be mediated by excess or undesired matrix-destroying metalloprotease activity or by an imbalance in the ratio of the MMPs to the TIMPs. These include: a) osteoarthritis (Woessner, et al., J. Biol.Chem., 259(6), 3633 (1984); Phadke, et al., J. Rheumatol. 10, 852 1983)), b) rheumatoid arthritis (Mullins, et al., Biochim. Biophys. Acta 695, 117 (1983)); Woolley, et al., Arthritis Rheum. 20, 1231 (1977); Gravallese, et al., Arthritis Rheum. 34, 1076 (1991)), c) septic arthritis (Williams, et al., Arthritis Rheum. 33, 533 (1990)), d) tumor metastasis (Reich, et al., Cancer Res., 48, 3307 (1988), and Matrisian, et al., Proc. Nat'l. Acad. Sci., USA 83, 9413, (1986)), e) periodontal diseases (Overall, et al., J. Periodontal Res. 22, 81 (1987)), f) corneal ulceration (Burns, et al., Invest. Opthalmol. Vis. Sci. 30, 1569 (1989)), g) proteinuria (Baricos, et al., Biochem. J. 254, 609 (1988)), h) coronary thrombosis from atherosclerotic plaque rupture (Henney, et al., Proc. Nat'l. Acad. Sci., USA 88, 8154 (1991)), I) aneurysmal aortic disease (Vine, et al., Clin. Sci. 81, 233 (1991)), j) birth control (Woessner, et al., Steroids 54, 491 (1989)), k) dystrophobic epidermolysis bullosa (Kronberger, et al., J. Invest. Dermatol. 79, 208 (1982)), and l) degenerative cartilage loss following traumatic joint injury, m) conditions leading to inflammatory responses, osteopenias mediated by MMP activity, n) tempero mandibular joint disease, o) demyelating diseases of the nervous system (Chantry, et al., J. Neurochem. 50, 688 (1988)).
[0008] The need for new therapies is especially important in the case of arthritic diseases. The primary disabling effect of osteoarthritis (OA), rheumatoid arthritis (RA) and septic arthritis is the progressive loss of articular, cartilage and thereby normal joint function. No marketed pharmaceutical agent is able to prevent or slow this cartilage loss, although nonsteroidal anti-inflammatory drugs (NSAIDs) have been given to control pain and swelling. The end result of these diseases is total loss of joint function which is only treatable by joint replacement surgery. MMP inhibitors are expected to halt or reverse the progression of cartilage loss and obviate or delay surgical intervention.
[0009] Proteases are critical elements at several stages in the progression of metastatic cancer. In this process, the proteolytic degradation of structural protein in the basal membrane allows for expansion of a tumor in the primary site, evasion from this site as well as homing and invasion in distant, secondary sites. Also, tumor induced angiogenesis is required for tumor growth and is dependent on proteolytic tissue remodeling. Transfection experiments with various types of proteases have shown that the matrix metalloproteases play a dominant role in these processes in particular gelatinases A and B (MMP-2 and MMP-9, respectively). For an overview of this field see Mullins, et al., Biochim. Biophys. Acta 695, 177 (1983); Ray, et al., Eur. Respir. J. 7, 2062 (1994); Birkedal-Hansen, et al., Crit. Rev. Oral Biol. Med. 4, 197 (1993).
[0010] Furthermore, it was demonstrated that inhibition of degradation of extracellular matrix by the native matrix metalloprotease inhibitor TIMP-2 (a protein) arrests cancer growth (DeClerck, et al., Cancer Res. 52, 701 (1992)) and that TIMP-2 inhibits tumor-induced angiogenesis in experimental systems (Moses, et al. Science 248, 1408 (1990)). For a review, see DeClerck, et al., Ann. N. Y. Acad. Sci. 732, 222 (1994). It was further demonstrated that the synthetic matrix metalloprotease inhibitor batimastat when given intraperitoneally inhibits human colon tumor growth and spread in an orthotopic model in nude mice (Wang, et al. Cancer Res. 54, 4726 (1994)) and prolongs the survival of mice bearing human ovarian carcinoma xenografts (Davies, et. al., Cancer Res. 53, 2087 (1993)). The use of this and related compounds has been described in Brown, et al., WO-9321942 A2 (931111).
[0011] There are several patents and patent applications claiming the use of metalloproteinase inhibitors for the retardation of metastatic cancer, promoting tumor regression, inhibiting cancer cell proliferation, slowing or preventing cartilage loss associated with osteoarthritis or for treatment of other diseases as noted above (e.g. Levy, et al., WO-9519965 A1; Beckett, et al., WO-9519956 A1; Beckett, et al., WO-9519957 A1; Beckett, et al., WO-9519961 A1; Brown, et al., WO-9321942 A2; Crimmin, et al., WO-9421625 A1; Dickens, et al., U.S. Pat. No. 4,599,361; Hughes, et al., U.S. Pat. No. 5,190,937; Broadhurst, et al., EP 574758 A1; Broadhurst, et al,. EP 276436; and Myers, et al., EP 520573 A1. The preferred compounds of these patents have peptide backbones with a zinc complexing group (hydroxamic acid, thiol, carboxylic acid or phosphinic acid) at one end and a variety of sidechains, both those found in the natural amino acids as well as those with more novel functional groups. Such small peptides are often poorly absorbed, exhibiting low oral bioavailability. They are also subject to rapid proteolytic metabolism, thus having short half lives. As an example, batimastat, the compound described in Brown, et al., WO-9321942 A2, can only be given intra peritoneally.
[0012] Certain 3-biphenoylpropanoic and 4-biaryloylbutanoic acids are described in the literature as anti-inflammatory, anti-platelet aggregation, anti-phlogistic, anti-proliferative, hypolipidemic, antirheumatic, analgesic, and hypocholesterolemic agents. In none of these examples is a reference made to MMP inhibition as a mechanism for the claimed therapeutic effect. Certain related compounds are also used as intermediates in the preparation of liquid crystals.
[0013] Specifically, Tomcufcik, et al., U.S. Pat. No. 3,784,701 claims certain substituted benzoylpropionic acids to treat inflammation and pain. These compounds include 3-biphenoylpropanoic acid (a.k.a. fenbufen) shown below.
[0014] Child, et al., J. Pharm. Sci., 66, 466 (1977) describes structure-activity relationships of several analogs of fenbufen. These include several compounds in which the biphenyl ring system is substituted or the propanoic acid portion is substituted with phenyl, halogen, hydroxyl or methyl, or the carboxylic acid or carbonyl functions are converted to a variety of derivatives. No compounds are described which contain a 4′-substituted biphenyl and a substituted propanoic acid portion combined in one molecule. The phenyl (compounds XLIX and LXXVII) and methyl (compound XLVII) substituted compounds shown below were described as inactive.
[0015] Kameo; et al., Chem. Pharm. Bull., 36, 2050 (1988) and Tomizawa, et al., JP patent 62132825 A2 describe certain substituted 3-biphenoylpropionic acid derivatives and analogs thereof including the following. Various compounds with other substituents on the propionic acid portion are described, but they do not contain biphenyl residues.
[0016] wherein X═H, 4′-Br, 4′-Cl, 4′-CH 3 , or 2′-Br.
[0017] Cousse, et al., Eur. J. Med. Chem., 22, 45 (1987) describe the following methyl and methylene substituted 3-biphenoyl-propanoic and -propenoic acids. The corresponding compounds in which the carbonyl is replaced with either CH 2 OH or CH 2 are also described.
[0018] wherein X═H, Cl, Br, CH 3 O, F, or NH 2 .
[0019] Nichl, et al. DE patent 1957750 also describes certain of the above methylene substituted biphenoylpropanoic acids.
[0020] El-Hashash, et al., Revue Roum. Chim. 23, 1581 (1978) describe products derived from β-aroyl-acrylic acid epoxides including the following biphenyl compound. No compounds substituted on the biphenyl portion are described.
[0021] Kitamura, et al., JP patent 60209539 describes certain biphenyl compounds used as intermediates for the production of liquid crystals including the following. The biphenyl is not substituted in these intermediates.
[0022] wherein R 1 is an alkyl of 1-10 carbons.
[0023] Thyes, et al., DE patent 2854475 uses the following compound as an intermediate. The biphenyl group is not substituted.
[0024] Sammour, et al., Egypt J. Chem. 15, 311 (1972) and Couquelet, et al., Bull. Soc. Chim. Fr. 9, 3196 (1971) describe certain dialkylamino substituted biphenoylpropanoic acids including the following. In no case is the biphenyl group substituted.
[0025] wherein R 1 , R 2 =alkyl, benzyl, H, or, together with the nitrogen, morpholinyl.
[0026] Others have disclosed a series of biphenyl-containing carboxylic acids, illustrated by the compound shown below, which inhibit neural endopeptidase (NEP 24.11), a membrane-bound zinc metalloprotease (Stanton, et al., Bioorg. Med. Chem. Lett. 4, 539 (1994); Lombaert, et al., Bioorg. Med. Chem. Lett. 4, 2715 (1994); Lombaert, et al., Bioorg. Med. Chem. Lett. 5, 145 (1995); Lombaert, et al., Bioorg. Med. Chem. Lett. 5, 151 (1995)).
[0027] It has been reported that N-carboxyalkyl derivatives containing a biphenylethylglycine, illustrated by the compound shown below, are inhibitors of stromelysin-1 (MMP-3), 72 kDA gelatinase (MMP-2) and collagenase (Durette, et al., WO-9529689).
[0028] It would be desirable to have effective MMP inhibitors which possess improved bioavailability and biological stability relative to the peptide-based compounds of the prior art, and which can-be optimized for use against particular target MMPs. Such compounds are the subject of the present application.
[0029] The development of efficacious MMP inhibitors would afford new therapies for diseases mediated by the presence of; or an excess of MMP activity, including osteoarthritis, rheumatoid arthritis, septic arthritis, tumor metastasis, periodontal diseases, comeal ulcerations, and proteinuria. Several inhibitors of MMPs have been described in the literature, including thiols (Beszant, et al., J. Med. Chem. 36, 4030 (1993), hydroxamic acids (Wahl, et al. Bioorg. Med. Chem. Lett. 5, 349 (1995) Conway, et al. J. Exp. Med. 182, 449 (1995); Porter, et al., Bioorg. Med. Chem. Lett. 4, 2741 (1994); Tomczuk, et al., Bioorg. Med. Chem. Lett. 5, 343 (1995); Castelhano, et al., Bioorg. Med. Chem. Lett. 5, 1415 (1995)), phosphorous-based acids (Bird, et al. J. Med. Chem. 37, 158 (1994); Morphy, et al., Bioorg. Med. Chem. Lett. 4, 2747 (1994); Kortylewicz, et al., J. Med. Chem. 33, 263 (1990)), and carboxylic acids (Chapman, et al. J. Med. Chem. 36, 4293 (1993); Brown, et al. J. Med. Chem. 37, 674 (1994); Morphy, et al., Bioorg. Med. Chem. Lett. 4, 2747 (1994); Stack, et al., Arch. Biochem. Biophys. 287, 240 (1991); Ye, et al., J. Med. Chem. 37, 206 (1994); Grobelny, et al., Biochemistry 24, 6145 (1985); Mookhtiar, et al., Biochemistry 27, 4299 (1988)). However, these inhibitors generally contain peptidic backbones, and thus usually exhibit low oral bioactivity due to poor absorption and short half lives due to rapid proteolysis. Therefore, there remains a need for improved MMP inhibitors.
SUMMARY OF THE INVENTION
[0030] This invention provides compounds having matrix metalloprotease inhibitory activity. These compounds are useful for inhibiting matrix metalloproteases and, therefore, combating conditions to which MMP's contribute. Accordingly, the present invention also provides pharmaceutical compositions and methods for treating such conditions.
[0031] The compounds described relate to a method of treating a mammal comprising administering to the mammal a matrix metalloprotease inhibiting amount of a compound according to the invention sufficient to:
[0032] (a) alleviate the effects of osteoarthritis, rheumatoid arthritis, septic arthtis, periodontal disease, comeal ulceration, proteinuria, aneurysmal aortic disease, dystrophobic epidermolysis, bullosa, conditions leading to inflammatory responses, osteopenias mediated by MMP activity, tempero mandibular joint disease, demyelating diseases of the nervous system;
[0033] (b) retard tumor metastasis or degenerative cartilage loss following traumatic joint injury;
[0034] (c) reduce coronary thrombosis from athrosclerotic plaque rupture; or
[0035] (d) temporarily reduce fertility (i.e., act as effective birth control agents).
[0036] The compounds of the present invention are also useful scientific research tools for studying functions and mechanisms of action of matrix metalloproteases in both in vivo and in vitro systems. Because of their MMP-inhibiting activity, the present compounds can be used to modulate MMP action, thereby allowing the researcher to observe the effects of reduced MMP activity in the experimental biological system under study.
[0037] This invention relates to compounds having matrix metalloprotease inhibitory activity and the generalized formula:
(T) x A-B-D-E-G (L)
[0038] In the above generalized formula (L), (T) x A represents a substituted or unsubstituted aromatic 6-membered ring or heteroaromatic 5-6 membered ring containing 1-2 atoms of N, O, or S. T represents one or more substituent groups, the subscript x represents the number of such
[0039] In the above generalized formula (L), T x A represents a substituted or unsubstituted aromatic 6-membered ring or heteroaromatic 5-6 membered ring containing 1-2 atoms independently selected from the group of N, O, or S. T represents a substituted acetylenic moiety.
[0040] In the generalized formula (L), B represents an aromatic 6-membered ring or a heteroaromatic 5-6 membered ring containing 1-2 atoms independently selected from the group of N, O, or S. It is referred to as the B ring or B unit. When N is employed in conjunction with either S or O in the B ring, these heteroatoms are separated by at least one carbon atom.
[0041] In the generalized formula (L), D represents
[0042] In the generalized formula (L), E represents a chain of n carbon atoms bearing m substituents R 6 in which the R 6 groups are independent substituents, or constitute spiro or nonspiro rings. Rings may be formed in two ways: a) two groups R 6 are joined, and taken together with the chain atom(s) to which the two R 6 group(s) are attached, and any intervening chain atoms, constitute a 3-7 membered ring, or b) one group R 6 is joined to the chain on which this one group R 6 resides, and taken together with the chain atom(s) to which the R 6 group is attached, and any intervening chain atoms, constitutes a 3-7 membered ring. The number n of carbon atoms in the chain is 2 or 3, and the number m of R 6 substituents is an integer of 1-3. The number of carbons in the totality of R 6 groups is at least two.
[0043] Each group R 6 is alkyl, alkenyl, alkynyl, heteroartyl, non-aromatic cyclic, and combinations thereof optionally substituted with one or more heteroatoms as described more fully below. In the
[0044] In the generalized formula (L), E represents a linear or cyclic alkyl moiety substituted with a mono- or bi-heterocyclic ring structure.
[0045] In the generalized formula (L), G represents —PO 3 H 2 -M
[0046] in which M represents —CO 2 H, —CON(R 11 ) 2, or —CO 2 R 12 , and R 13 represents any of the side chains of the 19 noncyclic naturally occurring amino acids.
[0047] Pharmaceutically acceptable salts of these compounds are also within the scope of the invention.
[0048] In most related reference compounds of the prior art, the biphenyl portion of the molecule is unsubstituted, and the propanoic or butanoic acid portion is either unsubstituted or has a single methyl or phenyl group. Presence of the larger phenyl group has been reported to cause prior art compounds to be inactive as anti-inflammatory analgesic agents. See, for example, Child, et al., J. Pharm. Sci. 66, 466(1977). By contrast, it has now been found that compounds which exhibit potent MMP inhibitory activity contain a substituent of significant size on the propanoic or butanoic portion of the molecule. The biphenyl portions of the best MMP inhibitors also preferably contain a substituent on the 4′-position, although when the propanoic or butanoic portions are optimally substituted, the unsubstituted biphenyl compounds of the invention have sufficient activity to be considered realistic drug candidates.
[0049] The foregoing merely summarizes certain aspects of the present invention and is not intended, nor should it be construed, to limit the invention in any way. All of the patents and other publications recited in this specification are hereby incorporated by reference in their entirety.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0050] More particularly, the compounds of the present invention are materials having matrix metalloprotease inhibitory activity and the generalized formula:
(T) x A-B-D-E-G (L)
[0051] in which (T) x A represents a substituted or unsubstituted aromatic or heteroaromatic moiety selected from the group consisting of:
[0052] Throughout this application, in the displayed chemical structures, an open bond indicates the point at which the structure joins to another group. For example,
[0053] in which R 1 represents H or alkyl of 1-3 carbons.
[0054] Throughout this application, in the displayed chemical structures, an open bond indicates the point at which the structure joins to another group. For example,
[0055] In these structures, the aromatic ring is referred to as the A ring or A unit, and T represents a substituent group, referred to as a T group or T unit. T is a substituted acetylenic moiety and x is 1.
[0056] The B ring of generalized formula (L) is a substituted or unsubstituted aromatic or heteroaromatic ring, in which any substituents are groups which do not cause the molecule to fail to fit the active site of the target enzyme, or disrupt the relative conformations of the A and B rings, such that they would be detrimental. Such substituents may be moieties such as lower alkyl, lower alkoxy, CN, NO 2 , halogen, etc., but are not to be limited to such groups.
[0057] In the generalized formula (L), B represents an aromatic or heteroaromatic ring selected from the group consisting of:
[0058] portion comprises 4-9 carbons and at least one N, O, or S heteroatom and the alkyl portion contains 1-4 carbons.
[0059] R 4 represents H; alkyl of 1-12 carbons; aryl of 6-10 carbons; heteroaryl comprising 4-9 carbons and at least one N, O, or S heteroatom; arylalkyl in which the aryl portion contains 6-10 carbons and the alkyl portion contains 1-4 carbons; heteroaryl-alkyl in which the heteroaryl portion comprises 4-9 carbons and at least one N, O, or S heteroatom and the alkyl portion contains 1-4 carbons; alkenyl of 2-12 carbons; alkynyl of 2-12 carbons; —(C q H 2q O) r R 5 in which q is 1-3, r is 1-3, and R 5 is H provided q is greater than 1, or R 5 is alkyl of 1-4 carbons, or phenyl; —(CH 2 ) s X in which s is 2-3 and X is halogen; or —C(O)R 2 .
[0060] Any unsaturation in a moiety which is attached to Q or which is part of Q is separated from any N, O, or S of Q by at least one carbon atom, and the number of substituents, designated x, is 0, 1, or 2.
[0061] The substituent group T can also be an acetylene containing moiety with the general formula:
R 30 (CH 2 ) n C≡C—
[0062] where n is 1-4 and R 30 is selected from the group consisting of: HO—, MeO—, N(n-Pr) 2 —, CH 3 CO 2 —, CH 3 CH 2 OCO 2 —, HO 2 C—, OHC—, Ph—, 3-HO—Ph—, and PhCH 2 O—, provided that when R 30 is Ph or 3-HO—Ph, n=0.
[0063] In the generalized formula (L), B represents an aromatic or heteroaromatic ring selected from the group consisting of:
[0064] in which R 1 is defined as above. These rings are referred to as the B ring or B unit.
[0065] Compounds of the general formula (L) include those in which the combination (T) x -A-B has the structure:
[0066] where Z may be (CH 2 ) e —C 6 H 4 —(CH 2 ) f or (CH 2 ) g , e=0-8, f=0-5 and g=0-14, r is 0-6. R 15 may be a straight, or cyclic alkyl group of 6-12 carbons atoms, preferably of 7-11 carbon atoms, and optionally may bear one or more pharmaceutically acceptable substituents which are discussed more fully below.
[0067] R 15 may also be a polyether of the formula R 32 O(C 2 H 4 O) h in which the subscript “h” is 1 or 2, and the group R 32 is a straight, branched or cyclic alkyl group of 1-5 carbon atoms, preferably of 1-3 carbon atoms and straight, or phenyl, or benzyl. R 32 optionally may bear one or more pharmaceutically-acceptable substituents which are discussed more fully below.
[0068] R 15 may also be a substituted alkynyl group of the formula:
R 33 (CH 2 ) b —C≡C—
[0069] in which the subscript “b” is 1-10 and the group R 33 is H—, HO— or R 34 O— and the group is preferably the HO— group. R 34 may be an alkyl group of 1-3 carbon atoms, or phenyl or benzyl. R 33 optionally may bear one or more pharmaceutically-acceptable substituents which are discussed more fully below.
[0070] R 15 may also be H, Cl, MeO or
[0071] wherein n is 0-4, R 17 is C 2 H 5 , allyl, or benzyl.
[0072] In the generalized formula (L), D represents the moieties:
[0073] In the generalized formula (L), E represents a moiety having the following formula:
[0074] wherein r is 0-2 and R 40 is a mono- or bi- heterocyclic structure. When r=0 the above structure takes the form
[0075] When r is 1 or 2, a cyclobutyl or cyclopentyl ring is formed, respectively. Each ring of the mono- or bi-heterocylic structures comprise 5-7 membered rings substituted with 1-3 heteroatoms independently selected from N, S, and O; one or two carbons of the ring are optionally carbonyl carbons; any sulfir of the ring is optionally —S(O)— or —S(O) 2 —; one or more ring members are optionally substituted with one or two methyl groups; and the heterocyclic structure is attached to
[0076] and the A unit is phenyl, the B unit is phenylene, m is 1, n is 2, and t is 0, then x is 1 or 2.
[0077] [0077] 13 ) —(CH 2 ) v ZR 8 in which v is an interger of 1 to 4, Z represents —S—, —S(O)—, —SO 2 —, or —O—, and R 8 is selected from the group consisting of alkyl of 1 to 12 carbons, aryl of 6 to 10 carbons, heteroaryl comprising 4 to 9 carbons and at least one N, O, or S heteroatom; arylalkyl in which the aryl portion contains 6 to 12 carbons and the alkyl portion contains 1 to 4 carbons; heteroarylalkyl in which the aryl portion contains 6 to 12 carbons and at least one N, O, or S heteroatom and the alkyl portion contains 1 to 4 carbons; —C(O)R 9 in which the R 9 represents alkyl of 2 to 6 carbons, aryl of 6 to 10 carbons, heteroaryl comprising 4 to 9 carbons and at least one N, O, or S heteroatom, and arylalkyl in which the aryl portion contains 6 to 10 carbons or is a heteroaryl comprising 4 to 9 carbons and at least one N, O, or S heteroatom, and the alkyl portion contains 1 to 4 carbons with the provisos that when R 8 is —C(O)R 9 , Z is —S— or —O—; when Z is —O—, R 8 may also be —(C q H 2q O) r R 5 in which q, r, and R 5 are as defined above; and when the A unit is phenyl, the B unit is phenylene, m is 1, n is 2, and v is 0, then x is 1 or 2; and
[0078] 14) —(CH 2 ) w SiR 10 3 in which w is an integer of 1 to 3, and R 10 represents alkyl of 1 to 2 carbons.
[0079] In addition, aryl or heteroaryl portions of any of the T or R 6 groups optionally may bear up to two substituents selected from the group consisting of —(CH 2 ) y C(R 11 )(R 12 )OH, —(CH 2 ) y OR 11 , —(CH 2 ) y SR 11 , —(CH 2 ) y S(O)R 11 , —(CH 2 ) y S(O) 2 R 11 , —(CH 2 ) y SO 2 N(R 11 ) 2 , —(CH 2 ) y N(R 11 ) 2 , —(CH 2 ) y N(R 11 )COR 12 , —OC(R 11 ) 2 O— in which both oxygen atoms are connected to the aryl ring,
[0080] The B ring is preferably a 1,4-phenylene or 2,5-thiophene ring, most preferably 1,4-phenylene.
[0081] The D unit is most preferably a carbonyl group.
[0082] In the E unit, r is preferably 0 or 2 and R 40 is preferably one of the following:
[0083] The G unit is most preferably a carboxylic acid group and is attached to the E unit at the 2 position, i.e., the carbon atom of the E unit beta to the D unit.
[0084] It is to be understood that as used herein, the term “alkyl” means straight, branched, cyclic, and polycyclic materials. The term “haloalkyl” means partially or fully halogenated alkyl groups such as —(CH 2 ) 2 Cl, —CF 3 and —C 6 F 13 for example.
[0085] The B ring of generalized formula (L) is a substituted or unsubstituted aromatic or heteroaromatic ring, in which any substituents are groups which do not cause the molecule to fail to fit the active site of the target enzyme, or disrupt the relative conformations of the A and B rings, such that they would be detrimental. Such groups may be moieties such as lower alkyl, lower alkoxy, CN, NO 2 , halogen, etc., but are not to be limited to such groups.
[0086] In the generalized formula (L), the A and B rings are preferably phenyl and phenylene, respectively, the A ring preferably bears at least one substituent group T preferably located on the position furthest from the position of the A ring which, is connected to the B ring, the D unit is preferably a carbonyl group, and the G unit is preferably a carboxyl group.
[0087] Certain embodiments include compounds having matrix metalloproteinase inhibitory activity and the following generalized formula:
[0088] where Z═(CH 2 ) e —C 6 H 4 —(CH 2 ) f or (CH 2 ) g , e=0-8, f=0-5, g=0-14, r is 0-6 and where y is 0, 2, or 3.
[0089] R 15 may be H, Cl, MeO or
[0090] wherein n is 0-4, R 17 is C 2 H 5 , allyl or benzyl, and R 40 is one of:
[0091] The most preferred compounds of generalized formula (L) are
[0092] wherein T is selected from a group consisting of:
[0093] r is 0-2, and R 40 is selected from the group consisting of:
[0094] The invention also relates to certain intermediates useful in the synthesis of some of the claimed inhibitors. These intermediates are compounds having the generalized formula
[0095] where Bn is benzyl, TMSE is trimethylsilyl ethyl and R 40 is as defined above.
[0096] Those skilled in the art will appreciate that many of the compounds of the invention exist in enantiomeric or diastereomeric forms, and that it is understood by the art that such stereoisomers generally exhibit different activities in biological systems. This invention encompasses all possible stereoisomers which possess inhibitory activity against an MMP, regardless of their stereoisomeric designations, as well as mixtures of stereoisomers in which at least one member possesses inhibitory activity.
[0097] The most prefered compounds of the present invention are as indicated and named in the list below:
[0098] I) 2-[(4′-chloro[1,1′-biphenyl]4-yl)carbonyl]-5-[(4-oxo-1,2,3-benzotriazin-3(4H)-yl)methyl]-cyclopentanecarboxylic acid,
[0099] II) 2-[(4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[phenoxymethoxymethyl]-cyclopentanecarboxylic acid,
[0100] III) 2-[4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[[(1-pyrrolidinylthioxomethyl)thio]methyl]-cyclopentanecarboxylic acid,
[0101] IV) 2-[(4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[(1,1-dioxido-3-oxo-1,2-benzisothiazol-2(3H)-yl)methyl]-cyclopentanecarboxylic acid,
[0102] V) 2-[(4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[1-oxo-2(1H)-phthalazinyl)methyl]-cyclopentanecarboxylic acid,
[0103] VI) 2-[4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[(2-oxo-3(2H)-benzoxazolyl)methyl]-cyclopentanecarboxylic acid,
[0104] VII) 2-[(4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[5,5-dimethyl-2,4-dioxo-3-oxazolidinyl-methyl]-cyclopentanecarboxylic acid,
[0105] VIII) 2-[(4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[(2,4-dioxo-3-thiazolidinyl)methyl]-cyclopentanecarboxylic acid,
[0106] IX) 2-[(4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[2,4,5-trioxo-1-imidazolidinyl)methyl]-cyclopentanecarboxyl acid
[0107] X) 2-[(4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[(3,6-dihydro-2,6-dioxo-1(2H)-pyrimidinyl)methyl]-cyclopentanecarboxylic acid,
[0108] XI) 2-[(4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[3,4-dihydro-2,4-dioxo-1(2H)-pyrimidinyl)methyl]-cyclopentanecarboxylic acid,
[0109] XII) 2-[(4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[(1,4-dihydro-2,4-dioxo-3(2H)-quinazolinyl)methyl]-cyclopentanecarboxylic acid,
[0110] XIII) 2-[(4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[3,4-dihydro-1,3-dioxo-2(1H)-isoquinolinyl)methyl]-cyclopentanecarboxylic acid,
[0111] XIV) 2-[(4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[(1,4-dihydro-4-oxo-3(2H)-quinazolinyl)methyl]-cyclopentanecarboxylic acid,
[0112] XV) 2-[4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[(1,3-dihydro-3-oxo-2H)-indazol-2-yl)methyl]-cyclopentanecarboxylic acid,
[0113] XVI) 2-[(4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[2,3-dihydro-1H-benzimidazol-1-yl)methyl]-cyclopentanecarboxylic acid,
[0114] XVII) 2-[(4′-chloro[1,1′-biphenyl]-4-yl)carbonyl]-5-[(3,4-dihydro-1,4-dioxo-2(1H)-phthalazinyl)methyl]-cyclopentanecarboxylic acid,
[0115] XVIII) R/S α-[2-(4′-chloro[1,1′-biphenyl]-4-yl)-2-oxoethyl]-1-oxo-2(1H)-phthalazinebutanoic acid,
[0116] XIX) R-α-[2-(4′-chloro[1,1′-biphenyl]-4-yl)-2-oxoethyl]-1-oxo-2(1H)-phthalazinebutanoic acid,
[0117] XX) S-α-[2-(4′-chloro[1,1′-biphenyl]-4-yl)-2-oxoethyl]-1-oxo-2(1H)-phthalazinebutanoic acid,
[0118] XXI) α-[2-(4′-chloro[1,1′-biphenyl]-4-yl)-2-oxoethyl]-4-oxo-1,2,3,-Benzotriazine-3(4H)-butanoic acid, and
[0119] XXII) α-[2-(4′-chloro[1,1′-biphenyl]-4-yl)-2-oxoethyl]-2,3-dihydro-5-methyl-2-oxo-1H-1,4-benzodiazepine-1-butanoic acid.
[0120] General Preparative Methods:
[0121] The compounds of the invention may be prepared readily by use of known chemical reactions and procedures. Nevertheless, the following general preparative methods are presented to aid the reader in synthesizing the inhibitors, with more detailed particular examples being presented below in the experimental section describing the working examples. All variable groups of these methods are as described in the generic description if they are not specifically defined below. The variable subscript n is independently defined for each method. When a variable group with a given symbol (i.e R 9 ) is used more than once in a given structure, it is to be understood that each of these groups may be independently varied within the range of definitions for that symbol.
[0122] General Method A—The compounds of this invention in which the rings A and B are substituted phenyl and phenylene respectively are conveniently prepared by use of a Friedel-Crafts reaction of a substituted biphenyl MII with an activated acyl-containing intermediate such as the succinic or glutaric anhydride derivative MIII or acid chloride MIV in the presence of a Lewis acid catalyst such as aluminum trichloride in an aprotic solvent such as 1,1,2,2-tetrachloroethane. The well known Friedel-Crafts reaction can be accomplished with use of many alternative solvents and acid catalysts as described by Berliner, Org. React., 5, 229, 1949 and Heaney, Comp. Org. Synth. 2, 733, 1991.
[0123] If the anhydride MIII is monosubstituted or multiply-substituted in an unsymmetrical way, the raw product MI-A often exists as a mixture of isomers via attack of the anhydride from either of the two carbonyls. The resultant isomers can be separated into pure forms by crystallization or chromatography using standard methods known to those skilled in the art.
[0124] When they are not commercially available, the succinic anhydrides MIE can be prepared via a Stobbe Condensation of a dialkyl succinate with an aldehyde or ketone (resulting in side chain R 6 ), followed by catalytic hydrogenation, hydrolysis of a hemiester intermediate to a diacid, and then conversion to the anhydride MIII by reaction with acetyl chloride or acetic anhydride. Alternatively, the hemiester intermediate is converted by treatment with thionyl chloride or oxalyl chloride to the acid chloride MIV. For a review of the Stobbe condensation, including lists of suitable solvents and bases see Johnson and Daub, Org. React., 6, 1,1951.
[0125] This method, as applied to the preparation of MIII (R 6 ═H, isobutyl and H, n-pentyl), has been described Wolanin, et al., U.S. Pat. No. 4,771,038.
[0126] Method A is especially useful for the preparation of cyclic compounds such as MI-A-3, in which two R 6 groups are connected in a methylene chain to form a 3-7 member ring. Small ring (3-5 member) anhydrides are readily available only as cis isomers which yield cis invention compounds MI-A-3. The trans compounds MI-A-4 are then prepared by treatment of MI-A-3 with a base such as DBU in THF. The substituted four member ring starting material anhydrides such as MIII-A-1 are formed in a photochemical 2+2 reaction as shown below. This method is especially useful for the preparation of compounds in which R 14 is acetoxy or acetoxymethylene. After the subsequent Friedel-Crafts reaction the acetate can be removed by basic hydrolysis and the carboxyl protected by conversion to 2-(trimethylsilyl)ethyl ester. The resultant intermediate with R 14 ═CH 2 OH can be converted to invention compounds with other R 14 groups by using procedures described in General Method G.
[0127] The Friedel-Crafts method is also useful when double bonds are found either between C-2 and C-3 of a succinoyl chain (from maleic anhydride or 1-cyclopentene-1,2-dicarboxylic anhydride, for example) or when a double bond is found in a side chain, such as in the use of itaconic anhydride as starting material to yield products in which two R 6 groups are found on one chain carbon together to form an exo-methylene (═CH 2 ) group. Subsequent uses of these compounds are described in Methods D.
[0128] General Method B—Alternatively the compounds MI can be prepared via a reaction sequence involving mono-alkylation of a dialkyl malonate MVI with an alkyl halide to form intermediate MVII, followed by alkylation with a halomethyl biphenyl ketone MVIII to yield intermediate MIX. Compounds of structure MIX are then hydrolyzed with aqueous base and heated to decarboxylate the malonic acid intermediate and yield MI-B-2 (Method B-1). By using one equivalent of aqueous base the esters MI-B-2 with R 12 as alkyl are obtained, and using more than two equivalents of base the acid compounds (R 12 ═H) are obtained. Optionally, heat is not used and the diacid or acid-ester MI-B-1 is obtained.
[0129] Alternatively, the diester intermediate MIX can be heated with a strong acids such as concentrated hydrochloric acid in acetic acid in a sealed tube at about 110° C. for about 24 hr to yield MI-B-1 (R 12 ═H). Alternatively, the reaction of MVI with MVIII can be conducted before that with the alkyl halide to yield the same ME (Method B-2).
[0130] Alternatively, a diester intermediate MXIX, which contains R 12 =allyl, can be exposed to Pd catalysts in the presence of pyrrolidine to yield MI-B-2 (R 12 ═H) (Dezeil, Tetrahedron Lett. 28, 4371, 1990.
[0131] Intermediates MVII are formed from biphenyls ME in a Friedel-Craft reaction with haloacetyl halides such as bromoacetyl bromide or chloroacetyl chloride. Alternatively, the biphenyl can be reacted with acetyl chloride or acetic anhydride and the resultant product halogenated with, for example, bromine to yield intermediates MVIII (X═Br).
[0132] Method B has the advantage of yielding single regio isomers when Method A yields mixtures. Method B is especially useful when the side chains R 6 contain aromatic or heteroaromatic rings that may participate in intramolecular acylation reactions to give side products if Method A were to be used. This method is also very useful when the R 6 group adjacent to the carboxyl of the final compound contains heteroatoms such as oxygen, sulfur, or nitrogen, or more complex functions such as imide rings.
[0133] When R 6 contains selected functional groups Z, malonate MVII can be prepared by alkylating a commercially available unsubstituted malonate with prenyl or allyl halide, subject this product to ozonalysis with reductive work-up, and the desired z group can be coupled via a Mitsunobu reaction (Mitsunobu, Synthesis 1, 1981). Alternatively, the intermediate alcohol can be subjected to alkylation conditions to provide malonate MVII containing the desired Z group.
[0134] General Method C—Especially useful is the use of chiral HPLC to separate the enantiomers of racemic product mixtures (see, for example, Arit, et al., Chem. Int. Ed. Engl. 12, 30 (1991)). The compounds of this invention can be prepared as pure enantiomers by use of a chiral auxiliary route. See, for example, Evans, Aldrichimica Acta, 15(2), 23, 1982 and other similar references known to one skilled in the art.
[0135] General Method D—Compounds in which R 6 are alkyl- or aryl- or heteroaryl- or acyl- or heteroarylcarbonyl-thiomethylene are prepared by methods analogous to those described in the patent WO 90/05719. Thus substituted itaconic anhydride MXVI (n=1) is reacted under Friedel-Crafts conditions to yield acid MI-D-1 which can be separated by chromatography or crystallization from small amounts of isomeric MI-D-5. Alternatively, MI-D-5s are obtained by reaction of invention compounds MI-D-4 (from any of Methods A through C) with formaldehyde in the presence of base.
[0136] Compounds MI-D-1 or MI-D-5 are then reacted with a mercapto derivative MXVII or MXVIII in the presence of catalyst such as potassium carbonate, ethylduisobutylarnine, tetrabutylammonium fluoride or free radical initiators such as azobisisobutyronitrile (AIBN) in a solvent such as diethylformamide or tetrahydrofuran to yield invention compounds MI-D-2, MI-D-3, MI-D-6, or MI-D-7.
[0137] General Method E—Biaryl compounds such as those of this application may also be prepared by Suzuki or Stille cross-coupling reactions of aryl or heteroaryl metallic compounds in which the metal is zinc, tin, magnesium, lithium, boron, silicon, copper, cadmium or the like with an aryl or heteroaryl halide or triflate (trifluoromethane-sulfonate) or the like. In the equation below either Met or X is the metal and the other is the halide or triflate (OTf). Pd(com) is a soluble complex of palladium such as tetrakis(triphenylphosphine)-palladium(O) or bis-(triphenylphosphine)-palladium(III)chloride. These methods are well known to those skilied in the art. See, for example, Suzuki, Pure Appi. Chem. 63, 213 (1994); Suzuki, Pure Appl. Chem. 63, 419 (1991); and Farina and Roth, “Metal-Organic Chemistry” Volume 5 (Chapter 1), 1994.
[0138] The starting materials MXXIII (B=1,4-phenylene) are readily formed using methods analogous to those of methods A, B, C, or D but using a halobenzene rather than a biphenyl as starting material. When desired, the materials in which X is halo can be converted to those in which X is metal by reactions well known to those skilled in the art, such as treatment of a bromo intermediate with hexamethylditin and palladium tetrakistriphenylphosphine in toluene at reflux to yield the trimethyltin intermediate. The starting materials MXXIII (B=heteroaryl) are most conveniently prepared by method C but using readily available heteroaryl rather than biphenyl starting materials. The intermediates MXXII are either commercial or easily prepared from commercial materials by methods well known to those skilled in the art.
[0139] These general methods are useful for the preparation of compounds for which Friedel-Crafts reactions such as those of Methods A, B, C, or D would lead to mixtures with various biaryl acylation patterns. Method E is also especially useful for the preparation of products in which the aryl groups, A or B, contain one or more heteroatoms (heteroaryls) such as those compounds that contain thiophene, furan, pyridine, pyrrole, oxazole, thiazole, pyrimidine or pyrazine rings or the like instead of phenyls.
[0140] General Method F—When the R 6 groups of method F form together a 4-7 member carbocyclic ring as in Intermediate MXXV below, the double bond can be moved out of conjugation with the ketone group by treatment with two equivalents of a strong base such as lithium diisopropylamide or lithium hexamethylsilylamide or the like followed by acid quench to yield compounds with the structure MXXVI. Reaction of MXXVI with mercapto derivatives using methods analogous to those of General Method D then leads to cyclic compounds MI-F-1 or MI-F-2.
[0141] General Method G—The compounds of this invention in which two R 6 groups are joined to form a substituted 5-member ring are most conveniently prepared by method G. In this method acid CLII (R═H) is prepared using the protocols described in Tetrahedron 37, Suppl., 411 (1981). The acid is protected as an ester [eg. R=benzyl (Bn) or 2-(trimethylsilyl)ethyl (TMSE)] by use of coupling agents such as 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride and procedures well known to those skilled in the art. Substituted bromobiphenyl CIII is converted to its Grignard reagent by treatment with magnesium and reacted with CLII to yield alcohol CVI. Alcohol CVI is eliminated via base treatment of its mesylate by using conditions well known to those skilled in the art to yield olefin CVII. Alternatively CIII is converted to a trimethyltin intermediate via initial metallation of the bromide with n-butyllithium at low temperature (−78° C.) followed by treatment with chlorotrimethyltin and CI is converted to an enoltriflate (CII) by reaction with 2-[N,N-bis(trifluoromethylsulfonyl)amino]-5-chloropyridine in the presence of a strong aprotic base. The tin and enoltriflate intermediates are then coupled in the presence of a Pd 0 catalyst, CuI and AsPh 3 to yield directly intermediate CVII. Ozonolysis of CVII (workup with methylsufide) yields aldehyde CVIII. Alternatively treatment with OsO 4 followed by HIO 4 converts CVII to CVIII.
[0142] Conversion of key intermediate CVIII to the targeted patent compounds is accomplished in several ways depending on the identity of side chain function Z. Reaction of CVIII with Wittig reagents followed by hydrogenation yields products in which Z is alkyl and or arylalkyl. Selective reduction of aldehyde CVIII with a reducing agent such as lithium tris [(3-ethyl-3pentyl)oxy]aluminum hydride (LTEPA) yields alcohol CIX. The alcohol is converted to phenyl ethers or a variety of heteroatom substituted derivatives used to generate sidechain Z via the Mitsunobu reaction using conditions well known to those skilled in the art (see Mitsunobu, Synthesis, 1 (1981)). Alternatively the alcohol of CIX is converted to a leaving group such as tosylate (CX) or bromide by conditions well known to those skilled in the art and then the leaving group is displaced by an appropriate nucleophile. Several examples of this type of reaction can be found in Norman, et al., J. Med. Chem. 37, 2552 (1994). Direct acylation of the alcohol CIX yields invention compounds in which Z=OAcyl and reaction of the alcohol with various alkyl halides in the presence of base yields alkyl ethers. In each case a final step is removal of acid blocking group R to yield acids (R═H) by using conditions which depend on the stability of R and Z, but in all cases well known to those skilled in the art such as removal of benzyl by base hydrolysis or of 2-(trimethylsilyl)ethyl by treatment with tetrabutylammonium fluoride.
[0143] General Method H—Amides of the acids of the invention compounds can be prepared from the acids by treatment in an appropriate solvent such as dichloromethane or dimethylformamide with a primary or secondary amine and a coupling agent such as dicyclohexylcarbodiimide. These reactions are well known to those skilled in the art. The amine component can be simple alkyl or arylalkyl substituted or can be amino acid derivatives in which the carboxyl is blocked and the amino group is free.
[0144] General Method I—The compounds of this invention in which (T) x is an alkynyl or substituted alkynyl are prepared according to general method I (Austin, J. Org. Chem. 46, 2280 (1981)). Intermediate MX is prepared according to methods A, B, C, D or G by starting with commercial MIII (R 1 ═Br). Reaction of M with substituted acetylene MXI in the presence of Cu(I)/palladate reagent gives invention compound MI-I-1. In certain cases, R 3 may be an alcohol blocked as trialkylsilyl. In such cases the silyl group can be removed by treatment with acids such as trifluoroacetic acid or HF—pyridine reagent.
[0145] Suitable pharmaceutically acceptable salts of the compounds of the present invention include addition salts formed with organic or inorganic bases. The salt forming ion derived from such bases can be metal ions, e.g., aluminum, alkali metal ions, such as sodium of potassium, alkaline earth metal ions such as calcium or magnesium, or an amine salt ion, of which a number are known for this purpose. Examples include ammonium salts, arylalkylamines such as dibenzylamine and N,N-dibenzylethylenediamine, lower alkylamines such as methylamine, t-butylamine, procaine, lower alkylpiperidines such as N-ethylpiperidine, cycloalkylamines such as cyclohexylamine or dicyclohexylarnine, 1-adamantylamine, benzathine, or salts derived from amino acids like arginine, lysine or the like. The physiologically acceptable salts such as the sodium or potassium salts and the amino acid salts can be used medicinally as described below and are preferred.
[0146] These and other salts which are not necessarily physiologically acceptable are useful in isolating or purifying a product acceptable for the purposes described below. For example, the use of commercially available enantiomerically pure amines such as (+)-cinchonine in suitable solvents can yield salt crystals of a single enatiomer of the invention compounds, leaving the opposite enantiomer in solution in a process often referred to as “classical resolution.” As one enantiomer of a given invention compound is usually substantially greater in physiological effect than its antipode, this active isomer can thus be found purified in either the crystals or the liquid phase. The salts are produced by reacting the acid form of the invention compound with an equivalent of the base supplying the desired basic ion in a medium in which the salt precipitates or in aqueous medium and then lyophilizing. The free acid form can be obtained from the salt by conventional neutralization techniques, e.g., with potassium bisulfate, hydrochloric acid, etc.
[0147] The compounds of the present invention have been found to inhibit the matrix metalloproteases MMP-3, MMP-9 and MMP-2, and to a lesser extent MMP-1, and are therefore useful for treating or preventing the conditions referred to in the background section. As other MMPs not listed above share a high degree of homology with those listed above, especially in the catalytic site, it is deemed that compounds of the invention should also inhibit such other MMPs to varying degrees. Varying the substituents on the biaryl portions of the molecules, as well as those of the propanoic or butanoic acid chains of the claimed compounds, has been demonstrated to affect the relative inhibition of the listed MMPs. Thus compounds of this general class can be “tuned” by selecting specific substituents such that inhibition of specific MMP(s) associated with specific pathological conditions can be enhanced while leaving non-involved MMPs less affected.
[0148] The method of treating matrix metalloprotease-mediated conditions may be practiced in mammals, including humans, which exhibit such conditions.
[0149] The inhibitors of the present invention are contemplated for use in veterinary and human applications. For such purposes, they will be employed in pharmaceutical compositions containing active ingredient(s) plus one or more pharmaceutically acceptable carriers, diluents, fillers, binders, and other excipients, depending on the administration mode and dosage form contemplated.
[0150] Administration of the inhibitors may be by any suitable mode known to those skilled in the art. Examples of suitable parenteral administration include intravenous, intraarticular, subcutaneous and intramuscular routes. Intravenous administration can be used to obtain acute regulation of peak plasma concentrations of the drug. Improved half-life and targeting of the drug to the joint cavities may be aided by entrapment of the drug in liposomes. It may be possible to improve the selectivity of liposomal targeting to the joint cavities by incorporation of ligands into the outside of the liposomes that bind to synovial-specific macromolecules. Alternatively intramuscular, intraarticular or subcutaneous depot injection with or without encapsulation of the drug into degradable microspheres e.g., comprising poly(DL-lactide-co-glycolide) may be used to obtain prolonged sustained drug release. For improved convenience of the dosage form it may be possible to use an i.p. implanted reservoir and septum such as the Percuseal system available from Pharmacia. Improved convenience and patient compliance may also be achieved by the use of either injector pens (e.g. the Novo Pin or Q-pen) or needle-free jet injectors (e.g. from Bioject, Mediject or Becton Dickinson). Prolonged zero-order or other precisely controlled release such as pulsatile release can also be achieved as needed using implantable pumps with delivery of the drug through a cannula into the synovial spaces. Examples include the subcutaneously implanted osmotic pumps available from ALZA, such as the ALZET osmotic pump.
[0151] Nasal delivery may be achieved by incorporation of the drug into bioadhesive particulate carriers (<200 μm) such as those comprising cellulose, polyacrylate or polycarbophil, in conjunction with suitable absorption enhancers such as phospholipids or acylcarnitines. Available systems include those developed by DanBiosys and Scios Nova.
[0152] A noteworthy attribute of the compounds of the present invention in contrast to those of various peptidic compounds referenced in the background section of this application is the demonstrated oral activity of the present compounds. Certain compounds have shown oral bioavailability in various animal models of up to 90-98%. Oral delivery may be achieved by incorporation of the drug into tablets, coated tablets, dragees, hard and soft gelatine capsules, solutions, emulsions or suspensions. Oral delivery may also be achieved by incorporation of the drug into enteric coated capsules designed to release the drug into the colon where digestive protease activity is low. Examples include the OROS-CT/Osmet™ and PULSINCAP™ systems from ALZA and Scherer Drug Delivery Systems respectively. Other systems use azo-crosslinked polymers that are degraded by colon specific bacterial azoreductases, or pH sensitive polyacrylate polymers that are activated by the rise in pH at the colon. The above systems may be used in conjunction with a wide range of available absorption enhancers.
[0153] Rectal delivery may be achieved by incorporation of the drug into suppositories.
[0154] The compounds of this invention can be manufactured into the above listed formulations by the addition of various therapeutically inert, inorganic or organic carriers well known to those skilled in the art. Examples of these include, but are not limited to, lactose, corn starch or derivatives thereof, talc, vegetable oils, waxes, fats, polyols such as polyethylene glycol, water, saccharose, alcohols, glycerin and the like. Various preservatives, emulsifiers, dispersants, flavorants, wetting agents, antioxidants, sweeteners, colorants, stabilizers, salts, buffers and the like are also added, as required to assist in the stabilization of the formulation or to assist in increasing bioavailability of the active ingredient(s) or to yield a formulation of acceptable flavor or odor in the case of oral dosing.
[0155] The amount of the pharmaceutical composition to be employed will depend on the recipient and the condition being treated. The requisite amount may be determined without undue experimentation by protocols known to those skilled in the art. Alternatively, the requisite amount may be calculated, based on a determination of the amount of target enzyme which must be inhibited in order to treat the condition.
[0156] The matrix metalloprotease inhibitors of the invention are useful not only for treatment of the physiological conditions discussed above, but are also useful in such activities as purification of metalloproteases and testing for matrix metalloprotease activity. Such activity testing can be both in vitro using natural or synthetic enzyme preparations or in vivo using, for example, animal models in which abnormal destructive enzyme levels are found spontaneously (use of genetically mutated or transgenic animals) or are induced by administration of exogenous agents or by surgery which disrupts joint stability.
[0157] Experimental:
[0158] General Procedures:
[0159] All reactions were performed in flamne-dried or oven-dried glassware under a positive pressure of argon and were stirred magnetically unless otherwise indicated. Sensitive liquids and solutions were transferred via syringe or cannula and were introduced into reaction vessels through rubber septa. Reaction product solutions were concentrated using a Buchi evaporator unless otherwise indicated.
[0160] Materials:
[0161] Commercial grade reagents and solvents were used without further purification except that diethyl ether and tetrahydrofuran were usually distilled under argon from benzophenone ketyl, and methylene chloride was distilled under argon from calcium hydride. Many of the specialty organic or organometallic starting materials and reagents were obtained from Aldrich, 1001 West Saint Paul Avenue, Milwaukee, Wis. 53233. Solvents are often obtained from EM Science as distributed by VWR Scientific.
[0162] Chromatography:
[0163] Analytical thin-layer chromatography (TLC) was performed on Whatman® pre-coated glass-backed silica gel 60 A F-254 250 μm plates. Visualization of spots was effected by one of the following techniques: (a) ultraviolet illumination, (b) exposure to iodine vapor, (c) immersion of the plate in a 10% solution of phosphomolybdic acid in ethanol followed by heating, and (d) immersion of the plate in a 3% solution of p-anisaldehyde in ethanol containing 0.5% concentrated sulfuric acid followed by heating, and e) immersion of the plate in a 5% solution of potassium permanganate in water containing 5% sodium carbonate followed by heating.
[0164] Column chromatography was performed using 230-400 mesh EM Science® silica gel.
[0165] Analytical high performance liquid chromatography (HPLC) was performed at 1 mL min −1 on a 4.6×250 mm Microsorb® column monitored at 288 nm, and semi-preparative HPLC was performed at 24 mL min −1 on a 21.4×250 mm Microsorb® column monitored at 288 mm.
[0166] Instrumentation:
[0167] Melting points (mp) were determined with a Thomas-Hoover melting point apparatus and are uncorrected.
[0168] Proton ( 1 H) nuclear magnetic resonance (NMR) spectra were measured with a General Electric GN-OMEGA 300 (300 MHz) spectrometer, and carbon thirteen ( 13 C) NMR spectra were measured with a General Electric GN-OMEGA 300 (75 MHz) spectrometer. Most of the compounds synthesized in the experiments below were analyzed by NMR, and the spectra were consistent with the proposed structures in each case.
[0169] Mass spectral (MS) data were obtained on a Kratos Concept 1-H spectrometer by liquid-cesium secondary ion (LCIMS), an updated version of fast atom bombardment (FAB). Most of the compounds systhesized in the experiments below were analyzed by mass spectroscopy, and the spectra were consistent with the proposed structures in each case.
[0170] General Comments:
[0171] For multi-step procedures, sequential steps are noted by numbers. Variations within steps are noted by letters. Dashed lines in tabular data indicates point of attachment.
EXAMPLE 1
Preparation of Compound I
[0172] [0172]
[0173] Step 1. A solution of exo-oxobicyclo [2.2.1]heptane-7-carboxylic acid [prepared using the protocols described in Author, Tetrahedron, 37, suppl., 411, 1981 (3.04 g, 19.7 mmol) in CH 2 Cl 2 (45 mL) was cooled to 0° C. and treated with 2-(trimethylsilyl) ethanol (2.7 mL 18.6 mmol), EDC (3.94 g, 20.55 mmol) and DMAP (0.11 g, 0.9 mmol). After warming to room temperature and stirring for 2 hrs., the reaction mixture was quenched with water and diluted with CH 2 Cl 2 . After separating the layers, the organic phase was washed with satd. aq. NaCl, dried over MgSO 4 and concentrated. Purification by MPLC (0-25% EtOAc-hexanes) provided the target compound (3.9 g, 78%) as a colorless oil. 1 H NMR (CDCl 3 ) δ 4.18 (m, 2H), 2.88 (m, 2H), 2.76 (m, 1H), 2.05 (m, 4H), 1.50 (m, 2H), 0.99 (t, J=8.4 Hz, 2H), 0.99 (s, 9H).
[0174] Step 2. A solution of the ketone from step 1 (3.18 g, 12.50 mmol) and 2-[N,N-bis(trifluoromethylsulfonyl)amino]-5-chloropyridine (6.6 g, 16.30 mmol) in THF was cooled to −78° C. and carefully treated with a 0.5M solution of KHMDS in toluene (24 mL, 12 mmol). After the addition was complete and the solution stirred for 2 h, the reaction mixture was quenched with water (30 mL), warmed to room temperature and diluted with EtOAc. The two phases were the separated. The organic layer was washed with satd. aq. NaCl, dried over MgSO 4 and concentrated. Purification by MPLC (0-15% EtOAc-hexanes) provided the target compound (4.2 g, 91%) as a colorless oil. 1 H NMR (CDCl 3 ) δ 5.75 (d, J=4.8 Hz, 1H), 4.13 (t, J=9.0 Hz, 2H), 3.18 (m, 2H), 2.62 (m, 1H), 2.62 (m, 2H), 1.41 (t, J=9.3 Hz, 1H), 1.23 (t, J=9.1 Hz, 1H), 0.96 (t, J=8.4 Hz, 2H), 0.04 (s, 9H).
[0175] Step 3. A solution of 4-chlorobiphenyl (3.0 g, 15.9 mmol) in acetic acid (50 mL) was carefully treated with bromine (1.1 mL, 20.7 mmol) at room temperature. The reaction mixture was heated to reflux for 4 h, cooled to room temperature and treated with excess propene until the mixture became clear. The solution was concentrated to a thick slurry, diluted with CH 2 Cl 2 (50 mL) and washed successively with water and 2N NaOH. The organic extract was dried over MgSO 4 , filtered and concentrated. Purification by re-crystallization form EtOAc gave the aryl bromide (3.57 g, 84%) as a white crystalline solid. 1 H NMR (CDCl 3 ) δ 7.57 (m, 2H), 7.48 (m, 2H), 7.41 (m, 4H).
[0176] Step 4. A solution of 4-bromo-4′-chlorobiphenyl (8.0 g, 30.0 mmol) in THF (120 mL) was cooled to −78° C. and carefully treated with n-BuLi (19.7 mL, 1.6 M solution in hexanes, 31.5 mmol). After stirring for 1 h, the mixture was treated with chlorotrimethyltin (33 mL, 1.0 M soln., 33.0 rnmol). After an additional 30 min., the solution was warmed to room temperature and concnetrated. The off-white solid was diluted with CH 2 Cl 2 (300 mL) and washed successively with water and satd. aq. NaCl. The organic layer was dried over MgSO 4 , filtered and concentrated. Purification by MPLC (hexanes) gave the desired aryltin compound (9.38 g, 89%) as a white crystalline solid. 1 H NMR (CDCl 3 ) δ 7.62 (m, 6H), 7.54 (m, 2H), 0.39 (s, 9H).
[0177] Step 5. A solution of the triflate from step 2 (4.2 g, 10.89 mmol), CuI (0.215 g, 1.1 mmol), AsPh 3 (0.339 g, 1.1 mmol), Cl 2 Pd(MeCN) 2 (0.215 g, 0.56 mmol) and a few crystals of BHT in 1-methyl-2-pyrrolidinone (11.5 mL) was lowered into an oil bath preheated to 85° C. After stirring 4 min., the biphenyltin derivative from step 4 (7.3 g, 20.7 mmol) was added in one portion. The mixture was stirred for 30 min., cooled to room temperature and diluted with EtOAc. After separating the phases, the aq. layer was back extracted with EtOAc and the combined organic layers dried over MgSO 4 , filtered and concentrated. The resulting residue was adsorbed on silica gel and purified by MPLC (0-15% EtOAc-hexanes) to give the coupled product (4.0 g, 86%) as a white crystalline solid. 1 H NMR (CDCl 3 ) δ 7.52 (m, 6H), 7.42 (m, 2H), 6.40 (d, J=3.3 Hz, 1H), 4.19 (t, J=10.2 Hz, 2H), 3.58 (m, 1H), 3.23 (m, 1H), 2.60 (m, 1H), 1.95 (m, 2H), 1.20 (m, 2H), 1.02 (d, J=7.5 Hz, 2H), 0.08 (s, 9H).
[0178] Step 6. A solution of the olefin from step 5 (3.60 g, 8.47 mmol) in 10% MeOH—CH 2 Cl 2 (200 mL) was cooled to −78° C. and treated with ozone as a gas added directly into the reaction mixture (10 min., 1 L/min.). After TLC indicated the absence of starting material the solution was purged with argon (15 min.), treated with methylsulfide (13 mL) and warmed to room temperature. After stirring overnight, the solution was concentrated to a residue which was purified by MPLC (0-15% EtOAc-hexanes) to give a mixture of the desired aldehyde and corresponding dimethyl acetal. The product mixture was dissolved in acetone (45 mL) and treated with CSA (0.192 g, 0.83 mmol) and water (0.13 mL, 16.5 mmol). After stirring overnight, the solution was concentrated and purified by MPLC (0-15% EtOAc-hexanes) to give the desired aldehyde (3.45 g, 89%) as a colorless oil.
[0179] NMR (CDCI 3 ) δ 9.78 (d, J=9.0 Hz, 1H), 8.05 (d, J=6.6 Hz, 2H), 7.65 (d, J=6.6 Hz, 2H), 7.55 (d, J=9.0 Hz, 2H), 7.44 (d, J=9.0 Hz, 2H), 4.15 (m, 3H), 3.87 (t, J=7.21 Hz, 1H), 3.15 (m, 1H), 2.20 (m, 1H), 2.03 (m, 1H), 1.86 (m, 1H), 1.58 (s, 1H), 1.25 (t, J=6.9 Hz, 1H), 0.93 (m, 2H), 0.00 (s, 9H).
[0180] Step 7. A solution of lithium aluminum hydride (1.9 mL, 1.0 M THF) in THF (6 mL) was treated with 3-ethyl-3-pentanol (0.83 g, 5.77 mmol) and heated to a gentle reflux for 1 h. The mixture was then cooled to room temperature.
[0181] A solution of the aldehyde intermediate from step 6 (0.85 g, 1.86 mmol) in THF (15 mL) was cooled to −78° C. and treated with the previously prepared solution of LTEPA in THF via cannula in a dropwise manner. After the addition was complete, the solution was stirred at −78° C. for 4 h and subsequently quenched with 2N HCl (4.6 mL). The reaction mixture was diluted with EtOAc and washed with water. The organic layer was dried over MgSO 4 , filtered and concentrated. Purification by MPLC (5-40% EtOAc-hexanes) afforded the desired aldehyde (0.640 g, 75%) as a white crystalline solid. 1 H NMR (CDCl 3 ) δ 8.05 (d, J=8.7 Hz, 2H), 7.65 (d, J=8.5 Hz, 2H), 7.55 (d, J=8.4 Hz, 2H), 7.44 (d, J=8.4 Hz, 2H), 4.15 (m, 2H), 3.76 (t, J=6.3 Hz, 2H), 3.28 (t, J=6.3 Hz, 2H), 2.48 (m, 1H), 2.35 (t, J=6.0 Hz, 1H), 2.18 (m, 1H), 1.91 (m, 2H), 1.57 (s, 1H), 1.35 (t, J=6.9 Hz, 1H), 0.91 (m, 2H), −0.01 (s, 9H).
[0182] Step 8. A solution of the alcohol from step 7 (0.050 g, 0.109 mmol), triphenylphosphine (0.057 g, 0.217 mmol) and benzo-1,2,3-triazin4(3H)-one (0.034 g, 0.231 mmol) in THF (2.5 mL) was treated with diethyl azodicarboxylate (0.035 mL, 0.222 mmol). The mixture was stirred at room temperature for 16 hrs., concentrated under reduced pressure and purified by MPLC (0-20% EtOAc-hexanes) to give the target compound (0.034 g, 53%). TLC: R f 0.16 (silica, 20% EtOAc-hexanes).
[0183] Step 9. A solution of the ester from step 8 (0.031 g, 0.052 mmol) in CH 2 Cl 2 (2 mL) was cooled to 0° C. and treated with TFA (0.25 mL). After stirring for 5 h, the solution was concentrated under reduced pressure and purified via flash colurin chromatography (0-5% MeOH—CH 2 Cl 2 ) to give the desired acid (0.023 g, 90%) as a white crystalline solid. MP 198-199° C.
EXAMPLE 2
Preparation of Compound II
[0184] [0184]
[0185] Step 1. The benzyl ester was prepared in a manner analogous to the one described for the corresponding 2-trimethylsilyl ester intermediate (example 1, steps 1-7). In this case, benzyl alcohol was used instead of 2-trmethylsilylethanol in step 1.
[0186] Step 2. A solution of the intermediate from step 1 (0.020 g, 0.045 mmol) and diisopropylethylamine (0.025 mL, 0.144 mmol) in CH 2 Cl 2 (1.5 mL) was treated with benzyl chloromethylether (0.016 mL, 0.099 mmol) and stirred at room temperature for 6 h. Purification of the concentrated reaction mixture, by flash column chromatography (5-20% EtOAc-hexanes) provided the desired ether (0.022 g, 86%). TLC: R f 0.25 (silica, 20% EtOAc-hexanes).
[0187] Step 3. A solution of the intermediate benzyl ester from step 2 (0.020 g, 0.035 mmol) in THF (0.4 mL) and ethanol (0.4 mL) was treated with NaOH solution (0.14 mL, 0.5 g/10 mL water). After stirring for 45 min. At room temperature, the mixture was diluted with EtOAc and quenched with 2N HCl (0.2 ml). The organic layer was washed with satd. aq. NaCl, dried over MgSO 4 and concentrated to give the desired acid (0.012 g, 72%). MP 112-113° C.
EXAMPLE 3
Preparation of Compound III
[0188] [0188]
[0189] Step 1. A solution of the alcohol from example 2, step 1 (0.100 g, 0.223 mmol) and diisopropylethylamine (0.05 mL, 0.287 mmol) in CH 2 Cl 2 (3.0 mL) was treated with p-toluenesulfonyl chloride (0.048 g, 0.249 mmol) and a crystal of DMAP. The mixture was stirred at room temperature for 16 hrs., concentrated under reduced pressure and purified by MPLC (0-20% EtOAc-hexanes) to give the desired tosylate (0.118 g, 88%). TLC: R f 0.23 (silica, 0-20% EtOAc-hexanes).
[0190] Step 2. A solution of the tosylate from step 1 (0.039 g, 0.066 mmol) and 18-crown-6 (0.044 g, 0.166 mmol) in DMF (0.7 mL) was treated with sodium pyrrolidine dithiocarbamate (0.035 g, 0.165 mmol) and stirred at room temperature for 16 h. The reaction mixture was diluted with EtOAc and water. After separating the phases, the organic layer was washed with satd. aq. NaCl, dried over MgSO 4 , filtered and concentrated. Purification by MPLC (3-15% EtOAc-hexanes) provided the desired product (0.038 g, 99%). TLC: R f 0.34 (silica, 0-20% EtOAc-hexanes).
[0191] Step 3. The deprotection of the benzyl ester intermediate from step 2 was accomplished using the same protocol as described for example 2 in step 3. MP 177-178° C.
[0192] The above methods for preparation of Examples 1-3 were, or could be used to prepare the series of biphenyl containing products found in Table 1.
TABLE 1 Example R 14 Isomer Characterization I R,S MP 198-199° C. II CH 2 OCH 2 OCH 2 Ph R,S MP 112-130° C. III R,S MP 177-178° C. IV R,S R f 0.33 (silica, 5% MeOH—CH 2 Cl 2) V R,S 219-220° C. VI R,S 207° C. VII R,S 210-211° C. VIII R,S 290-291° C. IX X XI XII XIII XIV XV XVI XVII
EXAMPLE 18
Preparation of Compound XVIII
[0193] [0193]
[0194] Step 1. A solution of pthlalazinone (1.00 g, 6.84 mmol), triphenylphosphine (1.79 g, 6.84 mmol) in THF (25 mL) was cooled to 0° C. and treated with 2-bromo ethanol (0.480 mL, 6.84 mmol) and diethyl azocarboxylate (1.07 mL, 6.84 mmol). After stirring 1 h at 0° C., the solution was warmed to room temperature and strirred for an additional 12 h. The resulting mixture was concentrated and purified by flash column chromatography (35% ethyl acetate-hexanes) to afford 1.40 g (81%) of bromo ethyl phthalazinone as a white solid. TLC: R f 0.65 (40% ethyl acetate-hexane).
[0195] Step 2. A solution of sodium hydride (0.040 g, 1.54 mmol) in THF (5 mL) was cooled to 0° C. and carefully treated with diallyl malonate (0.260 g, 1.41 mmol). After warming to room temperature and stirring for 20 min., bromo ethyl phthalazinone from step 1 (0.325 g, 1.28 mmol) was added in one portion and the mixture was heated to reflux for 18 h. The reaction mixture was diluted with saturated aq. NH 4 Cl (20 mL) and EtOAc (20 mL). The resulting organic phase was washed with water, dried over MgSO 4 , filtered, and concentrated to afford 0.240 g (52%) of a yellow oil. TLC: R f 0.60 (40% ethyl acetate-hexane).
[0196] Step 3. A 2 L, three-necked, round bottom flask was equipped with a mechanical stirrer, a thermometer and an argon inlet. The flask was charged with a solution of 4-chlorobiphenyl (48.30 g, 0.256 mol) in dichloromethane (500 mL). Bromoacetyl bromide (23 mL, 0.26 mol) was added via syringe and the solution was cooled with an ice bath to an internal temperature of 3° C. The thermometer was temporarily removed and AlCl 3 was added portionwise over 5 min. The internal temperature rose to 10° C. and white gas evolved from the opaque olive green reaction mixture. After 24 hrs. of stirring, the reaction was quenched by cautiously pouring into cold 10% HCl (1 L). The organic layer became cloudy yellow green. Chloroform was added to help dissolve the solids, but the organic layer never became transparent. The organics were concentrated on a rotary evaporator and dried further under vacuum. The crude product was a pale green solid (˜82 g) which was recrystallized from hot ethyl acetate to give 1-(2-bromoethanone)-4-(4-chlorophenyl)-benzene as brown needles (58.16 g). Concentration of the mother liquor followed by addition of hexanes delivered a second crop of crystals (11.06 g) which gave an NMR spectrum identical to that of the first crop. The total yield of the product was 87%. TLC: R f 0.30 (silica, 70% hexanes-dichlormethane).
[0197] Step 4. A solution of sodium hydride (0.020 g, 0.775 mmol) in THF (2.0 mL) was cooled to 0° C. and carefully treated with the diester from step 2. The ice bath was removed and the resulting mixture was stirred for 20 min. The reaction mixture was re-cooled to 0° C. and treated with 1-(2-bromoethanone)-4-(4-chlorophenyl)-benzene (0.200 g, 0.646 mmol) in one portion. The mixture was warmed to room temperature over 30 min and subsequently heated to reflux for 12 hrs. The reaction mixture was added to satd. aq. NH 4 Cl (10 mL) and diluted with EtOAc (10 mL). The resulting organic phase was washed with water (10 mL), dried over MgSO 4 , filtered and concentrated to afford 0.327 g (78%) of a yellow oil. TLC: R f 0.40 (silica, 40% ethyl acetate-hexane).
[0198] Step 5. A solution of the diester product from step 4 (0.327 g, 0.558 mmol) in 1,4 dioxane (5 mL) was treated with tetrakis(triphenylphosphine)palladium (0.006 g, 0.005 mmol) in one portion and pyrrolidone (0.102 mL, 1.22 mmol) added dropwise over 15 min. After stirring for 30 min. at room temperature, the reaction mixture was diluted with 1N HCl (20 mL) and EtOAc (20 mL). The resulting organic phase was washed with satd. aq. NaCl, dried over MgSO 4 , filtered, and concentrated to provide the diacid as a crude brown oil which was immediately carried on to step 6. TLC: R f 0.29 (silica, 5% methanol-methylene chloride).
[0199] Step 6. A solution of the diacid product from step 5 in 1,4 dioxane (25 mL) was heated to reflux for 24 h. After cooling to room temperature, the resulting mixture was concentrated to a gray solid. Recrystallization from ethyl acetate afforded 0.044 g (18%, two steps) of compound XVIII as a white solid. MP 232° C. TLC: R f 0.5 (silica, 10% methanol-methylene chloride).
EXAMPLE 19
Preparation of Compound XIX
[0200] [0200]
[0201] Step 1. A solution of sodium hydride (0.040 g, 1.54 mmol) in THF (100 mL) was cooled to 0° C. and treated with di-tert-butyl malonate (20.7 3 mL, 92.47 mmol) dropwise via dropping funnel, over 20 min. After stirring at room temperature for 30 min., 3,3-dimethylallyl bromide (9.7 mL, 83.22 mmol) was added. After stirring an additional 19 h, the reaction mixture was diluted with 10% HCl solution (100 mL) and EtOAc (100 mL). Ale resulting organic phase was washed with satd. aq. NaCl, dried over MgSO 4 , filtered, and concentrated to afford 25.74 g (94%)of a crude yellow oil. TLC: R f 0.60 (silica, 10% ethyl acetate-hexane).
[0202] Step 2. A solution of the crude olefin from step 1 (25.74 g, 90.50 mmol) in CH 2 Cl 2 (350 mL) and methanol (90 mL) was cooled to −78° C. and purged with O 2 for 20 min. O 3 was bubbled through the solution until a blue color remained (2 h). The solution was purged with O 2 for 20 min.; until the solution became colorless. After warming to 0° C., NaBH 4 (3.42 g, 90.50 mmol) was added in one portion. After several minutes the ice bath was removed and the mixture was stirred overnight. The mixture was concentrated, re-diluted in CH 2 Cl 2 , washed with water (100 mL), 10% HCl (100 mL), brine (50 mL), dried over MgSO 4 , filtered and concentrated into a colorless oil. Purification of 15.0 g of crude material by flash chromatography (30% ethyl acetate-hexanes) afforded 6.86 g (50%) as a colorless oil. TLC: R f 0.30 (silica, 35% ethyl acetate-hexane).
[0203] Step 3. The malonate intermediate was prepared in a manner analogous to the one described for the preparation of example 18, step 1. For this example, benzo-1,2,3-triazin-4(3H)-one was used in place of phthalazinone and the alcohol form step 2 was used in place of 2-bromo ethanol. TLC: R f 0.40 (silica, 40% ethyl acetate-hexane).
[0204] Step 4. The dialkylated malonate intermediate was prepared in a manner analogous to the one described for the preparation of example 18, step 2. In this example, the monoalkylated malonate from step 3 was alkylated with the 1-(2-bromoethone)-4-(4-chlorophenyl)-benzene. TLC: R f 0.50 (silica, 40% ethyl acetate-hexane).
[0205] Step 5. A solution of the diester from step 4 (4.61 g, 0.746 mmol) in 1,4 dioxane (10 mL) was treated with 4N HCl and heated to reflux for 10 h. After concnetrating to an oil, the residue was purified by flash chromatography (0-10% methanol-dichloromethane to give a yellow solid. MP 195° C.
EXAMPLE 20 and EXAMPLE 21
Preparation of Compunds XX and XXI
[0206] Example 19 was separated by chromatography on a chiral HPLC column (CH 2 Cl 2 EtOAc-hexanes). Example 20 was the first to come off the column. Example 21 eluted second.
[0207] Example 20. MS (FAB-LSMIS) 462 [M+H] +
[0208] Example 21. Anal. Calculated for C 25 H 20 ClN 3 O 4 : C, 65.01; H, 4.36; N, 9.10. Found C, 64.70; H, 4.06; N, 8.72.
EXAMPLE 22
Preparation of Compound XXII
[0209] [0209]
[0210] Step 1. A solution of di-tert-butyl(2-hydroxyethyl)malonate (0.500 g, 1.92 mmol), PPh 3 (0.555 g, 2.12 mmol) and CBr 4 (0.704 g, 2.12 mmol) in CH 2 Cl 2 (4.0 mL) was stirred at 0° C. for 5 min., then warmed to room temperature. After stirring for an additional 16 h, the reaction mixture was concentrated in vacuo and purified via column chromatography (5-10% ethyl acetate-hexanes) to give 0.615 g (99%) of the desired product. TLC: R f 0.7 (silica, 10% EtOAc-hexanes).
[0211] Step 2. A flask containing 1,3-dihydro-5-methyl-2H-1,4-benzodiazepin-2-one (0.324 g, 1.03 mmol) and Cs 2 CO 3 (0.900 g, 2.76 mmol) was dried under vacuum, flushed with Ar and charged with a solution of di-tert-butyl(2-bromoethyl)malonate (0.300 g, 0.929 mmol) in DMF (3.0 mL) at 0° C. The mixture was stirred at 0° C. for 15 min., room temperature for 15 min., and 120° C. for 21 h. The reaction mixture was diluted with EtOAc (250 mL) and washed with water (2×50 mL). The organic layer was separated, dried over MgSO 4 and concentrated. Purification by column chromatography (50-100% ethyl acetate-hexanes) afforded 0.017 g of the desired product. TLC: R f 0.5 (silica, 100% EtOAc).
[0212] Step 3. A flask containing the mono alkylated malonate from step 2 (0.37 g) and sodium t-butoxide (0.009 g, 0.089 mmol) was vacuum dried, flushed with Ar and diluted with THF (1.0 mL) at 0° C. After stirring at 0° C. for 30 min., the reaction mixture was charged with 4-bromoacetyl-4′-chlorobiphenyl (0.027 g, 0.089 mmol) and subsequently stirred at room temperature for an additional 5 h. The reaction mixture was diluted with CH 2 Cl 2 (75 mL) and washed with water (25 mL). The organic layer was separated, dried over MgSO 4 and concentrated. Crude purification by column chromatography (50-100% ethyl acetate-hexanes) afforded the desired product (0.100 g, 0.154 mmol) which was used directly in step 4.
[0213] Step 4. A solution of the malonate from step 3 (0.100 g, 0.154 mmol) in formic acid (1.0 mL) was stirred at room temperature for 6 hrs. The resulting solution was concentrated in vacuo and used directly in step 5.
[0214] Step 5. A solution of the product from step 4 in 1,4-dioxane (2.0 mL) was heated to 100° C. for 16 h. After cooling to room temperature, the solvent was removed in vacuo. Purification by column chromatography (ethyl acetate-hexanes-AcOH, 60:40:1) afforded 0.020 g of a mixture which contained the desired product. The mixture was purified via HPLC on a C18 column (acetonitrile-water) to furnish 2 mg of the target compound. HRMS 489.15720 (m+1), (calc. 488.15029).
EXAMPLE 23
Biological Assays of Invention Compounds
[0215] P218 Quenched Fluorescence Assay for MMP Inhibition:
[0216] The P218 quenched fluorescence assay (Microfluorometric Profiling Assay) is a modification of that originally described by Knight, et al., FEBS Lett. 296, 263 (1992) for a related substance and a variety of matrix metalloproteinases (MMPs) in cuvettes. The assay was run with each invention compound and the three MMPs, MMP-3, MMP-9 and MMP-2, analyzed in parallel, adapted as follows for a 96-well microtiter plate and a Hamilton AT® workstation.
[0217] P218 Fluorogenic Substrate: P218 is a synthetic substrate containing a 4-acetyl-7-methoxycoumarin (MCA) group in the N-terminal position and a 3-[2,4-dinitrophenyl]-L-2,3-diaminopropionyl (DPA) group internally. This is a modification of a peptide reported by Knight (1992) that was used as a substrate for matrix metalloproteinases. Once the P218 peptide is cleaved (putative clip site at the Ala-Leu bond), the fluorescence of the MCA group can be detected on a fluorometer with excitation at 328 nm and emission at 393 nm. P218 is currently being produced BACHEM exclusively for Bayer. P218 has the structure:
[0218] H-MCA-Pro-Lys-Pro-Leu-Ala-Leu-DPA-Ala-Arg-NH2 (MW 1332.2)
[0219] Recombinant Human CHO Stromelysin (MMP-3)
[0220] Recombinant Human CHO Pro-MMP-3: Human CHO pro-stromelysin-257 (pro-MMP-3) was expressed and purified as described by Housley, et al., J. Biol. Chem. 268, 4481 (1993).
[0221] Activation of Pro-MMP-3: Pro-MMP-3 at 1.72 μM (100 μg/mL) in 5 mM Tris at pH 7.5, 5 mM CaCl 2 , 25 mM NaCl, and 0.005% Brij-35 (MMP-3 activation buffer) was activated by incubation with TPCK (N-tosyl-(L)-phenylalanine chloromethyl ketone) trypsin (1:100 w/w to pro-MMP-3) at 25° C. for 30 min. The reaction was stopped by addition of soybean trypsin inhibitor (SBTI; 5:1 w/w to trypsin concentration). This activation protocol results in the formation of 45 kDa active MMP-3, which still contains the C-terminal portion of the enzyme.
[0222] Preparation of Human Recombinant Pro-Gelatinase A (MMP-2):
[0223] Recombinant Human Pro-MMP-2: Human pro-gelatinase A (pro-MMP-2) was prepared using a vaccinia expression system according to the method of Fridman, et al., J. Biol. Chem. 267, 15398 (1992).
[0224] Activation of Pro-MMP-2: Pro-MMP-2 at 252 mg/mL was diluted 1:5 to a final concentration of 50 μg/mL solution in 25 mM Tris at pH 7.5, 5 mM CaCl 2 , 150 mM NaCl, and 0.005% Brij-35 (MMP-2 activation buffer). p-Aminophenylmercuric acetate (APMA) was prepared in 10 mM (3.5 mg/mL) in 0.05 NaOH. The APMA solution was added at {fraction (1/20)} the reaction volume for a final AMPA concentration of 0.5 mM, and the enzyme was incubated at 37° C. for 30 min. Activated MMP-2 (15 mL) was dialyzed twice vs. 2 L of MMP-2 activation buffer (dialysis membranes were pre-treated with a solution consisting of 0.1% BSA in MMP-2 activation buffer for 1 min. followed by extensive H 2 O washing). The enzyme was concentrated on Centricon concentrators (concentrators were also pre-treated a solution consisting of 0.1% BSA in MMP-2 activation buffer for 1 min. followed by washing with H 2 O, then MMP-2 activation buffer) with re-dilution followed by re-concentration repeated twice. The enzyme was diluted to 7.5 mL (0.5 times the original volume) with MMP-2 activation buffer.
[0225] Preparation of Human Recombinant Pro-Gelatinase B (MMP-9):
[0226] Recombinant Human Pro-MMP-9: Human pro-gelatinase B (pro-MMP-9) derived from U937 cDNA as described by Wilhelm, et al. J. Biol. Chem. 264, 17213 (1989) was expressed as the full-length form using a baculovirus protein expression system. The pro-enzyme was purified using methods previously described by Hibbs, et al. J. Biol. Chem. 260, 2493 (1984).
[0227] Activation of Pro-MMP-9: Pro-MMP-2 20 μg/mL in 50 mM Tris at pH 7.4, 10 mM CaCl 2 , 150 mM NaCl, and 0.005% Brij-35 (MMP-9 activation buffer) was activated by incubation with 0.5 mM p-aminophenylmercuric acetate (APMA) for 3.5 h at 37° C. The enzyme was dialyzed against the same buffer to remove the APMA.
[0228] Instrumentation:
[0229] Hamiltion Microlab AT Plus: The MMP-Profiling Assay is performed robotically on a Hamilton MicroLab AT Plus®. The Hamilton is programmed to: (1) serially dilute up to 11 potential inhibitors automatically from a 2.5 mM stock in 100% DMSO; (2) distribute substrate followed by inhibitor into a 96 well Cytofluor plate; and (3) add a single enzyme to the plate with mixing to start the reaction. Subsequent plates for each additional enzyme are prepared automatically by beginning the program at the substrate addition point, remixing the diluted inhibitors and beginning the reaction by addition of enzyme. In this way, all MMP assays were done using the same inhibitor dilutions.
[0230] Millipore Cytofluor II. Following incubation, the plate was read on a Cytofluor II fluorometric plate reader with excitation at 340 nM and emission at 395 nM with the gain set at 80.
[0231] Buffers:
[0232] Microfluorometric Reaction Buffer (MRB): Dilution of test compounds, enzymes, and P218 substrate for the microfluorometric assay were made in microfluorometric reaction buffer consisting of 50 mM 2-(N-morpholino)ethanesulfonic acid (MES) at pH 6.5 with 10 mM CaCl 2 , 150 nM NaCl, 0.005% Brij-35 and 1% DMSO.
[0233] Methods:
[0234] MMP Microfluorometric Profiling Assay. The assay is done with a final substrate concentration of 6 μM P218 and approximately 0.5 to 0.8 nM MMP with variable drug concentrations. The Hamilton is programmed to serially dilute up to 11 compounds from a 2.5 mM stock (100% DMSO) to 10× the final compounds concentrations in the assay. Initially, the instrument delivers various amounts of microfluoromentric reaction buffer (MRB) to a 96 tube rack of 1 ml Marsh dilution tubes. The instrument then picks up 20 μl of inhibitor (2.5 mM) from the sample rack and mixes it with a buffer in row A of the Marsh rack, resulting in a 50 μM drug concentration. The inhibitors are then serially diluted to 10, 5, 1, 0.2, 0.05 and 0.01 μM. Position 1 on the sample rack contains only DMSO for the “enzyme-only” wells in the assay, which results in no inhibitor in column 1, rows A through H. The instrument then distributes 107 μl of P218 substrate (8.2 μM in MRB) to a single 96 well cytofluor microtiter plate. The instrument re-mixes and loads 14.5 μl of diluted compound from rows A to G in the Marsh rack to corresponding rows in the microtiter plate. (Row H represents the “background” row and 39.5 μl of MRB is delivered in placed of drug or enzyme). The reaction is started by adding 25 μl of the appropriate enzyme (at 5.86 times the final enzyme concentration) from a BSA treated reagent reservoir to each well, excluding Row H, the “background” row. (The enzyme reservoir is pretreated with 1% BSA in 50 mM Tris, pH 7.5 containing 150 mM NaCl for 1 hour at room temp., followed by extensive H 2 O washing and drying at room temp.).
[0235] After addition and mixing of the enzyme, the plate is covered and incubated for 25 min. at 37° C. Additional enzymes are tested in the same manner by beginning the Hamilton program with the distribution of P218 substrate to the microtiter plate, followed by re-mixing and distribution of the drug from the same Marsh rack to the microtiter plate. The second (or third, etc.) My to be tested is then distributed from a reagent rack to the microtiter plate with mixing, prior to covering and incubation. This is repeated for all additional MMP's to be tested.
[0236] IC50 Determination in Microfluorometric Assay: Data generated on the Cytofluor II is copied from an exported “.CSV” file to a master Excel spreadsheet. Data from several different MMPs (one 96 well plate per MMP) were calculated simultaneously. The percent inhibition is determination for each drug concentration by comparing the amount of hydrolysis (fluorescence units generated over 25 minutes of hydrolysis) of wells containing compound with the “enzyme only” wells in column 1. Following subtraction of the background the percent inhibition was calculated as:
((Control values−Treated values)/Control values)×100
[0237] Percent inhibitions were determined for inhibitor concentrations of 5, 1, 0.5, 0.1, 0.02, 0.005 and, 0.001 μM of drug. Linear regression analysis of percent inhibition versus log inhibitor concentration was used to obtain IC 50 values.
TABLE 1 MMP-9 MMP-3 Fluorogenic Fluorogenic MMP-2 Fluorogenic Example IC 50 IC 50 IC 50 1 1.7 0.34 0.39 2 17 24 9.5 3 31 67 21 4 9.2 2.1 4.2 5 4.2 2.3 1.4 6 4.1 4.3 0.5 7 14 110 10 8 2.0 6.2 1.0 18 59 32 13 19 47 4.7 2.4 20 320 84 57 21 6.5 2.1 1.5 22 140 120 24
[0238] Other embodiments of the invention will be apparent to those skilled in the art from a consideration of this specification or practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being indicated by the following claims.
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Matrix metalloprotease inhibiting compounds, pharmaceutical compositions thereof and a method of disease treatment using such compounds are presented. The compounds of the invention have the generalized formulas:
wherein r is 0-2, T is selected from
and R 40 is a mono- or bi-heterocyclic structure.
These compounds are useful for inhibiting matrix metalloproteases and, therefore, combating conditions to which MMP's contribute, such as osteoarthritis, rheumatoid arthritis, septic arthritis, periodontal disease, comeal ulceration, proteinuria, aneurysmal aortic disease, dystrophobic epidermolysis, bullosa, conditions leading to inflammatory responses, osteopenias mediated by MMP activity, tempero mandibular joint disease, demyelating diseases of the nervous system, tumor metastasis or degenerative cartilage loss following traumatic joint injury, and coronary thrombosis from athrosclerotic plaque rupture. The present invention also provides pharmaceutical compositions and methods for treating such conditions.
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This application is a continuation-in-part of DiMarchi et al., U.S. Ser. No. 08/381,247, filed Jan. 31, 1995, docket number X-9930 now abandoned.
FIELD OF THE INVENTION
The present invention is in the field of human medicine, particularly in the treatment of obesity and disorders associated with obesity. Most specifically the invention relates to anti-obesity proteins that when administered to a patient regulate fat tissue.
BACKGROUND OF THE INVENTION
Obesity, and especially upper body obesity, is a common and very serious public health problem in the United States and throughout the world. According to recent statistics, more than 25% of the United States population and 27% of the Canadian population are over weight. Kuczmarski, Amer. J. of Clin. Nut. 55:495S-502S (1992); Reeder et. al., Can. Med. Ass. J., 23:226-233 (1992). Upper body obesity is the strongest risk factor known for type II diabetes mellitus, and is a strong risk factor for cardiovascular disease and cancer as well. Recent estimates for the medical cost of obesity are $150,000,000,000 world wide. The problem has become serious enough that the surgeon general has begun an initiative to combat the ever increasing adiposity rampant in American society.
Much of this obesity induced pathology can be attributed to the strong association with dyslipidemia, hypertension, and insulin resistance. Many studies have demonstrated that reduction in obesity by diet and exercise reduces these risk factors dramatically. Unfortunately these treatments are largely unsuccessful with a failure rate reaching 95%. This failure may be due to the fact that the condition is strongly associated with genetically inherited factors that contribute to increased appetite, preference for highly caloric foods, reduced physical activity, and increased lipogenic metabolism. This indicates that people inheriting these genetic traits are prone to becoming obese regardless of their efforts to combat the condition. Therefore, a new pharmacological agent that can correct this adiposity handicap and allow the physician to successfully treat obese patients in spite of their genetic inheritance is needed.
The ob/ob mouse is a model of obesity and diabetes that is known to carry an autosomal recessive trait linked to a mutation in the sixth chromosome. Recently, Yiying Zhang and co-workers published the positional cloning of the mouse gene linked with this condition. Yiying Zhang et al. Nature 372: 425-32 (1994). This report disclosed a gene coding for a 167 amino acid protein with a 21 amino acid signal peptide that is exclusively expressed in adipose tissue. The report continues to disclose that a mutation resulting in the conversion of a codon for arginine at position 105 to a stop codon results in the expression of a truncated protein, which presumably is inactive.
Physiologist have postulated for years that, when a mammal overeats, the resulting excess fat signals to the brain that the body is obese which, in turn, causes the body to eat less and burn more fuel. G. R. Hervey, Nature 227: 629-631 (1969). This "feedback" model is supported by parabiotic experiments, which implicate a circulating hormone controlling adiposity. Based on this model, the protein, which is apparently encoded by the ob gene, is now speculated to be an adiposity regulating hormone.
Pharmacological agents which are biologically active and mimic the activity of this protein are useful to help patients regulate their appetite and metabolism and thereby control their adiposity. Until the present invention, such a pharmacological agent was unknown.
The present invention provides biologically active anti-obesity proteins. Such agents therefore allow patients to overcome their obesity handicap and live normal lives with a more normalized risk for type II diabetes, cardiovascular disease and cancer.
SUMMARY OF INVENTION
The present invention is directed to a biologically active anti-obesity protein of the Formula (I):
__________________________________________________________________________SEQ ID NO: 1__________________________________________________________________________1 5 10 15Val Xaa Asp Asp Thr Lys Thr Leu Ile Lys Thr Ile Val Thr Arg 20 25 30Ile Xaa Asp Ile Ser His Xaa Xaa Ser Val Ser Ser Lys Xaa Lys 35 40 45Val Thr Gly Leu Asp Phe Ile Pro Gly Leu His Pro Ile Leu Thr 50 55 60Leu Ser Lys Xaa Asp Xaa Thr Leu Ala Val Tyr Xaa Xaa Ile Leu 65 70 75Thr Ser Xaa Pro Ser Arg Xaa Val Ile Xaa Ile Ser Xaa Asp Leu 80 85 90Glu Xaa Leu Arg Asp Leu Leu His Val Leu Ala Phe Ser Lys Ser 95 100 105Cys His Leu Pro Xaa Ala Ser Gly Leu Glu Thr Leu Asp Ser Leu 110 115 120Gly Gly Val Leu Glu Ala Ser Gly Tyr Ser Thr Glu Val Val Ala 125 130 135Leu Ser Arg Leu Xaa Gly Ser Leu Xaa Asp Xaa Leu Xaa Xaa Leu 140Asp Leu Ser Pro Gly Cys__________________________________________________________________________
wherein:
Xaa at position 2 is Gln or Glu;
Xaa at position 17 is Asn, Asp or Gln;
Xaa at position 22 is Thr or Ala;
Xaa at position 23 is Gln, Glu or absent;
Xaa at position 29 is Gln or Glu;
Xaa at position 49 is Ile, Leu, Met or methionine sulfoxide;
Xaa at position 51 is Gln or Glu;
Xaa at position 57 is Gln or Glu;
Xaa at position 58 is Gln or Glu;
Xaa at position 63 is Ile, Leu, Met or methionine sulfoxide;
Xaa at position 67 is Asn, Asp or Gln;
Xaa at position 70 is Gln or Glu;
Xaa at position 73 is Asn, Asp or Gln;
Xaa at position 77 is Asn, Asp or Gln;
Xaa at position 95 is Trp or Gln;
Xaa at position 125 is Gln or Glu;
Xaa at position 129 is Gln or Glu;
Xaa at position 131 is Ile, Leu, Met or methionine sulfoxide;
Xaa at position 133 is Trp or Gln; and
xaa at position 134 is Gln or Glu.
The invention further provides a method of treating obesity, which comprises administering to a mammal in need thereof a protein of the Formula (I).
The invention further provides a pharmaceutical formulation, which comprises a protein of the Formula (I) together with one or more pharmaceutical acceptable diluents, carriers or excipients therefor.
DETAILED DESCRIPTION
As noted above the present invention provides a protein of the Formula (I):
__________________________________________________________________________SEQ ID NO: 1__________________________________________________________________________1 5 10 15Val Xaa Asp Asp Thr Lys Thr Leu Ile Lys Thr Ile Val Thr Arg 20 25 30Ile Xaa Asp Ile Ser His Xaa Xaa Ser Val Ser Ser Lys Xaa Lys 35 40 45Val Thr Gly Leu Asp Phe Ile Pro Gly Leu His Pro Ile Leu Thr 50 55 60Leu Ser Lys Xaa Asp Xaa Thr Leu Ala Val Tyr Xaa Xaa Ile Leu 65 70 75Thr Ser Xaa Pro Ser Arg Xaa Val Ile Xaa Ile Ser Xaa Asp Leu 80 85 90Glu Xaa Leu Arg Asp Leu Leu His Val Leu Ala Phe Ser Lys Ser 95 100 105Cys His Leu Pro Xaa Ala Ser Gly Leu Glu Thr Leu Asp Ser Leu 110 115 120Gly Gly Val Leu Glu Ala Ser Gly Tyr Ser Thr Glu Val Val Ala 125 130 135Leu Ser Arg Leu Xaa Gly Ser Leu Xaa Asp Xaa Leu Xaa Xaa Leu 140Asp Leu Ser Pro Gly Cys__________________________________________________________________________
wherein:
Xaa at position 2 is Gln or Glu;
Xaa at position 17 is Asn, Asp or Gln;
Xaa at position 22 is Thr or Ala;
Xaa at position 23 is Gln, Glu or absent;
Xaa at position 29 is Gln or Glu;
Xaa at position 49 is Ile, Leu, Met or methionine sulfoxide;
Xaa at position 51 is Gln or Glu;
Xaa at position 57 is Gln or Glu;
Xaa at position 58 is Gln or Glu;
Xaa at position 63 is Ile, Leu, Met or methionine sulfoxide;
Xaa at position 67 is Asn, Asp or Gln;
Xaa at position 70 is Gln or Glu;
Xaa at position 73 is Asn, Asp or Gln;
Xaa at position 77 is Asn, Asp or Gln;
Xaa at position 95 is Trp or Gln;
Xaa at position 125 is Gln or Glu;
Xaa at position 129 is Gln or Glu;
Xaa at position 131 is Ile, Leu, Met or methionine sulfoxide;
Xaa at position 133 is Trp or Gln; and
Xaa at position 134 is Gln or Glu.
The preferred proteins of the present invention are those of Formula (I) wherein:
Xaa at position 2 is Gln;
Xaa at position 17 is Asn;
Xaa at position 22 is Thr;
Xaa at position 23 is Gln;
Xaa at position 29 is Gln;
Xaa at position 49 is Met;
Xaa at position 51 is Gln;
Xaa at position 57 is Gln;
Xaa at position 58 is Gln;
Xaa at position 63 is Met;
Xaa at position 67 is Asn;
Xaa at position 70 is Gln;
Xaa at position 73 is Asn;
Xaa at position 77 is Asn;
Xaa at position 95 is Trp;
Xaa at position 125 is Gln;
Xaa at position 129 is Gln;
Xaa at position 131 is Met;
Xaa at position 133 is Trp;
Xaa at position 134 is Gln.
The amino acids abbreviations are accepted by the United States Patent and Trademark Office as set forth in 37 C.F.R. §1.822 (b)(2) (1993). One skilled in the art would recognize that certain amino acids are prone to rearrangement. For example, Asp may rearrange to aspartimide and isoasparigine as described in I. Schon et al., Int. J. Peptide Protein Res. 14: 485-94 (1979) and references cited therein. These rearrangement derivatives are included within the scope of the present invention. Unless otherwise indicated the amino acids are in the L configuration.
For purposes of the present invention, as disclosed and claimed herein, the following terms and abbreviations are defined as follows:
Base pair (bp)--refers to DNA or RNA. The abbreviations A,C,G, and T correspond to the 5'-monophosphate forms of the nucleotides (deoxy)adenine, (deoxy)cytidine, (deoxy)guanine, and (deoxy)thymine, respectively, when they occur in DNA molecules. The abbreviations U,C,G, and T correspond to the 5'-monophosphate forms of the nucleosides uracil, cytidine, guanine, and thymine, respectively when they occur in RNA molecules. In double stranded DNA, base pair may refer to a partnership of A with T or C with G. In a DNA/RNA heteroduplex, base pair may refer to a partnership of T with U or C with G.
Chelating Peptide--An amino acid sequence capable of complexing with a multivalent metal ion.
DNA--Deoyxribonucleic acid.
EDTA--an abbreviation for ethylenediamine tetraacetic acid.
ED 50 --an abbreviation for half-maximal value.
FAB-MS--an abbreviation for fast atom bombardment mass spectrometry.
Immunoreactive Protein(s)--a term used to collectively describe antibodies, fragments of antibodies capable of binding antigens of a similar nature as the parent antibody molecule from which they are derived, and single chain polypeptide binding molecules as described in PCT Application No. PCT/U.S. 87/02208, International Publication No. WO 88/01649.
mRNA--messenger RNA.
MWCO--an abbreviation for molecular weight cut-off.
Plasmid--an extrachromosomal self-replicating genetic element.
PMSF--an abbreviation for phenylmethylsulfonyl fluoride.
Reading frame--the nucleotide sequence from which translation occurs "read" in triplets by the translational apparatus of tRNA, ribosomes and associated factors, each triplet corresponding to a particular amino acid. Because each triplet is distinct and of the same length, the coding sequence must be a multiple of three. A base pair insertion or deletion (termed a frameshift mutation) may result in two different proteins being coded for by the same DNA segment. To insure against this, the triplet codons corresponding to the desired polypeptide must be aligned in multiples of three from the initiation codon, i.e. the correct "reading frame" must be maintained. In the creation of fusion proteins containing a chelating peptide, the reading frame of the DNA sequence encoding the structural protein must be maintained in the DNA sequence encoding the chelating peptide.
Recombinant DNA Cloning Vector--any autonomously replicating agent including, but not limited to, plasmids and phages, comprising a DNA molecule to which one or more additional DNA segments can or have been added.
Recombinant DNA Expression Vector--any recombinant DNA cloning vector in which a promoter has been incorporated.
Replicon--A DNA sequence that controls and allows for autonomous replication of a plasmid or other vector.
RNA--ribonucleic acid.
RP-HPLC--an abbreviation for reversed-phase high performance liquid chromatography.
Transcription--the process whereby information contained in a nucleotide sequence of DNA is transferred to a complementary RNA sequence.
Translation--the process whereby the genetic information of messenger RNA is used to specify and direct the synthesis of a polypeptide chain.
Tris--an abbreviation for tris(hydroxymethyl)aminomethane.
Treating--describes the management and care of a patient for the purpose of combating the disease, condition, or disorder and includes the administration of a compound of present invention to prevent the onset of the symptoms or complications, alleviating the symptoms or complications, or eliminating the disease, condition, or disorder. Treating obesity therefor includes the inhibition of food intake, the inhibition of weight gain, and inducing weight loss in patients in need thereof.
Vector--a replicon used for the transformation of cells in gene manipulation bearing polynucleotide sequences corresponding to appropriate protein molecules which, when combined with appropriate control sequences, confer specific properties on the host cell to be transformed. Plasmids, viruses, and bacteriophage are suitable vectors, since they are replicons in their own right. Artificial vectors are constructed by cutting and joining DNA molecules from different sources using restriction enzymes and ligases. Vectors include Recombinant DNA cloning vectors and Recombinant DNA expression vectors.
X-gal--an abbreviation for 5-bromo-4-chloro-3-idolyl beta-D-galactoside.
SEQ ID NO: 1 refers to the sequence set forth in the sequence listing and means an anti-obesity protein of the formula:
__________________________________________________________________________SEQ ID NO: 1__________________________________________________________________________1 5 10 15Val Xaa Asp Asp Thr Lys Thr Leu Ile Lys Thr Ile Val Thr Arg 20 25 30Ile Xaa Asp Ile Ser His Xaa Xaa Ser Val Ser Ser Lys Xaa Lys 35 40 45Val Thr Gly Leu Asp Phe Ile Pro Gly Leu His Pro Ile Leu Thr 50 55 60Leu Ser Lys Xaa Asp Xaa Thr Leu Ala Val Tyr Xaa Xaa Ile Leu 65 70 75Thr Ser Xaa Pro Ser Arg Xaa Val Ile Xaa Ile Ser Xaa Asp Leu 80 85 90Glu Xaa Leu Arg Asp Leu Leu His Val Leu Ala Phe Ser Lys Ser 95 100 105Cys His Leu Pro Xaa Ala Ser Gly Leu Glu Thr Leu Asp Ser Leu 110 115 120Gly Gly Val Leu Glu Ala Ser Gly Tyr Ser Thr Glu Val Val Ala 125 130 135Leu Ser Arg Leu Xaa Gly Ser Leu Xaa Asp Xaa Leu Xaa Xaa Leu 140Asp Leu Ser Pro Gly Cys__________________________________________________________________________
wherein:
Xaa at position 2 is Gln or Glu;
Xaa at position 17 is Asn, Asp or Gln;
Xaa at position 22 is Thr or Ala;
Xaa at position 23 is Gln, Glu or absent;
xaa at position 29 is Gln or Glu;
Xaa at position 49 is Ile, Leu, Met or methionine sulfoxide;
Xaa at position 51 is Gln or Glu;
Xaa at position 57 is Gln or Glu;
Xaa at position 58 is Gln or Glu;
Xaa at position 63 is Ile, Leu, Met or methionine sulfoxide;
Xaa at position 67 is Asn, Asp or Gln;
Xaa at position 70 is Gln or Glu;
Xaa at position 73 is Asn, Asp or Gln;
Xaa at position 77 is Asn, Asp or Gln;
Xaa at position 95 is Trp or Gln;
Xaa at position 125 is Gln or Glu;
Xaa at position 129 is Gln or Glu;
Xaa at position 131 is Ile, Leu, Met or methionine sulfoxide;
Xaa at position 133 is Trp or Gln; and
Xaa at position 134 is Gln or Glu.
Yiying Zhang et al. in Nature 372: 425-32 (December 1994) report the cloning of the murine obese (ob) mouse gene and present mouse DNA and the naturally occurring amino acid sequence of the obesity protein for the mouse and human. This protein is speculated to be a hormone that is secreted by fat cells and controls body weight.
The present invention provides biologically active proteins that provide effective treatment for obesity. Many of the claimed proteins offer additional advantages of stability, especially acid stability, and improved absorption characteristics.
The claimed proteins ordinarily are prepared by modification of the DNA encoding the claimed protein and thereafter expressing the DNA in recombinant cell culture. Techniques for making substitutional mutations at predetermined sites in DNA having a known sequence are well known, for example M13 primer mutagenesis. The mutations that might be made in the DNA encoding the present anti-obesity proteins must not place the sequence out of reading frame and preferably will not create complementary regions that could produce secondary mRNA structure. See DeBoer et al., EP 75,444A (1983).
The compounds of the present invention may be produced either by recombinant DNA technology or well known chemical procedures, such as solution or solid-phase peptide synthesis, or semi-synthesis in solution beginning with protein fragments coupled through conventional solution methods.
A. Solid Phase
The synthesis of the claimed protein may proceed by solid phase peptide synthesis or by recombinant methods. The principles of solid phase chemical synthesis of polypeptides are well known in the art and may be found in general texts in the area such as Dugas, H. and Penney, C., Bioorganic Chemistry Springer-Verlag, New York, pgs. 54-92 (1981). For example, peptides may be synthesized by solid-phase methodology utilizing an PE-Applied Biosystems 430A peptide synthesizer (commercially available from Applied Biosystems, Foster City Calif.) and synthesis cycles supplied by Applied Biosystems. Boc amino acids and other reagents are commercially available from PE-Applied Biosystems and other chemical supply houses. Sequential Boc chemistry using double couple protocols are applied to the starting p-methyl benzhydryl amine resins for the production of C-terminal carboxamides. For the production of C-terminal acids, the corresponding PAM resin is used. Arginine, Asparagine, Glutamine, Histidine and Methionine are coupled using preformed hydroxy benzotriazole esters. The following side chain protection may be used:
Arg, Tosyl
Asp, cyclohexyl or benzyl
Cys, 4-methylbenzyl
Glu, cyclohexyl
His, benzyloxymethyl
Lys, 2-chlorobenzyloxycarbonyl
Met, sulfoxide
Ser, Benzyl
Thr, Benzyl
Trp, formyl
Tyr, 4-bromo carbobenzoxy
Boc deprotection may be accomplished with trifluoroacetic acid (TFA) in methylene chloride. Formyl removal from Trp is accomplished by treatment of the peptidyl resin with 20% piperidine in dimethylformamide for 60 minutes at 4° C. Met(O) can be reduced by treatment of the peptidyl resin with TFA/dimethylsulfide/conHCl (95/5/1) at 25° C. for 60 minutes. Following the above pre-treatments, the peptides may be further deprotected and cleaved from the resin with anhydrous hydrogen fluoride containing a mixture of 10% m-cresol or m-cresol/10% p-thiocresol or m-cresol/p-thiocresol/dimethylsulfide. Cleavage of nhe side chain protecting group(s) and of the peptide from the resin is carried out at zero degrees Centigrade or below, preferably -20° C. for thirty minutes followed by thirty minutes 0° C. After removal of the HF, the peptide/resin is washed with ether. The peptide is extracted with glacial acetic acid and lyophilized. Purification is accomplished by reverse-phase C18 chromatography (Vydac) column in 0.1% TFA with a gradient of increasing acetonitrile concentration.
One skilled in the art recognizes that the solid phase synthesis could also be accomplished using the FMOC strategy and a TFA/scavenger cleavage mixture.
B. Recombinant Synthesis
The claimed proteins may also be produced by recombinant methods. Recombinant methods are preferred if a high yield is desired. The basic steps in the recombinant production of protein include:
a) construction of a synthetic or semi-synthetic (or isolation from natural sources) DNA encoding the claimed protein,
b) integrating the coding sequence into an expression vector in a manner suitable for the expression of the protein either alone or as a fusion protein,
c) transforming an appropriate eukaryotic or prokaryotic host cell with the expression vector, and
d) recovering and purifying the recombinantly produced protein.
2.a. Gene Construction
Synthetic genes, the in vitro or in vivo transcription and translation of which will result in the production of the protein may be constructed by techniques well known in the art. Owing to the natural degeneracy of the genetic code, the skilled artisan will recognize that a sizable yet definite number of DNA sequences may be constructed which encode the claimed proteins. In the preferred practice of the invention, synthesis is achieved by recombinant DNA technology.
Methodology of synthetic gene construction is well known in the art. For example, see Brown, et al. (1979) Methods in Enzymology, Academic Press, New York, Vol. 68, pgs. 109-151. The DNA sequence corresponding to the synthetic claimed protein gene may be generated using conventional DNA synthesizing apparatus such as the Applied Biosystems Model 380A or 380B DNA synthesizers (commercially available from Applied Biosystems, Inc., 850 Lincoln Center Drive, Foster City, Calif. 94404).
It may desirable in some applications to modify the coding sequence of the claimed protein so as to incorporate a convenient protease sensitive cleavage site, e.g., between the signal peptide and the structural protein facilitating the controlled excision of the signal peptide from the fusion protein construct.
The gene encoding the claimed protein may also be created by using polymerase chain reaction (PCR). The template can be a cDNA library (commercially available from CLONETECH or STRATAGENE) or mRNA isolated from human adipose tissue. Such methodologies are well known in the art Maniatis, et al. Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Press, Cold Spring Harbor Laboratory, Cold Spring Harbor, N. Y.(1989).
2.b. Direct expression or Fusion protein
The claimed protein may be made either by direct expression or as fusion protein comprising the claimed protein followed by enzymatic or chemical cleavage. A variety of peptidases (e.g. trypsin) which cleave a polypeptide at specific sites or digest the peptides from the amino or carboxy termini (e.g. diaminopeptidase) of the peptide chain are known. Furthermore, particular chemicals (e.g. cyanogen bromide) will cleave a polypeptide chain at specific sites. The skilled artisan will appreciate the modifications necessary to the amino acid sequence (and synthetic or semi-synthetic coding sequence if recombinant means are employed) to incorporate site-specific internal cleavage sites. See e.g., Carter P., Site Specific Proteolysis of Fusion Proteins, Ch. 13 in Protein Purification: From Molecular Mechanisms to Large scale Processes, American Chemical Soc., Washington, D.C. (1990).
2.c. Vector Construction
Construction of suitable vectors containing the desired coding and control sequences employ standard ligation techniques. Isolated plasmids or DNA fragments are cleaved, tailored, and religated in the form desired to form the plasmids required.
To effect the translation of the desired protein, one inserts the engineered synthetic DNA sequence in any of a plethora of appropriate recombinant DNA expression vectors through the use of appropriate restriction endonucleases. The claimed protein is a relatively large protein. A synthetic coding sequence is designed to possess restriction endonuclease cleavage sites at either end of the transcript to facilitate isolation from and integration into these expression and amplification and expression plasmids. The isolated cDNA coding sequence may be readily modified by the use of synthetic linkers to facilitate the incorporation of this sequence into the desired cloning vectors by techniques well known in the art. The particular endonucleases employed will be dictated by the restriction endonuclease cleavage pattern of the parent expression vector to be employed. The choice of restriction sites are chosen so as to properly orient the coding sequence with control sequences to achieve proper in-frame reading and expression of the claimed protein.
In general, plasmid vectors containing promoters and control sequences which are derived from species compatible with the host cell are used with these hosts. The vector ordinarily carries a replication site as well as marker sequences which are capable of providing phenotypic selection in transformed cells. For example, E, coli is typically transformed using pBR322, a plasmid derived from an E. coli species (Bolivar, et al., Gene 2: 95 (1977)). Plasmid pBR322 contains genes for ampicillin and tetracycline resistance and thus provides easy means for identifying transformed cells. The pBR322 plasmid, or other microbial plasmid must also contain or be modified to contain promoters and other control elements commonly used in recombinant DNA technology.
The desired coding sequence is inserted into an expression vector in the proper orientation to be transcribed from a promoter and ribosome binding site, both of which should be functional in the host cell in which the protein is to be expressed. An example of such an expression vector is a plasmid described in Belagaje et al., U.S. Pat. No. 5,304,493, the teachings of which are herein incorporated by reference. The gene encoding A-C-B proinsulin described in U.S. Pat. No. 5,304,493 can be removed from the plasmid pRB182 with restriction enzymes NdeI and BamHI. The genes encoding the protein of the present invention can be inserted into the plasmid backbone on a NdeI/BamHI restriction fragment cassette.
2.d. Procaryotic expression
In general, procaryotes are used for cloning of DNA sequences in constructing the vectors useful in the invention. For example, E. coli K12 strain 294 (ATCC No. 31446) is particularly useful. Other microbial strains which may be used include E. coli B and E. coli X1776 (ATCC No. 31537). These examples are illustrative rather than limiting.
Prokaryotes also are used for expression. The aforementioned strains, as well as E. coli W3110 (prototrophic, ATCC No. 27325), bacilli such as Bacillus subtills, and other enterobacteriaceae such as Salmonella typhimurium or Serratia marcescans, and various pseudomonas species may be used. Promoters suitable for use with prokaryotic hosts include the β-lactamase (vector pGX2907 [ATCC 39344] contains the replicon and β-lactamase gene) and lactose promoter systems (Chang et al., Nature, 275:615 (1978); and Goeddel et al., Nature 281:544 (1979)), alkaline phosphatase, the tryptophan (trp) promoter system (vector pATH1 [ATCC 37695] is designed to facilitate expression of an open reading frame as a trpE fusion protein under control of the trp promoter) and hybrid promoters such as the tac promoter (isolatable from plasmid pDR540 ATCC-37282). However, other functional bacterial promoters, whose nucleotide sequences are generally known, enable one of skill in the art ligate them to DNA encoding the protein using linkers or adaptors to supply any required restriction sites. Promoters for use in bacterial systems also will contain a Shine-Dalgarno sequence operably linked to the DNA encoding protein.
2.e. Eucaryotic expression
The protein may be recombinantly produced in eukaryotic expression systems. Preferred promoters controlling transcription in mammalian host cells may be obtained from various sources, for example, the genomes of viruses such as: polyoma, Simian Virus 40 (SV40), adenovirus, retroviruses, hepatitis-B virus and most preferably cytomegalovirus, or from heterologous mammalian promoters, e.g. β-actin promoter. The early and late promoters of the SV40 virus are conveniently obtained as an SV40 restriction fragment which also contains the SV40 viral origin of replication. Fiers, et al., Nature, 273:113 (1978). The entire SV40 genome may be obtained from plasmid pBRSV, ATCC 45019. The immediate early promoter of the human cytomegalovirus may be obtained from plasmid pCMBβ (ATCC 77177). Of course, promoters from the host cell or related species also are useful herein.
Transcription of a DNA encoding the claimed protein by higher eukaryotes is increased by inserting an enhancer sequence into the vector. Enhancers are cis-acting elements of DNA, usually about 10-300 bp, that act on a promoter to increase its transcription. Enhancers are relatively orientation and position independent having been found 5' (Laimins, L. et al., PNAS 78:993 (1981)) and 3'l (Lusky, M. L., et al., Mol. Cell Bio. 3:1108 (1983)) to the transcription unit, within an intron (Banerji, J. L. et al., Cell 33:729 (1983)) as well as within the coding sequence itself (Osborne, T. F., et al., Mol. Cell Bio. 4:1293 (1984)). Many enhancer sequences are now known from mammalian genes (globin, RSV, SV40, EMC, elastase, albumin, a-fetoprotein and insulin). Typically, however, one will use an enhancer from a eukaryotic cell virus. Examples include the SV40 late enhancer, the cytomegalovirus early promoter enhancer, the polyoma enhancer on the late side of the replication origin, and adenovirus enhancers.
Expression vectors used in eukaryotic host cells (yeast, fungi, insect, plant, animal, human or nucleated cells from other multicellular organisms) will also contain sequences necessary for the termination of transcription which may affect mRNA expression. These regions are transcribed as polyadenylated segments in the untranslated portion of the mRNA encoding protein. The 3' untranslated regions also include transcription termination sites.
Expression vectors may contain a selection gene, also termed a selectable marker. Examples of suitable selectable markers for mammalian cells are dihydrofolate reductase (DHFR, which may be derived from the BglII/HindIII restriction fragment of pJOD-10 [ATCC 68815]), thymidine kinase (herpes simplex virus thymidine kinase is contained on the BamHI fragment of vP-5 clone [ATCC 2028]) or neomycin (G418) resistance genes (obtainable from pNN414 yeast artificial chromosome vector [ATCC 37682]). When such selectable markers are successfully transferred into a mammalian host cell, the transfected mammalian host cell can survive if placed under selective pressure. There are two widely used distinct categories of selective regimes. The first category is based on a cell's metabolism and the use of a mutant cell line which lacks the ability to grow without a supplemented media. Two examples are: CHO DHFR 31 cells (ATCC CRL-9096) and mouse LTK 31 cells (L-M(TK-) ATCC CCL-2.3). These cells lack the ability to grow without the addition of such nutrients as thymidine or hypoxanthine. Because these cells lack certain genes necessary for a complete nucleotide synthesis pathway, they cannot survive unless the missing nucleotides are provided in a supplemented media. An alternative to supplementing the media is to introduce an intact DHFR or TK gene into cells lacking the respective genes, thus altering their growth requirements. Individual cells which were not transformed with the DHFR or TK gene will not be capable of survival in nonsupplemented media.
The second category is dominant selection which refers to a selection scheme used in any cell type and does not require the use of a mutant cell line. These schemes typically use a drug to arrest growth of a host cell. Those cells which have a novel gene would express a protein conveying drug resistance and would survive the selection. Examples of such dominant selection the drugs neomycin, Southern P. and Berg, P., J. Molec. Appl. Genet, 1: 327 (1982), mycophenolic acid, Mulligan, R. C. and Berg, P. Science 209:1422 (1980), or hygromycin, Sugden, B. et al., Mol Cell. Biol. 5:410-413 (1985). The three examples given above employ bacterial genes under eukaryotic control to convey resistance to the appropriate drug G418 or neomycin (geneticin), xgpt (mycophenolic acid) or hygromycin, respectively.
A preferred vector for eucaryotic expression is pRc/CMV. pRc/CMV is commercially available from Invitrogen Corporation, 3985 Sorrento Valley Blvd., San Diego, Calif. 92121. To confirm correct sequences in plasmids constructed, the ligation mixtures are used to transform E. coli K12 strain DH5a (ATCC 31446) and successful transformants selected by antibiotic resistance where appropriate. Plasmids from the transformants are prepared, analyzed by restriction and/or sequence by the method of Messing, et al., Nucleic Acids Res. 9:309 (1981).
Host cells may be transformed with the expression vectors of this invention and cultured in conventional nutrient media modified as is appropriate for inducing promoters, selecting transformants or amplifying genes. The culture conditions, such as temperature, pH and the like, are those previously used with the host cell selected for expression, and will be apparent to the ordinarily skilled artisan. The techniques of transforming cells with the aforementioned vectors are well known in the art and may be found in such general references as Maniatis, et al., Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Press, Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y. (1989), or Current Protocols in Molecular Biology (1989) and supplements.
Preferred suitable host cells for expressing the vectors encoding the claimed proteins in higher eukaryotes include: African green monkey kidney line cell line transformed by SV40 (COS-7, ATCC CRL-1651); transformed human primary embryonal kidney cell line 293, (Graham, F. L. et al., J. Gen Virol. 36:59-72 (1977), Virology 77:319-329, Virology 86:10-21); baby hamster kidney cells (BHK-21(C-13), ATCC CCL-10, Virology 16:147 (1962)); chinese hamster ovary cells CHO-DHFR- (ATCC CRL-9096), mouse Sertoli cells (TM4, ATCC CRL-1715, Biol. Reprod. 23:243-250 (1980)); african green monkey kidney cells (VERO 76, ATCC CRL-1587); human cervical epitheloid carcinoma cells (HeLa, ATCC CCL-2); canine kidney cells (MDCK, ATCC CCL-34); buffalo rat liver cells (BRL 3A, ATCC CRL-1442); human diploid lung cells (WI-38, ATCC CCL-75); human hepatocellular carcinoma cells (Hep G2, ATCC HB-8065);and mouse mammary tumor cells (MMT 060562, ATCC CCL51).
2.f. Yeast expression
In addition to prokaryotes, eukaryotic microbes such as yeast cultures may also be used. Saccharomyces cerevisiae, or common baker's yeast is the most commonly used eukaryotic microorganism, although a number of other strains are commonly available. For expression in Saccharomyces, the plasmid YRp7, for example, (ATCC-40053, Stinchcomb, et al., Nature 282:39 (1979); Kingsman et al., Gene 7:141 (1979); Tschemper et al., Gene 10:157 (1980)) is commonly used. This plasmid already contains the trp gene which provides a selection marker for a mutant strain of yeast lacking the ability to grow in tryptophan, for example ATCC no. 44076 or PEP4-1 (Jones, Genetics 85:12 (1977)).
Suitable promoting sequences for use with yeast hosts include the promoters for 3-phosphoglycerate kinase (found on plasmid pAP12BD ATCC 53231 and described in U.S. Pat. No. 4,935,350, Jun. 19, 1990) or other glycolytic enzymes such as enolase (found on plasmid pAC1 ATCC 39532), glyceraldehyde-3-phosphate dehydrogenase (derived from plasmid pHcGAPC1 ATCC 57090, 57091), zymomonas mobilis (U.S. Pat. No. 5,000,000 issued Mar. 19, 1991), hexokinase, pyruvate decarboxylase, phosphofructokinase, glucose-6-phosphate isomerase, 3-phosphoglycerate mutase, pyruvate kinase, triosephosphate isomerase, phosphoglucose isomerase, and glucokinase.
Other yeast promoters, which are inducible promoters having the additional advantage of transcription controlled by growth conditions, are the promoter regions for alcohol dehydrogenase 2, isocytochrome C, acid phosphatase, degradative enzymes associated with nitrogen metabolism, metallothionein (contained on plasmid vector pCL28XhoLHBPV ATCC 39475, U.S. Pat. No. 4,840,896), glyceraldehyde 3-phosphate dehydrogenase, and enzymes responsible for maltose and galactose (GALl found on plasmid pRY121 ATCC 37658) utilization. Suitable vectors and promoters for use in yeast expression are further described in R. Hitzeman et al., European Patent Publication No. 73,657A. Yeast enhancers such as the UAS Gal from Saccharomyces cerevisiae (found in conjunction with the CYC1 promoter on plasmid YEpsec-hIlbeta ATCC 67024), also are advantageously used with yeast promoters.
The following examples are presented to further illustrate the preparation of the claimed proteins. The scope of the present invention is not to be construed as merely consisting of the following examples.
EXAMPLE 1
A DNA sequence encoding the following protein sequence: ##STR1## is obtained using standard PCR methodology. A forward primer (5'-GG GG CAT ATG AGG GTA CCT ATC CAG AAA GTC CAG GAT GAC AC) (SEQ. ID NO:2) and a reverse primer (5'-GG GG GGATC CTA TTA GCA CCC GGG AGA CAG GTC CAG CTG CCA CAA CAT) (SEQ. ID NO:3) is used to amplify sequences from a human fat cell library (commercially available from CLONETECH). The PCR product is cloned into PCR-Script (available from STRATAGENE) and sequenced.
EXAMPLE 2
Vector Construction
A plasmid containing the DNA sequence encoding the desired claimed protein is constructed to include NdeI and BamHI restriction sites. The plasmid carrying the cloned PCR product is digested with NdeI and BamHI restriction enzymes. The small ˜450bp fragment is gel-purified and ligated into the vector pRB182 from which the coding sequence for A-C-B proinsulin is deleted. The ligation products are transformed into E. coli DH10B (commercially available from GIBCO-BRL) and colonies growing on tryprone-yeast (DIFCO) plates supplemented with 10 μg/mL of tetracycline are analyzed. Plasmid DNA is isolated, digested with NdeI and BamHI and the resulting fragments are separated by agarose gel electrophoresis. Plasmids containing the expected ˜450bp NdeI to BamHI fragment are kept. E. coli B BL21 (DE3) (commercially available from NOVOGEN) are transformed with this second plasmid expression suitable for culture for protein production.
The techniques of transforming cells with the aforementioned vectors are well known in the art and may be found in such general references as Maniatis, et al. (1988) Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Press, Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y. or Current Protocols in Molecular Biology (1989) and supplements. The techniques involved in the transformation of E. coli cells used in the preferred practice of the invention as exemplified herein are well known in the art. The precise conditions under which the transformed E. coli cells are cultured is dependent on the nature of the E. coli host cell line and the expression or cloning vectors employed. For example, vectors which incorporate thermoinducible promoter-operator regions, such as the c1857 thermoinducible lambda-phage promoter-operator region, require a temperature shift from about 30 to about 40 degrees C. in the culture conditions so as to induce protein synthesis.
In the preferred embodiment of the invention E. coli K12 RV308 cells are employed as host cells but numerous other cell lines are available such as, but not limited to, E. coli K12 L201, L687, L693, L507, L640, L641, L695, L814 (E. coli B). The transformed host cells are then plated on appropriate media under the selective pressure of the antibiotic corresponding to the resistance gone present on the expression plasmid. The cultures are then incubated for a time and temperature appropriate to the host cell line employed.
Proteins which are expressed in high-level bacterial expression systems characteristically aggregate in granules or inclusion bodies which contain high levels of the overexpressed protein. Kreuger et al., in Protein Folding, Gierasch and King, eds., pgs 136-142 (1990), American Association for the Advancement of Science Publication No. 89-18S, Washington, D.C. Such protein aggregates must be solubilized to provide further purification and isolation of the desired protein product. Id. A variety of techniques using strongly denaturing solutions such as guanidinium-HCl and/or weakly denaturing solutions such as dithiothreitol (DTT) are used to solubilize the proteins.
Gradual removal of the denaturing agents (often by dialysis) in a solution allows the denatured protein to assume its native conformation. The particular conditions for denaturation and folding are determined by the particular protein expression system and/or the protein in question.
Preferably, the present proteins are expressed as Met-Arg-SEQ ID NO: 1 so that the expressed proteins may be readily converted to the claimed protein with Cathepsin C. The purification of proteins is by techniques known in the art and includes reverse phase chromatography, affinity chromatography, and size exclusion.
The claimed proteins contain two cysteine residues. Thus, a di-sulfide bond may be formed to stabilize the protein. The present invention includes proteins of the Formula (I) wherein the Cys at position 91 of SEQ ID NO: 1 is crosslinked to Cys at position 141 of SEQ ID NO: 1 as well as those proteins without such di-sulfide bonds.
In addition the proteins of the present invention may exist, particularly when formulated, as dimers, trimers, tetramers, and other multimers. Such multimers are included within the scope of the present invention.
The present invention provides a method for treating obesity. The method comprises administering to the organism an effective amount of anti-obesity protein in a dose between about 1 and 1000 μg/kg. A preferred dose is from about 10 to 100 μg/kg of active compound. A typical daily dose for an adult human is from about 0.5 to 100 mg. In practicing this method, compounds of the Formula (I) can be administered in a single daily dose or in multiple doses per day. The treatment regime may require administration over extended periods of time. The amount per administered dose or the total amount administered will be determined by the physician and depend on such factors as the nature and severity of the disease, the age and general health of the patient and the tolerance of the patient to the compound.
The instant invention further provides pharmaceutical formulations comprising compounds of the Formula (I). The proteins, preferably in the form of a pharmaceutically acceptable salt, can be formulated for nasal, bronchal, transdermal, or parenteral administration for the therapeutic or prophylactic treatment of obesity. For example, compounds of the Formula (I) can be admixed with conventional pharmaceutical carriers and excipients. The compositions comprising claimed proteins contain from about 0.1 to 90% by weight of the active protein, preferably in a soluble form, and more generally from about 10 to 30%.
For intravenous (IV) use, the protein is administered in commonly used intravenous fluid(s) and administered by infusion. Such fluids, for example, physiological saline, Ringer's solution or 5% dextrose solution can be used.
For intramuscular preparations, a sterile formulation, preferably a suitable soluble salt form of a protein of the Formula (I), for example the hydrochloride salt, can be dissolved and administered in a pharmaceutical diluent such as pyrogen-free water (distilled), physiological saline or 5% glucose solution. A suitable insoluble form of the compound may be prepared and administered as a suspension in an aqueous base or a pharmaceutically acceptable oil base, e.g. an ester of a long chain fatty acid such as ethyl oleate.
It may also be desirable to administer the compounds of Formula (I) intranasally. Formulations useful in the intranasal absorption of proteins are well known in the art. Nasal formulations comprise the protein and carboxyvinyl polymer preferably selected from the group comprising the acrylic acid series hydrophilic crosslinked polymer, e.g. carbopole 934, 940, 941 (Goodrich Co.). The polymer accelerates absorption of the protein, and gives suitable viscosity to prevent discharge from nose. Suitable content of the polymer is 0.05-2 weight %. By neutralisation of the polymer with basic substance, thickening effect is increased. The amount of active compound is commonly 0.1-10%. The nasal preparation may be in drop form, spraying applicator or aerosol form.
The ability of the present compounds to treat obesity is demonstrated in vivo as follows:
Biological Testing for Anti-obesity proteins
Parabiotic experiments suggest that a protein is released by peripheral adipose tissue and that the protein is able to control body weight gain in normal, as well as obese mice. Therefore, the most closely related biological test is to inject the test article by any of several routes of administration (e.g. i.v., s.c., i.p., or by minipump or cannula) and then to monitor food and water consumption, body weight gain, plasma chemistry or hormones (glucose, insulin, ACTH, corticosterone, GH, T4) over various time periods.
Suitable test animals include normal mice (ICR, etc.) and obese mice (ob/ob , Avy/a, KK-Ay, tubby, fat). The ob/ob mouse model of obesity and diabetes is generally accepted in the art as being indicative of the obesity condition. Controls for non-specific effects for these injections are done using vehicle with or without the active agent of similar composition in the same animal monitoring the same parameters or the active agent itself in animals that are thought to lack the receptor (db/db mice, fa/fa or cp/cp rats). Proteins demonstrating activity in these models will demonstrate similar activity in other mammals, particularly humans.
Since the target tissue is expected to be the hypothalamus where food intake and lipogenic state are regulated, a similar model is to inject the test article directly into the brain (e.g. i.c.v. injection via lateral or third ventricles, or directly into specific hypothalamic nuclei (e.g. arcuate, paraventricular, perifornical nuclei). The same parameters as above could be measured, or the release of neurotransmitters that are known to regulate feeding or metabolism could be monitored (e.g. NPY, galanin, norepinephrine, dopamine, β-endorphin release).
Similar studies are accomplished in vitro using isolated hypothalamic tissue in a perifusion or tissue bath system. In this situation, the release of neurotransmitters or electrophysiological changes is monitored.
The compounds are active in at least one of the above biological tests and are anti-obesity agents. As such, they are useful in treating obesity and those disorders implicated by obesity. However, the proteins are not only useful as therapeutic agents; one skilled in the art recognizes that the proteins are useful in the production of antibodies for diagnostic use and, as proteins, are useful as feed additives for animals. Furthermore, the compounds are useful for controlling weight for cosmetic purposes in mammals. A cosmetic purpose seeks to control the weight of a mammal to improve bodily appearance. The mammal is not necessarily obese. Such cosmetic use forms part of the present invention.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 3(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 141 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /note="Xaa at position 2 is Glnor Glu;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 17(D) OTHER INFORMATION: /note="Xaa at position 17 is Asn,Asp or Gln;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 22(D) OTHER INFORMATION: /note="Xaa at position 22 is Thror Ala;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 23(D) OTHER INFORMATION: /note="Xaa at position 23 is Glnor Glu or absent;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 29(D) OTHER INFORMATION: /note="Xaa at position 29 is Glnor Glu;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 49(D) OTHER INFORMATION: /note="Xaa at position 49 is Ile,Leu, Met or methionine sulfoxide;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 51(D) OTHER INFORMATION: /note="Xaa at position 51 is Glnor Glu;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 57(D) OTHER INFORMATION: /note="Xaa at position 57 is Glnor Glu;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 58(D) OTHER INFORMATION: /note="Xaa at position 58 is Glnor Glu;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 63(D) OTHER INFORMATION: /note="Xaa at position 63 is Ile,Leu, Met or methionine sulfoxide;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 67(D) OTHER INFORMATION: /note="Xaa at position 67 is Asn,Asp or Gln;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 70(D) OTHER INFORMATION: /note="Xaa at position 70 is Glnor Glu;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 73(D) OTHER INFORMATION: /note="Xaa at position 73 is Asn,Asp or Gln;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 77(D) OTHER INFORMATION: /note="Xaa at position 77 is Asn,Asp or Gln;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 95(D) OTHER INFORMATION: /note="Xaa at position 95 is Trpor Gln;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 125(D) OTHER INFORMATION: /note="Xaa at position 125 is Glnor Glu;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 129(D) OTHER INFORMATION: /note="Xaa at position 129 is Glnor Glu;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 131(D) OTHER INFORMATION: /note="Xaa at position 131 isIle, Leu, Met or methionine sulfoxide;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 133(D) OTHER INFORMATION: /note="Xaa at position 133 is Trpor Gln;"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 134(D) OTHER INFORMATION: /note="Xaa at position 134 is Glnor Glu"(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:ValXaaAspAspThrLysThrLeuIleLysThrIleValThrArgIle151015XaaAspIleSerHisXaaXaaSerValSerSerLysXaaLysValThr202530GlyLeuAspPheIleProGlyLeuHisProIleLeuThrLeuSerLys354045XaaAspXaaThrLeuAlaValTyrXaaXaaIleLeuThrSerXaaPro505560SerArgXaaValIleXaaIleSerXaaAspLeuGluXaaLeuArgAsp65707580LeuLeuHisValLeuAlaPheSerLysSerCysHisLeuProXaaAla859095SerGlyLeuGluThrLeuAspSerLeuGlyGlyValLeuGluAlaSer100105110GlyTyrSerThrGluValValAlaLeuSerArgLeuXaaGlySerLeu115120125XaaAspXaaLeuXaaXaaLeuAspLeuSerProGlyCys130135140(2) INFORMATION FOR SEQ ID NO:2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 42 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: DNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:GGGGCATATGAGGGTACCTATCCAGAAAGTCCAGGATGACAC42(2) INFORMATION FOR SEQ ID NO:3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 48 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: DNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:GGGGGGATCCTATTAGCACCCGGGAGACAGGTCCAGCTGCCACAACAT48__________________________________________________________________________
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The present invention provides anti-obesity proteins, which when administered to a patient regulate fat tissue. Accordingly, such agents allow patients to overcome their obesity handicap and live normal lives with much reduced risk for type II diabetes, cardiovascular disease and cancer.
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RELATED APPLICATION
[0001] This Application is a Divisional of U.S. application Ser. No. 12/206,897, titled “SWING DOOR,” filed Sep. 9, 2008, (pending) which is commonly assigned and incorporated herein by reference.
FIELD
[0002] The present disclosure relates generally to swing type garage doors and in particular the present disclosure relates to loading and use of swing type garage doors
BACKGROUND
[0003] Garage doors of the swing-type are typically comprised of a door that remains in a single panel configuration even when the door is being opened and is open. Such doors are often opened and closed using hydraulic cylinders. These swing-type doors are typically of either unitary construction, or are manufactured in sections that must be assembled when the door sections are delivered to an installation site, requiring additional time and effort to assemble the door.
[0004] Further, swing type doors may have a truss permanently attached to a bottom of the door that provides added stability against drooping of the door when it is open. These built-on trusses require additional materials, and are permanent, so they can be obstacles in front of a door, as well as potential tripping points. Further doors with permanent trusses either require shipping a more unwieldy portion of door, or additional assembly time and effort when the door sections arrive at the installation location.
[0005] Wind loading on doors in high wind conditions can be very high. Such wind loading can lead to bowing or even buckling of doors. Some bracing systems for doors employ additional cross bracing within the door body frame, but even additional bracing cannot prevent damage in higher winds.
[0006] For the reasons stated above, and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for improvements in swing type door bracing, trussing, and load distribution.
SUMMARY
[0007] In one embodiment, a swing type garage door includes a door body rotationally connected to a door frame, the door body rotatable between a first closed position and a second open position. The door body includes a trussing system with vertical truss members and horizontal truss members, the horizontal members having openings through which the vertical members extend, the openings having sides on either side of the vertical truss member, to distribute a load on the door body to the door frame in both a vertical and a horizontal direction.
[0008] In another embodiment, a swing type garage door includes a door body rotationally connected to a door frame, the door body rotatable between a first closed position and a second open position. The door body includes a first section and a second section hingedly connected with a hinge, the door body foldable from a first operating configuration in which the first and the second sections are pinned so that they form a substantially rigid door body, and a second transport configuration for storage and transport in which the first and second sections are folded about the hinge to reduce the effective dimensions of the door body.
[0009] In still another embodiment, a swing type garage door includes a door body rotationally connected to a door frame, the door body rotatable between a first closed position and a second open position. The door body has a main door body section and a door load truss section, the door load truss section hingedly connected at a bottom of the main door body and rotatable between a first configuration in which the main door body section and the door load truss section are substantially coplanar and a second configuration in which the door load truss section is substantially perpendicular to the main door body section.
[0010] In another embodiment, a swing type garage door includes a door body rotationally connected to a door frame, the door body rotatable between a first closed position and a second open position. The door body has at least one brace rotatably connected to the door body on an interior thereof, the at least one brace rotatably movable between a first bracing position in which the brace is positioned substantially perpendicular to a plane of the door body and a second storage position in which the brace is substantially coplanar and parallel to the door body.
[0011] Other embodiments are described and claimed.
BRIEF DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is an isometric view of a garage door according to one embodiment of the present invention;
[0013] FIG. 1A is a more detailed view of a portion of the garage door of FIG. 1 ;
[0014] FIG. 2 is an isometric view of a garage door according to another embodiment of the present invention;
[0015] FIG. 3 is an isometric view of a garage door having a door load truss according to another embodiment of the present invention;
[0016] FIG. 3A is a view of the garage door of FIG. 3 with the door load truss in another position;
[0017] FIG. 3B is a view of the garage door of FIG. 3A with the door shown in an open position;
[0018] FIG. 4 is an isometric view of a garage door having door braces according to another embodiment of the present invention; and
[0019] FIG. 4A is a view of the garage door of FIG. 4 with the door braces in a folded position.
DETAILED DESCRIPTION
[0020] In the following detailed description of the embodiments, reference is made to the accompanying drawings that form a part hereof. In the drawings, like numerals describe substantially similar components throughout the several views. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized and structural, logical, and electrical changes may be made without departing from the scope of the present invention.
[0021] The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present disclosure is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.
[0022] Referring to FIG. 1 , a one piece swing type garage door 100 has vertical 102 and horizontal 104 trussing that intersects in a number of locations over the span of the door 100 . The vertical trussing pieces 102 and horizontal trussing pieces 104 serve to distribute a load on the door from the trussing to the external frame 106 of the door, which is typically stronger than the door itself Typical doors may have both horizontal and vertical trussing, or one or the other. However, for door 100 , the horizontal and vertical trussing are interconnected to distribute load in both the horizontal and the vertical directions.
[0023] To accomplish this, the horizontal and vertical trussing is constructed as shown in greater detail in FIG. 1A . Individual vertical truss member 152 and individual horizontal truss member 154 are shown at an intersection 156 thereof. Horizontal truss member 154 has an opening 158 through which vertical truss member 152 extends. Horizontal truss member 154 has opening 158 configured in size in one embodiment to fit a width 160 of vertical truss member 152 . Sides 162 and 164 of horizontal truss member 154 are on either side of the vertical truss member 152 . Because of this, when assembled, the truss members 152 and 154 provide a distributed load from stress from either side of the door. In one embodiment, the vertical truss members 152 and vertical truss members 154 are joined at the intersection 1566 , for example by bolting, welding, epoxying, or the like.
[0024] The interconnection of the vertical and horizontal truss members spreads a load on the door 100 over the entire frame. Loads, such as from lifting of the door 100 and wind loading, are dispersed both horizontally and vertically, as opposed to traditional loads being dispersed only vertically.
[0025] Door hydraulics 108 are connected between the frame 106 and the door body 110 so as to open the door 100 by moving the door body 110 in response to the door hydraulics 108 . Hydraulics 108 are hinged so as to rotate about their mounting points at the door frame 106 and at the door body 110 . When hydraulics 108 are actuated, using a hydraulic motor or hydraulic controller (not shown), a hydraulic cylinder of the hydraulics 108 extends and opens the door. The door body 110 is hingedly connected to door frame 106 along its top 112 , and rotates on a rotational axis 114 between open and closed positions.
[0026] If there is an increased wind load or expected extra wind load on a door such as door 100 , the depth of the horizontal trusses is increased in one embodiment. In contrast, typical doors would increase the number of vertical trusses or make them much larger in size and thickness, adding extra weight. The increase in the depth of the horizontal trusses, that is their depth in a direction substantially perpendicular to the face of the door 100 , which adds some weight, but not much, for the resulting increase in handling a wind load.
[0027] FIG. 2 shows a door 200 according to another embodiment of the present invention. Door 200 has a hinge 202 extending horizontally across the door, hingedly connecting top section 204 and bottom section 206 of the door 200 . The hinge 202 allows the door 200 to be shipped in a folded orientation, while still having the sections 204 and 206 connected to each other. This makes the door 200 easier to ship, and also requires less installation time than a typical door, since a typical door is shipped in sections that must be assembled on site. The hinge 202 extends in this embodiment horizontally along the door 200 . In shipping, the door 200 is folded along hinge 202 . To prepare the door 200 for installation, the door is unfolded, and pins 208 are used to pin the top and bottom sections 204 and 206 together quickly and reliably.
[0028] In yet another embodiment, a door 300 is shown in FIGS. 3 , 3 A, and 3 B. Door 300 has a hinge 302 hingedly connecting a top section 306 and a door load truss section 304 . In normal operation of the door 300 when it is closed ( FIG. 3 ), the sections 304 and 306 are co-planar and locked in that position with pins 308 , so that the door 300 functions as any other door. However, when the door 300 is opened (FIG. 3 B), the door load truss section 304 is rotated about hinge 302 to a position in which it is substantially perpendicular to the section 306 , forming a door load truss that assists in prevention of sagging of the door 300 , due to its weight and/or size, during opening and while the door 300 is open. In this embodiment, then, the door load truss 304 is only used as a load truss when the door 300 is open. In contrast, normal door load trusses are permanently affixed in a position where they are substantially perpendicular to the face of the door. These normal door load trusses require additional materials, and present potential obstacles when working around the door. The folding truss allows a cleaner profile for the door when it is down, but still provides the horizontal stability of a permanent truss when the door is opened or is in the open position.
[0029] As shown in FIG. 3A , the hinged operation of the door load truss section 304 does not interfere with the closing of the door 300 , and the door load truss section 304 can be maintained in its load bearing position in which it is substantially perpendicular to door face 301 of section 306 . In this configuration, the door load truss section 304 also provides windage loading support for the door 300 .
[0030] In still another embodiment, shown in FIGS. 4 and 4A , door 400 has at least one (two are shown, although more or fewer are within the scope of the disclosure) added brace 402 . Brace 402 is in one embodiment movable on hinges 404 between a first position in which brace 402 is substantially perpendicular to door face 401 and a second folded-in position in which brace 402 is substantially parallel and adjacent to door face 401 (see FIG. 4A ). Brace 402 has a first vertical member 406 and a second vertical member 408 substantially parallel to first vertical member 406 . Vertical members 406 and 408 are separated by horizontal members 410 . When the brace 402 is in its first position, it can in one embodiment be pinned or otherwise secured to a floor 420 to provide additional wind loading for the door 400 . If pinned, brace 402 has a pin 412 that may be placed through a hole or opening 414 in brace 402 and which extends into a hole 422 in the floor 420 or the like. In its first position, brace 402 provides additional structural support for the door 400 , and the ability to secure the brace to floor 420 provides further structural stability especially in high wind situations. When two braces 402 are used and are in their first positions, the door frame is loaded in three sections.
[0031] Door braces are attached to the main door section 412 for added wind loading and stiffening when the door 400 is down. For high wind situations, such as for a hurricane or the like, the normally folded door braces 402 are extended to be substantially perpendicular to the door. When additional wind loading is required, the braces are unfolded to approximately a 90 degree angle to the door, adding additional stability and loading. The braces can then be pinned to the floor or the like. Also, the positioning of the braces breaks the loading down into approximately three equal pieces of the main door. Alternatively, the braces 402 can be permanently or semi-permanently pinned in their first open positions if desired.
[0032] One of more of the embodiments and variations described above can be integrated with a door of the type described. The hinged door load truss 304 of FIG. 3 can be used on other types of doors as well.
[0033] Combinations are within scope of the disclosure, for example a door can have the hinged sections of FIG. 2 combined with the horizontal and vertical integrated trussing of FIG. 1 . Such combinations will be understood by those of skill in the art to be within the scope of the disclosure.
CONCLUSION
[0034] A swing-type garage door has been described that includes in various embodiments one or more of: hinged sections for ease of transfer and installation; integrated horizontal and vertical trussing to distribute wind loading; a door load truss that is integral with the door and only folds perpendicular for opening and open doors; and door braces pinnable to a floor for additional structural stability in storms and the like.
[0035] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
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A swing type garage door has one or more of several features, including a door body rotationally connected to a door frame, the door body having one or more of: a trussing system having vertical and horizontal truss members, the horizontal members having openings through which the vertical members extend to distribute a load on the door body to the door frame in both a vertical and a horizontal direction; first and second sections hingedly connected with a hinge to allow ease in transport; a main door body section and a door load truss section hingedly connected at a bottom of the main door body to provide load trussing when the door is open; and at least one brace rotatably connected to the door body on an interior thereof and rotatable between a first bracing position and a second storage position to brace in high wind loading conditions.
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BACKGROUND OF THE INVENTION
Desks have evolved from simple table-like structures into some fairly complex designs. One example of such designs is found in U.S. Pat. No. 4,646,655 to Robolin for a Data Processing Work Station. A tubular framework is provided having multiple shelves for holding various components of a data processing system. Another example is found in U.S. Pat. No. 4,561,619 to Robillard et al. for a Movable CRT Pedestal. This design involves the use of a laterally movable support for the video display monitor. The support also includes telescoping arms for adjusting the distance of the monitor from the user.
Certain other desk designs involve the use of slanted and/or wrap-around work surfaces. Such designs can be found as early as 1903, as shown by U.S. Pat. No. 744,888 to Widman et al., for an Office Desk. This desk has a slanted work surface with a recessed central portion so as to wrap around the user. Another example is found in U.S. Pat. No. 1,293,952 to Shirley for a Desk, featuring a wrap-around design with storage compartments therein.
Many of these designs, however, are limited to a certain defined application. Thus, a desk designed specifically for a data processing work station may lack a writing surface. Others may not be able to accommodate a computer system or may make use of the keyboard or other components difficult or tiring.
SUMMARY OF THE INVENTION
It is therefore, one of the principal objects of the present invention to provide an adjustable desk-top assembly which can support a multiplicity of functions, such as a data processing station including storage capability, as well as a writing or drawing work surface, and which is convenient and comfortable for the user.
Another object of the present invention is to provide a desk-top assembly which can be retrofitted to a plurality of pedestals for converting existing desks, and which can be easily moved and installed on such pedestals.
A further object of the present invention is to provide a desk top assembly in which the work surface can be adjusted to suit the user and which is durable for providing a long service life.
These and other objects are attained by the present invention which relates to an adjustable desk-top assembly having a work surface capable of assuming a slope. The work surface is provided with a faceted, cut-out portion for allowing the user easy access to the rear portions of the desk-top assembly. Extending around the perimeter of the desk-top assembly are compartments for receiving and storing components of a computer system or the like. The work surface is easily adjusted to accommodate the user and the task, and can also be used to partially secure the components in the compartments.
Various additional objects and advantages will become apparent from the following detailed description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present adjustable desk-top assembly, shown here in installed position on a conventional desk pedestal;
FIG. 2 is a side elevational view, shown partially in cross-section, showing one embodiment of the adjustment mechanism for the work surface of the present invention the section being taken on line 2--2 of FIG. 1;
FIG. 3 is a partial cross-sectional view of the present desk-top assembly, the view being taken on line 3--3 of FIG. 2;
FIG. 4 is a partial perspective view of one of the internal compartments of the present invention, shown here with the cover removed;
FIG. 5 is a perspective view of an alternate embodiment of the present desk-top assembly, shown here with the work surface removed to illustrate the adjustment mechanism; and
FIG. 6 is a partial cross-sectional view showing in detail the alternate embodiment of the adjustment mechanism, the view being taken on line 6--6 of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more specifically to the drawings and to FIG. 1 in particula, numeral 10 designates generally the adjustable desk top assembly of the present invention. The desk top assembly is shown here in installed position over a conventional desk pedestal 12 having the typical frame and drawers 14, however, it is to be understood that the present invention can be installed over any suitable pedestal, for example, that shown in FIG. 5. Similarly, the present desk top assembly is shown as being composed of wood. This however, is not meant to limit the present invention in any way as there are any number of suitable materials which could be employed to construct the present invention, for example, plastic or metal.
The present desk top assembly includes a generally rectangular frame defined by a base member or lower panel member 16, generally vertical side and back panel members 18 and 20 respectively, which panels extend perpendicularly from the base member 16, and a generally planar upper panel member 22, which is disposed generally parallel to the lower panel 16. In addition, front panels 24 are secured to each of the side panels 18 and a plurality of door means or inside panels 26 are provided adjacent the front panels 24 and between the upper and lower panels to effectively form an enclosed box like structure having the central portion thereof cutout, as shown in FIG. 1. The cutout portion is generally semicircular, with a preferred embodiment being shown in which the cutout portion is faceted for reasons which will be more fully explained hereinafter.
The work surface 28 of the present desk top assembly is disposed within the cutout portion of the upper or top panel 22 and has a faceted inner edge corresponding to the facets formed in the top panel 22. The outwardly facing edge or edge which faces the user has a cutout portion indicated by numeral 30, allowing the user to be positioned close to the work surface, thus, the front side of the desk, which is the side opposite the rear panel 20, is considered the user's station and is, as shown in FIG. 1, in the region defined by and adjacent to edge 30 which defines the generally semicircular cut-out portion of work surface 28. This has several advantages. As shown in FIG. 1, the work surface 28 includes right and left extension 32 and 34 respectively on either side of the cutout portion defined by edge 30. This provides an arm rest for writing for either a right or left handed user. In addition, the cutout portion defined by edge 30 allows the user to easily reach any components or other materials which are stored in the compartments behind panel 26. Referring to FIGS. 2 and 3, the range of movement for the work surface is detailed. A securing means 35 including a bar 36 fastened secured near the front edge of the work surface 28 by brackets 38, thereby providing a pivot point. The ends of bar 36 are effectively secured within the desk top assembly, being secured within slots or apertures 4 formed near the bottom portion of side panels 26 as shown in FIG. 3.
Referring to FIG. 2, one embodiment of a device for adjusting the back edge of the work surface 28 is illustrated. A spacer block 42 is disposed beneath the back edge of the work surface 28 for adjusting the elevation of the work surface relative to the base member 16. This slope imparted to the work surface may vary from approximately zero to approximately 45 degrees by adjusting the spacer forwardly or rearwardly beneath the back edge of the work surface 28. With this embodiment, as the spacer is moved to the extreme forward portion, the back edge of the work surface can ride down the slope of the triangular spacer block for making incremental adjustments in the slope of the work surface, the securement of the front edge by bar 36 preventing the work surface from sliding. The block may also be removed completely for providing the work surface with essentially no slope.
As noted previously, the present desk top assembly is constructed so as to define a plurality of compartments which may be used for a variety of purposes, such as the storage of components for a data processing system. The compartments may or may not be provided with internal walls, however, all are defined at the front of the compartment by the inside panels 26. Suitable fastening means, such as brackets 44 and screws 46 are used internally to secure the panels 26 to the base member 16. Once secured, access to the screws and brackets is obtained by lifting the top panel 22 off of the present assembly, the symmetrical configuration making such lifting relatively easy, or by sliding the panel forwardly or back to gain access. Referring still to FIG. 4, with any of the panels 26 removed, the slope of work surface 28 can be adjusted so as to permit access to the component stored behind that particular panel 26 or its corresponding slot. For example, disposed in the open compartment in FIG. 4 could be a disk drive unit which could be conveniently stored therein, such units generally requiring access only to the disk insertion slots after they have been connected to the system. In similar fashion, any wiring or other connections can be conveniently disposed within the compartments, thus keeping the wires protected and out of sight.
The adjustability of the work surface 28 also serves a security function, in that increasing the slope of the work surface as shown in FIG. 1 serves to cut off from view the components disposed in the various compartments, thereby reducing the possibility that the components will be either accidently activated or stolen. When the components are again needed by the operator, the slope of the work surface 28 need only be reduced so as to allow access to the component as shown in FIG. 4.
FIGS. 5 and 6 illustrate an alternate embodiment of an adjustment means for moving the work surface 28. In addition, illustrated is the applicability of the present desk top assembly to a pedestal other than the conventional desk pedestal shown in FIG. 1. This pedestal 48 is comprised mainly of a set of legs only, illustrating that the present invention is an essentially self contained unit which can be mounted on a plurality of pedestal means. Another modification is shown in FIG. 5, where a portion of the top panel 22 has been removed and a video display monitor 50 is inserted therein. As can be seen from FIG. 5, the present desk top assembly has sufficient depth to receive and secure the monitor, while the inside panel 26 in front of the installed monitor may be removed for access to any monitor controls which are disposed below the level of the top surface 22.
The work surface 28 has been shown in phantom lines in FIGS. 5 and 6 so as to clearly show the adjustment means used for this embodiment. Extending between the right and left sides of the base member 16 and secured thereto is a transverse support bar 52. Extending upwardly through the bar is at least one and preferably two jack screws 54 which are disposed for axial movement therein. Secured to the underside of bar 52 is a bracket means 56 for securing a pulley 58 or similar means therein. Each of the jack screws is threadedly engaged by a pulley 58 the pulleys being connected through a cable 60 or other suitable means. The cable extends around both pulleys 58 and around a third pulley 62 which is operatively connected to a motor 64 or similar means for moving the pulley and cable arrangement. The motor is mounted inside one of the compartments on base member 16 and has a shaft 66 extending downwardly therefrom to fixedly engage and turn pulleys 62. This in turn causes rotation of pulleys 58 which operate to move the jack screws vertically due to the threaded engagement with the pulleys. This vertical movement of the jack screw serves to adjust the slope of the work surface 28 to the level desired by the user. The motor 64 is connected through power cord 68 to a suitable source of power and the motor may have a conveniently mounted switch 70 or similar means for activating the motor.
The use and operation of the present adjustable desk top assembly have been described hereinabove. The present assembly may be installed over conventional desk pedestals, drafting table supports, or a number of other suitable support means. The adjustable work surface is capable of assuming a slope and can be adjusted for comfort in writing, typing, drawing or any of a number of tasks, including simply reading. A number of suitable materials may be used for constructing the present desk top assembly ranging from solid wood or veneered products to lightweight metals or plastic. Similarly, the present invention can be scaled to any desired size making it suitable for home, school or office environments.
While an embodiment and a modification of an adjustable desk top assembly have been shown and described in detail herein, various other changes and modifications may be made without departing from the scope of the present invention.
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An adjustable desk-top assembly is disclosed having upper, lower, and inner side panels, the upper and lower panels being spaced apart for forming a compartmentalized enclosure. The desk-top has an adjustable work surface capable of assuming a slope and a centralized cut-out portion therein for extending in a semi-circle around the user of the desk. The inner or door panels, are releasably secured and can be removed for accommodating any of a number of suitable components. The slope imparted to the work surface can be adjusted to an optimum level for the particular task and, by imparting greater slope and covering the components therein, a security measure is also provided.
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BACKGROUND
The subject matter disclosed herein relates generally to gas turbine systems, and more particularly, to systems and methods for reducing combustion dynamics, and more specifically, for reducing modal coupling of combustion dynamics within a gas turbine engine.
Gas turbine systems generally include a gas turbine engine having a compressor section, a combustor section, and a turbine section. The combustor section may include one or more combustors (e.g., combustion cans), each combustor having a primary combustion zone and a secondary combustion zone (e.g., late lean injection (LLI) system) downstream from the primary combustion zone. A fuel and/or fuel-air (e.g., oxidant) mixture may be routed into the primary and secondary combustion zones through fuel nozzles, and each combustion zone may be configured to combust the mixture of the fuel and oxidant to generate hot combustion gases that drive one or more turbine stages in the turbine section.
The generation of the hot combustion gases can create combustion dynamics, which occur when the flame dynamics (also known as the oscillating component of the heat release) interact with, or excite, one or more acoustic modes of the combustor, to result in pressure oscillations in the combustor. Combustion dynamics can occur at multiple discrete frequencies or across a range of frequencies, and can travel both upstream and downstream relative to the respective combustor. For example, the pressure waves may travel downstream into the turbine section, e.g., through one or more turbine stages, or upstream into the fuel system. Certain downstream components of the turbine section can potentially respond to the combustion dynamics, particularly if the combustion dynamics generated by the individual combustors exhibit an in-phase and coherent relationship with each other, and have frequencies at or near the natural or resonant frequencies of the components. In general, “coherence” refers to the strength of the linear relationship between two dynamic signals, and is strongly influenced by the degree of frequency overlap between them. In certain embodiments, “coherence” can be used as a measure of the modal coupling, or combustor-to-combustor acoustic interaction, exhibited by the combustion system.
Accordingly, a need exists to control the combustion dynamics, and/or modal coupling of the combustion dynamics, to reduce the possibility of any unwanted sympathetic vibratory response (e.g., resonant behavior) of components in the turbine system.
BRIEF DESCRIPTION
Certain embodiments commensurate in scope with the originally claimed invention are summarized below. These embodiments are not intended to limit the scope of the claimed invention, but rather these embodiments are intended only to provide a brief summary of possible forms of the invention. Indeed, the invention may encompass a variety of forms that may be similar to or different from the embodiments set forth below.
In a first embodiment, a system includes a gas turbine engine having a first combustor and a second combustor. The first combustor includes a first fuel conduit having a first plurality of injectors. The first plurality of injectors are disposed in a first configuration within the first combustor along a first fuel path, and the first plurality of injectors are configured to route a fuel to a first combustion chamber. The system further includes a second combustor which includes a second fuel conduit having a second plurality of injectors. The second plurality of injectors are disposed in a second configuration within the second combustor along a second fuel path, and the second plurality of injectors are configured to route the fuel to a second combustion chamber. The second configuration has at least one difference relative to the first configuration.
In a second embodiment, a system includes a second combustor having a second fuel conduit, which includes a second plurality of fuel injectors with a second arrangement. The second plurality of fuel injectors are configured to route the fuel to a second secondary combustion zone of the second combustor. The second plurality of fuel injectors comprises a third injector having at least one difference relative to a fourth injector.
In a third embodiment, a method includes controlling a first combustion dynamic of a first combustor or a first flame dynamic of a first set of fuel injectors of the first combustor with a first arrangement of the first set of fuel injectors. The method further includes controlling a second combustion dynamic of a second combustor or a second flame dynamic of a second set of fuel injectors of the second combustor with a second arrangement of the second set of fuel injectors. The first arrangement comprises at least one difference relative to the second arrangement.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
FIG. 1 is a schematic of an embodiment of a gas turbine system having a plurality of combustors, where each combustor of the plurality of combustors is equipped with a late lean injection (LLI) fuel circuit having a plurality of LLI injectors in a LLI injector arrangement;
FIG. 2 is a cross-sectional schematic of an embodiment of one of the combustors of FIG. 1 , where the combustor is operably coupled to the LLI fuel circuit and a controller;
FIG. 3 is a schematic of an embodiment of the gas turbine system of FIG. 1 , illustrating a plurality of combustors each having a plurality of late lean injectors, where the arrangement of the late lean injectors in each of the plurality of combustors varies between combustors to control combustion dynamics and therefore modal coupling of combustion dynamics, thereby reducing the possibility of unwanted vibratory responses in downstream components;
FIG. 4 is a cross-sectional schematic of an embodiment of a first combustor in the system of FIG. 3 , wherein the first combustor includes a first circumferential distribution of injectors;
FIG. 5 is a cross-sectional schematic of an embodiment of a second combustor in the system of FIG. 3 , wherein the second combustor includes a second circumferential distribution of injectors that is different than the first circumferential distribution; and
FIG. 6 is a cross-sectional schematic of an embodiment of a third combustor in the system of FIG. 3 , wherein the third combustor includes a third circumferential distribution of the injectors 18 that is different than the first and second circumferential distribution.
DETAILED DESCRIPTION
One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
The present disclosure is directed towards reducing combustion dynamics and/or modal coupling of combustion dynamics, to reduce unwanted vibratory responses in downstream components. As described above, a combustor within the gas turbine system combusts an oxidant-fuel mixture to generate hot combustion gases that drive one or more turbine stages in the gas turbine. In some situations, the combustion system may create combustion dynamics due to the combustion process, characteristics of intake fluid flows (e.g., fuel, oxidant, diluent, etc.) into the combustor, and various other factors. The combustion dynamics may be characterized as pressure fluctuations, pulsations, oscillations, and/or waves at certain frequencies. Collectively, the combustion dynamics can potentially cause vibratory responses and/or resonant behavior in various components upstream and/or downstream from the combustor. For example, the combustion dynamics (e.g., at certain frequencies, ranges of frequencies, amplitudes, combustor-to-combustor phases, etc.) can travel both upstream and downstream in the gas turbine system. If the gas turbine combustors, upstream components, and/or downstream components have natural or resonant frequencies that are driven by these pressure fluctuations (i.e. combustion dynamics), then the pressure fluctuations can potentially cause vibration, stress, fatigue, etc. The components may include combustor liners, combustor flow sleeves, combustor caps, fuel nozzles, turbine nozzles, turbine blades, turbine shrouds, turbine wheels, bearings, fuel supply assemblies, or any combination thereof. The downstream components are of specific interest, as they are more sensitive to combustion tones that are in-phase and coherent. Thus, reducing coherence specifically reduces the possibility of unwanted vibrations in downstream components.
As discussed in detail below, the disclosed embodiments may vary the position and/or location of one or more injectors (e.g., late lean injectors) within a fuel supply assembly (e.g., late lean injection (LLI) fuel circuit) within, between, and/or among one or more combustors of the gas turbine system. More specifically, the disclosed embodiments may vary the position of the late lean injectors via axial staggering and/or circumferential grouping to modify the fuel-air ratio of each injector, or a group of injectors, and/or the distribution of the heat release, modifying the flame dynamics, and therefore the combustion dynamics of the gas turbine combustor (e.g., varying the frequency, amplitude, range of frequencies, or any combination thereof). In addition, modifying the arrangement of late lean injectors may also alter the geometries of the fuel volumes, and therefore, may alter the acoustic response of the fuel system. Referred to in the art as fuel system impedance, modifying the acoustic response of the late lean injector fuel system can affect the interaction between the flame dynamics and the acoustic response of the combustor, which can, in turn, alter the combustion dynamics amplitude and/or frequency, coherence, range of frequencies, or any combination thereof). As noted above, a gas turbine system may include one or more combustors (e.g., combustor cans, combustors, etc.), and each combustor may be configured with a primary combustion zone and a secondary combustion zone. Specifically, in some embodiments, the secondary combustion zone may include an LLI fuel circuit configured to route a secondary fuel into a secondary combustion zone for combustion. In certain embodiments, each LLI fuel circuit includes one or more fuel lines configured to provide the secondary fuel to one or more fuel injectors (e.g., LLI injectors) that route the secondary fuel into the secondary combustion zone. In particular, the position of each LLI injector among the plurality of LLI injectors within a combustor may be varied relative to the other LLI injectors within the same combustor, between LLI injectors of an adjacent combustor, and/or among the LLI injectors of any of the plurality of combustors within the gas turbine system. In some embodiments, the LLI injectors may be varied via axial staggering such that the LLI injectors are shifted along an axial axis within the combustor and/or between combustors. In some embodiments, the LLI injectors may be varied via circumferential grouping such that the LLI injectors are distributed or grouped differently on a plane in the circumferential direction within the combustor and/or between combustors.
In certain embodiments, varying the arrangement, configuration, and/or function of the LLI injectors of the gas turbine system may change the heat release energy distribution and/or flame shape, thereby driving different flame dynamic behavior in each combustor and shifting the combustion dynamics frequency between the combustors of the system. Since coherence may be indicative of the similarity of the combustion dynamics frequency between the combustors, shifting the combustion dynamics frequency between the combustors of the system may decrease coherence between combustors. In certain implementations, the combustor tone may be smeared or spread out over a greater frequency range, reducing combustion dynamics amplitude and potentially reducing coherence. Particularly, varying the arrangement of LLI injectors of a particular combustor relative to the LLI injectors of another combustor within the system may vary both the heat release distribution, as well as, that particular combustor's fuel side impedance relative to other combustors, thereby changing the coupling between the acoustic and heat release perturbations, driving a flame dynamic behavior that is different than the flame dynamic behavior of one or more of the other combustors of the system. Accordingly, the resulting combustion dynamics frequencies between the combustors are different, thereby reducing coherence and therefore, modal coupling of the combustors.
With the forgoing in mind, FIG. 1 is a schematic of an embodiment of a gas turbine system 10 having a plurality of combustors 12 , wherein each combustor 12 is equipped with a secondary fuel circuit, such as a LLI fuel circuit 14 . In certain embodiments, one or more of the combustors 12 of the system 10 may not be equipped with a secondary fuel circuit. The LLI fuel circuit 14 may be configured to route a secondary fuel 16 , such as a liquid and/or gas fuel into the combustors 12 . For example, the secondary fuel 16 may be routed to one or more secondary fuel injectors of the combustor 12 , such as the LLI fuel injectors 18 . In particular, the arrangement of the LLI fuel injectors 18 for one or more combustors 12 may be varied relative to the LLI fuel injectors 18 of other combustors 12 within the system 10 . As noted above and as further described in detail below, varying the arrangement and/or configuration of the LLI injectors 18 within the system 10 may change the heat release energy distribution and/or flame shape between the combustors 12 , thereby driving different flame dynamic behavior in each combustor 12 and shifting the combustion dynamics frequency between the combustors 12 of the system 10 . Accordingly, the resulting combustion dynamics frequencies between the combustors 12 are different, thereby reducing coherence and therefore, modal coupling of the combustors 12 .
The gas turbine system 10 includes one or more combustors 12 having the plurality of injectors 18 (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more injectors 18 ), a compressor 20 , and a turbine 22 . The combustors 12 include primary fuel nozzles 24 which route a primary fuel 26 , such as a liquid fuel and/or a gas fuel into the combustors 12 for combustion within a primary combustion zone 28 . Likewise, the combustors 12 include the LLI injectors 18 which route the secondary fuel 16 into the combustors 12 for combustion within a secondary combustion zone 30 . The combustors 12 ignite and combust an oxidant-fuel mixture, and then hot combustion gases 32 are passed into the turbine 22 . The turbine 22 includes turbine blades that are coupled to a shaft 34 , which is also coupled to several other components throughout the system 10 . As the combustion gases 32 pass through the turbine blades in the turbine 22 , the turbine 22 is driven into rotation, which causes the shaft 34 to rotate. Eventually, the combustion gases 32 exit the turbine system 10 via an exhaust outlet 36 . Further, the shaft 34 may be coupled to a load 38 , which is powered via rotation of the shaft 34 . For example, the load 38 may be any suitable device that may generate power via the rotational output of the turbine system 10 , such as an external mechanical load. For instance, the load 38 may include an electrical generator, the propeller of an airplane, and so forth.
In an embodiment of the turbine system 10 , compressor blades are included as components of the compressor 20 . The blades within the compressor 20 are coupled to the shaft 34 , and will rotate as the shaft 34 is driven to rotate by the turbine 22 , as described above. The rotation of the blades within the compressor 20 compress air (or any suitable oxidant) 40 from an air inlet 42 into pressurized air 44 (e.g., pressurized oxidant). The pressurized oxidant 44 is then fed into the primary fuel nozzles 24 and the secondary fuel nozzles (i.e. late lean injectors 18 ) of the combustors 12 . The primary fuel nozzles 24 and the secondary fuel nozzles (i.e. late lean injectors 18 ) mix the pressurized oxidant 44 and fuel (e.g., the primary fuel 26 ) to produce a suitable mixture ratio for combustion (e.g., a combustion that causes the fuel to more completely burn) so as not to waste fuel or cause excess emissions.
In some embodiments, the physical location of one or more LLI injectors 18 may vary relative to LLI injectors 18 within and/or between combustors 12 . For example, the position and/or arrangement of the LLI injectors 18 of a first combustor 13 may be different than the position and/or arrangement of the LLI injectors 18 of another combustor 12 , such as an adjacent (or non-adjacent) second combustor 15 . In the illustrated embodiment, the LLI injectors 18 of the first combustor 13 are disposed closer to the exit of the combustor 46 (and further from a head end 48 ) compared to the LLI injectors 18 of the second combustor 15 . In other words, the LLI injectors 18 of the combustor 12 may be shifted along an axial direction or axis 50 (e.g., a longitudinal axis), such that the position of the LLI injectors 18 may vary between the combustors 12 . It should be noted that in other embodiments, the position of the LLI injectors 18 may be varied along a circumferential direction or axis 54 . As noted above, varying the arrangement of the LLI injectors 18 of one combustor 12 relative to another may change the heat release energy distribution and/or flame shape at each LLI injector 18 , thereby driving different flame dynamic behaviors and shifting the frequency response between the combustors 12 .
In some embodiments, the system 10 may include a controller 56 configured to regulate the one or more LLI circuits 14 , where each LLI circuit 14 is associated with the combustor 12 . The controller 56 (e.g., industrial controller, or any suitable computing device, such as desktop computer, tablet, smart phone, etc.) may include a processor and a memory (e.g., non-transitory machine readable media) suitable for executing and storing computer instruction and/or control logic. For example, the processor may include general-purpose or application-specific microprocessors. Likewise, the memory may include volatile and/or non-volatile memory, random access memory (RAM), read only memory (ROM), flash memory, hard disk drives (HDD), removable disk drives and/or removable disks (e.g., CDs, DVDs, Blu-ray Discs, USB pen drives, etc.), or any combination thereof.
In certain embodiments, the controller 56 may be useful in regulating the secondary fuel 16 routed to one or more LLI injectors 18 via the one or more LLI fuel circuits 14 . For example, in some embodiments, the controller 56 may be configured to bias the secondary fuel 16 routed through the LLI fuel circuit 14 to the LLI injectors 18 of a particular combustor 12 . For example, for a particular combustor 12 , the controller 56 may route more secondary fuel 16 to certain LLI injectors 18 than others. Indeed, in certain embodiments, the controller 56 may be configured to bias the secondary fuel 16 such that one or more LLI injectors 18 of a particular combustor 12 receive the secondary fuel 16 while the remaining LLI injectors 18 of the combustor 12 do not. The LLI fuel circuit 14 may include one or more circuits supplying one or more cans, or valves, to facilitate injector-level fuel flow control.
In addition, in some embodiments, the controller 56 may be configured to bias the secondary fuel 16 routed to one or more LLI injectors 18 of different combustors 12 of the system 10 . For example, the controller 56 may route more secondary fuel 16 to one or more LLI injectors 18 of the first combustor 13 than one or more LLI injectors 18 of the second combustor 15 . In such embodiments, the position and/or configuration of the LLI injectors 18 of the first combustor 13 and the second combustor 15 may be approximately the same, but the LLI injectors 18 may have a different operation based in part on how the controller 56 is configured to regulate the LLI circuits 14 and/or the secondary fuel 16 associated with each combustor 12 . In this manner, the controller 56 may be configured to change the operation of the LLI injectors 18 to reduce combustion dynamics without necessarily varying the arrangement and/or configuration of the injectors 18 . For example, the controller 56 may be configured to vary the function of the LLI injectors 18 in a manner that changes the heat release energy distribution and/or flame shape of the injectors 18 between the combustors 12 , such that different flame dynamic behavior is driven and the resulting combustion dynamics frequencies are shifted.
FIG. 2 is a schematic of an embodiment of one of the combustors 12 of FIG. 1 , where the combustor 12 is operatively coupled to the LLI fuel circuit 14 and the controller 56 . As noted above, the LLI fuel circuit 14 may be configured to route the secondary fuel 16 to the one or more LLI injectors 18 of the combustor 12 . Further, the controller 56 may be configured to regulate the LLI fuel circuit 14 and/or the secondary fuel 16 routed to the one or more LLI injectors 18 . In certain embodiments, the position and/or configuration of the LLI injectors 18 may be varied relative to the LLI injectors 18 of other combustors 12 within the system 10 . Further, in some embodiments, such as in the illustrated embodiment, the controller 56 may be configured to control the operation of one or more LLI injectors 18 of a particular combustor 12 , such that the LLI injectors 18 of the combustor 12 have different heat release energy distributions and/or flame shapes, such that different flame dynamic behaviors are driven and the resulting combustion dynamics frequencies are shifted. In this manner, the combustor 12 may be regulated to have reduced coherence behavior (as described in detail below), and therefore may reduce the possibility of modal coupling between and/or among the combustors 12 within the system 12 (as described in detail with respect to FIG. 3 ).
The combustor 12 includes the head end 48 having an end cover 60 , a combustor cap assembly 62 , the primary combustion zone 28 , and the secondary combustion zone 30 . The end cover 60 and the combustor cap assembly 62 may be configured to support the primary fuel nozzles 24 in the head end 48 . In the illustrated embodiment, the primary fuel nozzles 24 route the primary fuel 26 to the primary combustion zone 28 . Further, the primary fuel nozzles 24 receive the pressurized oxidant (e.g., pressurized air) 44 from the annulus 66 (e.g., between liner 68 and flow sleeve 70 ) of the combustor 12 and combine the pressurized oxidant 44 with the primary fuel 26 to form an oxidant/fuel mixture that is ignited and combusted in the primary combustion zone 28 to form combustion gases (e.g., exhaust). The combustion gases flow in a direction 72 to the secondary combustion zone 30 . The LLI fuel circuit 14 provides the secondary fuel 16 to the one or more LLI injectors 18 , which may be configured to route the secondary fuel 16 to the secondary combustion zone 30 . In particular, the LLI injectors 18 receive and route the secondary fuel 16 into the stream of combustion gases in the secondary combustion zone 30 , flowing in the downstream direction 72 . Further, the LLI injectors 18 may receive the pressurized oxidant 44 from the annulus 66 of the combustor 12 and/or directly from the compressor discharge, and combine the pressurized oxidant 44 with the secondary fuel 16 to form an oxidant/fuel mixture that is ignited and combusted in the secondary combustion zone 30 to form additional combustion gases. More specifically, the pressurized oxidant 44 flows through the annulus 66 between the liner 68 and the flow sleeve 70 of the combustor 12 to reach the head end 48 . The combustion gases flow in the direction 72 towards the exit 46 of the combustor 12 , and pass into the turbine 22 , as noted above.
As described above, combustion dynamics (e.g., generation of hot combustion gases) within the primary combustion zone 28 and/or the secondary combustion zone 30 may lead to unwanted vibratory responses in downstream components. Accordingly, it may be beneficial to control the combustion dynamics, and/or the modal coupling of the combustion dynamics between various combustors 12 of the system 10 , to help reduce the possibility of any unwanted sympathetic vibratory responses (e.g., resonant behavior) of components within the system 10 . In certain embodiments, the controller 56 may be configured to regulate the LLI fuel circuit 14 and control the secondary fuel 16 routed to one or more LLI injectors 18 of the combustor 12 . For example, in the illustrated embodiment, the controller 56 may be configured to bias the amount of secondary fuel 16 routed to a first injector 19 , a second injector 21 , a third injector 23 , and a fourth injector 25 . In particular, the controller 56 may be configured to regulate the LLI circuit 14 in order to bias the secondary fuel 16 such that the first injector 19 and the third injector 23 receive more secondary fuel 16 than the second injector 21 and the fourth injector 25 . Accordingly, the heat release energy distribution and/or the flame shape of the first and third injectors 19 , 23 may be different than the heat release energy distribution and/or the flame shape of the second and fourth injectors 21 , 25 . Further, the flame shape of the first and third injectors 19 , 23 may be different than the flame shape of the second and fourth injectors 21 , 25 . In some situations, the controller 56 may be configured to bias all (or almost all) of the secondary fuel 16 away from one or more injectors 18 , such that one or more injectors 18 contribute minimally to the combustion gases generated in the secondary combustion zone 30 . In some situations, the controller 56 may be configured to bias some of the secondary fuel 16 away from one or more injectors 18 of the combustor, such that the injectors 18 contribute in various amounts to the combustion gases generated in the secondary combustion zone 30 .
In some embodiments, the controller 56 may be configured to vary the arrangement of the functioning LLI injectors 18 by controlling the LLI fuel circuit 14 and regulating the amount of secondary fuel 16 routed to each injector 18 of the combustor 12 . In certain embodiments, the controller 56 may bias the secondary fuel 16 to the first and second injectors 19 , 21 in the first combustor 13 , and may bias the secondary fuel 16 to the third and fourth injectors 23 , 25 in the second combustor 15 , as further described with respect to FIG. 3 . In this manner, the controller 16 may be configured to regulate and/or vary the heat release energy distribution and/or the flame shape of the injectors 18 within one or more combustors 12 , thereby driving different flame dynamic behaviors within and between combustors 12 of the system 10 . In this manner, the combustion dynamics frequency within and/or between combustors 12 may be shifted, such that there is decreased coherence between the combustors 12 .
FIG. 3 is a schematic of an embodiment of the gas turbine system 10 of FIG. 1 , illustrating a plurality of combustors 12 each equipped with the LLI fuel circuit 14 having a plurality of LLI injectors 18 (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more injectors 18 ). In the illustrated embodiment, the gas turbine system 10 includes four combustors 12 coupled to the turbine 22 . In some embodiments, the system 10 may include any number of combustors 12 , such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more combustors 12 coupled to the turbine 22 . In addition, one or more of the LLI fuel circuits 14 associated with the combustors 12 may be operatively coupled to the controller 56 . In particular, in certain embodiments, the one or more LLI injectors 18 of each combustor 12 may have a particular arrangement (e.g., configuration, position, etc.) and/or may be controlled by the controller 56 to have a particular operation configured to help reduce coherent behavior within the system 10 , as further described in detail below. More specifically, the arrangement and/or the operation of the LLI injectors 18 may vary within and/or between the combustors 12 of the system, such that the LLI injectors 18 are driven at different flame dynamic behaviors and have varied fuel system impedances, thereby generating combustion dynamics frequencies that are shifted between the combustors 12 of the system 10 . Since coherence may be indicative of the similarity of the combustion dynamics frequencies between the combustors, shifting the combustion dynamics frequencies between the combustors of the system may reduce coherence between combustors 12 .
In certain embodiments, the position of one or more LLI injectors 18 may be shifted along the axial direction or axis 50 of the system, such that the position of the LLI injectors 18 vary between the combustors 12 . For example, the LLI injectors 18 of the first combustor 13 may be disposed approximately a first distance 80 from the endcover 60 of the first combustor 13 . In addition, the LLI injectors 18 of the second combustor 15 may be disposed approximately a second distance 82 from the endcover 60 of the second combustor 15 , where the second distance 82 may be greater than the first distance 80 . It should be noted that in some embodiments, the second distance 82 may be less than and/or approximately the same as the first distance 80 , such that the LLI injectors 18 of the second combustor 15 are closer to the head end 48 than the LLI injectors 18 of the first combustor 13 , or such that the LLI injectors 18 of the first and second combustors 13 , 15 are approximately the same.
In some embodiments, the position of one or more LLI injectors 18 may be shifted along the axial direction or axis 50 , such that the position of the LLI injectors 18 vary within, as well as between the combustors 12 . For example, each LLI injector 18 of a third combustor 81 may be disposed at a different distance from the endcover 60 of the third combustor 81 . In addition, each LLI injector 18 of a fourth combustor 83 may be disposed at approximately a different distance from the endcover 60 of the fourth combustor 83 . For example, in the third combustor 81 , a third distance 84 from the endcover 60 to the third injector 23 may be less than a fourth distance 86 from the endcover 60 to the fourth injector 25 . It should be noted that in some embodiments, the third distance 84 may be greater than the fourth distance 86 .
In some embodiments, the distance between various pairs of injectors 18 of a particular combustor may vary within that particular combustor. For example, a fifth distance 88 between the third and fourth injectors 23 , 25 may be greater than a sixth distance 90 between the first and second injectors 19 , 21 of the third combustor 81 . In this manner, the injectors 18 of the third combustor 81 may be axially staggered along the axial direction 50 within the combustor 81 . It should be noted that the distance between the injectors 18 (e.g., the fifth or sixth distances 88 and 90 ) may be any distance. Further, in some embodiments, the injectors 18 of the third combustor 81 may be axially staggered relative to the injectors 18 of the fourth combustor 83 . For example, the fifth distance 88 between the third and fourth injectors 23 , 25 may be greater than the sixth distance 90 between a fifth and a sixth injector 85 , 87 , respectively. In this manner, varying the position of the injectors 18 via axial staggering along the axial direction 50 between and/or within the combustors 12 (e.g., the first and second combustors 13 , 15 and/or the third and fourth combustors 81 , 83 , etc.) may vary the heat release energy distribution and/or flame shape, thereby driving different flame dynamic behaviors between combustors 12 . Accordingly, different flame dynamic behavior is driven and the resulting combustion dynamics frequencies are shifted between the combustors 12 .
In certain embodiments, the controller 56 may be operatively coupled to one or more LLI circuits 14 associated with one or more combustors 12 . In particular, the controller 56 may be configured to control a particular LLI circuit 14 by regulating the amount of secondary fuel 16 routed and/or biased to the one or more injectors 18 of the combustor 12 associated with that particular LLI circuit 14 . For example, in the illustrated embodiment, the controller 56 may be operatively coupled to a third LLI fuel circuit 14 associated with the third combustor 81 and a fourth LLI fuel circuit 14 associated with the fourth combustors 83 . In some situations, the controller 56 may be configured to bias the secondary fuel 16 routed to the injectors 18 of the third and fourth combustor 81 , 83 according to a particular arrangement, such that only the injectors 18 in specific positions are fueled. For example, the controller 56 may be configured to route secondary fuel 16 to the second injector 21 , the third injector 23 , the sixth injector 87 , and a seventh injector 89 and away from the first injector 19 , the fourth injector 25 , the fifth injector 85 , and an eighth injector 91 . Accordingly, as illustrated, the heat release distribution and/or the flame shape of the injectors 18 biased with more secondary fuel 16 may be different than the injectors 18 biased with less secondary fuel 16 , thereby driving different flame dynamic behaviors between combustors 12 . As such, different flame dynamic behavior is driven and the resulting combustion dynamics frequencies are shifted between the third and fourth combustors 81 , 83 .
In some embodiments, the system 10 may include one or more groups (e.g., 1, 2, 3, 4, 5, or more) of combustors 12 , where each group of combustors 12 includes one or more combustors 12 (e.g., 1, 2, 3, 4, 5, or more). In some situations, each group of combustors 12 may include identical combustors 12 that differ from one or more other groups of combustors 12 within the system 10 . For example, a first group of combustors 12 may include identical combustors 12 having a particular arrangement of LLI injectors 18 , and a second group of combustors 12 may include identical combustors 12 having a second arrangement of LLI injectors 18 . Further, the first and second arrangements of LLI injectors 18 may be different in one or more ways, as described above. Accordingly, the first group of combustors 12 may produce a flame dynamic behavior and a fuel system impedance that is different from the flame dynamic behavior and the fuel system impedance of the second group of combustors 12 within the system 10 , thereby generating combustion dynamics frequencies that are shifted between the combustors 12 of the system 10 .
For example, in certain embodiments, a first group of combustors 12 may include identical combustors 12 each having a first arrangement of LLI injectors 18 , a second group of combustors 12 may include identical combustors 12 each having a second arrangement of LLI injectors 18 , and a third group of combustors 12 may include identical combustors 12 each having a third arrangement of LLI injectors 18 . Further, the arrangements of the LLI injectors 18 of each group of combustors may be different from each other in one or more ways, as described with respect to FIGS. 3-6 . Accordingly, the LLI injectors 18 of the first group of combustors 12 may be arranged to achieve a first flame dynamic behavior or fuel system impedance, the LLI injectors 18 of the second group of the combustors 12 may be arranged in a configuration different from the baseline configuration to achieve a second flame dynamic behavior or fuel system impedance, and the LLI injectors 18 of the third group of the combustors 12 may be arranged in a configuration different form the baseline configuration to achieve a third flame dynamic behavior or fuel system impedance. The first, second, and third flame dynamic behavior or fuel system impedance may be different from one another. As a result, the combustion dynamics frequencies are shifted between the different groups of combustors 12 of the system 10 . In certain embodiments, the controller 56 may be configured to control the configuration of the LLI injectors 18 within each group of combustors 12 , as further described above. Though three groups and three frequencies are described, it should be clear that any number of groups and/or frequencies may be employed.
In some embodiments, in addition to axial staggering of injectors 18 , the position and/or arrangement of the injectors 18 may be varied within, between, and/or among one or more combustors 12 of the system 10 via circumferential grouping, as further described with respect to FIGS. 4, 5, and 6 . For example, the grouping and/or distribution of the LLI injectors 18 along one or more axes in the circumferential direction 54 may be varied between combustors 12 , as further described in detail with respect to FIGS. 4-6 .
FIG. 4 is a cross-sectional schematic of an embodiment of the first combustor 13 in the system 10 taken along line 4 - 4 of FIG. 3 , wherein the first combustor 13 includes a first circumferential distribution 92 of the injectors 18 along a particular axis in the circumferential direction 54 . For example, in the illustrated embodiment, a first set 94 having three injectors 18 and a second set 96 having one injector 18 are circumferentially disposed (e.g., arranged, configured, etc.) approximately along a first circumferential axis 98 , as shown in FIG. 3 . Each set of injectors 18 may be configured to route the secondary fuel 16 to the secondary combustion zone 30 of the first combustor 13 . In particular, varying the configuration and/or arrangement of the injectors 18 within the combustor 12 and/or between combustors 12 (e.g., the first combustor 13 and the second combustor 15 ) may vary the heat release energy distribution and/or flame shapes, thereby driving different flame dynamic behaviors and shifting the frequency response between the combustors 12 . For example, in some embodiments, the injectors 18 of the first combustor 13 may be disposed along the first circumferential axis 98 in a manner that is different than the position and/or arrangement of the injectors 18 of the second combustor 15 . More specifically, the first set 94 of injectors 18 may be spatially disposed and/or grouped away from the second set 96 of injectors 18 along the same circumferential axis 98 of the first combustor 13 . Indeed, each injector 18 may be spaced at any circumferential distance from another injector 18 of the first combustor 13 , such that certain injectors 18 may be spaced closer to each other than other injectors 18 . In some embodiments, the circumferential grouping of the injectors 18 in the first combustor 13 may differ from the circumferential grouping of the injectors 18 in an adjacent combustor 12 , such as the second combustor 15 , as further described in detail with respect to FIG. 5 and FIG. 6 .
FIG. 5 is a cross-sectional schematic of an embodiment of the second combustor 15 in the system 10 taken along line 5 - 5 of FIG. 3 , wherein the second combustor 15 includes a second circumferential distribution 100 of the injectors 18 along a particular axis in the circumferential direction 54 . For example, in the illustrated embodiment, the second circumferential distribution 100 comprises four injectors 18 configured to route the secondary fuel 16 to the secondary combustion zone 30 of the second combustor 15 . In particular, the second circumferential distribution 100 may include one or more injectors 18 (e.g., a first circumferential injector 102 , a second circumferential injector 104 , a third circumferential injector 106 , and a fourth circumferential injector 108 ) having approximately the same circumferential distance between them. For example, the first, second, third and fourth circumferential injectors 102 , 104 , 106 , 108 may be disposed at 90 degree increments along a circumferential axis 54 , such that the first injector 102 and the third injector 106 are oppositely disposed (e.g. separated by approximately 180 degrees in the circumferential direction 54 ), and the second injector 104 and the fourth injector 108 are also oppositely disposed (separated by approximately 180 degrees in the circumferential direction 54 ) as shown in FIG. 5 . Accordingly, any two circumferential injectors in the illustrated embodiment may be disposed at approximately a first angle 110 , such as the first angle 110 at approximately 90 degrees. It should be noted that in other embodiments, the first angle 110 separating any two injectors 18 may be any suitable angle, such as between approximately 1 to 359 degrees, 5 to 10 degrees, 10 to 20 degrees, 20 to 45 degrees, 45 to 90 degrees, 90 to 180 degrees, 180 to 360 degrees, etc. For example, in the illustrated embodiment, the first circumferential injector 102 may be disposed at approximately 45 degrees from the second circumferential injectors 104 , rather than at approximately 90 degrees. In addition, the first angle 110 between any two circumferential injectors 102 , 104 , 106 , or 108 may be varied between the combustors 12 for different circumferential configurations and/or arrangements between combustors 12 , as further described with respect to FIG. 6 .
In this manner, the injectors 18 of the first combustor 13 may be configured and/or arranged differently than the injectors 18 of the second combustor 15 . Indeed, as noted above, varying the configuration and/or arrangement of the injectors 18 within the combustor 12 and/or between combustors 12 (e.g., the first combustor 13 and the second combustor 15 ) may vary the heat release energy distribution and/or flame shapes, thereby driving different flame dynamic behaviors and shifting the frequency response between the combustors 12 .
FIG. 6 is a cross-sectional schematic of an embodiment of the third combustor 81 in the system 10 taken along line 6 - 6 of FIG. 3 , wherein the third combustor 81 includes a third circumferential distribution 112 of the injectors 18 along a particular axis in the circumferential direction 54 . For example, in the illustrated embodiment, the third circumferential distribution 112 comprises four injectors 18 configured to route the secondary fuel 16 to the secondary combustion zone 30 of the third combustor 81 . In particular, the arrangement of the first injector 19 , the second injector 21 , the third injector 23 , and the fourth injector 25 of the third combustor 81 may be different than the arrangement of the first circumferential injector 102 , the second circumferential injector 104 , the third circumferential injector 106 , and the fourth circumferential injector 108 of the second combustor 15 . For example, similar to the injectors 18 of the second combustor 15 , the injectors 18 of the third combustor 81 may be disposed at 90 degree increments along a circumferential direction 54 , such that the first injector 19 and the third injector 23 , and the second injector and the fourth injector 25 , are approximately 180 degrees apart. However, each of the injectors 18 of the third combustor 81 may be offset by approximately a second angle 113 relative to each of the injectors 18 of the second combustor 15 . For example, the first injector 19 of the third combustor 81 may be offset approximately by the second angle 113 (e.g., approximately 45 degrees) relative to the first circumferential injector 102 of the second combustor 15 . It should be noted that in other embodiments, the second angle 113 is representative of the angle offset between any two combustors 12 and may be any suitable angle, such as between approximately 1 to 359 degrees, 5 to 10 degrees, 10 to 20 degrees, 20 to 45 degrees, 45 to 90 degrees, 90 to 180 degrees, 180 to 360 degrees, etc.
In this manner, the injectors 18 of the second combustor 15 may be configured and/or arranged differently than the injectors 18 of the third combustor 81 . Indeed, as noted above, varying the configuration and/or arrangement of the injectors 18 within the combustor 12 and/or between combustors 12 (e.g., the second combustor 15 and the third combustor 81 ) may vary the heat release energy distribution and/or flame shapes, thereby driving different flame dynamic behaviors and shifting the frequency response between the combustors 12 .
Technical effects of the disclosure include varying the position and/or location of the one or more injectors 18 of the fuel supply circuit 14 associated with each of the one or more combustors 12 of the system 10 . Specifically, the position and/or arrangement of the injectors 18 may be varied within, between, and/or among the one or more combustors 12 via axial staggering and/or circumferential grouping to modify the heat release energy distribution and/or the fuel system impedance of the LLI fuel system, and therefore the combustion dynamics of the gas turbine combustor (e.g., varying the frequency, amplitude, combustor-to-combustor coherence, range of frequencies, or any combination thereof). For example, the injectors 18 of a particular combustor 12 may be shifted along the axial direction or axis 50 (e.g., a longitudinal axis) of that combustor 12 , such that the position of the injectors 18 may axially vary between the combustors 12 of the system 10 . Likewise, the injectors 18 of a particular combustor 12 may be circumferentially grouped and/or distributed along the circumferential direction 54 of that combustor 12 , such that the position and/or arrangement of the injectors 18 may circumferentially vary between the combustors 12 of the system 10 . It should be noted that in certain embodiments, the injectors 18 of the system 10 may be varied axially and/or circumferentially between the combustors 12 .
In certain embodiments, the controller 56 may be may be utilized to regulate the secondary fuel 16 routed to one or more LLI injectors 18 via the LLI fuel circuit 14 . For example, in some embodiments, the controller 56 may be configured to bias the secondary fuel 16 routed through the LLI fuel circuit 14 to the LLI injectors 18 of a particular combustor 12 . In this manner, the controller 56 may be configured to change the operation of the LLI injectors 18 to reduce combustion dynamics without necessarily varying the arrangement and/or configuration of the injectors 18 .
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
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A system includes a gas turbine engine having a first combustor and a second combustor. The first combustor includes a first fuel conduit having a first plurality of injectors. The first plurality of injectors are disposed in a first configuration within the first combustor along a first fuel path, and the first plurality of injectors are configured to route a fuel to a first combustion chamber. The system further includes a second combustor having a second fuel conduit having a second plurality of injectors. The second plurality of injectors are disposed in a second configuration within the second combustor along a second fuel path, and the second plurality of injectors are configured to route the fuel to a second combustion chamber. The second configuration has at least one difference relative to the first configuration.
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention provides a process for depositing a thin layer of a ceramic composition and a product obtained thereby.
Description of the Background
A large number of oxide ceramics have potential application in the microelectronics field. Among these, can be mentioned perovskites, which may be used in dielectric applications such as ferroelectrics PbTi x Zr 1-x O 3 , or transparent conductive materials such as oxides of In x Sn 1-x O, or as superconductors Containing copper and oxides of elements such as (Y, Ba), (Bi, Sr, Ca), or (Ti, Ba, Ca).
These compounds must be deposited in thin layers on substrates such as aluminum oxide, silicon, or silica (SiO 2 ), on which buffer layers, such as other oxides or precious metals, may have been preliminarily deposited so as to act as electrical contacts (or insulators) or to provide better adhesion of the ceramic film on the substrate.
One widely-used technique for depositing ceramic films is serigraphy, in which oxide powders which have preliminarily undergone reaction are mixed with a binding agent and are applied to the substrate. Then, heating is effected to remove the organic binding agent and to obtain the sintering of the powder grains, thus giving an improved ceramic density, as well as improved electronic properties, and, if desired, optical properties such as transparency.
The reproducibility and reliability of the properties of films deposited in this way are linked to their microstructure and to the heat treatment to which the films are subjected.
Required integration into increasingly reduced systems dictates the use of initial submicronic powders so as to obtain a low degree of coarseness. However, this is obtained with difficulty when using conventional methods of synthesis based on mixtures of dry powders. Furthermore, the possible anisotropy of properties linked to an anisotropy of the crystalline structure of the material itself may require the texturing of the ceramic, by aligning the grains parallel to the substrate. This may be obtained by direct crystallization of the phases oriented by the substrate.
The crystallization and densification of the desired phase are carried out conventionally at temperatures approaching the melting point of the materials, in order to ensure the free mobility of the cations. Unfortunately, in the case of a deposit on a substrate, this also causes reactions with the substrate, or with other layers in the case of multilayer procedures.
Furthermore, the difference in coefficients of expansion of the various elements produces cracking at high temperatures. Therefore, a need exists for processes which utilize low temperatures of synthesis. Another reason for the observed cracking at high temperatures may be the volatility of some elements (Pb, Bi) at high temperatures.
One possible low-cost process for film deposition is synthesis using solutions in which the homogeneous mixture of elements makes it possible to ignore the problem of the ionic diffusion barrier, and thus, to lower the synthesis temperature. The difficulty then lies in obtaining solutions whose rheological properties allow the deposit of homogeneous films prior to thermal treatment.
Interesting precursors of these syntheses in solution are the alkoxides (sol-gel procedures). The hydrolysis of these precursors leads to the condensation of the polymeric lattices of oxides and hydroxides, the precursors of the desired phases. Nevertheless, it is sometimes not obvious that the hydrolysis rate must be controlled in the case of synthesis of complex phases containing a large number of elements possessing different properties. It is difficult to control simultaneously chemical homogeneity, which allow the synthesis temperature to be lowered, and the rheology desired for the deposit. Furthermore, alkoxides are not always easy to handle.
The procedure may thus begin with ionic solutions whose viscosity and elasticity have been modified by the presence of modifying agents added to the solvents (glycol, glycerol, citric acid), such as polyalcohols and polyacids, which lead to the production of polymer resins. However, not all of these additives are necessarily compatible with the cations. In addition, a solution is needed which adheres well to the substrate during deposit. This is a complicated procedure, and the substance obtained is deposited with difficulty using the method called "the spinning technique."
Thus, a need continues to exist for a process for depositing a thin layer of a ceramic composition in a simple manner which enables the combination of a large number of different chemical systems, while avoiding the drawbacks of the conventional methods.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an advantageous process for depositing a thin layer of a ceramic composition on a substrate.
It is also an object of this invention to provide a product composed of a ceramic composition in the form of a thin layer deposited on a substrate.
The above objects and others which will be described hereinbelow are provided by a process for depositing a thin layer of a ceramic composition on a substrate, which entails:
a) dissolving basic constituents of the ceramic composition, which are added in simple or mixed form to a solvent;
b) adding to the solution, acetylacetone and hexamethylene- tetramine in proportions suitable to the deposit method used;
c) maturing or polymerizing the substance obtained in step b);
d) depositing a layer of the substance on the substrate;
e) drying the deposited layer, and
f) sintering the layer or layers deposited at low temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing the loss of mass of a substance according to the present invention, and of its derivative, as a function of temperature;
FIG. 2 represents an hysteresis cycle; and
FIG. 3 is a diagram illustrating the variable capacitance of a ceramic composition deposited on silicon in accordance with the invention, as a function of voltage.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a process for depositing a thin layer of a ceramic composition based on the use of an homogeneous solution whose rheology can be adapted to the "wafer-spinning" deposit of multi-compound systems. The cations are solubilized in a solution in which polymerization (or maturation) is caused by the reaction of two organic compounds: acetylacetane (ACAC) and hexamethylenetetramine (HMTA).
The two compounds (ACAC and HMTA) used in the invention procedure are preferably added in the optimal molar ratio of 2 moles of ACAC for 1 mole of HMTA. In an acidic medium, these compounds react, giving a polymeric species. Since, moreover, they form very good complexing agents, especially acetylacetone, independently of the cations, cations remain solubilized in the polymeric medium when it forms and during drying on the deposit substrate.
The scope of the present invention includes the replacement of one of these compounds, or even both, with another compound or compounds which produce the same effect and lead to the same result.
The present procedure is doubly advantageous. It facilitates, first, the adaptation to a large number of different systems, thereby making it possible to combine in solution, in a single synthesis, elements whose chemical behaviors are very different. Second, it facilitates an adaptation of the rheology. Once the synthesis is obtained, a polymer is formed which chelates the cations and whose concentration determines viscosity. The substance obtained is viscous and wetting, and it can then be modified by simple removal of the solvent. It does not change over time, thus allowing storage of the depositing solution and a rigorous control of its adaptation to the deposit method selected.
The present invention will now be further illustrated by reference to certain examples which are provided solely for purposes of illustration and are not intended to be limitative.
EXAMPLE
8.5 g of titanium tetrabutoxide Ti (OBut) 4 and 9.2 g of lead acetate are dissolved in 50 ml of acetic acid. Next, 10 ml of acetylacetone and 4 g of hexamethylenetetramine are added. The solution, yellow at the outset, turns red and becomes viscous, before reaching a stable state after several hours. Its viscosity can then be adjusted by evaporating the acetic acid. As used herein, the term "stable state" means a constant viscosity.
The substance obtained may be used as is for a wafer--spinning deposit (deposit conditions: 20 seconds, 2,000 rotations per minute) on substrates such as corundum and silicon preliminarily coated with platinum (by means of vacuum deposit), so as to ensure good electrical conduction.
Depending on the thickness of the entire layer to be deposited, it may be necessary to perform the deposit operation in several steps, and thus to dry each deposited layer before depositing a new one. Drying may take place at 300° C. in an oven.
Once the desired thickness of the layer is obtained, the layer undergoes sintering at a temperature of approximately 700°-750° C., an operation which does not alter the substrate on which the layer is deposited.
Thermal gravimetric analysis and differential calorimetry conducted on the lead titanate thus deposited show that one advantage of the method is the gradual and uniform loss of mass of the substance when the temperature increases.
In addition to acetic acid, propanol or methoxyethanol may be used as solvents.
FIG. 1 is a diagram giving, as a function of temperature, the curve of the loss of mass (curve 1 corresponding to the lefthand Y-axis) and its derivative curve (curve 2 corresponding to the right-hand Y-axis). Indeed, the gradual and uniform loss may be ascertained as a function of temperature. This shows an advantage of the present method, which consists in not causing an excessively violent oxidation of the organic portion, which would produce cracking in the film. The exothermal phenomena are completed at 700° C., temperature at which the phase is crystallized.
The thickness of the layers obtained may vary between 0.2 and 5 μm per layer. Thus, layers thicker than those produced by conventional sol-gel methods are obtained, but very thin layers can also be obtained because of the excellent surface quality of the layer.
The electric properties of the layers deposited on platinum (electrode deposited by cathodic spraying on an oriented silicon substrate 100) and directly on doped silicon (having a resistivity of less than 0.01Ωcm) are qiven in Table 1 at the end of the description. Electrical measurements are made on the silver metallization contacts deposited on the surface of the layer and which have a surface area of 7 mm 2 . In this table, mention is made of the measured capacity C, the losses tg σ, the insulating resistance, the breakdown voltage V c in volts (for a ceramic layer whose thickness is approximately 1 μm), the voltage corresponding to the coercive field V coerc , and the remanence R of the polarization (for the metal-insulator-metal structure on platinum) and of the capacitance (for the metalinsulator-semiconductor structure on silicon).
On platinum, because of the low value of the dielectric losses (3%), of the high value of the insulating resistance (100 MΩ) and of the breakdown voltage (40V), 60-Hz hysteresis cycles have been produced using the Sawyer and Tower method. One of these cycles is shown in FIG. 2, in which the Y-axis shows polarization P and the X-axis, the electric field E applied. Coercive voltage is at most equal to 16 V, and the remanent polarization is at least equal to 4.3 μC/cm 2 .
On doped silicon, the capacitance value is slightly lower, probably because of a series capacitance caused in the semiconductor by interface states. A capacitance-memory effect has, however, been observed on this metal-insulator-semiconductor (MIS) structure. FIG. 3 is a diagram showing the capacitance C as a function of voltage. It will be noted that the capacitancevoltage curve is asymmetrical for rising and declining voltages between -20 volts and +20 volts. Peaks approaching + or -6 volts caused by the switching of ferroelectric ranges are superposed on the normal declining curve of the MIS structure.
The present invention makes it possible to create thin layers possessing large surface areas without defects and having a thickness of less than one micron on different metal (or metalcoated) semiconductor or insulator substrates, by means of a simple, low-cost procedure requiring widely-available and inexpensive raw materials. Applications include the fields of non-volatile memories, integrated optics, devices incorporating superconductors, and acoustic or pyroelectric detectors.
The deposits according to the invention have a low degree of surface coarseness and a very good surface quality because of the fineness and homogeneity of the ceramic grains.
______________________________________C tgσ Ri V.sub.c V.sub.coerc(nF) (%) MΩ (V) (V) R______________________________________On 1 1 100 40 16 0.3 μCplatinum 4.3 μC/cm.sup.2On 0.8 9 1900 40 6 0.15 nFsilicon (2.1 nF/cm.sup.2)______________________________________
Having described the present invention, it will now be apparent to one of ordinary skill in the art that many changes and modifications can be made to the above embodiments without departing from the spirit and the scope of the present invention.
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A process for depositing a thin layer of a ceramic composition on a substrate, which comprises:
a) dissolving basic constituents of the ceramic composition, which are added in simple or mixed form to a solvent;
b) adding to the solution, acetylacetone and hexamethylene tetramine in proportions suitable to the deposit method used;
c) maturing or polymerizing the substance obtained in step b);
d) depositing a layer of the substance on a substrate;
e) drying the deposited layer, and
f) sintering the layer deposited at low temperature.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for controlling the differential hydraulic pressure across a variable displacement hydraulic motor which can be used for mechanically actuating a device such as a component on an aircraft.
2. Description of the Prior Art
Aircraft include devices such as flaps, rudders, etc. which must be mechanically actuated during flight to maintain proper control of the aircraft. It is known that these devices can be mechanically actuated by means of a hydraulic motor which is driven by a hydraulic power supply of the aircraft.
It is also known to employ a variable displacement hydraulic motor to mechanically actuate these kinds of devices on an aircraft. The speed-load torque profile of the variable displacement hydraulic motor is such that at high torque and low speed, the motor operates at maximum displacement and near its high speed at minimum displacement. Intermediate the two, the motor operates with a variable displacement, the displacement varying to maintain a constant flow. To maintain a constant flow, it is necessary to maintain a near constant differential pressure across the motor.
A known apparatus for controlling the differential hydraulic pressure across the variable displacement hydraulic motor is shown in FIG. 1 of the drawings. As illustrated therein, the variable displacement hydraulic motor 10 comprises a wobbler 11 which is adjustable for controlling the displacement of the motor. A high-pressure control piston 12 and a low-pressure control piston 13 are operatively connected to the wobbler for adjusting the wobbler to respectively increase and decrease the motor displacement with actuation of the pistons. Pressurized hydraulic fluid is supplied to and returned from the motor 10 by way of the lines b 1 and b 2 . A shuttle valve 14 is acted upon by the pressurized hydraulic fluid in both of the lines b 1 and b 2 such that the valve moves to allow communication between the one of the lines b 1 and b 2 having the highest pressure and high pressure line 15 downstream of the shuttle valve 14. The other of the lines b 1 and b 2 , having lower pressure is communicated with low pressure line 16 by way of the shuttle valve 14.
The high pressure fluid from high pressure line 15 and the low pressure fluid from low pressure line 16 are communicated to opposite sides of the spool valve of a compensator valve 17. When the differential pressure ΔP across the motor 10 exceeds a predetermined amount, the high pressure in line 15 overcomes the upward force on the spool valve of compensator valve 17 caused by the low pressure from line 16 and the force of a spring in the compensator valve to move the spool valve downward as shown in FIG. 1 thereby communicating the high pressure in line 15 with the high pressure control piston 12. The low pressure in line 16 is communicated with the low-pressure control piston 13 as shown in FIG. 1. Introduction of high pressure fluid to the control piston 12 overcomes the opposing force on the wobbler 11 from the low pressure control piston 13 and of spring 18 to increase the displacement of the motor 10 which, in turn, will decrease the pressure differential ΔP between the lines b 1 and b 2 of the motor 10. In the aforementioned intermediate region of the motor's speed-load torque profile ΔP will decrease until there is a force balance on the spool of the compensator valve 17. This will occur in the vicinity of a predetermined set point. The pressure differential ΔP will exceed the predetermined amount when either a high opposing load or a high aiding load is placed upon the output shaft 19 of the motor 10, resulting in an increase in the motor displacement with both opposing and aiding loads.
The ever increasing performance requirements of advanced aircraft are placing even more demanding peak flow requirements on the hydraulic power supplies. Fully variable displacement motor driven actuation systems offer the potential to significantly reduce the peak flow requirement but do so at the expense of simplicity and cost. There is a need for an improved mechanically controlled variable displacement hydraulic motor driven actuation arrangement which realizes much of the hydraulic flow savings of the fully variable scheme while maintaining the simplicity, low cost and reliability of conventional actuation systems.
Other examples of hydraulic systems employing variable displacement hydraulic motors and control arrangements therefor are shown in U.S. Pat. Nos. 3,465,680; 3,635,021 and 4,478,136.
SUMMARY OF INVENTION
An object of the present invention is to provide an improved method and apparatus for controlling the differential hydraulic pressure across a variable displacement hydraulic motor and a method and an apparatus for mechanically actuating a device employing the same, which reduce the peak flow requirements on the hydraulic power supply during operation of the motor. This enables additional flow to be available to operate other actuators or devices and reduces the demand on heat exchangers required to remove excess heat generated by the hydraulic controls.
These and other objects are attained by the apparatus of the invention for controlling the differential hydraulic pressure across a variable displacement hydraulic motor. The apparatus comprises means for adjusting the displacement of the motor as a function of the differential pressure across the motor to maintain a near constant differential pressure across the motor when the motor is operating under an opposing load, and means for reducing the displacement of the motor to a minimum when the motor is operating under an aiding load. The means for reducing also reduces the displacement of the motor to a minimum when the motor is operating under no load. The apparatus further comprises means for limiting the maximum flow of the hydraulic fluid from the motor to thereby limit the maximum operating speed of the motor. By minimizing the displacement, hence flow of hydraulic fluid, during aiding load and no load or light load operations, the flow required for the hydraulic motor can be minimized thereby making the hydraulic fluid from a hydraulic supply available to other hydraulic motors for actuating other devices, and reducing the heat generated because of high fluid pressure differentials across control valves in the apparatus.
More specifically, according to a disclosed form of the invention, the apparatus controls the differential hydraulic pressure across a variable displacement hydraulic motor having a wobbler which is adjustable for controlling the displacement of the motor. The apparatus comprises first and second control pistons, means operatively connecting each of the pistons to the wobbler for adjusting the wobbler to respectively increase and decrease the motor displacement with actuation of the pistons, means responsive to the pressure difference between an input hydraulic fluid pressure to the motor and an output hydraulic fluid pressure from the motor for communicating the first control piston with the higher pressure one of the input hydraulic fluid pressure and the output hydraulic fluid pressure when the fluid pressure differential exceeds a predetermined amount, and means for communicating the second control piston with the pressure of the output hydraulic fluid.
According to an additional feature of the invention, the apparatus comprises valve means for selectively changing the direction of hydraulic fluid flow through the motor for reversing the direction of operation of the motor. The means for communicating the second control piston with the output hydraulic fluid communicates with the output hydraulic fluid in a fluid return line downstream of the valve means.
The disclosed invention is also particularly directed to an apparatus for mechanically actuating a device, such as a flap, rudder, etc. on an aircraft, with a variable displacement hydraulic motor driven by hydraulic fluid from an aircraft hydraulic power supply. The apparatus comprises a device to be mechanically actuated, a variable displacement hydraulic motor, means for mechanically connecting the output of the motor to the device for actuating the device, a hydraulic power supply for supplying hydraulic fluid for driving the motor, fluid passage means for supplying pressurized fluid to the motor from the hydraulic power supply and for returning pressurized fluid from the motor to the hydraulic power supply, and means for controlling the differential hydraulic pressure across the motor by adjusting the displacement of the motor to maintain a near constant differential pressure across the motor when the motor is operating under an opposing load in an intermediate region of its speed-load torque profile, and including means for reducing the displacement of the motor to a minimum when the motor is operating under an aiding load.
Thus, a method of controlling the differential hydraulic pressure across a variable displacement hydraulic motor according to the invention comprises the step of adjusting the displacement of the motor as a function of differential pressure across the motor for maintaining a near constant differential pressure across the motor, and the steps of reducing the displacement of the motor to a minimum when the motor experiences an aiding load thereby minimizing the flow requirements of the motor. The step of reducing the displacement of the motor to a minimum is also preferably performed when no load or a light opposing load is applied to the motor. The method further includes the step of limiting the maximum motor speed by limiting the flow of hydraulic fluid returning from the motor to a hydraulic fluid supply.
According to the disclosed embodiment, the method is for controlling the differential hydraulic pressure across a variable displacement hydraulic motor having a wobbler which is adjustable for controlling the displacement of the motor and first and second hydraulic pressure responsive control piston means for adjusting the wobbler to respectively increase and decrease the motor displacement depending upon the hydraulic pressures applied to the piston means. The method comprises the steps of applying hydraulic fluid pressure from the higher of an input hydraulic fluid pressure to the motor and output hydraulic fluid pressure from the motor to the first control piston means when the pressure difference between the input hydraulic fluid pressure and the output hydraulic fluid pressure exceeds a predetermined amount, while, in the case of an opposing load on the motor, applying hydraulic fluid pressure from the lower of the input hydraulic fluid pressure and the output hydraulic fluid pressure to the second control piston means whereby the first control piston means overrides the second control piston means and the wobbler is adjusted to increase the motor displacement, and while, in the case of an aiding load on the motor, applying hydraulic fluid pressure from the higher hydraulic fluid pressure to the second control piston means. The second control piston means has a slightly or somewhat larger piston face area than that of the first control piston means whereby the first control piston means is overridden by the second control piston means so that the wobbler is adjusted to decrease the motor displacement to a minimum thereby minimizing the hydraulic fluid flow requirements of the motor.
These and other objects, features and advantages of the present invention will become more apparent from the following description when taken in connection with the accompanying drawings which show, for purposes of illustration only, one preferred embodiment in accordance with the present invention.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic illustration, partially in cross-section, of a known apparatus for controlling the differential hydraulic pressure across a variable displacement hydraulic motor;
FIG. 2 is a schematic diagram, partially in cross-section, of an apparatus according to the invention for controlling the differential hydraulic pressure across a variable displacement hydraulic motor;
FIG. 3 is a diagram of an apparatus for mechanically actuating a device with a variable displacement hydraulic motor driven by hydraulic fluid from a hydraulic power supply according to the invention; and
FIG. 4 is a characteristic speed-load torque profile of a hydraulic motor according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, an apparatus 20 according to the invention for controlling the differential hydraulic pressure ΔP across a variable displacement hydraulic motor 10 is shown in FIG. 2. The motor 10 comprises a wobbler 11 with a high pressure control piston 12 and a low pressure control piston 13 being operatively connected thereto for adjusting the wobbler to respectively increase and decrease the motor displacement with actuation of the pistons. A shuttle valve 14 communicates the higher pressure line of the hydraulic input and output lines C 1 and C 2 for the motor 10 with the high pressure line 15 while communicating the lower pressure line of C 1 and C 2 with low pressure line 16.
The spool valve of compensator valve 17 is moved downwardly to communicate the high pressure line 15 with the high pressure control piston 12 when the pressure differential ΔP between the input and output of the motor 10 exceeds a predetermined set amount so as to overcome the biasing force of the spring within the compensator valve 17 and the low pressure on the opposing side of the spool valve of the compensator valve. High pressure on the control piston 12 biases the wobbler 11 in a direction for increasing the displacement of the motor 10. The lower pressure control piston 13 is communicated with the output hydraulic fluid from the motor 10 by way of the line CP 2 , a four-way electrohydraulic valve 21 and one of the lines C 1 and C 2 depending upon the position of the valve 21.
As a result of this arrangement, in the case of an opposing load on the output shaft 19 of the motor 10 from the device to be actuated 22, where line C 1 is inputting hydraulic fluid to the motor from a supply, the pressure in the line C 1 will exceed that in the return line C 2 and the lower fluid pressure in line C 2 will be communicated with the low pressure control piston 13 by way of the valve 21 and line CP 2 . The application of high pressure to the control piston 12 will overcome the opposing force from the lower fluid pressure in the control piston 13 and spring 22 therein to increase the displacement of the motor 10. However, if an aiding load is applied to the shaft 19 from the device 22 to be actuated, the pressure in the output line C 2 will be higher than the pressure in the input line C 1 due to the action of the flow limiter 24. Since according to the invention the high pressure in line C 2 will be communicated with both the control piston 12 and the control piston 13, and because the area of the face of the control piston 13 is somewhat greater than that of the control piston 12, the force from the control piston 13 will override that of the control piston 12 and adjust the wobbler 11 for minimizing the displacement of the motor 10 thereby minimizing the flow requirements of the motor during operation with an aiding load. As noted above, this offers the advantages of reducing peak flow requirements and allowing available hydraulic fluid to be supplied to other hydraulic apparatus in the aircraft. The lower flow will also will reduce the heat generated by any restrictions in the flow lines caused by the setting of the four-way valve 21 which is responsive to controller 23 and, in turn, the flight instructions from the pilot, for example.
A flow limiter 24 is provided in the hydraulic fluid return line downstream of the four-way valve 21 for limiting the maximum flow of hydraulic fluid from the motor to thereby limit the maximum operating speed of the motor. In particular, the flow limiter 24 limits the flow from the motor 10 of the apparatus 20 to a predefined value and prevents the motor from exceeding the speed defined by Q L /D min at steady state, where QL equals flow limited (inch cubed/min) and D min equals minimum displacement (inch cubed/rev).
The shuttle valve 14 of the apparatus 20 of FIG. 2 operates like the shuttle valve 14 in the prior art apparatus of FIG. 1. Specifically, the shuttle valve 14 in FIG. 2 switches the lines 15 and 16 to lines C 1 and C 2 such that line 15 has the highest pressure of C 1 and C 2 while line 16 has the lower pressure as noted above. Likewise, the compensator valve 17 of the apparatus 20 of FIG. 2 operates like the corresponding compensator valve in the apparatus of FIG. 1. The compensator valve 17 comprises a spool valve spring loaded at one end as generally shown in the drawing. The valve controls pressure in the line CP 1 . The valve vents to case or return line. As previously indicated, the low pressure in line 16 and the high pressure in line 15 communicate with respective ends of the spool valve of the compensator valve. The spring pre-load of the valve is sized such that the valve opens to communicate line CP 1 with line 15 at a set pressure ΔP across the motor.
The block diagram of the apparatus of the invention as shown in FIG. 3 illustrates an aircraft hydraulic supply 25 which supplies pressurized fluid for driving the variable displacement hydraulic motor 10 of the apparatus 20 as shown in FIG. 2. The mechanical output of the motor 10 is employed to actuate a device 22 of the aircraft such as a rudder, flap, etc. The electronic controller 23 receives feedback information concerning the position or other condition of the device to be actuated. This information and control instructions from the pilot, for example, determine the output control signals from the controller 23 to the four-way electrohydraulic servo valve 21 which controls the position of the actuator.
The characteristic speed-load torque profile of a hydraulic motor 10 of the apparatus 20 of the invention is shown in FIG. 4. As seen therein, there are four distinct regions. Namely, at high torque and low speed the motor operates at maximum displacement and near the high speed end at minimum displacement. Intermediate to the two, the motor operates with a variable displacement varying to maintain a constant flow. To maintain a constant flow, it is necessary to maintain a near constant differential pressure across the motor. Above a predefined speed, the motor operates at minimum displacement but at a constant flow, limited by the flow limiter 24. The above-described apparatus 20 of the invention controls the differential pressure ΔP across the motor near constant in the intermediate, variable displacement region of its speed-load torque profile, and also drives the motor to minimum displacement at zero or aiding load or to maximum displacement if the opposing load exceeds a predefined value.
Illustratively, upon application of an opposing load to the output shaft 19 of the motor 10 of the apparatus 20 in FIG. 2, the pressure differential ΔP across the hydraulic input and output of the motor will increase to accommodate the load. In this case, the fluid pressure in the line C 1 , as the input line, will be high and therefore pressure in line C 1 will be communicated to the line 15 by way of the shuttle valve 14, while the relatively lower pressure in line C 2 will be communicated with the line 16 by way of shuttle valve 14. If the pressure differential ΔP is higher than the set point of the compensator valve 17, the compensator valve will open to allow flow of the high pressure fluid in line 15 into the chamber of the control piston 12 which will cause the piston to stroke in that the pressure on the control piston 12 from the line CP 1 will be high enough to overcome the fluid pressure force and spring load on control piston 13. Consequently, the displacement of the motor will increase. As displacement is increased, the pressure differential ΔP will decrease until there is a force balance on the spool. This will occur in the vicinity of the set point. If an opposing load on the output shaft 19 of the motor 10 is sufficiently high, determined by sizing, the motor 10 will operate at maximum displacement, with the compensator valve 17 fully ported to line 15. No regulation will then occur.
If an aiding load is applied to the output shaft 19, the pressure in the return line, line C 2 in the example, will be communicated with line 15 and that in supply line C 1 will be relatively lower and will be communicated with line 16. Again, the compensator valve 17 will open and the control piston will try to stroke the wobbler to increase the displacement of the motor 10. However, since line CP 2 is in communication with the return line C 2 by way of the valve 21, the pressure in line CP 2 will almost equal the pressure in line C 2 . Since the pressure in line CP 2 acts on the somewhat larger control piston face area of control piston 13, augmented with the pre-load of spring 22, the control piston 13 will counter the force from the control piston 12 and stroke the displacement to a minimum. The flow out of line CP 1 will be either leakage to case or pumped into line 15. Thus, with aiding load, the motor will operate at minimum displacement. Its speed will be checked by the flow limiter 24 downstream of the valve 21. Also, if no load is applied, the situation described for aiding load will apply. The pressures in the lines C 1 and C 2 will be nearly equal but the spring pre-load and the larger face area in the control piston 13 will ensure that the displacement remains at minimum.
From the above, it can be seen that the apparatus and method for controlling the differential hydraulic pressure across a variable displacement hydraulic motor of the invention are useful in a power drive unit, particularly for an aircraft, for extracting power from a hydraulic power source, typically constant pressure, and delivering it to a rotary mechanical load, typically of the actuator type. The apparatus provides control for full four quadrant operation, that is, both positive and negative rotation of the motor, and of positive and negative load. Further, the apparatus provides the capability to start and stop rotation of the motor in either direction under both positive and negative loads as commanded by the electronic controller. Moreover, the apparatus provides the ability to hydromechanically limit the maximum hydraulic flow consumed under opposing loads (positive rotation, positive load or negative rotation, negative load) by means of reducing the motor displacement so as to improve the efficiency of the power drive unit. In addition, the apparatus of the invention provides the ability to absorb an aiding load (positive rotation, negative load or negative rotation, positive load) without pumping hydraulic fluid back to the supply while limiting flow and thus speed.
This is accomplished in the apparatus of the invention through the use of the pressure compensator valve in combination with a shuttle valve so as to control pressure difference across the motor to be a constant set value for opposing loads for either direction of rotation, i.e., for positive rotation with an opposing load the motor displacement is varied to maintain the pressure in line C 1 a constant value above that in line C 2 ; for negative rotation with an opposing load line C 2 pressure is maintained a constant value above line C 1 pressure. This applies only within the limits of the motor displacement. With the motor at its maximum displacement, the pressure difference is higher than the set point, while it is lower than the set point for displacement at the minimum value. A conventional four-way electrohydraulic servo valve employed in combination with a flow limiter controls the motor motion for either direction of rotation with either opposing or aiding loads, i.e., true four quadrant operation.
The fluid pressure line running from the low pressure control piston 13 to the fluid line between the servo valve 21 and the flow limiter 24 functions to keep the motor 10 on the minimum displacement during aiding loads and avoids a stability problem inherent in the known apparatus of FIG. 1.
While I have shown and described only one embodiment in accordance with the present invention it is understood that the same is not limited thereto, but is susceptible to numerous changes and modifications as known to those skilled in the art. For example, the method and apparatus of the invention are not limited to use in an aircraft but could be employed for the control of hydraulic systems in other machinery. Therefore, I do not wish to be limited to the details shown or described herein, but intend to cover all such changes and modifications as are encompassed by the scope of the appended claims.
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A method and apparatus for controlling the differential hydraulic fluid pressure (ΔP) across a variable displacement hydraulic motor (10) wherein the displacement of the motor is adjusted as a function of the differential fluid pressure across the motor to maintain a near constant differential pressure across the motor when the motor is operating under an opposing load and in an intermediate region of its speed-load torque profile (FIG. 4). In order to minimize the flow requirements of the motor, the displacement of the motor is reduced to minimum when the motor is operating under an aiding load or no load. The method and apparatus are useful in an apparatus for mechanically actuating a device (22) with the variable displacement hydraulic motor (10) driven by hydraulic fluid from a hydraulic power supply (25) such as an aircraft power supply for operating components of the aircraft, e.g. rudder, wing, etc.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method for deriving equivalent circuit model of passive components. The invention relates particularly to a method for deriving the equivalent circuit models, a simulator, and a storage medium that are capable of performing simulation in a time domain by a common procedure which is independent from types of the passive components.
BACKGROUND OF THE INVENTION
[0002] According to trend toward use of high frequencies and high-speed digitization in data communication devices, it has been important recently to perform highly accurate circuit simulation in a time domain of electronic circuits including passive components.
[0003] Regarding the electronic devices, it is very difficult to estimate electric characteristics of a complicated electronic circuit when the circuit is being designed. For manufacturing the circuit, a lot of trial is repeated in which an actual prototype assembly of the circuit is made and measured in its electric characteristic, and the circuit is designed over again if the assembly does not exhibits desired electric characteristic.
[0004] Circuit simulations for estimating electric characteristics of the electronic circuit are performed with a circuit simulator consisting of a computer and software in order to reduce the trial. As the software, for example, a Simulation Program with Integrated Circuit Emphasis (SPICE) developed by the University of California is known.
[0005] A circuit simulation requires an equivalent circuit model, which specifies electric characteristics of semiconductor devices, such as transistors, FETs, and diodes, and passive components, such as resistors, capacitors, and inductors. It is important to establish a highly accurate equivalent circuit model of the circuit components since accurateness of the circuit simulation depends greatly upon accuracy of the equivalent circuit model.
[0006] For a capacitor, one of the passive components, equivalent circuit models that use comparatively small number of circuit components have been provided. The model includes a three-element model in which first capacitor C 1 , first resistor R 1 , and first inductor L 1 are connected in series as shown in FIG. 6A, and a five-element model in which a series connection of first capacitor C 1 and first resistor R 1 and a series connection of second capacitor C 2 and second resistor R 2 are connected in parallel, and first inductor L 1 is connected in series to the parallel circuit, as shown in FIG. 6B. However, these conventional equivalent circuit models do not have satisfying accuracy. As shown in FIGS. 6C and 6D, the conventional models hardly reproduce an impedance having complex frequency dependence. FIG. 6C shows a real part of the impedance, and FIG. 6D shows a capacitance component of the impedance. Calculated values of a three-element model are represented by solid lines, and calculated values of a five-element model are represented by broken lines. FIGS. 6C and 6D show large differences between the calculated values and actually-measured values given by dotted lines.
[0007] Therefore, for electronic circuits including capacitors, an estimation result of a circuit simulator does not often match with electric characteristics of an actual circuit, and this prevents electronic circuits using the circuit simulator from being designed efficiency.
DISCLOSURE OF THE INVENTION
[0008] By a method for deriving an equivalent circuit model, a circuit simulator accurately estimates electric characteristics of an actual passive component.
[0009] The method includes:
[0010] Providing impedance Z(fe) at each of sample frequencies f 1 , . . . ,f N (where f 1 <f n ) is given as
Z ( f n )= R ( f n )+ jx ( f n )
[0011] where
[0012] Z is the impedance of a capacitor,
[0013] R is a real part of Z,
[0014] X is an imaginary part of Z,
[0015] f n is a value of each sample frequency (n=1, 2, . . . ,N), and
[0016] j is the imaginary unit;
[0017] Forming an equivalent circuit model by adopting any of an RC circuit consisting of a resistance and a capacitance, an RL circuit consisting of a resistance and an inductance, and an RCL circuit consisting of the RC circuit and the RL circuit connected in series;
[0018] Composing an evaluation function Q({right arrow over (P)}) in accordance with formulae:
Q ( P → ) = ∑ n = 1 N q ( R M ( f n , P → ) , X M ( f n , P → ) , R ( f n ) , X ( f n ) ) ; and q ( R M , X M , R , X ) = C R | R M - R | 2 | R | d + C X | X M - X | 2 | X | d + C Z | Z M - Z | 2 | Z | d ,
[0019] where an impedance of the equivalent circuit model is defined as
Z M ( f n , {right arrow over (P)} )= R M ( f n , {right arrow over (P)} )+ jX M ( f n , {right arrow over (P)} ),
[0020] where,
[0021] Z M is the impedance of the equivalent circuit model,
[0022] R M is a real part of Z M ,
[0023] X M is an imaginary part of Z M ,
[0024] f n is the value of each sample frequency (n=1, 2, . . . ,N),
[0025] j is the imaginary unit,
[0026] {right arrow over (P)}=(P 1 ,P 2 , . . . P K ) is a circuit constant vector including elements being values of R, C and L, and
[0027] C R , C X , and C Z are positive real numbers or zero; and
[0028] Determining the circuit constant vector {right arrow over (P)} by minimizing the evaluation function Q({right arrow over (P)}).
[0029] This method of deriving equivalent circuit model is applicable commonly to capacitors regardless of their kinds, and is also applicable in general to other passive components, such as resistors and inductors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] [0030]FIG. 1 is a flowchart showing a method for deriving an equivalent circuit model of a capacitor according to exemplary embodiments of the present invention.
[0031] [0031]FIG. 2A is a diagram of an RC ladder circuit which is an equivalent circuit model of a capacitor according to the embodiments.
[0032] [0032]FIG. 2B is a diagram of an RL ladder circuit which is an equivalent circuit model of a capacitor according to the embodiments.
[0033] [0033]FIG. 2C is a diagram of an RCL ladder circuit which is an equivalent circuit model of a capacitor according to the exemplary embodiments.
[0034] [0034]FIG. 3A through FIG. 3E are diagrams of RC circuits which are other equivalent circuit models of a capacitor.
[0035] [0035]FIG. 3L through FIG. 3P are diagrams of RL circuits which are still other equivalent circuit models of a capacitor.
[0036] [0036]FIG. 4 is a flowchart showing a method of determining circuit constant vectors of the ladder circuits shown in FIG. 2A through FIG. 2C.
[0037] [0037]FIG. 5A shows an equivalent circuit model of a solid tantalum electrolytic capacitor according to the embodiments.
[0038] [0038]FIG. 5B is a graphical representation showing a real part of a reproduced impedance of the solid tantalum electrolytic capacitor according to the embodiments.
[0039] [0039]FIG. 5C is a graphical representation showing a reproduced capacitance of the solid tantalum electrolytic capacitor according to the embodiments.
[0040] [0040]FIG. 6A shows a three-element model representing an equivalent circuit model of a solid tantalum electrolytic in a conventional method.
[0041] [0041]FIG. 6B shows a five-element model in a conventional method.
[0042] [0042]FIG. 6C is a graphical representation showing a real part of a reproduced impedance of the solid tantalum electrolytic capacitor by the conventional method.
[0043] [0043]FIG. 6D is a graphical representation showing a reproduced capacitance of the solid tantalum electrolytic capacitor by the conventional method.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0044] (Exemplary Embodiment 1)
[0045] [0045]FIG. 1 is a flowchart of processes in a method for deriving an equivalent circuit model of a capacitor according to an exemplary embodiment. Impedances as sampled values for frequencies shown by equation 1, which will be described later, are provided. (Step 11 ). Using frequency-independent resistance (R), capacitance (C), and inductance (L), one of an RC circuit consisting of the resistor and the capacitor, an RL circuit consisting of the resistor and the inductor, and an RCL circuit consisting of the RC circuit and the RL circuit connected in series is formed as an equivalent circuit model representing a circuit enabling a simulation in a time domain (step 12 ). An evaluation function defined by equation 3, described later, is set with equations 1 and 2 (step 13 ). A circuit constant vector is determined by minimizing equation 3 (step 14 ).
[0046] [0046]FIG. 2A through FIG. 2C show circuit diagrams of the equivalent circuit models of a capacitor according to the embodiment. FIG. 2A illustrates a single-stage RC ladder circuit having first resistance R C ( 1 ) and first capacitance C( 1 ) connected in series, a two-stage RC ladder circuit having a series circuit consisting of second resistance R C ( 2 ) and second capacitance C( 2 ) connected in parallel with the first capacitance C( 1 ), and an N C -stage RC ladder circuit (“N C ” is a natural number) formed similarly. FIG. 2B illustrates a single-stage RL ladder circuit having first resistance R L ( 1 ) and first inductance L( 1 ) connected in series, a two-stage RL ladder circuit having a series circuit consisting of second resistance R L ( 2 ) and second inductance L( 2 ) connected in parallel with first inductance L( 1 ), and an NL-stage RL ladder circuit (“N L ” is a natural number) formed similarly. FIG. 2C shows an (N C +N L )-stage RCL ladder circuit composed of the N C -stage RC ladder circuit and the N L -stage RL ladder circuit that are connected in series.
[0047] Besides those circuit diagrams shown in FIG. 2A through FIG. 2C, other diagrams are useful as long as constructing an equivalent circuit model of a capacitor, such as RC circuits shown in FIG. 3A through FIG. 3E, RL circuits shown in the FIG. 3L through FIG. 3P, and RCL circuits formed by connecting in series any of the RC circuits with any of the RL circuits (not shown in these figures). If using the diagrams, however, it is necessary to determine values of circuit components by another method suitable for each of the diagrams.
[0048] [0048]FIG. 4 is a flowchart showing a method of determining the circuit constant vector of any of the ladder circuits shown in FIG. 2A through FIG. 2C according to this exemplary embodiment. This corresponds to Step 14 of FIG. 1. In accordance with equations 6 through 9 discussed below, values of circuit components of the RC circuit in FIG. 2A through FIG. 2C are distributed at an equal ratio (step 41 ). A ratio for the equal-ratio distribution of the circuit component values is determined by minimizing equation 4 described later (step 42 ). A circuit constant vector is calculated by minimizing equation 4 using, as initial values, the circuit component values distributed at the ratio of equal-ratio distribution determined in step 42 (step 43 ). Values of circuit components of the RL circuit in one of FIG. 2A through FIG. 2C are distributed at an equal ratio in accordance with equations 8 through 11 discussed later (step 44 ). A ratio for the equal-ratio distribution of the circuit component values is determined by minimizing equation 5 described later (step 45 ). A circuit constant vector is calculated by minimizing equation 5, using, as initial values, the circuit component values distributed at the ratio of the equal-ratio distribution determined in the step 45 (step 46 ). Then, the evaluation function defined by the equation 3 is set (step 47 ). An RCL circuit is formed by connecting in series the RC circuit composed in step 41 through step 43 and the RL circuit composed in step 44 through step 46 (step 48 ). A circuit constant vector of the RCL circuit is determined by minimizing equation 3 (step 49 ).
[0049] For a tantalum solid electrolytic capacitor, a procedure for deriving a highly-accurate equivalent circuit model will be described hereinafter in detail with reference to FIG. 1.
[0050] For each of the sample frequencies, impedance Z (f n ) given by:
Z ( f n )= R ( f n )+ jX ( f n ) (Equation 1)
[0051] is provided. (step 11 ),
[0052] where
[0053] Z is the impedance of the capacitor,
[0054] R is arealpart of Z,
[0055] X is an imaginary part of Z,
[0056] f n is a sample frequency (n=1, 2, . . . ,N), and
[0057] j is the imaginary unit.
[0058] Using frequency-independent resistances (R), capacitances (C) and inductances (L), one of an RC circuit consisting of the resistance and the capacitance, an RL circuit consisting of the resistance and the inductance, and an RCL circuit consisting of the RC circuit and the RL circuit connected in series is formed as an equivalent circuit model representing the circuit enabling a simulation in a time domain. In this embodiment, 5 (five) is chosen for both numbers N C and N L representing the circuit diagrams shown in FIG. 2A through FIG. 2C, to form a ten-stage RCL ladder circuit by connecting in series a five-stage RC ladder circuit and a five-stage RL ladder circuit (step 12 ).
[0059] Impedance exhibited by the equivalent circuit model formed in step 12 is defined as:
Z M ( f n ,{right arrow over (P)} )= R M ( f n , {right arrow over (P)} )+ jX M ( f n , {right arrow over (P)} ) (Equation 2),
[0060] where
[0061] Z M is the impedance of the equivalent circuit model,
[0062] R M isarealpartof Z M ,
[0063] X M is an imaginary part of Z M ,
[0064] f n is the value of each sample frequency (n=1, 2, . . . ,N),
[0065] j is the imaginary unit, and
[0066] {right arrow over (P)}=(P 1 ,P 2 , . . . P K ) is a circuit constant vector having elements as values of R, C and L,
[0067] An evaluation function Q({right arrow over (P)}) given by
Q ( P → ) = ∑ n = 1 N q ( R M ( f n , P → ) , X M ( f n , P → ) , R ( f n ) , X ( f n ) ) ( Equation 3 )
[0068] is composed (step 13 ). Here,
q ( R M , X M , R , X ) = C R | R M - R | 2 | R | d + C X | X M - X | 2 | X | d + C Z | Z M - Z | 2 | Z | d
[0069] where d is “0” for an evaluation of an absolute square error and is “2” for an evaluation of relative square error, and C R , C X , and C Z are “0” or any positive real numbers for assigning weights to respective terms.
[0070] When a real part R(f n ) of given impedance becomes a minimum value R m at frequency f m , instead of the ten-stage RCL ladder circuit as the equivalent circuit model, a combination of an N C -stage RC ladder circuit and one resistor connected in series may be formed if m=N, or another combination of an N L -stage RL ladder circuit and one resistor connected in series may be formed if m=1
[0071] In this embodiment, although 5 (five) was chosen for the numbers of stages, N C and N L , this is not restrictive, and the numbers of stages, N C and N L may be different from each other. For the solid tantalum electrolytic capacitor, a condition of N C =5 and N L =5 provides the model with generally satisfying accuracy according to a result of changing the number of the stages and repeating derivation of the circuit model of this embodiment. Numbers N C and N L may be determined for other types of capacitors by repeating derivation in the same manner.
[0072] A procedure shown in FIG. 4 is applied for determining component values of the circuit in step 14 . The procedure will be described hereafter according to FIG. 4.
[0073] Values of the circuit components for the five-stage RC ladder circuit are distributed at an equal ratio (step 41 ) in accordance with:
A ( P → ) = ∑ n = 1 N a ( R M ( f n , P → ) , X M ( f n , P → ) , R ( f n ) - xR 0 , X ( f n ) ) , ( Equation 6 )
[0074] where 0:5≦x≦1,
B ( P → ) = ∑ n = 1 N b ( R M ( f n , P → ) , X M ( f n , P → ) , R ( f n ) - ( 1 - x ) R 0 , X ( f n ) ) , ( Equation 7 )
[0075] where 0≦x≦1,
Rc ( 1 ) = ( 1 - x ) R 0 , ∑ k = 1 Nc C ( k ) = - 1 2 π f 1 X ( f 1 ) , ( Equation 8 )
[0076] and
Rc ( k+ 1)=α c·Rc ( k ), C ( k+ 1)=β c·C ( k ) (Equation 9).
[0077] In other words, since the minimum value of the real part of impedance R 0 is 0.018 Ω, and since a capacitance in a low frequency region is 66.5 μF according to FIG. 5B and FIG. 5C, respectively,
Rc ( k+ 1)=α C·R C ( k ), C ( k+ 1)=β C·C ( k ) (Equation 9)
[0078] stand applicable for k=1, 2, 3 and 4 when x=½, under the conditions of
Rc ( 1 ) = 0.018 × 10 - 3 2 , ∑ k = 1 5 C ( k ) = 66.5 × 10 6 .
[0079] Coefficients α C and β C are obtained by minimizing evaluation function A({right arrow over (P)}) set in the step 13 , as α C =20.6, and β C =0.37 (step 42 ).
[0080] Values of the circuit components are determined by minimizing the evaluation function A({right arrow over (P)}) set in third step 13 from initial values of the component values given by the coefficients α C and β C obtained in the step 42 (step 43 ). Table 1 shows the determined circuit component values.
TABLE 1 Rc(1) = 1.12 × 10 −02 C(1) = 2.29 × 10 −05 Rc(2) = 8.75 × 10 −02 C(2) = 3.12 × 10 −05 Rc(3) = 3.89 × 10 +00 C(3) = 4091 × 10 −17 Rc(4) = 8.03 × 10 +01 C(4) = 2.71 × 10 −06 Rc(5) = 1.67 × 10 +03 C(5) = 3.10 × 10 −06
[0081] Values of the circuit components for the five-stage RL ladder circuit are distributed at an equal ratio (step 44 ) in accordance with equations 8 and 9 and the following equations:
R L ( 1 ) = x · R 0 , L ( 1 ) = X ( f N ) 2 π f N ; ( Equation 10 )
[0082] and
R L ( k+ 1)=α L ·R L ( K ), L ( k+ 1)=β L ·L ( k ) (Equation 11).
[0083] In other words, since the minimum value of the real part of impedance R 0 is 0.018 Ω, and since a capacitance in a high frequency region is 1.14 nH according to FIG. 5B and FIG. 5C, respectively, the following equations
R L ( 1 ) = 0.018 × 10 - 3 2 , and
L (1)=1.14×10 −9
[0084] are applicable for k=1, 2, 3 and 4 when x=½, under the conditions of
R L ( k+ 1)= α L ·R L ( K ), L ( k+ 1)=β L ·L ( k ) (Equation 11)
[0085] Coefficients α L and β L are obtained by minimizing evaluation function B({right arrow over (P)}) set in step 13 , as α L =150.7, and β L =3.47 (step 45 ).
[0086] In 4f-th step 46 , values of the circuit components are determined by minimizing evaluation function B({right arrow over (P)}) set in step 13 from initial values of the component values given by coefficients α L and β L obtained in 4e-th step 45 . The circuit component values are shown in Table 2.
TABLE 2 R L (1) = 6.13 × 10 −03 L(1) = 1.57 × 10 −09 R L (2) = 1.60 × 10 −01 L(2) = 7.24 × 10 −09 R L (3) = 2.18 × 10 +00 L(3) = 9.93 × 10 −09 R L (4) = 3.41 × 10 +01 L(4) = 2.19 × 10 −06 R L (5) = 5.35 × 10 +02 L(5) = 7.15 × 10 −16
[0087] The estimation function Q(P) defined by equation 3 (step 47). That is,
Q ( P → ) = ∑ n = 1 m q ( R M ( f n , P → ) , X M ( f n , P → ) , R ( f n ) - R 0 / 2 , X ( f n ) ) , and q ( R M , X M , R , X ) = c R | R M - ( R - R 0 / 2 ) | 2 | R | d + c X | X M - X | 2 | X | d + c Z | Z M - Z | 2 | Z | d ,
[0088] where C X <<C Z <<C R , in order to assign a greater weight to a relative square error of the real part, since accuracy of the real part of impedance is not easily assured.
[0089] A ten-stage RCL ladder circuit is formed by connecting in series the five-stage RC ladder circuit composed in step 41 through step 43 and the five-stage RL ladder circuit composed in step 44 through step 46 (step 48).
[0090] Values of circuit components of the ten-stage RCL ladder circuit formed in step 48 are determined by minimizing evaluation function Q({right arrow over (P)}) set in step 47 (step 49 ). Table 3 shows the determined circuit component values.
TABLE 3 R C (1) = 1.24 × 10 −02 C(1) = 2.25 × 10 −05 R C (2) = 6.00 × 10 −02 C(2) = 3.85 × 10 −05 R C (3) = 3.90 × 10 +00 C(3) = 2.07 × 10 −17 R C (4) = 8.04 × 10 +01 C(4) = 2.79 × 10 −06 R C (5) = 1.67 × 10 +03 C(5) = 4.49 × 10 −06 R L (1) = 5.24 × 10 −03 L(1) = 1.24 × 10 −09 R L (2) = 2.66 × 10 −01 L(2) = 9.59 × 10 −09 R L (3) = 2.18 × 10 +00 L(3) = 4.51 × 10 −09 R L (4) = 3.41 × 10 +01 L(4) = 3.68 × 10 −06 R L (1) = 5.35 × 10 +02 L(5) = 4.65 × 10 −16
[0091] The equivalent circuit model derived as above, a result of reproduction of the real parts of impedance, and a result of reproduction of the capacitances are shown in FIG. 5A, FIG. 5B, and FIG. 5C, respectively. With the equivalent circuit model, an accuracy including a relative error less than 10% is ensured in reproduction of impedances across all points of the sampling frequencies.
[0092] (Exemplary Embodiment 2)
[0093] In a method of deriving an equivalent circuit model of exemplary embodiment 2, an RCL circuit is formed as an equivalent circuit model wherein the real part R(f n ) of impedance becomes minimum value R 0 at sample frequency f m (f m ≠f 1 and f m ≠f n ), in step 12 of exemplary embodiment 1, and evaluation function in a low frequency region f m+1 ≦f n ≦f m is calculated according to:
A ( P -> ) = ∑ n = 1 N a ( R M ( f n , P -> ) , X M ( f n , P -> ) , R ( f n ) - ( 1 - x ) R 0 , X ( f n ) ) ( Equation 4 )
[0094] where (0≦x≦1), instead of the evaluation function defined by equation 3 in step 13 . Further, factors x and d are set as x=½ and d=2 in calculation of evaluation function in a high frequency region f m+1 ≦f n ≦f N according to
B ( P -> ) = ∑ n = 1 N b ( R M ( f n , P -> ) , X M ( f n , P -> ) , R ( f n ) - ( 1 - x ) R 0 , X ( f n ) ) ( Equation 5 )
[0095] where 0≦x≦1. That is,
A ( P -> ) = ∑ n = 1 N a ( R M ( f n , P -> ) , X M ( f n , P -> ) , R ( f n ) - ( 1 - x ) R 0 , X ( f n ) ) ,
a ( R M , X M , R , X ) = c R R M - ( R - R 0 / 2 ) 2 R d + c X X M - X 2 X d + c Z Z M - Z 2 Z d , B ( P -> ) = ∑ n = 1 N b ( R M ( f n , P -> ) , X M ( f n , P -> ) , R ( f n ) - ( 1 - x ) R 0 , X ( f n ) ) , and b ( R M , X M , R , X ) = c R R M - ( R - R 0 / 2 ) 2 R d + c X X M - X 2 X d + c Z Z M - Z 2 Z d ,
[0096] where C X <<C Z <<C R , in order to assign a greater weight to a relative square error of the real part, since it is considerably difficult to ensure accuracy of the real part of impedance.
[0097] (Exemplary Embodiment 3)
[0098] An RC circuit is formed as an equivalent circuit model in which a real part R(f n ) of impedance becomes minimum value R 0 at sample frequency of f m (f m =f N ) in step 12 of embodiment 1, and an evaluation function in an entire frequency region f 1 ≦f n ≦f N is calculated according to:
A ( P -> ) = ∑ n = 1 m a ( R M ( f n , P -> ) , X M ( f n , P -> ) , R ( f n ) - ( 1 - x ) R 0 , X ( f n ) ) ( Equation 6 )
[0099] where 0≦x≦1, instead of the evaluation function in step 13 . A new RC circuit is then completed by connecting additionally a resistance xR 0 in series to the above RC circuit.
[0100] (Exemplary Embodiment 4)
[0101] An RL circuit is formed as an equivalent circuit model in which a real part R(f n ) of impedance becomes minimum value R 0 at sample frequency of f m (f m =f N ), in step 12 of embodiment 1, and an evaluation function in an entire frequency region f 1 ≦f n ≦f N is calculated according to:
B ( P -> ) = ∑ n = 1 m b ( R M ( f n , P -> ) , X M ( f n , P -> ) , R ( f n ) - ( 1 - x ) R 0 , X ( f n ) ) ( Equation 7 )
[0102] where 0≦x≦1, instead of the evaluation function in third step, and further, a new RL circuit is completed by connecting additionally a resistance (1-x)R 0 in series to the above RL circuit.
[0103] (Exemplary Embodiment 5)
[0104] In addition to embodiment 2, in this embodiment, evaluation function A({right arrow over (P)}) is minimized in any of a single-stage RC ladder circuit having a first resistance and a first capacitance connected in series, a two-stage RC ladder circuit having a series circuit consisting of a second resistance and a second capacitance connected in parallel with the first capacitance, and an Nc-stage RC ladder circuit (“N C ” is a natural number) formed in the same manner, and evaluation function B({right arrow over (P)}) is minimized in any of a single-stage RL ladder circuit having a first resistance and a first inductance connected in series, a two-stage RL ladder circuit having a series circuit consisting of a second resistance and a second inductance connected in parallel with the first inductance, and an N L -stage RL ladder circuit (“N L ” is a natural number) formed in the same manner.
[0105] (Exemplary Embodiment 6)
[0106] In addition to embodiment 3, in this embodiment, evaluation function A({right arrow over (P)}) in any of a single-stage RC ladder circuit having a first resistance and a first capacitance connected in series, a two-stage RC ladder circuit having a series circuit consisting of a second resistance and a second capacitance connected in parallel with the first capacitance, and an N C -stage RC ladder circuit (“N C ” is a natural number) formed in the same manner.
[0107] (Exemplary Embodiment 7)
[0108] In addition to embodiment 4, in this embodiment, evaluation function B({right arrow over (P)}) is minimized in any of a single-stage RL ladder circuit having a first resistance and a first inductance connected in series, a two-stage RL ladder circuit having a series circuit consisting of a second resistance and a second inductance connected in parallel with the first inductance, and an N L -stage RL ladder circuit (“N L ” is a natural number) formed in the same manner.
[0109] The foregoing embodiments can be implemented in combination, and a number of stages in the RC ladder circuit and the RL ladder circuit can be set freely as desired.
[0110] Although methods of deriving the equivalent circuit models for capacitors are explained, a simulator for deriving an equivalent circuit model according to these methods can be conducted. Furthermore, another simulator for analyzing frequency response and/or time response of a circuit with using the equivalent circuit model for capacitors can be conducted.
[0111] In addition, a computer-readable recording medium storing a program containing the function of deriving an equivalent circuit model based on these methods of deriving equivalent circuit model can be provided. Moreover, another computer-readable recording medium storing a program containing the function of analyzing frequency response and/or time response of a circuit in the similar manner with using the equivalent circuit model for capacitors can be provided.
INDUSTRIAL APPLICABILITY
[0112] By a method of deriving an equivalent circuit model for capacitors according to the present invention and a circuit simulation using the equivalent circuit model yealize accurate prediction for operation of a circuit including capacitors. This improves efficiency of designing electronic circuits. In addition, the method of the invention is applicable not only to the capacitors but also to other passive components, such as resistors and inductors.
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A method of deriving an equivalent circuit model for a passive component includes a first step of providing a given frequency characteristic of a capacitor, a second step of forming one of an RC circuit, an RL circuit, and an RCL circuit using frequency-independent resistances (R), capacitances (C) and/or inductances (L), as the equivalent circuit model representing a circuit capable of performing a simulation in a time domain, a third step of composing an evaluation function for evaluating accuracy of the equivalent circuit model formed in the second step, and a fourth step of determining values of the circuit components by minimizing the evaluation function composed in the third step. The method with a simulator adapted for implementing this method and a computer-readable storage medium containing a recorded program, derives the equivalent circuit model for a capacitor. The model is capable of performing a simulation in the time domain using a common procedure not dependent upon types of passive components.
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CLAIM OF PRIORITY
This application claims priority under 35 U.S.C. 119(e)(1) to U.S. Provisional Application No. 61/092,958 filed Aug. 29, 2008.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to multi-core, multi-processing, factory multi-core and DSP multi-core. More specifically, the present invention uses prioritized interrupts for optimization.
BACKGROUND OF THE INVENTION
This application addresses the problem of devoting data processing capability to a variety of user applications while providing efficient use of hardware resources and electric power. An initial response to a need for greater data processing capability is to operate the central processing unit at higher speeds. Increasing the rate of operation of a central processing unit enables greater data processing operations per unit time. This is not a complete solution because memory speed often cannot keep pace with processor speed. The mismatch of processor speed and memory speed can be minimized using memory cache, but such memory cache introduces other problems. Often high processor speeds require deep pipelining. Deep pipelining extends the processing time required to process conditional branches. Thus increased processor speed can achieve only limited improvement. Another potential response is multi-processing. The central processing unit and at least some auxiliary circuits are duplicated. Additional data processor cores enable greater data processing operations per unit time.
Moving from a uni-processor system to a multi-processor system involves numerous problems. In theory providing additional data processor cores permits additional data processing operations. However, proper programming of a multi-processor system to advantageously exploit additional data processor cores is difficult. One technique attempting to solve this problem is called symmetrical multi-processing (SMP). In symmetrical multi-processing each of the plural data processor cores is identical and operates on the same operating system and application programs. It is up to the operating system programmer to divide the data processing operations among the plural data processor cores for advantageous operation. This is not the only possible difficulty with SMP. Data processor cores in SMP may operate on data at the same memory addresses such as operating system file structures and application program data structures. Any write to memory by one data processor core may alter the data used by another data processor core. The typical response to this problem is to allow only one data processor core to access a portion of memory at one time using a technique such as spin locks and repeated polling by a data processor not currently granted access. This is liable to cause the second data processor core to stall waiting for the first data processor core to complete its access to memory. The problems with sharing memory are compounded when the identical data processor cores include caches. With caches each data processor core must snoop a memory write by any other data processor core to assure cache coherence. This process requires a lot of hardware and takes time. Adding additional data processor cores requires such additional resources that eventually no additional data processing capability is achieved by such addition.
Another multi-processing model is called the factory model. The factory model multi-processing requires the software developer to manually divide the data processing operation into plural sequential tasks. Data processing then flows from data processor core to data processor core in the task sequence. This division of the task is static and not altered during operation of the multi-processor system. This is called the factory model in analogy to a factory assembly line. This factory model tends to avoid the data collisions of the SMP model because the data processor cores are working on different aspects of the data processing operation. This model tends to work best for data flow operations such as audio or video data streaming. This factory model is often used in digital signal processing (DSP) operations which typically have many of these data flow operations. There are problems with this factory model as well. The task of dividing the data processing operation into sequential tasks is generally not simple. For even loading of the data processor cores is required to best utilize this factory model. Any uneven loading is reflected in one or more data processor cores being unproductive while waiting for data from a prior data processor core or waiting for a next data processor core to take its data output. The nature of the data processing operation may preclude even loading of the plural data processor cores. Processes programmed using the factory model do not scale well. Even small changes in the underlying data processing operation to be performed by the system may require complete re-engineering of the task division.
SUMMARY OF THE INVENTION
This invention relates to more optimal uses of a multi-core system to maximize utilization of data processor cores and minimize power use. The invention uses prioritized interrupts and optional in-built methods to allow systems to run more efficiently with less programmer effort.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of this invention are illustrated in the drawings, in which:
FIG. 1 shows a factory multi-core checkerboard consisting of an array of data processor cores connected to shared memory units applicable to the present invention (prior art);
FIG. 2 shows a four data processor core cluster such that each data processor core's interrupt controller (IC) is memory mapped onto the bus and each data processor core is a master on the bus;
FIGS. 3A , 3 B and 3 C show an example load balancing system with four data processor cores which routes interrupts to a set of data processor cores in a cluster;
FIG. 4 shows a master slave system with two data processor cores;
FIG. 5 is a flow chart of the steps of producing a program suitable for performing a known data processing function on a multi-processor system of this invention;
FIG. 6 is a flow chart of the steps of running the program of FIG. 5 on a multi-processor system of this invention;
FIG. 7 shows multiple planes of operation based on priority; and
FIG. 8 shows a simple system running the same code in parallel, with cross triggered synchronization to allow verification of common results between data processor cores.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
This invention is a method and apparatus for factory multi-core data processor utilizing prioritized interrupts for optimization. This application describes numerous details to provide an understanding of the present invention. One skilled in the art will appreciate that one may practice the present invention without these details. This application does not describe some well known subject matter in detail to not obscure the description of the invention.
This invention is a multi-core system containing plural data processor cores interconnected with memory and peripherals in a single integrated circuit. The topology may be checkerboard, hierarchical, clusters or other forms. FIG. 1 illustrates the preferred checkerboard topology. This invention uses prioritized interrupts to add value to many forms of processing. The anticipated optimal use of this invention is not symmetrical multiprocessing (SMP) in the standard meaning. This invention anticipates that memory caches within the data processor cores are sub-optimal and not envisioned.
FIG. 1 illustrates a factory multi-core checkerboard consisting of an array of data processor cores 131 , 132 , 133 , 134 , 135 , 136 , 137 , 138 and 139 connected to shared memories 111 , 112 , 113 , 114 , 115 , 116 , 117 , 118 , 119 , 120 , 121 and 122 . As illustrated in FIG. 1 , each memory 111 , 112 , 113 , 114 , 115 , 116 , 117 , 118 , 119 , 120 , 121 and 122 may be accessed by up to four data processor cores 131 , 132 , 133 , 134 , 135 , 136 , 137 , 138 and 139 . For example, FIG. 1 illustrates that shared memory 115 may be accessed by data processor cores 131 , 132 , 134 and 135 . As illustrated in FIG. 1 , each data processor cores 131 , 132 , 133 , 134 , 135 , 136 , 137 , 138 and 139 may accesses up to four memories 111 , 112 , 113 , 114 , 115 , 116 , 117 , 118 , 119 , 120 , 121 and 122 . For example, FIG. 1 illustrates that data processor core 135 may be access memories 115 , 116 , 118 and 119 . FIG. 1 illustrates a preferred embodiment for higher count multi-core designs that is predictable in processing time and layout. In the preferred embodiment, there are no caches and each shared memory 111 , 112 , 113 , 114 , 115 , 116 , 117 , 118 , 119 , 120 , 121 and 122 is a multi-port memory. Such a multi-port memory may be constructed using a memory four times faster that the data processor cores with each data processor core having one access each four memory cycles. This ensures deterministic behavior.
FIG. 2 shows an example of a four data processor core cluster. In the example of FIG. 1 , each data processor core 220 , 230 , 240 and 250 has a corresponding interrupt controller (IC) 221 , 231 , 241 and 251 . Each IC 221 , 231 , 241 and 251 has an interrupt register memory mapped onto bus 200 . Each data processor core 220 , 230 , 240 and 250 includes a corresponding central processing unit (CPU) 222 , 232 , 242 and 252 that is a master on bus 200 . In the preferred embodiment, triggering an interrupt via a request from software is a memory mapped operation. A write to a particular memory address corresponding to the interrupt register of an IC of the target data processor core triggers an interrupt. Software triggered interrupts may be purely by memory mapped access as described, by inter-core wiring, by an interrupt bus or some combination. External interrupts 210 are wired to corresponding IC 221 , 231 , 241 and 251 in the normal fashion.
In the system illustrated in FIG. 2 one data processor core many notify one or more other data processor cores via interrupt that it has completed processing. If data is to be passed, it would normally be done via pointers to shared memory. This model is valuable because interrupts are a natural aspect of any data processor architecture. This enables the following functions such as sleeping until synchronization and performing work on less important tasks until synchronization. This avoids factoring of code as is typical in DSPs. This may be flattened to all running on one data processor core where the interrupts are serviced by the single data processor core or fewer data processor cores than the maximum without modifications. This does not need special mechanisms or hardware for synchronization. This can add meaning to different software triggered interrupts enabling adding new event types cheaply.
In the preferred embodiment illustrated in FIG. 2 , external interrupts are wired into the interrupt controllers from peripherals in the same manner as in typical prior art systems. Internal interrupts between data processor cores are handled by memory mapped triggering. Therefore one data processor core may interrupt another by writing to the address associated with the other data processor core's interrupt trigger register. Writing to this trigger register indicates the target data processor core and the identity of the interrupt. The routing mechanism may be wired, via an interrupt bus, via a daisy chain from one interrupt controller to the next or via a mix of such connectivity between and within cluster data processor cores and out of cluster data processor cores. In an alternative embodiment writing to the trigger register of the selected data processor core is passed by normal bus to the interrupt controller of a slave data processor core providing directed triggering. It is possible to employ both these alternates in one system.
FIGS. 3A , 3 B and 3 C illustrate alternatives of a load balancing system which routes interrupts to a cluster of data processor cores. The example illustrated in FIGS. 3A , 3 B and 3 C include four data processor cores. FIG. 3A shows a hyper-interrupt controller (HIC) 310 which acts as a multiplexer to route interrupts to the appropriate data processor core 220 , 230 , 240 and 250 . HIC 310 uses status of each data processor core to make decisions.
Hyper-interrupt controller 310 feeds interrupts to the least loaded data processor core. This decision is based on which data processor core is least loaded or has the lowest priority. In a four data processor core system such as illustrated in FIG. 3A , the priority of a new interrupt request is compared against the priority of data processor cores 220 , 230 , 240 and 250 . If the interrupt priority is below the priority of all four data processor cores 220 , 230 , 240 and 250 , HIC 310 stalls the interrupt and holds it pending. If the interrupt priority is higher than the priority of one or more of data processor cores 220 , 230 , 240 and 250 , HIC 310 routes the interrupt to the data processor core with the lowest priority. This ensures optimal use of data processor cores 220 , 230 , 240 and 250 . HIC 310 does not pass an interrupt request to a data processor core until the data processor core can service it. This avoids thrashing and spurious interrupts. As noted above, in the preferred embodiment data processor cores 220 , 230 , 240 and 250 have no cache memory. Thus there is no cost to running the interrupt on any data processor core. In contrast a typical SMP system may lose a lot of time due to cache snoop and flush/load operations.
Load balanced systems can service systems events far more efficiently, while maintaining real time or even hard real time characteristics. Systems which pre-determine routing suffer when the load is not naturally balanced in time and priority. The load balanced system of this invention frees the system developer from trying to understand both periodicity, overlapping periodicity and load versus time. Modeling the load balancing system of this invention is far easier than the prior art. This model matches the normal modeling of a single data processor core system. Further, rate monotonic (deadline) systems can be constructed safely in most cases. This invention is further advantageous because it works well in systems with very varying loads. When the load is low, only one data processor core is active. This saves power. As the load increases, more data processor cores are automatically added based on rate to completion. Thus data processor cores are highly utilized for minimum power use. This invention is advantageous over running one data processor core very fast or varying its speed. When increasing the speed of a single data processor core past a certain speed, the memory system cannot keep up. Thus this prior art technique would require caches or faster, more power hungry memory.
The preferred embodiment of HIC 310 is a separate module which intercepts interrupts and re-feeds them to a set of interrupt controllers within the data processor cores as illustrated in FIG. 3A . FIG. 3B illustrates a first alternative. FIG. 3B illustrates HIC 311 acting as the only interrupt controller for data processor cores 320 , 330 , 340 and 350 . HIC 311 distributes interrupts among data processor cores 320 , 330 , 340 and 350 in the same manner as described above for HIC 310 . FIG. 3C illustrates yet another alternative. FIG. 3C illustrates interrupt controllers 323 , 333 , 343 and 353 of respective data processor cores 321 , 331 , 341 and 351 communicating via lines 327 , 337 and 347 . Using this communication interrupt controllers 323 , 333 , 343 and 353 handle the multiplexing of interrupts. This distributes interrupts among data processor cores 321 , 331 , 341 and 351 in the same manner as described above for HIC 310 .
FIG. 4 shows a master/slave system with two data processor cores 420 and 430 . Master data processor core 420 sends requests to slave data processor core 430 via request line 425 . These requests include interrupt requests. Slave data processor core 430 performs the requested data processing and signals completion via completion line 435 . This completion corresponds to a return from interrupt operation if slave data processor core 430 is servicing an interrupt. FIG. 4 illustrates only a single slave data processor core but those skilled in the art would realize that plural slave data processor cores are feasible.
The system illustrated in FIG. 4 allows one data processor core of a cluster of four data processor cores, for example, to farm out threads of execution to other data processor cores. Each such receiving data processor core signals completion back to the master data processor core. The interrupt model optimizes this hand off process. Master data processor core 420 signals which thread is transferred to a slave data processor core 430 using the interrupt number. Upon completion of the interrupt, the slave data processor core 430 signals back to master data processor core 420 via an interrupt. Using priorities permits a choice of three use models: master data processor core 420 takes the completion interrupt as higher priority to be able to immediately farm out any next thread; a rendezvous model allows master data processor core 420 to wait for completion of slave threads plus its own thread; and a factory model allows slave data processor core(s) 430 to process data tasks while master data processor core 420 unpacks the incoming data and optionally packs outgoing data. The factory model allows master data processor core 420 to choose whether to de-power slave data processor core(s) 430 and handle the tasks itself based on load. This provides minimum power use.
As in the load balancing model illustrated in FIGS. 3A , 3 B and 3 C, this master/slave model uses hardware to facilitate task distribution without putting the burden on software or system design. The task model is another variant of interrupt distribution but includes a controlling master data processor core. Using a master data processor core is far more appropriate for certain types of applications such as farming out workload not specifically associated with a hardware event. For example, video decoding often needs to move and process a set of pixel blocks in a pixel block operation that are computationally expensive. By farming out each pixel block, the complete task can be completed faster. A master data processor core is needed to correctly stitch the blocks back together. Likewise for any data that can be partitioned and worked on separately. Integration of the processing of many sensors is another example where the task model is appropriate. The time oriented nature of this processing makes it simpler to split out task processing to slave data processor cores and use the master data processor core to integrate the results. Another example is the routing and treating slave data processor cores as micro-engines.
The preferred embodiment adds a register bit to the interrupt controllers or HIC 310 which marks one data processor core within a cluster as master and the other data processor core(s) as slaves. For each slave data processor core a return from interrupt generates an interrupt back to the master data processor core. The system defines a range of interrupts which are slave interrupts. This return from interrupt behavior only applies to these slave interrupts. Slave interrupts will have a higher priority, either statically or dynamically to ensure that slave requests take precedence over other actions.
FIG. 5 illustrates flow chart 500 for producing program suitable for performing on a multi-processor system of this invention. It is assumed that the data processing task to be performed by the multi-processor system is known to the same extent that a computer programmer knows the data processing task to be coded for a single data processor system. Flow chart 500 begins at start block 500 . Block 502 divides the data processing operation into a number of discrete tasks. This task is similar to that needed in programming a single processor system that typically operates on a time-shared basis. Block 503 links these tasks into chains. The base data processing operation often requires sequential operations. The chains formed in block 503 follows the sequential operations of the base data processing operation. Block 504 assigns priorities to these tasks. This process is similar to that normally performed by a programmer in a single processor, real-time data processing operation. In both cases the programmer must determine the priority of operation among competing tasks. In block 505 these tasks are converted into interrupt service routines suitable for interrupt processing. As an alternative these tasks can be formed into real-time operating system assignable tasks or thread pieces. This process includes intake procedures and hand-off procedures on interrupt completion. If the task must transfer data to a sequential task in a chain, the conversion must account for this data transfer. This data transfer will typically take the form whereby the end of the prior task moves the data to a commonly accessible memory location and the location is noted by passing pointers. The next task in the chain receives the pointers and accesses the designated data. Flow chart 500 ends at end block 506 .
FIG. 6 illustrates flow chart 600 of a supervisor program controlling the execution of a program produced according to FIG. 5 in a multi-processor system. Flow chart 600 begins with start block 601 . Block 602 assigns the next task. Upon initial operation of flow chart 600 the next task is the first task as defined by the chains of block 503 of FIG. 5 . As noted in conjunction with FIG. 5 such tasks are implemented as interrupt service routines. At test block 603 the multi-processor system performs currently running tasks while waiting for an interrupt. If no interrupt is received (No at test block 603 ), flow chart returns to text block 605 to wait for a next interrupt. If an interrupt is received (Yes at test block 603 ), then flow chart 600 advances to test block 604 . Test block 604 determines whether the just received interrupt is an end of task interrupt. Note that completion of a task generally triggers an interrupt. If the just received interrupt is not an end of task interrupt (No at text block 604 ), then block 605 assigns the interrupt according to the priority rules previously described. Flow chart 600 advances to test block 603 to again wait for an interrupt. If the just received interrupt is an end of task interrupt (Yes at text block 604 ), then flow chart 600 advances to block 602 . Block 602 assigns a next task according to the chains defined by block 503 of FIG. 5 . This next task assignment includes triggering the corresponding interrupt and assigning this interrupt.
FIG. 7 shows multiple planes of operation based on priority according to a program generated according to FIG. 5 and executed according to FIG. 6 . Note that FIG. 7 does not try to represent time. FIG. 7 illustrates nine data processor cores 731 , 732 , 733 , 734 , 735 , 736 , 737 , 738 and 738 and three priorities. FIG. 7 illustrates a highest priority task passing: from data processor core 731 to data processor cores 732 and 734 ; from data processor core 732 to data processor core 735 ; from data processor core 734 to data processor core 738 ; from data processor core 735 to data processor cores 736 and 738 ; from data processor core 736 to data processor core 738 ; from data processor core 739 to data processor core 738 ; and from data processor core 738 to data processor core 737 . FIG. 7 illustrates a medium priority task passing: from data processor core 732 to data processor core 735 ; from data processor 735 to data processor core 734 ; from data processor core 734 to data processor core 738 ; and from data processor core 738 to data processor core 739 . FIG. 7 illustrates a lowest priority task passing: from data processor core 733 to data processor core 736 ; from data processor core 736 to data processor core 732 ; from data processor core 732 to data processor core 731 ; and from data processor core 731 to data processor core 734 . This is illustrative only and typical systems will have far more priorities and planes. Note that one plane or priority may have multiple waves of processing separated in time, in space (which data processor cores are used) or because load permits.
The prior art has used factory models to optimize stream processing, parallel processing and pipelined processing, this invention uses prioritized interrupts allowing multiple planes of such wave fronts. According to this invention task priority or deadline timing can choose priorities. For example, a static priority model may give highest priority to one stream of data and so the interrupts ensure they immediately process this data stream as it moves through the data processor cores. At the same time lower priority data streams will run otherwise. This priority technique maximizes utilization of the data processor cores. The lower priority processing may have less immediate need, be refinement passes or be trending or other integrate-able data of a more varying nature.
Another example uses deadline based priorities. Deadline based priority pushes priorities up as the deadline gets closer. This can be used with load balancing or master/slave to minimize number of data processor cores employed to optimize power use. Common examples of lower priority processing include housekeeping, heuristics, system-wide processing, maintenance and safety analysis or integrity checking. The system may collect a previous computation data set and rerun it through a different data processor core set to verify correctness via a hardware check or using a stronger and slower algorithm to validate accuracy.
The preferred embodiment requires a proper prioritized interrupt model within each data processor core to prioritize the flow of execution and data. An extended embodiment uses load balancing to route traffic to maximize utilization.
FIG. 8 illustrates a simple system running the same code in parallel, with cross triggered synchronization to allow verification of common results between each data processor core. At time T 1 , data processor core 801 performs a first part of the task and generates data 810 sent to data processor core 801 at time T 2 and data 811 sent to data processor core 802 at time T 2 . Also at time T 1 , data processor core 802 performs the first part of the task and generates data 820 sent to data processor core 802 at time T 2 and data 821 sent to data processor core 801 at time T 2 . At time T 2 , data processor core 801 compares data 810 and 821 while data processor core 802 compares data 820 and 811 . Assuming a match at both data processor cores 801 and 802 , both data processor cores perform a second part of the task. Data processor core 801 performs the second part of the task and generates data 830 sent to data processor core 801 at time T 3 and data 831 sent to data processor core 802 at time T 3 . Also at time T 2 , data processor core 802 performs the second part of the task and generates data 840 sent to data processor core 802 at time T 3 and data 821 sent to data processor core 801 at time T 3 . Remedial action is triggered if either data processor core 801 or 802 detects a non-match. A similar compare and continue operation occurs at time T 3 . More complex systems are also possible where the synchronization is done less or more often and where an arbitration among data processor cores determines whether to proceed. The two parallel operations could use identical software. Such a system may also use different software in different data processor cores because only results have to match.
Two or three parallel paths through a set of data processor cores with check-points using interrupt rendezvous verifies correctness in safety systems. Using interrupts permits the topology to be setup dynamically and even changed over time to ensure maximal chance of detecting problems. An errant data processor core can be removed with the data processing path routed around it. The isolated data processor core could then run self-checks controlled by another data processor core.
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This invention relates to multi-core, multi-processing, factory multi-core and DSP multi-core. The nature of the invention is related to more optimal uses of a multi-core system to maximize utilization of the processor cores and minimize power use. The novel and inventive steps are focused on use of interrupts and prioritized interrupts, along with optional in-built methods, to allow systems to run more efficiently and with less effort on the part of the programmer.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the production of polyhydroxyalkanoate by the culture of microorganisms which produce same.
Poly-3-hydroxybutyrate is a linear polyester of D(−)-3-hydroxybutyrate. It was first discovered in Bacillus megaterium in 1925. Polyhydroxy-butyrate accumulates in intracellular granules of a wide variety of bacteria. The granules appear to be membrane bound and can be stained with Sudan Black dye. The polymer is produced under conditions of nutrient limitation and acts as a reserve of carbon and energy. The molecular weight of the polyhydroxybutyrate varies from around 50,000 to greater than 1,000,000, depending on the microorganisms involved, the conditions of growth, and the method employed for extraction of the polyhydroxybutyrate. Polyhydroxybutyrate is an ideal carbon reserve as it exists in the cell in a highly reduced state, (it is virtually insoluble), and exerts negligible osmotic pressure.
Polyhydroxybutyrate and related poly-hydroxy-alkanoates, such as poly-3-hydroxyvalerate and poly-3-hydroxyoctanoate, are biodegradable thermo-plastics of considerable commercial importance.
The term “polyhydroxyalkanoate” as used hereinafter includes copolymers of polyhydroxy-butyrate with other polyhydroxyalkanoates such as poly-3-hydroxyvalerate.
2. Background Information
Polyhydroxyalkanoate is biodegradable and is broken down rapidly by soil microorganisms. It is thermoplastic (it melts at 180° C.) and can readily be moulded into diverse forms using technology well-established for the other thermoplastics materials such as high-density polyethylene which melts at around the same temperature (190° C.). The material is ideal for the production of biodegradable packaging which will degrade in landfill sites and sewage farms. The polymer is biocompatible, as well as biodegradable, and is well tolerated by the mammalian, including human, body, its degradation product, 3-hydroxybutyrate, is a normal mammalian metabolite. However, polyhydroxyalkanoate degrades only slowly in the body and its medical uses are limited to those applications where long term degradation is required.
Polyhydroxyalkanoate, produced by the microorganism Alcaligenes eutrophus , is manufactured, as a copolymer with of polyhydroxy-butyrate and polhydroxyvalerate, by Imperial Chemical Industries PLC and sold under the Trade Mark BIOPOL. It is normally supplied in the form of pellets for thermoprocessing. However, polyhydroxyalkanoate is more expensive to manufacture by existing methods than, say, polyethylene. It is, therefore, desirable that new, more economic production of polyhydroxy-alkanoate be provided.
SUMMARY OF THE INVENTION
An object of the present invention is to provide materials and a method for the efficient production of polyhydroxyalkanoate.
According to the present invention there are provided gene fragments isolated from the bacterium Chromatium vinosum and encoding PHA polymerase, acetoacetyl CoA reductase and β-ketothiolase.
Preferably the C. vinosum is of the strain designated D, available to the public from the Deutsche Sammlung fur Mikroorganismen under the Accession Number 180.
The invention also provides a 16.5 kb EcoR1 fragment of C. vinosum DNA, designated PP10, hybridizable to a 5.2 kb SmaI/EcoR1 fragment, designated SE52 isolated from Alcaligenes eutrophus and known to contain all three of said genes responsible for expression of PHAS.
The invention further provides a fragment of the said PP10 fragment, designated SE45, encoding the PHA-synthase and β-ketothiolase genes and a region, designated SB24, encoding the acetoacetyl CoA reductase gene.
The invention also provides a recombinant genome of a microorganism, preferably a bacterium or a plant, which contains one or more of said fragments designated PP10, SE45 and region SB24.
Finally, the invention provides a method for the manufacture of PHAs, comprising culturing the microorganism Chromatium vinosum , or a bacterium of a different species having stably incorporated within its genome by transformation one or more PHA synthesising genes from Chromatium vinosum.
The biosynthesis of polyhydroxyalkanoate from the substrate, acetyl-CoA involves three enzyme-catalysed steps.
The three enzymes involved are β-ketot hiolase, acetoactyl-CoA-reductase and polyhydroxy-butyrate-synthase, the genes for which have been cloned from Chromatium vinosum . The three genes are known to facilitate production of polyhydroxyalkanoates, the reactions involved being represented as follows:
BRIEF DESCRIPTION OF THE DRAWING
The invention will now be described with reference to the accompanying drawings, of which;
FIG. 1 is the physical map of the 16.5 kb EcoR1 fragment of Chromatium vinosum DNA, designated PP10. The positions of the restriction sites and positions and names of the sub-fragments are shown. PHA-synthase and β-ketothiolase genes are located in fragment SE45 and acetoacetyl CoA reductase in region SB24;
FIG. 2 is the map of PP10 showing the positions of the β-ketothiolase and acetoacetyl CoA reductase genes and of the PHA-synthase gene open reading frames ORF2 and ORF3.
FIG. 3 is the complete nucleotide sequence of fragment SE45 (SEQ ID NO:1). The transcriptional start sites and terminators for the β-ketothiolase gene and for ORF3 and ORF2 are shown. The positions of the “−10” and “−35” sequences are also shown, as are the positions of the putative ribosome binding sites (“s/d”). Translational start and stop (*) codon are also marked and the amino acid sequences of the β-ketothiolase (SEQ ID NO:2), ORF2 (SEQ ID NO:3) and ORF3 (SEQ ID NO:4) are give.
FIG. 4 shows the alignment of the amino acid sequences of Chromatium vinosum ORF3 (SEQ ID NO:4) with PHA polymerase of Alcaligenes eutrophus (SEQ ID NO:5) and PHA polymerases 1 and 2 of Pseudomonas oleovorans (SEQ ID NO:6 and SEQ ID NO:7).
FIG. 5 shows the complete nucleotide sequence of the DNA encoding PHA synthesis genes from Chromatium vinosum (SEQ ID NO:8) The positions of PHA polymerase (phbC) (SEQ ID NO:4), acetoacetyl CoA reductase (phbB) (SEQ ID NO:9) and ketothiolase (phbA) (SEQ ID NO:2), genes are shown and also; the positions of ORF2 (SEQ ID NO:3), ORF4, (SEQ ID NO:10) ORF5 (SEQ ID NO:11) and ORF7 (SEQ ID NO:12).
FIG. 6 shows the alignment of the amino acid sequences of ketothiolases encoded by C. vinosum (C.v.) (SEQ ID NO:2), A. eutrophus (A.e.) (SEQ ID NO:13), Zoogloea ramigera (Z.r ) (SEQ ID NO:14), Escherichia coli (E.c) (SEQ ID NO:10), Saccharomyces uvarum (S.u) (SEQ ID NO:17) and Rattus norvegicus (R.n.) (SEQ ID NO:17).
FIG. 7 shows the alignment of the amino acid sequences of acetoacetyl CoA reductases encoded by C. vinosum (Cv) (SEQ ID NO:17), A. eutrophus (A.e. ) (SEQ ID NO:18) and Z. ramigera (Z.r.) (SEQ ID NO:18)
FIG. 8 is a Table (Table 1) showing the heterolocous expression in Escherichia coli of DNA fragments from C. vinosum . Activities of PHA biosynthetic enzymes expressed by the different fragments are shown. The levels of PHA accumulated in E. coli transformed with the fragments are also given.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Example
The organism C. vinosum was a gift from Dr J. Imhoff of the University of Bonn, Germany.
1. Isolation of DNA Fragments from C. vinosum Encoding PHA Synthesis Genes
A 5.2 kb SmaI/EcoRI fragment (SE52), which codes for all three PHA biosynthetic genes has previously been isolated from Alcaligenes eutrophus [Schubert et al., J. Bacteriol. 170 (1988)]. This fragment was used to detect PHA biosynthetic genes of C. vinosum . EcoRI restricted genomic DNA of C. vinosum was blotted on to a nylon membrane and hybridized with biotinylated SE52 DNA. One signal appeared, representing a DNA fragment of 16.5 kb.
A λL47 gene bank from C. vinosum genomic DNA was prepared and plates with approximately 800 plaques were blotted on to nylon membranes and hybridized with biotinylated SE52 DNA. One positive recombinant phage was isolated, which harboured a 16.5 kb EcoRI fragment, which was designated PP10 (FIG. 1 ). With PP10 and a 9.4 kb EcoRI/PstI subfragient (EP94) of PP10, the phenotype of the wild type could be restored in PHA-negative mutants of A. eutrophus.
Expression studies in E. coli (see below) showed that a 4.5 kb SmaI/EcoRI (SE45) subfragment of EP94 encodes for PHA synthase and β-ketothiolase. The nucleotide sequence of this fragment was determined by the dideoxy-chain termination method of Sanger et al. with alkaline denatured double stranded plasmid DNA. The T7-polymerase sequencing kit of Pharmacia, Uppsala, Sweden, was used with 7-deazaguanosine- 5 ′-tri-phosphate instead of dGTP. Most of the sequence was determined with a set of unidirectional overlapping deletion clones generated by exonuclease III digestion. For sequencing regions which were not covered by the deletion plasmids synthetic oligonucleotides were used.
It was not possible to clone the 4.9 kb SmaI/PstI fragment PS49 in a multi-copy vector. Therefore, fragment EP94 (FIG. 1) was treated with Exonuclease Bal31, ligated to Bluescript Sk and transferred to E. coli X1- 1 Blue. A clone was isolated which harboured Bluescript SK with a 5.5 kb fragment (B55) and which expressed β-ketothiolase and NADH-dependent reductase activity. 3146 base pairs of B55 were part of the SE45 fragment. The other part (approximately 2350 base pairs, SB24) has been sequenced applying the primer hopping strategy. The sequence and the position of the reductase gene on SB24 are known. The results of these studies, including the organisation of the PHA biosynthetic genes in C. vinosum and the sites of the ketothiolase, reductase and PHA synthase genes are shown in FIG. 2 . The determination of the full sequence of SB24 is in progress.
2. Sequence Analysis of the C. vinosum PHB Synthetic Genes
The nucleotide sequence of SE45 is shown in FIG. 3 (SEQ ID NO:1). The fragment size of SE45 is 4506 bp.
2.1 PHB Synthase
The fragment sequence corresponding to the PHB synthase gene is designated as ORF3. The determination of synthase activity of deleted plasmids containing SE45 (See below) gave evidence that expression of ORF2 is also required for expression of synthase activity.
ORF2 and ORF3 are transcribed as an operon. The determination of the transcription start site of ORF2 was conducted by S1 nuclease mapping. This site occurs at bp 3059 from the 3′ end of SE45. A putative “−10” site, given as 5′-ACAGAT-3′occurs at bp 3073-3078, and a “−35” site occurs at bp 3092-3099. A putative ribosome binding Site occurs at bp 3040-3045. The translation start codon commences at bp 3030. The translation stop codon occurs at bp 1958.
The putative ribosome binding site of ORF3 occurs at bp 1907-1911. The translation start ATG for ORF3 occurs at bp 1899, and the translation stop codon at bp 833. Putative transcriptional terminator sites occur at hairpin structures at bp 773-786 and 796-823.
ORF2 encodes, apolypypeptide of 358 amino acids with a MW of 40525 da (SEQ ID NO:5). ORF3 encodes a poly eptide of 356 amino acids with a MW of 39739 da (SEQ ID NO:4). The gene size of ORF3 is approximately 30% smaller as compared with the PHA polymerase genes of A. eutrophus and P. oleovorans . The alignments of the primary structures of C. vinosum PHA polymerase, A. eutrophus PHA polymerase and P. oleovorans PHA polymerases 1 and 2 are shown in FIG. 4 . Thus the ORF3 C. vinosum polymerase is shorter than the other polymerase enzymes, lacking the first 172 amino acids from the NH 2 terminus of the A. eutrophus PRA polymerase, and the first 148 amino acids of the Pseudomonas polymerases . The amino acid sequence of ORF3 (SEQ ID NO:4) exhibited an overall homology of 25% to the polymerase of A. eutrophus , with certain discrete regions of conserved sequence.
The amino acid sequence of ORF2 (SEQ ID NO:3) showed no significant homology to other enzymes in the NBRF gene bank.
2.2 βketothiolase
The β ketothiolase and acetoacetyl CoA reductase genes are transcribed in opposite direction to ORF2 and ORF3 (FIG. 2 ). A “−10” site in the identified ketothiolase promoter occurs at bp 3105-3111, and a “−35”site at bp 3082-3086. A putative ribosome binding site occurs at bp 3167-3171. The translation starts signal occurs at bp 3181. The translation stop codon occurs at bp 4361.
The aligments of the primary structures of β ketothiolases from Chromatium vinosum and other sources are shown in FIG. 5 . Considerable homology is apparent between the amino acid sequences of ketothiolases from C. vinosum and other bacterial and non-bacterial sources.
2.3 Acetoacetyl CoA Reductase
The alignments of the primary structures of acetoacetyl CoA reductases from C. vinosum, A. eutrophus and z. ramigera are shown in FIG. 6 . All three reductases are of similar chain length, while considerable homology is apparent between the sequences of reductases from these bacteria.
The Chromatium vinosum PHA synthetic genes therefore differ from the PHA synthetic genes of A. eutrophus and P. oleovorans in the following respects:
i) Whereas A. eutrophus PHB polymerase, acetoacetyl CoA reductase and β ketothiolase genes are all transcribed as an operon, in C. vinosum the ketothiolase and reductase genes are transcribed separately from the polymerase, and are transcribed in the opposite direction to the polymerase ORF3 and ORF2 genes.
ii) In contrast to A. eutrophus , where one gene product is required for polymerase activity, in C. vinosum two gene products, represented by ORF2 and ORF3 are required for expression of polymerase activity.
iii) The C. vinosum ORF3 polymerase is 172 amino acids shorter, at the amino terminus, than the A. eutrophus polymerase, and 148 amino acids shorter than the P. oleovorans polymerases 1 and 2. The C. vinosum ORF3 shows only 25% homology with the primary sequence of the A. eutrophus polymerase.
iv) The A. eutrophus acetoacetyl CoA reductase enzyme involved in PHB synthesis is NADPH specific, while the C. vinosum enzyme exhibits a marked preference for NADH.
Between the structural genes for ketothiolase and acetoacetyl CoA reductase of Chromatium vinosum , two open reading frames (ORF4 (SEQ ID NO:10), and ORF5 (SEQ ID NO:11) appear, and downstream from the reductase gene an ORF7 has been identified (FIG. 5 ). No additional ORFs were identified in the PHA coding region of A. eutrophus.
3. Expression of C. Vinosum PHB Synthetic Genes in Other Bacteria.
With fragments PP10 and EP94 the ability to synthesise PHB could be restored to PHB negative mutants of A. eutrophus . Recombinant strains of the FHB negative mutant A. eutrophus PHB-4, transformed with these fragments, were able to synthesise polymers containing 3-hydroxybutyrate and 3-hydroxyisovalerate at significant proportions, when supplied with appropriate substrates.
Studies on expression of C. vinosum DNA fragments in E. coli are presented in Table 1. Thus E. coli transformed with plasmids containing fragments PP10 and EP94 expressed PHB polymerase, acetoacetyl CoA reductase and β ketothiolase activities. They also synthesised PHB up to between 10 and 12% dry weight. E. coli transformed with plasmids containing fragment SE45 expressed PHB polymerase and β ketothiolase, but not acetoacetyl CoA reductase, and were unable to synthesise PHB.
4. Polymer Biochemistry
The specific optical rotations of methyl 3-hydroxybutyric acid liberated by methanolysis of PHB from C. vinosum (accumulated from acetate), from A. eutrophus PHB-4 pHP1014:PP10 (accumulated from fructose) and E. coli S17-1 pSUP202:PP10 (accumulated from glucose) were all negative. The determined values of the specific optical rotation were similar to those for PHB isolated from A. eutrophus (accumulated from fructose).
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Genes encoding polyhydroxyalkanoate synthase, β-ketothiolase and acetoacetyl CoA reductase are isolated from the publicly available bacterium Chromatium vinosum . Recombinant genomes of plants or other species of bacteria which contain these genes are capable of producing polyalkanoate polymers. The nucleotide sequences of the said three genees have been determined.
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FIELD OF THE INVENTION
[0001] The present invention relates to a wrought single piece weld-free filter element, such as an inlet frame or an outlet plate. The plate or frame is hollow in the middle and is contiguous around its perimeter. Advantageously, the filter elements may be mounted in a filter press assembly at an angle to increase drainage.
BACKGROUND OF THE INVENTION
[0002] A horizontal-type filter press is known, for example, from U.S. Pat. No. 4,737,285 to Krulitsch et al, herein incorporated in its entirety by reference. In this patent, a horizontal-type filter press is disclosed which includes a plurality of filter elements supported on cross beams between a head and press cover. Filter aids disposed between the filter elements are moved by the filter press closing mechanism to seal the press edges located at each of the filter elements.
[0003] Filter presses of this type are known for clarifying filtration, sterilizing filtration, or residue filtration of liquids. These types of filter presses are used in the chemical industry, pharmaceutical industry, beverage industries and other industrial applications.
[0004] In a particular type of press, filtration must take place in a sealed system. Such a filter press is disclosed in U.S. Pat. No. 5,366,627, assigned to Stavo Industries, Inc., the assignee of the present application, and herein incorporated in its entirety by reference.
[0005] In these known filter units, the filter elements have inlets and outlets which are manufactured by using a casting process, by welding individual pieces of wrought metal or casting metal into a single piece. In these known embodiments, the processes of welding and casting require the further processing of metal by adding heat to allow for the formation of the final product. The heat modifies the molecular structure of the metal of the filter elements and produces areas that are stressed and areas that contain voids.
[0006] In the use of filter elements in the pharmaceutical and other industries, it is essential that sterilization of the component parts of the filter elements be possible. Accordingly, all surfaces must be free of voids or pits that can harbour contaminants. Additionally, the stress that is induced upon the metal from the heating process may cause the inlet frame or outlet plate to become slightly warped. This can lead to excessive liquid leakage from the filter unit between the filter elements, which liquid must either be discarded or reprocessed.
[0007] Accordingly, there is a need for a filter plate and filter frame free of heat stress and casting-voids, that is fully uniform in thickness.
[0008] In addition, pharmaceutical and biotech fluids are extremely valuable and filter hold-up volumes can become costly. Following completion of the production cycle, current plate and frame filter presses can require that up to 90% of the liquid remaining in the filter be reprocessed or discarded.
[0009] Accordingly, there is a need for a filter element that maximizes drainage.
SUMMARY OF THE INVENTION
[0010] The filter plate or frame of the present invention is derived from a single solid plate of metal or alloy by any one of various means, such as cutting with a water-jet, laser, wire EDM, plasma, CNC, etc. The solid plate of the metal or alloy may be 0.5-2.0 inches thick and 36 inches square, for example. Nested plates or frames of decreasing dimensions may be formed.
[0011] Most important is that the plate or frame does not require further heating or bending to provide the finished product. The plate or frame can be of any shape, be it square, rectangular, circular, triangular, etc. in any dimension, and can be of any practical thickness. If the plate or frame requires support members on the non-liquid contact sides, they can be included as an integral part of the frame, they can be welded to the plate or frame, or they can be fastened to the plate or frame as these additions will not affect the potential sterilization of the portions of the frame which is to come in contact with processed product.
[0012] In a modified filter plate or filter frame, taking advantage of a unified single piece structure or using traditional frame forming technology, advantageous draining can be achieved by tilting a traditional square shaped outlet plate at an angle of 45° in a filter press assembly. This locates a part of the outlet plate at a lowermost location having sidewalls extending at an angle to the horizontal converging at the outlet port, aiding in drainage of filtrate through a process outlet. For uniformity the inlet frame may also be fitted in a filter press assembly at 45° to provide a need for only one set of guide bars, engaging the support ears of the plates and frames.
[0013] Accordingly, it is one object of the present invention to produce a weld free filter plate or frame in the liquid contact and sealing surface areas of a filter press assembly.
[0014] It is another object of the present invention to produce a filter plate or frame free of pits and voids normally associated with casting or welding processes.
[0015] It is another object of the present invention to produce a unitary, integral filter plate or frame cut from a solid plate of metal or alloy without the use of heat so as to provide flatness to both sides of the plate and frame and thereby minimize leakage in a filter press assembly.
[0016] It is still yet another object of the present invention to produce a filter plate or frame having integral support pins located on an interior surface of the plate or frame for use in mounting opposed screen sections in the plate or frame.
[0017] It is still yet another object of the present invention to produce a filter press assembly having an outlet plate with sidewalls converging towards an outlet port positioned at a lowermost extremity of the outlet plate for increased drainage from the outlet plates of the filter press assembly.
[0018] These and other objects of the invention, as well as many of the intended advantages thereof, will become more readily apparent when reference is made to the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a plan view of a known inlet frame or outlet plate for a filter press assembly, having been manufactured by welding together four triangular pieces and four straight pieces and subsequently attaching two laterally extending ears by welding.
[0020] [0020]FIG. 2 is a cross-sectional view taken along line 2 - 2 of FIG. 1.
[0021] [0021]FIG. 3 is a schematic illustration of the method of the present invention used for forming a plurality of filter elements from a plate or billet of metal or alloy by use of laser or water-jet technology, for example.
[0022] [0022]FIG. 4 is a plan view of a formed inlet frame or outlet plate produced by the method illustrated in FIG. 3, formed of a single integral piece without voids or defects and having consistent flatness side to side.
[0023] [0023]FIG. 5 is a cross-sectional view taken along line 5 - 5 of FIG. 4.
[0024] [0024]FIG. 6 is a perspective view of an inlet frame or outlet plate formed according to the method illustrated in FIG. 3, and including slots leading to port holes on one side of the filter element, as an exemplary illustrative embodiment, and including integral formed support projections for mounting of filtration screens inside of the filter elements.
[0025] [0025]FIG. 7 is an enlarged view of one corner of the filter element shown in FIG. 6, having a tapered slot leading to a port hole.
[0026] [0026]FIG. 8 is a cross-sectional view taken along line 8 - 8 of FIG. 7.
[0027] [0027]FIG. 9 is an exemplary filter element formed according to the process shown in FIG. 3, or alternatively, formed by the known method of welding as shown in FIGS. 1 and 2.
[0028] [0028]FIG. 10 is an enlarged view of one corner of the filter element shown in FIG. 9.
[0029] [0029]FIG. 11 is a perspective view of a filter press assembly with the filter elements of FIGS. 4, 6 or 9 mounted in the filter press in a “diamond-shape” configuration, tilted at an angle of 45°, as compared to traditional filter presses, so as to increase drainage through the outlet plate of the filter elements.
[0030] [0030]FIG. 12 is an alternate embodiment of a filter element for mounting in a traditional filter press and having the advantages of sidewalls of the interior surface converging to an outlet port leading to a process outlet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] In describing a preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
[0032] [0032]FIGS. 1 and 2 are illustrative of prior art filter elements 20 such as an inlet frame or an outlet plate which make up the alternating components between a fixed head and a movable head of a filter press assembly. Traditionally, the filter element 20 was formed by interconnecting four triangular shaped sections 22 a , 22 b , 22 c and 22 d with four bar stock sections 24 a , 24 b , 24 c and 24 d by a series of welds 26 . The support ears 28 a , 28 b are also welded to bar sections 24 b , 24 d , respectively, by welds 30 .
[0033] The use of filter presses in certain industries, such as the pharmaceutical industry for example, requires sterilization of component parts. As expected, a filter element as shown in FIG. 1, includes many pits and voids, particularly, at the welds 26 . Therefore, to comply with the requirements of the pharmaceutical industry, extensive finishing of the frame element 20 is required.
[0034] Also, by the use of high heat welding to connect the various components, the molecular structure of the various components is altered producing warps to various degrees of deformation. This leads to a lack of overall flatness at opposed sides 32 a , 32 b of the filter element 20 .
[0035] When a plurality of filter elements are assembled in a filter press, this lack of flatness will form gaps between the filter elements through which filtrate may leak during the filtering operation. This causes waste of product which must be discarded or reprocessed. Therefore, additional finishing of the filter element is also required to avoid this defect.
[0036] To avoid the defects exemplified by the welded filter element of FIGS. 1 and 2, it has been discovered that a flat metal or alloy plate 40 approximating the thickness of the desired end product can be used to produce a plurality of unitary filter elements 42 a , 42 b , 42 c , 42 d ., for example. As shown in solid lines in FIG. 3, the filter element 42 a is being cut by a water-jet device 44 .
[0037] The device 44 is programmed to cut along the dotted lines of FIG. 3 to form a plurality of filter elements. It is even possible to nest various sizes of filter elements one within the other to maximize usage of the plate 40 .
[0038] The exemplary embodiment of water-jet cutting, does not produce heat, and thereby avoids disparities in flatness from side to side of the formed filter elements. Also, by the unitary structure of the formed filter element, no defects or voids are produced in the critical areas of the filter elements which require sterilization when used in certain industries. Therefore, with minimal finishing, the completed, unitary filter elements as formed. The filter element may be further processed to produce an inlet frame or an outlet plate as is known in the industry.
[0039] As shown in FIGS. 4 and 5, the unitary filter element may integrally include support pins 44 a , 44 b , 44 c for use in mounting certain filter support structures in the interior 46 of the filter element 42 a . Also, support ears 48 a , 48 b may be formed integrally with the filter element, thus avoiding another potential location to harbour potential harmful contamination.
[0040] In another exemplary filter element 50 , also formed according to the process illustrated in FIG. 3, the filter element may include slots or holes 52 a , 52 b leading to two of the four side ports formed at the corners of the filter element 50 . In this embodiment, projecting support structures 54 a through 54 g are formed integrally with the frame element 50 .
[0041] [0041]FIGS. 7 and 8 illustrate the connection of the slot 52 a to a port 56 a of the four side ports 56 a through 56 d . Depending upon the positioning of the filter element as an inlet frame or outlet plate, in the path of the process inlet or the process outlet, liquid will flow into the interior of the inlet frame or exit from an outlet plate.
[0042] [0042]FIG. 9 is illustrative of a filter element 60 which may be formed by the method illustrated in FIG. 3 or the known method of welding to produce a filter element as shown in FIG. 1. FIG. 9 also includes slots or holes 62 a , 62 b which may be used to form an inlet frame or an outlet plate depending upon the positioning of the filter element 60 .
[0043] Another aspect of the present invention is the use of the filter elements 42 a , 50 , 60 as shown in FIGS. 4, 6 and 9 , respectively, in a filter press assembly. Any of the these filter elements is schematically shown in FIG. 11 as filter elements 70 interposed between layers of filter media 72 . In the filter press 80 the filter elements are mounted between a fixed head 82 and a movable head 84 to compress the filter media 72 between the filter element 70 .
[0044] However, in the filter press 80 shown in FIG. 11, the filter elements are arranged, offset at an angle of 45° with respect to the arrangement of filter elements in a traditional filter press. This orientation produces a diamond shape configuration having one corner 86 a positioned at a lowermost extremity of each filter element 70 . This is achieved by mounting the support ears 88 a , 88 b , on two support rods 90 a , 90 b , with support rod 90 a positioned lower than support rod 90 b . By this arrangement, the filter element 70 arranged as an outlet plate, passes all of the residual liquid retained within the outlet plate along interior side walls converging to the process outlet port 92 a of each filter element arranged as an outlet plate.
[0045] In the closed configuration of the filter press, the process outlet would thereby pass through the port 94 of the fixed head 82 . Vastly improved transmission of residual liquid from the filter element is thereby achieved as compared to a traditional arrangement of the filter elements with the parallel sidewalls arranged vertically and the top and bottom surfaces arranged horizontally.
[0046] To achieve the same effect as tilted filter elements in FIG. 11, filter element 96 in FIG. 12 has interior sidewalls 98 a , 98 b converging towards port 100 by hole or slot 102 . Port 98 is part of the process outlet of a filter press assembly.
[0047] Filter element 96 can be used in a traditional filter press assembly with parallel, equal height support bars. It may be necessary to also include adapter or transfer plates adjacent to the fixed head and moveable head to compensate for the displaced orientation of the flow through the process inlet and process outlet formed by a plurality of filter elements 96 . Nevertheless, the advantages for drainage of converging sidewalls in filter elements 70 in FIG. 11, can be realized by the similarly situated converging sidewalls 98 a , 98 b of filter element 96 mounted in a filter press with its bottom surface oriented horizontally.
[0048] The foregoing description should be considered as illustrative only of the principles of the invention. 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 wrought metal single piece filter outlet plate or inlet frame, which is weld free in the liquid contact areas and sealing surface areas. The frame is used as an inlet frame or as an outlet plate for a horizontal or vertical type filter unit. The support ears on the sides of the plate and frame are an integral part of the wrought plate or frame, welded to the plate or frame or attached to the plate or frame utilizing any number of fasteners. Advantageously, the filter elements may be mounted in a filter press assembly at an angle to increase drainage.
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BACKGROUND OF THE INVENTION
The advantages of sustained release products are widely recognized in the art and are of extreme importance in the pharmaceutical field. Through the use of such products, orally administered medications can be delivered continuously at a uniform rate over a prolonged period of time so as to provide a stable, predetermined concentration of a drug in the bloodstream, without requiring close monitoring and frequent re-administration.
The sustained release character of such products is achieved by one of two methods: 1) providing a sustained release coating upon tablets or microspheres wherein slow release of the active occurs via either gradual permeation through or gradual breakdown of this coating or 2) providing a sustained release matrix, such as a fat, a wax, or a polymeric material intermixed with the active ingredient in the tablet itself. See, e.g., Manford Robinson, "Sustained Action Dosage Forms" in The Theory and Practice of Industrial Pharmacy, ch. 14 (L. Lachman et al., eds., 2d ed., 1976).
Such sustained release matrix formulations are typically prepared by methods involving pre-granulating the active ingredient together with the matrix material via a wet granulation, solvent granulation, shear-melt or roto-melt granulation, or a wet pre-adsorption technique. In these techniques, a liquid phase is used in order to uniformly mix and/or closely contact the ingredients together so as to provide an evenly distributed matrix in intimate association with the active ingredient. These formation processes help prevent creation of interspersed quick-release zones which would result in discontinuous dissolution of the tablet and thus cause bioconcentration spikes of active ingredient in the patient. They frequently also result in tablets of a relatively higher density than the dry mixed ones, thus allowing the use of tablets, for a given dose, that are smaller than those made by dry mixing for the same intended release rate.
However, these liquid phase methods require a multiplicity of steps and equipment for storage, handling, and dispensing of liquids, for drying, and/or for heating of the ingredients. When the liquid is water, its volume must be very carefully controlled so as to prevent any disintegrant in the formula from swelling. Also, water is incompatible with hygroscopic active ingredients. Yet, when the liquid is instead a volatile organic solvent, additional precautions must be taken to address the risks of fire, explosion, and worker exposure. Where a melt processing technique is used, heating presents a risk of inactivation of at least some of the active material and is incompatible for use with some active ingredients.
Thus, dry mixing has sometimes been used to form sustained release matrix tablets. This technique involves pre-mixing the matrix material with the active ingredient, without the use of added liquids or heat, so that only ambient humidity, temperature, and particle-to-particle surface interactions and/or static electrical attraction foster adherence, if any, of the ingredients to one another.
For example, U.S. Pat. No. 4,259,314 to Lowey employs a mixture of cellulose ethers--hydroxypropylmethylcellulose ("HPMC") and hydroxypropyl cellulose--to form a sustained release matrix in which the cellulose ether mixture has a weighted average viscosity rating of 250-4500 cps, and preferably 1200-2900 cps. These are equilibrated under an atmosphere having up to 40% relative humidity and then pre-mixed together before drying to a moisture content of 1% or less. The active and other remaining ingredients (after they have equilibrated under ≦40% humidity) are combined with the cellulose ether mixture and the resulting combination is compressed at ≦40% humidity to produce a tablet.
U.S. Pat. No. 5,451,409 to Rencher et al. discloses a dry mixed pseudoephedrine tablet in which a mixture of hydroxypropyl cellulose and hydroxyethyl cellulose forms the sustained release matrix; 0.5-10% HPMC is also added as a binder.
U.S. Pat. No. 5,085,865 to Nayak discloses a two-layer tablet wherein one layer, which may be formed using a dry mixing process, comprises a 60 mg pseudoephedrine controlled release matrix formulation. The matrix or "sustained release agent" comprises cellulose ethers--hydroxypropyl and/or hydroxyethyl cellulose--and, preferably also, sodium croscarmelose; this agent is present in an amount equivalent to at least twice that of pseudoephedrine. Up to half of the cellulose ether component may consist of HPMC.
SUMMARY OF THE INVENTION
The present invention comprises extended-release tablets of an active ingredient, a sustained release HPMC matrix and a microcrystalline cellulose disintegrant. A dry mixing, direct compression method for producing such tablets is also claimed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a preferred embodiment of the present invention a combination comprising at least one active ingredient together with hydroxypropylmethylcellulose (HPMC) and microcrystalline cellulose is directly compressed to form tablets. Preferably, the composition is prepared by dry mixing the ingredients.
Preferably, one of the active ingredients is pseudoephedrine or a pharmacologically acceptable salt thereof, such as pseudoephedrine hydrochloride or pseudoephedrine sulfate, or a mixture thereof. More preferred is pseudoephedrine hydrochloride. Preferably about 15-25% of the active ingredient, based on the final weight of the tablets, is used; more preferably, about 16-22%; most preferably about 17-20%. In a preferred embodiment, the amount of active ingredient used is that which is sufficient to produce tablets, each comprising about 120 mg of active ingredient. In an alternate embodiment, the amount of active utilized is sufficient to produce tablets comprising about 60 mg of active ingredient each.
The HPMC preferably has a hydroxypropyl content of less than 9% and a molecular weight below 50K. More preferably, the molecular weight is below about 30K. A preferred HPMC is Methocel® K100LV (produced by The Dow Chemical Co. of Midland, Mich.). Preferably about 20-40% HPMC is used, more preferably about 25-30%.
Suitable microcrystalline cellulose products include Emcocel® (produced by the Edward Mendell Co. of Patterson, N.Y.), Avicel® (produced by FMC Corp. of Philadelphia, Pa.), and mixtures thereof. In a preferred embodiment, about 25-50%, by final weight of the tablets, of microcrystalline cellulose is used, more preferably about 25-30%. Not more than a combined amount of about 80% (by final weight of the tablets) of disintegrant/binder and HPMC should be used. Also, the amount of microcrystalline cellulose should not substantially exceed that of HPMC, e.g., by more than 20-25% by weight.
Glidants, fillers, and other excipients that may be used in the preferred embodiments include those described, e.g., in Handbook of Pharmaceutical Excipients (J. C. Boylan et al., eds., 1986) and in H. A. Lieberman et al., Pharmaceutical Dosage Forms: Tablets (2d ed. 1990). Excipients generally may include: binders and adhesives; disintegrants, absorbents, and adsorbents; glidants and lubricants; fillers and diluents; and colorants, sweeteners, and flavoring agents.
Preferred fillers include calcium salts and sugars, for example, calcium phosphates, calcium sulfates, mannitol, lactose, and mixtures thereof. More preferred fillers include dicalcium phosphate, tribasic calcium phosphate, directly compressible calcium sulfate, directly compressible mannitol, anhydrous lactose, flowable lactose (e.g., Fast Flo® lactose produced by Foremost Farms USA of Baraboo, Wis.), and mixtures thereof. Most preferred is dicalcium phosphate (CaHPO). Preferably, about 20-40% by weight filler, based on the final weight of the tablets, is employed. However, where the filler consists of one or more sugars alone, preferably about 20-30% of filler is used.
Preferred glidants include colloidal silica and precipitated silica. A preferred colloidal silica is Cab-o-Sil® produced by the Cabot Corp. of Boston, Mass.; a preferred precipitated silica is Syloid® produced by W.R. Grace Co. of New York, N.Y. Preferably, about 0.2-2% by weight of glidant, based on the final weight of the tablets, is employed. Where colloidal silica alone is used, the tablets will preferably comprise about 0.2-0.8% by weight glidant, more preferably about 0.25-0.75%.
Preferred lubricants include sodium stearyl fumarate and metal stearates, alone or in combination with stearic acid. More preferred lubricants include magnesium stearate, zinc stearate, calcium stearate, and mixtures thereof, alone or in combination with stearic acid. Preferably about 0.2-2%, by final weight of the tablets, of lubricant is used, more preferably about 0.25-1.25%. For example, where magnesium stearate is the sole lubricant, the tablets preferably comprise about 0.3-0.5% lubricant; where a magnesium stearate-stearic acid mixture is used as the lubricant, about 0.25% magnesium stearate may be mixed with as much as about 1% stearic acid.
In the preferred embodiment mixing procedure, the active ingredient, e.g., pseudoephedrine, the glidant, e.g., colloidal silica and the filler, e.g., dicalcium phosphate dihydrate, are passed through a security screen into a clean and dry blender, preferably in the order indicated. After mixing for 5 minutes, this mix is milled through a clean and dry mill equipped with a stainless steel, drilled hole screen, into a clean suitable container.
The microcrystalline cellulose disintegrant, the above milled mixture and the hydroxypropylmethylcellulose are then passed in the order indicated through a fme mesh security screen and into a clean and dry blender. They are mixed for 15 minutes, following which a lubricant, e.g., magnesium stearate is screened into the blender and mixed in for an additional 3 minutes.
After the foregoing combination has been produced with thorough mixing, it is directly compressed to form tablets, i.e. any solid form, e.g., caplets. These are then coated with a pharmaceutically acceptable coating. Preferred coatings include cellulose ether-based coatings, such as HPMC-based coatings. A preferred coating is Opadry, produced by Colorcon, Inc. of West Point, Pa. Preferably about 0.54% by weight of coating is used (in terms of weight added to the uncoated tablet), more preferably about 1-2%. A wax, e.g., an edible wax such as carnauba wax may also be applied as a second coating thereover.
EXAMPLE 1
120 mg pseudoephedrine hydrochloride caplets were prepared as described above, using a Methocel K100LV matrix. These were administered, one each, to 12 human subject volunteers comprising Group A (the test group); 12 Sudafed® 12 Hour Caplets (Warner Wellcome Consumer Healthcare) were administered, one each, to 12 human subject volunteers comprising Group B (the comparison group). Plasma concentrations of the active ingredient were determined by capillary gas chromatography on plasma separated from blood samples drawn from each patient at 0, 1, 2, 3, 4, 4.5, 5, 5.5, 6, 6.5, 7, 8, 10, 12, 16, 24, 30, and 36 hours post-administration. This example demonstrates that the dry mixed, direct compression product of the present invention is bioequivalent to the national brand, 12 hour release pseudoephedrine tablets.
The above description is considered that of the preferred embodiment(s) only and it is understood that the embodiment(s) described above are merely for illustrative purposes. Variations of the methods and resulting compositions described herein as the preferred embodiment(s) of the invention may be apparent to those in this field once they have studied the above description. Such variations are considered to be within the scope of the invention, which is intended to be limited only to the scope of the claims as interpreted according to the principles of patent law, including the doctrine of equivalents.
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Pseudoephedrine hydrochloride extended-release tablets including a sustained release hydroxypropylmethylcellulose matrix and a microcrystalline cellulose disintegrant formed by a dry mixed, direct compression method.
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[0001] This application claims priority of U.S. Provisional Patent Application Ser. No. 61/074,278, filed Jun. 20, 2008, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Solar cells are typically manufactured using the same processes used for other semiconductor devices, often using silicon as the substrate material. A semiconductor solar cell is a simple device having an in-built electric field that separates the charge carriers generated through the absorption of photons in the semiconductor material. This electric-field is typically created through the formation of a p-n junction (diode) which is created by differential doping of the semiconductor material. Doping a part of the semiconductor substrate (e.g. surface region) with impurities of opposite polarity forms a p-n junction that may be used as a photovoltaic device converting light into electricity.
[0003] FIG. 1 shows a cross section of a representative substrate 100 , comprising a solar cell. Photons 10 enter the solar cell 100 through the top surface 105 , as signified by the arrows. These photons pass through an anti-reflective coating 110 , designed to maximize the number of photons that penetrate the substrate 100 and minimize those that are reflected away from the substrate.
[0004] Internally, the substrate 100 is formed so as to have a p-n junction 120 . This junction is shown as being substantially parallel to the top surface 105 of the substrate 100 although there are other implementations where the junction may not be parallel to the surface. The solar cell is fabricated such that the photons enter the substrate through the n-doped region, also known as the emitter 130 . The photons with sufficient energy (above the bandgap of the semiconductor) are able to promote an electron within the semiconductor material's valence band to the conduction band. Associated with this free electron is a corresponding positively charged hole in the valence band. In order to generate a photocurrent that can drive an external load, these electron hole (e-h) pairs need to be separated. This is done through the built-in electric field at the p-n junction. Thus any e-h pairs that are generated in the depletion region of the p-n junction get separated, as are any other minority carriers that diffuse to the depletion region of the device. Since a majority of the incident photons are absorbed in near surface regions of the device, the minority carriers generated in the emitter need to diffuse across the depth of the emitter to reach the depletion region and get swept across to the other side. Thus to maximize the collection of photo-generated current and minimize the chances of carrier recombination in the emitter, it is preferable to have the emitter region 130 be very shallow.
[0005] Some photons pass through the emitter region 130 and enter the base 140 . These photons can then excite electrons within the base 140 , which are free to move into the emitter region 130 , while the associated holes remain in the base 140 . As a result of the charge separation caused by the presence of this p-n junction, the extra carriers (electrons and holes) generated by the photons can then be used to drive an external load to complete the circuit.
[0006] By externally connecting the emitter region 130 to the base 140 through an external load, it is possible to conduct current and therefore provide power. To achieve this, contacts 150 , typically metallic, are placed on the outer surface of the emitter region and the base. Since the base does not receive the photons directly, typically its contact 150 b is placed along the entire outer surface. In contrast, the outer surface of the emitter region receives photons and therefore cannot be completely covered with contacts. However, if the electrons have to travel great distances to the contact, the series resistance of the cell increases, which lowers the power output. In an attempt to balance these two considerations; the distance that the free electrons must travel to the contact, and the amount of exposed emitter surface 160 ; most applications use contacts 150 a that are in the form of fingers. FIG. 2 shows a top view of the solar cell of FIG. 1 . The contacts are typically formed so as to be relatively thin, while extending the width of the solar cell. In this way, free electrons need not travel great distances, but much of the outer surface of the emitter is exposed to the photons. Typical contact fingers 150 a on the front side of the wafer are 0.3 mm with an accuracy of ±0.1 mm. These fingers 150 a are typically spaced between 1-5 mm apart from one another. While these dimensions are typical, other dimensions are possible and contemplated herein.
[0007] A further enhancement to solar cells is the addition of heavily doped substrate contact regions. FIG. 3 shows a cross section of this enhanced solar cell. The cell is as described above in connection with FIG. 1 , but includes heavily n-doped contact regions 170 . These heavily doped contact regions 170 correspond to the areas where the metallic fingers 150 a will be affixed to the substrate 100 . The introduction of these heavily doped contact regions 170 allows much better contact between the substrate 100 and the metallic fingers 150 a and significantly lowers the series resistance of the cell. This pattern of including heavily doped regions on the surface of the substrate is commonly referred to as selective emitter design.
[0008] A selective emitter design for a solar cell also has the advantage of higher efficiency cells due to reduced minority carrier losses through recombination due to lower dopant/impurity dose in the exposed regions of the emitter layer. The higher doping under the contact regions provides a field that repels the minority carriers generated in the emitter and pushes them towards the p-n junction.
[0009] This design can be extended by having narrow highly doped lines between the metallization lines. Such lines could be orthogonal to the metallization lines. These highly doped, low resistance lines allow charge to flow across the emitter to the contacts, and reduce the series resistance of the emitter.
[0010] Such structures are typically made using traditional lithography (on hard masks) and thermal diffusion. An alternative is to use implantation in conjunction with a traditional lithographic mask, which can then be removed easily before dopant activation. Yet another alternative is to use a stencil mask in the implanter to define the highly doped areas for the contacts. All of these techniques utilize a fixed masking layer (either directly on the substrate or in the beamline).
[0011] All of these alternatives have significant drawbacks. For example, the processes enumerated above all contain multiple process steps. This causes the cost of the manufacturing process to be prohibitive. These options also suffer from the limitations associated with the special handling of solar wafers, such as aligning the mask with the substrate and the cross contamination with materials that are dispersed from the mask during ion implantation.
[0012] Therefore, these exists a need to produce solar cells having selective emitters for increased efficiency, while producing these cells at lower cost. A simpler, more cost effective method of manufacturing solar cells is required. While initially applicable to solar cells, the techniques described herein are applicable to other doping applications.
SUMMARY OF THE INVENTION
[0013] A improved, lower cost method of producing solar cells utilizing selective emitter design is disclosed. The contact regions are created on the substrate without the use of lithography or masks. The method utilizes ion implantation technology, and the relatively low accuracy requirements of the contact regions to reduce the process steps needed to produce a solar cell. In some embodiments, the current of the ion beam is selectively modified to create the highly doped contact regions. In other embodiments, the ion beam is focused, either through the use of an aperture or via adjustments to the beam line components to create the necessary doping profile. In still other embodiments, the wafer scan rate is modified to create the desired ion implantation pattern. These techniques can also be used in other ion implanter applications.
BRIEF DESCRIPTION OF THE FIGURES
[0014] FIG. 1 shows a cross section of a solar cell of the prior art;
[0015] FIG. 2 shows a top view of the solar cell of FIG. 1 ;
[0016] FIG. 3 shows a cross section of a solar cell using selective emitter design;
[0017] FIG. 4 shows a top view of the solar cell of FIG. 3 ;
[0018] FIG. 5 shows a coordinate system used with the present disclosure;
[0019] FIG. 6 shows a traditional ion implantation system;
[0020] FIG. 7 shows a graph of substrate holder speed as a function of substrate position;
[0021] FIG. 8 shows a graph of scanner frequency as a function of substrate position;
[0022] FIG. 9 shows a pulsed extraction electrode power supply for use with the ion implanter of FIG. 6 ;
[0023] FIG. 10 a shows a set of plates in the open position for use with the ion implanter of FIG. 6 ;
[0024] FIG. 10 b shows a set of plates in the closed position for use with the ion implanter of FIG. 6 ;
[0025] FIG. 11 a shows an aperture in the open position for use with the ion implanter of FIG. 6 ;
[0026] FIG. 11 b shows an aperture in the closed position for use with the ion implanter of FIG. 6 ;
[0027] FIG. 12 a shows a representative scanning waveform used to create non-uniform dosing;
[0028] FIG. 12 b shows a representative substrate creating using the scanning waveform of FIG. 12 a; and
[0029] FIG. 13 shows an embodiment wherein the scanning waveform is used to adjust a focusing element.
DETAILED DESCRIPTION OF THE INVENTION
[0030] As described above, solar cells utilizing selective emitter design are most advantageous, however the manufacturing process needed to create such cells can be cost prohibitive. By understanding the relative accuracy and requirements of the solar cell, it is possible to manufacture solar cells having a selective emitter design without the costly lithography and masking process steps.
[0031] FIG. 4 shows a top view of the solar cell manufactured using the methods of the present disclosure. The solar cell is formed on a semiconductor substrate 100 . The substrate can be any convenient size, including but not limited to circular, rectangular, or square. Although not a requirement, it is preferable that the width of the substrate 100 be less than the width of the ion beam used to implant ions in the substrate 100 . However, no such limitation exists with respect to the orthogonal direction of the substrate. In other words, a substrate 100 can be arbitrarily long, and can be in the shape of roll of solar cell material. Typically, the substrates for solar cells are very thin, often on the order of 300 microns thick or less.
[0032] As described above, the solar cell has an n-doped emitter region and a p-doped base. The substrate is typically p-doped and forms the base, while ion implantation is used to create the emitter region. A block diagram of a representative ion implanter 600 is shown in FIG. 6 . An ion source 610 generates ions of a desired species, such as phosphorus or boron. A set of electrodes (not shown) is typically used to attract the ions from the ion source. By using an electrical potential of opposite polarity to the ions of interest, the electrodes draw the ions from the ion source, and the ions accelerate through the electrode. These attracted ions are then formed into a beam, which then passes through a source filter 620 . The source filter is preferably located near the ion source. The ions within the beam are accelerated/decelerated in column 630 to the desired energy level. A mass analyzer magnet 640 , having an aperture 645 , is used to remove unwanted components from the ion beam, resulting in an ion beam 650 having the desired energy and mass characteristics passing through resolving aperture 645 .
[0033] In certain embodiments, the ion beam 650 is a spot beam. In this scenario, the ion beam passes through a scanner 660 , preferably an electrostatic scanner, which deflects the ion beam 650 to produce a scanned beam 655 wherein the individual beamlets 657 have trajectories which diverge from scan source 665 . In certain embodiments, the scanner 660 comprises separated scan plates in communication with a scan generator. The scan generator creates a scan voltage waveform, such as a sine, sawtooth or triangle waveform having amplitude and frequency components, which is applied to the scan plates. In a preferred embodiment, the scanning waveform is typically very close to being a triangle wave (constant slope), so as to uniformly expose the scanned beam at every position of the substrate for nearly the same amount of time. Deviations from the triangle are used to make the beam uniform. The resultant electric field causes the ion beam to diverge as shown in FIG. 6 .
[0034] An angle corrector 670 is adapted to deflect the divergent ion beamlets 657 into a set of beamlets having substantially parallel trajectories. Preferably, the angle corrector 670 comprises a magnet coil and magnetic pole pieces that are spaced apart to form a gap, through which the ion beamlets pass. The coil is energized so as to create a magnetic field within the gap, which deflects the ion beamlets in accordance with the strength and direction of the applied magnetic field. The magnetic field is adjusted by varying the current through the magnet coil. Alternatively, other structures, such as parallelizing lenses, can also be utilized to perform this function.
[0035] Following the angle corrector 670 , the scanned beam is targeted toward the substrate, such as the solar cell to be processed. The scanned beam typically has a height (Y dimension) that is much smaller than its width (X dimension). This height is much smaller than the substrate, thus at any particular time, only a portion of the substrate is exposed to the ion beam. To expose the entire substrate to the ion beam, the substrate must be moved relative to the beam location.
[0036] The solar cell is attached to a substrate holder. The substrate holder provides a plurality of degrees of movement. For example, the substrate holder can be moved in the direction orthogonal to the scanned beam. A sample coordinate system in shown in FIG. 5 . Assume the beam is in the XZ plane. This beam can be a ribbon beam, or a scanned spot beam. The substrate holder can move in the Y direction. By doing so, the entire surface of the substrate 100 can be exposed to the ion beam, assuming that the substrate 100 has a smaller width than the ion beam (in the X dimension).
[0037] There are a number of methods that can be used to create the doping pattern shown in FIG. 4 . Some of these methods require the wafer to be implanted in two separate process steps, while others can achieve the desired result in only one pass.
[0038] For clarity, the term “exposed emitter region” will be used to denote the lightly doped portions of the emitter region. The term “contact region” will be used to denote the heavily doped portions of the emitter region. The term “emitter region” refers to any n-doped portion of the substrate.
[0039] In several embodiments, the lightly doped exposed emitter region 160 is created by traditional implantation techniques. For example, a low current ion beam can be used to implant the entire surface of the substrate 100 at a uniform doping level.
[0040] In the case of a ribbon beam, the substrate 100 is positioned between the two ends of the beam, and the substrate holder moves the substrate 100 in the Y direction until the entire substrate has been exposed to the beam. The amount of doping that results from the implantation is proportional to the current of the ion beam, and the dwell time, which is the amount of time that a particular area is exposed to the ion beam. In other words, greater dwell time and/or higher current will result in heavier doping of the irradiated area.
[0041] Thus, by properly moderating the speed of the substrate scan, and/or the current of the ion beam, the substrate can be exposed to the required low dosage to create the exposed emitter region 160 .
[0042] In the case of a scanned spot beam, the beam is normally scanned along the X direction. The substrate holder then moves the substrate in the Y direction. Using this combination of movements, the entire substrate is exposed. The same result can be obtained using a fixed spot beam and moving the substrate holder in both the X and Y directions, until the entire surface is exposed. These and other methods of implanting a substrate are known to those of ordinary skill in the art, and are all contemplated herein.
[0043] In all cases, the resulting ion beam has a width (in the X dimension) much greater than its height (in the Y dimension). Thus, if aspect ratio is defined as width/height, the resultant ion beam has an aspect ratio greater than 2, preferably greater than 10.
[0044] Once the emitter region 130 has been uniformly doped, the highly doped contact regions 170 are implanted during a second implantation step. This can be accomplished in a number of ways.
[0045] In one embodiment, the movement of the substrate holder is modified so as to create longer dwell times at the regions corresponding to the contacts for the metallic fingers. In other words, the substrate holder is moved more quickly in the Y direction over those portions of the substrate that are not to be further implanted (i.e. the exposed emitter regions 160 ). Once the ion beam is positioned over a region that is to be heavily doped (i.e. the contact region 170 ), the speed of the substrate holder in the Y direction slows. This slower speed is maintained while the ion beam is over the contact region. Once that region has been fully exposed, the translational speed of the substrate holder increases so as to quickly pass over the subsequent lightly doped exposed emitter region 160 . This process is repeated until the entire substrate has been implanted.
[0046] FIG. 7 shows a graph slowing the relative speed of the substrate holder in the Y direction, as a function of the position of the substrate. Note that when the exposed emitter region 160 is exposed to the ion beam, the speed is increased. When the contact region 170 is exposed to the ion beam, the speed is slowed to increase the doping dose. In some embodiments, the speed may be varied continuously between 2 levels to have continuously graded dopant profiles with regions of high doping (for contacts) with lightly doped regions in between. Such a velocity profile could be sinusoidal or triangular.
[0047] In the case of a spot beam, a similar technique can be used to move the substrate holder at a variable speed in the Y direction, based on the position on the substrate. If the substrate holder also moves in the X direction to scan across the wafer, the holder can vary the speed in the X direction to achieve the same results described above. In other words, the substrate holder moves quickly in the X direction while exposing lightly doped exposed emitter regions of the substrate, but slows when exposing the contact regions. Alternatively, the speeds of the substrate holder can be varied in both the X and Y directions if desired.
[0048] Alternatively, the scanner 660 can be controlled to create a similar result. Assume, in a scanned spot beam implementation, for example, that the substrate holder moves in the Y direction, and that the scanner 660 causes the spot beam to move in the X direction. By varying the frequency of the sawtooth wave used to control the scanner, the rate that the spot beam traverses the substrate can be modified. In one scenario, the frequency of the scanner control signal is increased as the ion beam passes over the exposed emitter region, and is slowed when the ion is exposed to the contact region. FIG. 8 shows a graph representing this embodiment. In this way, the dwell time of the exposed emitter region is less than that of the contact region. In another scenario, the waveform of the scanner control signal is modified so that the spot beam is positioned so as not to strike the substrate when passing through the exposed emitter region, and only scans when in the contact region. Combining the modification to the scanner input waveform with an alteration to the speed of the substrate holder in the Y direction can also be performed.
[0049] It should be noted that the embodiments presented above, i.e. modifications to the speed of the substrate holder in the X and/or Y directions, and modifications to the scanner frequency, can be employed in either two pass or single pass mode.
[0050] In single pass mode, the speed of the substrate holder in the Y direction is such that the required low dosage of ions is implanted in the exposed emitter region. Obviously, in this mode, the beam must pass over the substrate at all locations; it is only the dwell time at the various locations that is modified.
[0051] In dual pass mode, the speed of the substrate holder in the Y direction can be increased significantly over the exposed emitter region 160 , as this area has already been doped. Alternatively, in the case of a spot beam, the beam can be positioned so as not to hit the substrate in the exposed emitter region 160 , and only be exposed to the substrate while in the contact region 170 .
[0052] While the above methods are mostly concerned with varying the dwell time of the ion beam for various portions of the substrate to vary the doping doses, other methods can be used to create the desired implantation pattern.
[0053] One such technique to create the desired implantation pattern is to vary the ion beam current based on the region of the substrate. This can be accomplished in a number of ways.
[0054] In one embodiment, the ion beam is adjusted by varying the voltage used at the extraction electrodes. FIG. 9 shows a simplified ion implantation system, with only the ion source 600 and the substrate holder 710 shown for clarity. The ion source 600 is used to generate the ion beam 730 to be implanted on the substrate 100 . These ions are attracted through the extraction slit 700 of the ion source by one or more sets of extraction electrodes 720 . The electrical potential of these electrodes 720 determines the resulting ion beam current. For example, if the electrical potential of the electrodes 720 is very similar to that of the chamber walls of the ion source 600 , the flow of ions out of the ion source 600 will be minimal, as there is no attraction to the electrode. Conversely, if the electrical potential is dramatically different than the chamber walls of the ion source, the ions will be strongly attracted to the electrodes 720 . This will result in an ion beam 730 of much higher current. By varying the electrical potential of the electrodes 720 based on the position of the substrate with respect to the ion beam, the desired implantation pattern can be attained.
[0055] FIG. 9 shows the use of a pulsed extraction power supply 740 that is activated whenever the contact region 170 of the substrate 100 is in a position where the ion beam will irradiate it. The pulse is then deactivated whenever the ion beam exposes the exposed emitter region 160 .
[0056] Other components of the ion implantation system can be similarly controlled so as to vary the ion beam current. There are numerous components that can be adjusted in the beam line. For example, a focusing lens element can be pulsed periodically to focus and defocus the beam as the substrate is being scanned to create alternating regions of high and low dopant doses. Such focusing elements may be magnetic (i.e. quadrupole lenses) or electrostatic (i.e. Einzel lenses). The defocusing or focusing of the beam changes the amount of beam that is transmitted into the process chamber (and irradiates the substrate), thus varying the effective beam current incident on the workpiece. In such a scenario, it is possible to dope the entire substrate in a single pass implantation. Alternatively, two passes can be used, if desired. Similarly, other beamline components that control the transmission of beam through the implanter may be changed. Such components include Acceleration/Deceleration voltages, Magnet settings, and the like.
[0057] In another embodiment, apertures are used to modify the beam width. In one scenario, two plates 800 , 810 , shown in FIG. 10 a, are used to create a variable width aperture 820 . In one embodiment, the plates lie on opposite sides of the ion beam 730 , and move toward one another to close the aperture 820 . When the ion beam is scanning the contact region, the plates 800 , 810 are separated, as shown in FIG. 10 a, allowing the beam to pass through. When the ion beam is to scan the exposed emitter region 160 , the plates 800 , 810 move toward one another, so as to minimize or eliminate the aperture 820 , as shown in FIG. 10 b.
[0058] In another scenario, the aperture is used to create the implant pattern. A device, such as that shown in FIGS. 11 a and 11 b, is used to create the alternating pattern. For example, the device may consist of a rotating barrel or cylinder with a through slit, or aperture, such as along the diameter. The device is rotated about an axis normal to the direction of travel of the ion beam. As this cylinder is rotated about the X axis (axis in which the beam is scanned), the beam can only irradiate the substrate when the slit, or aperture, in the rotating device becomes aligned with the beam direction. FIG. 11 a shows the orientation of the aperture when the beam is able to pass through the device. FIG. 11 b shows an orientation where the beam is unable to irradiate the substrate. The relative positions of the apertures on the opposing sides of the cylinder, as well as the width of the opposing apertures determine the duty cycle of the implant pattern. For example, wider apertures enable the passage of the beam over a wider range of angular rotation, while narrow apertures permit the passage of the beam over a smaller range of angular rotation. The speed at which the device rotates determines the frequency at which the ion beam irradiates the substrate. While a cylinder is described above, other shaped devices can also be used, as long as the rotation of the device causes the apertures to align such that the ion beam can periodically pass through the device.
[0059] To create the desired implantation patterns, it is important for the system to understand the position of the substrate relative to the ion beam. In other words, the system must be aware that the contact region is being exposed in order to supply the proper amount of ions. This information can be determined in a number of ways.
[0060] First, the system can rely strictly on timing. In other words, the synchronization of the substrate holder to the other components of the system is accomplished based on the time elapsed since the start of the operation.
[0061] A more accurate approach is to include patterns at the edge of the substrate. The system can determine the position of the substrate with respect to the ion beam based on these patterns, and operate accordingly. This method is preferably in that the system does not need any information concerning the implant pattern prior to starting the operation. The patterns on the substrate supply the necessary information for the system to correctly implant the substrate. Such patterns and marking systems are well known to those skilled in the art.
[0062] Much of the above description discloses methods of varying the dose or the beam transmission characteristics, based on the vertical position (i.e. Y direction) of the substrate. In other words, the dose can be varied as a function of the substrate location that is being exposed to the ion beam. It is also possible to vary the beam transmission characteristics based on the scan position of the beam (i.e. in the X direction).
[0063] Referring to FIG. 6 , in certain embodiments, a spot beam is used. In this scenario, the ion beam passes through an electrostatic scanner 660 , which deflects the ion beam 650 to produce a scanned beam 655 . The scan generator creates a scan voltage waveform, such as a sine, sawtooth or triangle waveform having amplitude and frequency components, which is applied to the scan plates. In most embodiments, the scanning waveform is typically very close to being a triangle wave (constant slope), so as to uniformly expose the scanned beam at every position of the substrate for nearly the same amount of time.
[0064] The scanner waveform can be utilized in a variety of ways to vary the dose implanted on the substrate. In one embodiment, the typically triangular waveform is replaced with an alternative waveform. In much the same way that the workpiece can be moved at different rates to vary the dose in the vertical direction (i.e. along the Y axis), modifications to the scan waveform can produce similar effects in the horizontal direction (i.e. along the X axis). FIG. 12 a shows a scanning waveform that could be used to generate three areas of high dosing on a substrate in the X direction. The slope of the waveform indicates the speed at which the scanner moves the ion beam across the substrate in the X direction. Those portions of the waveform with very small slopes will create higher doses than those portions with steeper slopes. FIG. 12 b shows the resulting substrate dosing, with three areas of high dosing, corresponding to the three portions of the waveform with small slopes, while the remainder of the substrate is lightly dosed.
[0065] Alternatively, the scanner waveform can be used to vary the adjustable beamline components. In the simplest embodiment, a threshold detector can be used to enable or disable an adjustable beamline component. FIG. 13 shows a threshold detector 900 having one or threshold detection points. The detector receives the scanning waveform from the scanning waveform generator 910 and varies its output such that the adjustable beamline component is enabled when the amplitude of the scanning waveform is between certain values, and is disabled at other times. Such an embodiment can be used to create vertical strips of high dosing on the substrate. By using a plurality of thresholds, it is possible to create patterns similar to that shown in FIG. 12 b. For example, assume that the amplitude of the scanning waveform varies between 0 volts and 1 volt. In one embodiment, the threshold detector circuit may enable its output its output if the amplitude of the scanning waveform is between 0.15V and 0.3V, between 0.45V and 0.60V, or between 0.75V and 0.9V. Such a configuration would yield three vertical stripes of higher dosing. Obviously, other embodiments are possible and within the scope of the disclosure.
[0066] By combining information about the substrate's position relative to the ion beam with the scanning waveform, more complex patterns can be created on the substrate. In one embodiment, the workpiece support is moved at a constant rate so that time can be used to estimate the position of the substrate relative to the ion beam. A counter or timer is then used, in conjunction with the scanning waveform and the above described threshold detector, to create patterns of dosing which vary as a function of both horizontal and vertical position.
[0067] In another embodiment, patterns on the substrate are used to determine the vertical position of the substrate with respect to the ion beam. This information is then used in combination with the scanning waveform to create an output used to control the adjustable beamline component.
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A improved, lower cost method of producing solar cells utilizing selective emitter design is disclosed. The contact regions are created on the substrate without the use of lithography or masks. The method utilizes ion implantation technology, and the relatively low accuracy requirements of the contact regions to reduce the process steps needed to produce a solar cell. In some embodiments, the current of the ion beam is selectively modified to create the highly doped contact regions. In other embodiments, the ion beam is focused, either through the use of an aperture or via adjustments to the beam line components to create the necessary doping profile. In still other embodiments, the wafer scan rate is modified to create the desired ion implantation pattern.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of electronically aided navigation through a facility and in particular to a method and apparatus for guiding visually impaired individuals along a route in a facility to obtain items or visit locations chosen by the individual.
BACKGROUND INFORMATION
[0002] Various methods and systems have been devised to aid visually impaired individuals in unfamiliar surroundings. Devices and systems have been developed in the past to guide the visually impaired by utilizing detection devices to warn the user of obstacles. These prior art systems merely react and signal the user of obstacles and do not aid the user in navigating a route.
[0003] Other devices have been developed which aid visually impaired individuals toward specific locations by utilizing remote modules located at specific locations and a mobile module carried by the individual recording distances and transmitting information to the user. Although these devices do aid visually impaired individuals to be more mobile and self-sufficient they do not allow for the user to detail his own task list and have the system create a route for him to travel in a manner to efficiently accomplish the tasks on the list.
[0004] It would be a benefit therefore to have a navigation system that allows an individual to create his own task list and have a route provided to accomplish the tasks listed. It would be a further benefit to have a navigation system that allows an individual to create his own task list and electronically submit it to a service provider for the preparation and downloading of a route into the user's personal digital device so as to navigate the route and complete the tasks within a particular facility. It would be a still further benefit to have a navigation system that is adapted for use with many existing electronic label systems currently existing in facilities.
SUMMARY OF THE INVENTION
[0005] It is thus an object of the present invention to provide a navigation system that allows an individual to create his own task list and have a route provided for the individual to accomplish the tasks on the list.
[0006] It is a further object of the present invention to provide a navigation system that allows an individual to create his own task list and electronically submit it to a facility for the preparation and downloading of a route into the user's personal digital device so as to navigate the route and complete the tasks within the particular facility.
[0007] It is a still further object of the present invention to provide a navigation system that interacts with many systems already existing in facilities.
[0008] Accordingly, a system and method of the type for aiding a user in navigating a route through a facility so as too efficiently locate specific items within a facility is provided. The system includes a facility processor having a database and software stored thereon for mapping an interactive route from selected location to selected location within a facility, a label located proximate individual items, the label electronically communicating information specific to the item it is associated with, and a digital device having the interactive route electronically stored thereon, the digital device electronically communicating with the facility processor and the labels for tracking movement of the digital device along the route via communication with the labels and communicating a direction to move to follow the route.
[0009] A user creates a list of items to acquire, or locations to visit that are specific to a facility. The user then provides this list to a facility processor at the facility or via a network. An interactive route is then created to provide an efficient route for the user to locate all the items on the list. This route is downloaded onto the user's digital device for utilization in the facility. The system utilizes two-way communication between the labels and the digital device and the digital device and the facility processor when necessary to navigate through the facility. The digital device indicates a direction to follow until a listed item is located. The system may utilize any means necessary, such as visual, audio, and/or physical stimulation, to communicate to the user a direction to travel or when an item is located. This system may be used by the visually impaired. The interactive route program may also allow the user to skip items or move through the list and select specific items, the route being adjusted according to the item selected.
[0010] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0012] [0012]FIG. 1 is an illustration of the navigation system of the present invention.
[0013] [0013]FIG. 2 is a system diagram of a data processing system, including hardware and firmware, which may be used to implement the present invention.
[0014] [0014]FIG. 3 is an illustration of a navigation system of the present invention utilizing radio frequency (RF) communication.
[0015] [0015]FIG. 4 is a flowchart of a method of initiating the navigation system of the present invention.
[0016] [0016]FIGS. 5A, 5B, 5 C is a flowchart of a method of the navigation system of the present invention.
DETAILED DESCRIPTION
[0017] Refer now to the drawings wherein depicted elements are not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several figures.
[0018] [0018]FIG. 1 is an illustration of the navigation system of the present invention generally designated by the numeral 10 . Navigation system 10 includes a facility processor 12 , a personal digital device 14 , and a facility 16 . System 10 as shown is adapted for use in a facility such as a grocery store or other sales facility. It should be recognized that navigation system 10 of the present invention may be utilized in many different types of facilities, such as, but not limited to grocery stores, department stores, hardware stores, entertainment centers and the like. For brevity and clarity navigation 10 is described for utilization in a grocery store for aiding visually impaired persons to navigate shopping routes to obtain particular items.
[0019] Facility processor 12 may be a dedicated personal computer system, a store controller, or a manager's workstation. Facility processor 12 may be a stand-alone processor or connected to other processors, such as, but not limited to, a corporate headquarters, through a network (not shown). Typically, facility processors will contain inventory data, facility location of inventory, price lists, and promotional offers among other data necessary to operate a sales facility.
[0020] Personal digital device 14 is an independently powered, stand-alone, two-way wireless communication device. Personal digital device 14 may be a device such as, but not limited to, a personal digital assistant, laptop computer, cell phone or other similar device. Personal digital device 10 will have software loaded to allow communication with facility processor 12 and labels 18 (FIG. 3).
[0021] A representative hardware environment which can be used for practicing the present invention is depicted with reference to FIG. 2, which illustrates the hardware configuration of a data processing system 213 in accordance with the subject invention. The representative system may be utilized, in whole or in part, for various elements of the present invention such as facility processor 12 , personal digital device 14 , and label 18 shown in FIG. 3.
[0022] The data processing system 213 includes a central processing unit (CPU) 210 , such as a conventional microprocessor, and a number of other units interconnected via a system bus 212 . The data processing system 213 includes a random access memory (RAM) 214 and a read only memory (ROM) 216 , and may include flash memory. Data processing system 213 may also include an I/O adapter 218 for connecting peripheral devices such as disk units 220 and tape drives 240 to the bus 212 , a user interface adapter 222 for connecting a keyboard 224 , a mouse 226 and/or other user interface devices such as a touch screen device to the bus 212 , a communication adapter 234 for connecting the data processing system 213 to a data processing network 242 , and a display adapter 236 for connecting the bus 212 to a display device 238 which may include sound. The CPU 210 may include other circuitry not shown herein, which will include circuitry found within a microprocessor, e.g., an execution unit, a bus interface unit, an arithmetic logic unit (ALU), etc. The CPU 210 may also reside on a single integrated circuit (IC).
[0023] [0023]FIG. 3 is an illustration of navigation system 10 of the present invention utilizing radio frequency (RF) communication. As shown, facility 16 includes facility processor 12 and a plurality of labels 18 . Facility processor 12 contains stored information such as store inventory, price lists, store diagrams, label 18 locations in the facility, and promotional information. Facility processor 12 may include software which allows mapping of the locations of labels 18 in facility 16 . Facility processor 12 is connected to one or more RF links 20 for transmitting and receiving radio frequencies. It should be recognized that the system is described utilizing radio frequency, however, infrared technology or hard-wire communication may be utilized.
[0024] Each label 18 may be an independently powered, stand-alone, two-way communication device. Label 18 may be a radio frequency identification tag. Labels 18 are placed along shelves, such as in a grocery store, adjacent to a product that it identifies. As represented in FIG. 3, labels 18 have been placed on two rows of shelves forming an aisle. Labels 18 may be loaded with information such as the location of label 18 , the item represented, item price, and promotional offers. This information may be pre-loaded and/or edited via communication from facility processor 12 . Labels 18 may be programmed to transmit information back to facility processor 12 .
[0025] The electronic label system as shown in FIG. 3 may be utilized with systems available for use in retail facilities. The present invention utilizes these in-place and readably available systems in-part, to aid the visually impaired to shop in a self-sufficient and timely manner.
[0026] A user creates a task list and has an interactive route, created to locate each item listed, loaded via a network or directly from facility processor 12 at facility 16 into personal digital device 14 . Once the route is downloaded and the user and personal digital device 14 enter a particular facility 16 , personal digital device 14 polls labels 18 within transmission range. When a label 18 is polled it will respond with an item identification such as a barcode and may transmit a location and additional information. When personal digital device 14 receives the signal from a label 18 , it processes the information sent, comparing it to the route identified and indicates to the user if it is a product he desires or may indicate that the user is to move forward or in a different direction. Personal digital device 14 may transmit the received barcode from a label 18 and send it to facility processor 12 to receive the location of personal digital device 14 for routing information. The personal digital device may provide information to the user utilizing audible, visible, and/or physical stimulation methods such as a synthetic voice, buzzers, vibration, braille display, or lights depending on the ability of the user.
[0027] By requesting as little information as possible from labels 18 , the label's battery life is prolonged. Additionally, if the wireless link between label 18 and personal digital device 14 is limited limited to a very short range, navigation system 10 can more accurately pinpoint the location of the shopper on the route.
[0028] [0028]FIG. 4 is a flowchart of a method of initiating navigation system 10 of the present invention described with reference to FIGS. 1 through 3. A shopper creates a shopping list, step 410 . The shopper then transmits the list to facility processor 12 , step 420 . The shopper may transmit the list to facility processor 12 via a network or upload the list at facility 16 . The list may be a hard copy and scanned into facility processor 12 . In step 430 , facility processor 12 compares the listed items to the location of the items in the store and creates an optimal route through facility 16 to obtain the items listed. The route may be recalculated during use if the user elects to skip an item listed. In step 440 , the route is loaded into personal digital device 14 of the user either over a network or at facility 16 .
[0029] [0029]FIG. 5A is a flowchart of a method of navigation system 10 of the present invention described in relation to FIGS. 1 through 4. Once the shopper has the route loaded into his personal digital device 14 ,he initiates the programing and shopping route in step 510 . In step 510 , the shopper initiates the navigation program by inputting a request for the first product. The shopper may input the request by typing it into the personal digital device 14 , utilizing voice recognition, utilizing a dedicated key on the personal digital device 14 , or any other method known to operate a computing device by the visually impaired. In step 520 , personal digital device 14 queries a label 18 for a barcode. If more than one label 18 transmits a barcode, personal digital device 14 accepts the strongest signal. In step 530 , personal digital device 14 queries label 18 for a location; if no location is transmitted from label 18 , the information is obtained from facility processor 12 . In step 540 , if personal digital device 14 recognizes the barcode as an item listed, the process continues as shown in FIG. 5B. If the barcode is not recognized as an item desired, personal digital device 14 compares the location of the previous label 18 with that of the current label 18 location, step 550 . In step 560 , personal digital device 14 determines if the shopper is moving in the correct direction. If the shopper is not moving in the correct direction, the correct direction is calculated, step 570 , and the correct direction is indicated to the shopper in step 590 . If the shopper is moving in the correct direction, that direction is set in step 580 and is indicated to the shopper in step 590 . This process is continued until the shopper locates the first item listed.
[0030] [0030]FIG. 5B is a flowchart of a method of navigation system 10 of the present invention described in relation to FIGS. 1 through 5A. FIG. 5B is an illustration of the found product process of system 10 . Once the barcode transmitted from a label 18 matches an item listed, an indication is given to the shopper that the item is located, step 600 . In step 610 , personal digital device 14 inquires if the shopper responds to the found item. If the shopper does not respond to personal digital device 14 , the barcode is again checked against the item listed, step 620 . If the barcode matches the listed item, the process resets to step 600 . This loop continues for a set number of times. If the barcode does not match the listed item, the process resets to step 520 . If the shopper responds that the item is found, personal digital device 14 queries if the shopper would like a price check, step 630 . If price is requested, personal digital device 14 queries label 18 and/or facility processor 12 for the price, step 640 . The price received is then stored in a running price total, step 650 . Then system 10 is set to locate the next item listed in step 660 and the process continues as shown in FIG. 5C. If the shopper does not request a price in step 630 , system 10 waits a specified time for a response, step 670 . If the preset wait time passes, step 680 , system 10 is set to the next product listed, step 660 . If the shopper indicates by pushing a button or submits a response in another manner established for another item in step 690 , the method continues as shown in FIG. 5C. If the shopper does not give an indication as to price request in steps 670 - 690 , the program repeats a set number of times before moving to step 660 .
[0031] [0031]FIG. 5C is a flowchart of a method of navigation system 10 of the present invention described in relation to FIGS. 1 through 5B. FIG. 5C illustrates the next selection process which may be utilized at anytime, for example if the shopper decides to reduce the list because of time constraints or money concerns. In step 700 , personal digital device 14 provides for selection of a previous item or next item. This step may always be available by vocal command or by physical command and also includes indications from personal digital device 14 to the shopper of the next item to pursue. Whichever direction the shopper chooses to go through the list, once an item is selected personal digital device 14 calculates a route to the selected item, steps 710 and 720 . In step 710 , the shopper selects an item earlier in the list and the interactive route recalculates a route from the current location. In step 720 , the interactive route recalculates a route from the current location to the item selected that is not the next listed item in the original list. In step 730 , the item is selected and the direction to move is indicated to the shopper, step 740 . The process then continues to step 510 . The process may be terminated upon the shoppers request or once all the listed items have been found. Upon completion of the item list, digital device 14 may indicate a route to a payment station and/or exit (not shown).
[0032] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. It should be recognized that the present method and system may be utilized by any individual to speed shopping or locating items in a facility. The label may be a wireless communication device that does not have the ability to visually display information.
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A system and method of the type for aiding a user in navigating a route through a facility so as too efficiently locate specific items within a facility is provided. The system includes a facility processor having a database and software stored thereon for mapping an interactive route from selected location to selected location within a facility, a label located proximate individual items, the label electronically communicating information specific to the item it is associated with, and a digital device having the interactive route electronically stored thereon, the digital device electronically communicating with the facility processor and the labels for tracking movement of the digital device along the route via communication with the labels and communicating a direction to move to follow the route.
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This is a division of application Ser. No. 382,056 filed July 24, 1973, now U.S. Pat. No. 3,917,486.
BACKGROUND OF THE INVENTION
Methods are well-known to plate tin over metallic surfaces. The instant baths and methods are to be distinguished from the techniques based upon electrolytic deposition and electroless plating.
Electrolytic plating is the production of adherent deposits of metals on conductive surfaces carried out by passage of electric current through an electroplating solution. The plating rate is determined by the current density impressed on the surface being plated.
Electroless plating is a method of metal deposition without the assistance of an external supply of electrons but, requiring an agent present in the processing solution capable of reducing the ions to be deposited. The process is further characterized by the catalytic nature of the surface which enables the metal to be plated to any thickness. Typically, such solutions comprise a solvent, a supply of ions of the metal to be deposited, an agent capable of reducing the ions of the metal to be deposited, a complexing agent for the ions of the metal to be deposited, and a pH regulator.
Among other problems, a major difficulty is sometimes encountered with depositing electroless metal on closely defined areas. There is a tendency for non-sensitive areas after prolonged immersion in or contact with electroless metal solutions to receive scattered or random metal deposits. In addition, the electroless metal solutions sometimes produce metal deposits which contain a substantial amount of hydrogen causing the deposits to be brittle, breaking under rough mechanical handling and bending.
Immersion plating or "contact plating" depends, however, upon a galvanic displacement reaction. The current instead of being furnished from an outside source, arises from reaction of the substrate itself and the metal being plated. Because of this, metal thickness has traditionally been limited to 10 to 50 millionths of an inch. As the immersion process depends upon the electrolytic action of the base metal, deposition stops as soon as the base metal is entirely covered forming a very thin deposit.
SUMMARY OF THE INVENTION
This invention is concerned with immersion plating and its attendant advantages which include, among others: immersion deposits which are decidedly adherent; deposits with considerable resistance to corrosion; the production of dense impervious deposits; and the ability to deposit metal on closely defined areas of metallized surface.
It has been found that up to about 300 millionths of an inch of tin can be plated in accordance with the present invention to provide surprisingly good solderability immediately after plating and particularly, after exposure to adverse conditions often required in subsequent fabrication.
Additionally, the high quality of solderability provided by this invention endures for a period in excess of six months of storage under normal stock room conditions.
Moreover, the chemical resistance of the tin plate of the present invention is surprisingly excellent. The tin plate remains solderable after exposure to normal printed circuit processing chemicals i.e., chromic acid, dilute hydrochloric acid, etc., and will remain bright after cleaning with trichloroethylene, Freon, isopropyl alcohol and other normal flux-removing solvents.
It has additionally been discovered that optimum solderability is achieved by the present invention with plating thicknesses of only between 50-100 millionths inch. Plating of greater thickness under the present invention is now possible by merely extending the immerison time of the plating process. However, it has been found that such greater thicknesses do not improve the solderability characteristics to any appreciable degree. The tenacious tin plate achieved by the present invention achieves much greater solderability characteristics than even thicker tin plates formed by other processes. The much improved solderability with relatively thin plate thickness, therefore, proves to be a great economic saving.
Accordingly, the present invention has the following objects.
It is an object of the present invention to provide an immersion tin plating bath effective in plating over normally inadequate thicknesses of copper and other metallized surfaces, particularly that produced by ductile electroless copper.
It is another object of the present invention to provide a new immersion tin plating bath which will not attack solder masks and other material on the surfaces of the board to be plated.
It is a further object of the present invention to provide a new method of depositing tin by contact or immersion plating in greater thickness than has heretofore been accomplished, in an amount up to about 300 millionths of an inch.
It is an additional object of the present invention to provide a method of improving the solderability characteristics of printed circuitry.
It is still a further object of the present invention to provide a method of depositing a smooth, even, tin coating to surface metal increasing its resistance to shelf aging and corrosive chemicals.
Other objects and advantages of the invention will be set forth in part hereinafter and in part will be obvious herefrom, or may be learned by practice with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the present invention, there are provided immersion tin plating bath compositions for depositing a smooth, even tin coating on metallized surfaces, comprising a soluble stannous salt, a sulfur component, a mineral acid, and a wetting agent. The metal of the substrate surface must have an electronegativity greater than tin in order that it be capable of chemically displacing tin from the tin bath.
A further preferred feature of the invention is to provide a process for depositing a smooth, even tin coating on a metallized surface, said process comprising immersing into a tin plating bath comprising a soluble stannous salt, a sulfur component which comprises at least two sulfur containing compounds, a mineral acid, and a wetting agent, an article having a metallized surface capable of chemically displacing tin from the tin plating bath, wherein the article is immersed in the bath until tin forms in a continuous coating on said metallized surface.
A still further preferred embodiment of the invention is in a process for the manufacture of printed circuit boards having a smooth, even tin coating over areas of clean copper circuitry having grease-free and oxide-free copper surfaces, comprising the steps of:
(1) immersing said circuit boards into an agitated immersion tin plating bath comprising a soluble stannous salt, a sulfur component, a mineral acid, and a wetting agent for such time until a continuous coating of tin forms on said copper surfaces;
(2) rinsing said boards, and
(3) drying said boards.
THE BATH
Immersion tin baths are not new and have been used for many years, particularly in decorative plating. The combination of a stannous salt and HCl has been known, but such a bath proves inadequate in the plating of tin over metal circuitry. For one thing, the tin plated surface was found to be porous and crystalline on the copper substrate. It has been now discovered that by adding a wetting agent to this composition, a beautiful, smooth plate can be achieved which yields exceptionally improved tin thickness. It has also been found that the addition of a sulfur component aids in removal of impurities and secondary reaction products and generally enhances the stability of the bath. The tin bath of the present invention is capable of forming a tin plate up to about 300 millionths of an inch being so non-porous it can act as an etch resist. The result is improved plating and a more efficient bath.
Among the stannous salts found operable in the present invention include soluble organic and inorganic acid salts of tin. While applicant does not limit himself to any specific stannous salt, illustrative of those contemplated within this invention are stannous salts of halides, nitrates, acetate, boron-fluoride complexes, and sulfates.
Organic anionic, non-ionic and cationic surface active agents have been found useful as the wetting agents in the present invention. Preferred wetting agents include fluorinated carboxylic acids such as FC-98, manufactured by the Minnesota Mining and Manufacturing Company and the Triton-X series of wetting agents manufactured by the Rohm and Haas Company.
The acids effective in the present invention are strong inorganic and organic acids. The preferred inorganic acids are the mineral acids such as hydrochloric acid, sulfuric acid, nitric acid and phosphoric acid. Useful organic acids include, for example, acetic acid and formic acid.
The sulfur component useful in the present invention includes organic and inorganic sulfur-containing compounds. The sulfur component comprises at least two sulfur-containing compounds. Examples of organic compounds include aliphatic sulfur-nitrogen compounds, such as thiocarbamates, e.g. thiourea; 5-membered heterocyclics containing S-N in the 5-membered ring, such as, thiazoles and isothiazoles; dithiols, e.g., 1,2-ethanedithiol; 6-membered heterocyclics containing S-N in the ring such as thiazines, e.g., 1,2-benzisothiazine, benzothiazine; thioamine acids such as methionine, cystine, cysteine; and, thio derivatives of alkyl glycols. Examples of inorganic compounds include alkali metal sulfides, alkali metal thiocyanates and alkali metal dithionates.
It is important however, that no matter what sulfur compounds are used, alkali metal polysulfides should be present within a certain limited range of concentrations, preferably between about 0.005 to about 0.2 g/l of the total bath composition.
Commercial imported thiourea is often used to prepare the plating bath of the present invention. Commercial imported thiourea is distinguished from, for example, reagent grade thiourea as the commercial grade has a greater concentration of sulfides present. An example of such a commercial grade thiourea is that manufactured by the DeGussa Company.
It has been found that when a fresh bath has been prepared and a commercial imported thiourea has been used as the sulfur component, a greenish-brown precipitate is formed. Articles in the plating bath plate unacceptably for about the first hour. It has been found that when this precipitate is eliminated as by filtration, plating can be accomplished, but an unacceptable crystalline tin deposit forms. It has been found that if after the precipitate is removed there is added an alkali metal polysulfide of the general formula, M 2 S x , wherein x is a number from 2 to 5, in amounts of about 0.005-0.2 g/l of the bath composition, the tin bath composition is capable of depositing a smooth, even tin coating.
Where reagent grade or chemically pure thiourea is used, no precipitate is formed but a granular tin plating occurs which is very porous and unacceptable. While no filtering is necessary, the addition of an alkali metal polysulfide of the general formula M 2 S x , where x is from 2 to 5 in an amount between 0.005-0.2 g/l will cause the tin bath composition to plate a smooth, even tin coating. If too much of the poysulfide compound is used, a dull brownish plate will be formed instead of the normal semi-matte silver-white coating. This dullish brown plate is easily cleaned, however, with a solution of potassium chloride.
It is therefore seen that the addition of a specified amount of an alkali metal polysulfide to the tin plating bath causes unusually and unexpectedly smooth, lustrous plating. Where commercial grade thiourea is used, which actually contains appreciable and varying amounts of sulfides, such sulfides must be eliminated first to allow the addition of a known quantity of polysulfides. Where a reagent grade thiourea is used which does not contain appreciable amounts of sulfides, no filtering step is necessary and the specified amount of alkali metal polysulfides may be added directly.
The immersion tin plating bath may be formulated in either of two procedures. First, de-ionized or distilled water in an amount equivalent to about 70% of the required final bath volume is heated to the bath operating temperature of 50°-80° C. The chemicals as discussed above are added while stirring. After the chemicals are added, the remainder of water is added to bring the bath to full volume.
THE PLATING PROCESS
With respect to the process, in order for successful tin plating to be accomplished, the copper or other metallized surface on a panel or board must be free from grease and oxide films. The industry generally uses many types of cleaning cycles. The treatment afforded the surface to be plated depends upon the cleanliness of the material to be treated and associate factors. Scrubbing with conventional alkaline cleaners is used to remove heavy soils. Oxides may be removed from the metal surfaces by application thereto of a dilute acid solution such as dilute sulfuric hydrochloric acid, or a light etching solution such as a 25% solution of ammonium persulfate in water. Often both of these solutions may be employed, separated with a water rinse step. The treatment period and temperature of this cleaning cycle are significant, in that elevated temperatures and extended periods of time may result in removal not only of the oxide materials but of the metal itself. The panel or board containing the metal surface is rinsed thoroughly after this cleaning step with water to remove all residue of etching compounds. Care should be taken to avoid the formation of further oxide film during rinsing as a result of air oxidation.
If the condition of the materials permits, a sanding operation with a fine abrasive can also be used to remove oxides.
The boards or panels containing the metal surfaces are usually transported from process to process on racks. In view of the nature of the immersion tin baths special precaution must be taken as to the choice of the material of these racks. Polypropylene or coated stainless steel racks are recommended. Uncoated stainless steel racks can be used for short runs, but as the bath contains a sulfur compound, caution should be taken to prevent contamination of the rack and fouling of the bath. Racks made of iron and other metals easily attacked by corrosive acids such as hydrochloric acid should also be avoided.
The immersion tin bath must be agitated when in use to prevent localized starved spots. Air agitation should not be used but, rack agitation proves quite effective. Mild agitation for a minute upon entering the bath solution ensures uniform coverage. Also found very effective is the use of a propellor mixer, sufficient to circulate solution through a rack without introducing air.
The tin plating bath of the present invention is generally operated at a temperature of 50°-80° C. Storing the bath composition at temperatures of 50° C. or higher tends to accelerate the decomposition of thiourea. However, it should be noted that at temperatures below about 50° C., the chemicals begin to salt out of the solution.
Upon formulation and heating, the bath should be a pale green color. The color will gradually turn to a coffee color, usually after two to three hours. During this transitional period of coffee color, parts should not be plated.
The color change is believed to be due to the formation of a precipitate, stannous sulfide. The precipitate will do-deposit on any parts being plated during the transitional period, causing grey-black deposits and occasionally a rust-colored dusty deposit. These deposits can easily be removed by a light brushing of the part with water. However, a dust-free, deposit-free operation may be accomplished by completely removing the precipitate by filtering the hot bath solution through a 10 micron glass filter. Again, it is noted that if the solution cools below 50° C., it will salt out.
The bath should remain covered when not in use to avoid iron or alkaline contamination.
When the copper surface being plated becomes grey and spotty, the bath is depleted and should be either discarded or re-activated.
The effective life of the tin plating bath of course, depends upon many factors. It has been found, however, that when the bath is operated at its preferred conditions, e.g. 60° C.± 5° C. and it is at its preferred formulation, the bath will plate 30-35 square feet of copper area per gallon of bath with tin 70-80 millionths inch thick.
The preferred operating conditions and bath formulations (in Example 2 below) were used in the compilation of data for this analysis. It is therefore seen that it would take about 40 minutes of immersion plating time to achieve a tin coating of 80 millionths of an inch thickness.
After the panels have plated to the desired thickness, the rack is transferred to a water rinse. The use of warm water is recommended to ensure complete removal of plating salts and to avoid staining upon drying. Poor rinsing is the primary cause of stained and dull tin plated circuits. A typical effective rinsing operation comprises a warm water rinse of 100°-120° F. for five minutes.
After rinsing, the panels may be routinely air dried, or more preferably be either forced air dried using clean air or a warm oven bake operated at temperatures of approximately 150°-300° F.
The normal thickness of tin plating (about 80 millionths inch) will withstand optional mild brushing such as wire brushing or optional light pumice brushing. Such optional wire brushing will provide a pleasing shiny appearance and minimize fingerprint as well as other stains. In addition, optional wire brushing provides the most solderable surface. Optional Scotch-brite brushing will also yield fine results when set at as light a pressure as possible. In all such optional brushing operations, the machines should be thoroughly cleaned and free of contaminants such as sulfuric acid, copperbrite, etc. Such contaminants can eventually oxidize the tin surface.
EXAMPLE I
Precleaning Cycles
The typical process will begin with a pre-cleaning cycle to insure that the copper or other metallic surfaces to be plated are grease and oxide free. The cleaning cycle used usually depends upon the degree of contamination of the surface. A typical mild pre-cleaning cycle would comprise the following steps for the designated time periods:
______________________________________(a) Altrex Soak* 5 minutes (150° F-180° F)(b) Water rinse 1 minute(c) 10% H.sub.2 SO.sub.4 dip 30 seconds(d) Water rinse 1 minute______________________________________ *Altrex is the tradename of a mild alkaline detergent manufactured by Wyandotte Chemicals Corp., Wyandotte, Michigan.
While the above pre-cleaning cycle is usually quite adequate a stronger cleaning cycle is also often used consisting of the following steps:
______________________________________(a) Ammonium persulfate dip 30 seconds(25% APS at 120° F)(b) Water rinse 1 minute(c) 10% H.sub.2 SO.sub.4 dip 15 seconds(d) Water rinse 1 minute (allow to drain)______________________________________
EXAMPLE II
An immersion tin plating bath was prepared in accordance with the present invention as indicated below:
______________________________________Stannous chloride 21 g/lThiourea** 90 g/lConcentrated HCl(37% aqueous) 36 ml/lFC-98 0.5 g/lPotassium polysulfides*** 0.1 g/lDeionized water Balance______________________________________ **Chemically pure grade ***Sulfurated potash as manufactured by the Fisher Scientific Company.
In the above formulation FC-98 is a fluorinated carboxylic acid wetting agent manufactured by the Minnesota Mining and Manufacturing Company. The bath formulated above was 12 liters (3.18 gallons).
After being pre-cleaned in accordance with the mild pre-cleaning cycle of Example I above, circuit boards were immersed on racks into the tin plating bath formulated above. These circuit boards contained the following copper surface areas:
______________________________________No. of Boards Dimensions = Copper Surface Area______________________________________ 24 pcs. 21/2" × 8" 6.67 sq. ft.135 pcs. 6" × 8" 89.33 sq. ft. 31 pcs. sample circuits 5.00 sq. ft. 101.00 sq. ft.______________________________________
The bath was operated at a temperature of 65° C. with initial agitation by vibration of the racks. The boards were removed from the bath after 40 minutes and several microsections were made of the plated boards. The results indicated the average plated thickness of the tin was 80 millionths inch.
The yield of the bath was then calculated, based upon the volume of the bath, 12 liters or 3.18 gallons, and the average surface plate thickness of 80 millionths inch: ##EQU1##
Therefore, the bath of the above formulation operated at the above conditions yielded a tin plate of 80 millionths inch thick over 32 square feet of copper per gallon of bath.
To determine the optimum and maximum life of the plating bath additional experiments were made increasing the surface area of copper in the tin bath. It was found that when more than 101 sq. ft. of copper surface was immersed into the 3.18 gallon bath, the copper surface became grey and spotty indicating the bath was depleted before it could adequately plate the copper surfaces. Therefore, it is seen that 32 sq. ft. of copper surface per gallon of bath represents an optimum yield.
While the above examples are illustrative of the tin plating bath composition and process of tin plating, variations of the process and compositions have proved equally as effective. For example, the components in the preferred composition of the tin bath may be present in the following ranges of concentration based upon the total bath composition:
______________________________________Stannous salt 15 - 30 g/lSulfur component 15 - 120 g/lMineral Acid 25 - 50 ml/lWetting agent 1 - 10 g/lWater Balance______________________________________
It is noted that the sulfur component comprises an alkali metal polysulfide and at least one other sulfur compound as described earlier. The ratio between the polysulfide and the other sulfur compounds comprising the sulfur component can vary widely. For example, where polysulfides are present with only one other sulfur-containing compound, the ratio of the former to the latter may be between about 0.004% to 1.3%. Solder masks and legends can be applied either before or after tin plating. If the solder mask is applied before tin plating, traditional and customary techniques may be employed but with special precaution to employ a sufficient cure of the mask before the plating operation. The solder mask should be applied over a clean, wire brushed surface. A single pass through the gas-fired oven at 250° F. is not a sufficient cure to withstand the subsequent contact with the tin bath. Insufficient cure will cause the solder mask to blister in the tin bath. The following bakes enumerated below are merely illustrative of the minimum bakes which have proved quite adequate in protecting the solder mask during tin bath procedure:
(a) 2 passes through a gas-fired oven at 250° F.
(b) 30 minutes at 250° F. oven bake
(c) 15 minutes at 320° F. oven bake
Application of the solder mask over the plated tin is done in the same manner as solder masking over solder plate. However, the tin under the solder mask will re-flow upon prolonged exposure to molten solder, in excess of 8 seconds. The tin re-flow causes the solder mask to wrinkle. This is the same phenomenon as observed with the mask over solder.
Legends are best applied after tin plating. The problem with legends applied prior to tin plating is limited to where legends are applied directly to a copper surface. The tin bath tends to lift off legends where they adhere to copper.
If the legend is applied over the epoxy mask or the base material only, no lifting will occur in the tin bath. Legends generally will remain their normal color during 40 minutes exposure to the tin bath. White legend may tint a very pale green, but the color change is almost imperceptible.
The tin plating process of the present invention may be accomplished on circuit boards containing areas of nickel gold plating. The preferred procedure is to first screen a clear mask over the nickel-gold fingers. Then the boards are cleaned in accordance with the pre-cleaning cycle hereinabove discussed and plated with tin. After the tin plate and rinsing procedures, the fingers may be stripped by conventional procedures including Blakeslee strip.
An alternative procedure for tin plating a board containing nickel-gold fingers is to first tape the fingers in the conventional manner. Commonly available platers tape may be used and applied firmly to fingers to avoid solution creepage. The boards are then cleaned in accordance with the pre-cleaning cycle hereinabove described, tin plated, rinsed and finally the tape is removed.
It has been found that high quality solderability has been achieved after exposure of 50-80 millionths inch of tin plate after the following conditions:
(1) Humidity conditioning at 35° C. and 90% relative humidity for 96 hrs;
(2) Baking at 320° F. for 1 hour, or 250° F. for 2 hours or 3 passes through Gas Fired Oven at 250° F. or 120° F. for 3 hours;
(3) Exposure to 35° C. temperature and 90% relative humidity for 10 days.
Additionally, the high quality of solderability provided by this invention extends for long periods of time.
The invention in its broadest aspects is not limited to the specific steps, processes and composition shown and described but departures may be made therefrom within the scope of the accompanying claims without departing from the principles of the invention and without sacrificing its chief advantages.
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The present invention relates to a novel immersion tin bath composition and a novel and improved method of depositing a smooth, even, metallic tin coating over metallic surfaces, providing improved solderability.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to memory access in computer systems, and more specifically, how to control user access to particular areas of memory.
[0003] 2. Description of Related Art
[0004] In a System Area Network (SAN), the hardware provides a message passing mechanism which can be used for Input/Output devices (I/O) and interprocess communications between general computing nodes (IPC). Consumers access SAN message passing hardware by posting send/receive messages to send/receive work queues on a SAN channel adapter (CA). The send/receive work queues (WQ) are assigned to a consumer as a queue pair (QP). The messages can be sent over five different transport types: Reliable Connected (RC), Reliable datagram (RD), Unreliable Connected (UC), Unreliable Datagram (UD), and Raw Datagram (RawD). Consumers retrieve the results of these messages from a completion queue (CQ) through SAN send and receive work completions (WC). The source channel adapter takes care of segmenting outbound messages and sending them to the destination. The destination channel adapter takes care of reassembling inbound messages and placing them in the memory space designated by the destination's consumer. Two channel adapter types are present, a host channel adapter (HCA) and a target channel adapter (TCA). The host channel adapter is used by general purpose computing nodes to access the SAN fabric. Consumers use SAN verbs to access host channel adapter functions. The channel interface (CI) interprets verbs and directly accesses the channel adapter.
[0005] The HCA transfers data received on Infiniband (IB) links directly to its host system main memory and also fetches data from system main memory to be transmitted on these IB links. Currently, there are no mechanisms to provide protection against unauthorized access of this memory or to point to specific areas (regions and windows) of memory, each of which uses its own translation tables to translate the virtual addresses that reference this memory into the real addresses that the CI hardware needs to directly access it.
[0006] Therefore, it would be desirable to have mechanisms to provide protection against unauthorized access of host system main memory, as well as mechanisms that point to specific areas of this memory, which translate virtual addresses for the memory into real addresses for the CI hardware.
SUMMARY OF THE INVENTION
[0007] The present invention provides a method, system and program for controlling access to computer memory. The present invention comprises receiving a work request from a user, wherein the work request comprises an index portion and a protection portion. The index portion of the work request is used to locate an element in an address translation and protection table. The protection portion of the work request is then compared with a protection key in the table element, and access to memory is granted only if the protection portion and protection key match.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] 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 objectives 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:
[0009] [0009]FIG. 1 is a diagram of a network computing system is illustrated in accordance with a preferred embodiment of the present invention;
[0010] [0010]FIG. 2 is a functional block diagram of a host processor node in accordance with a preferred embodiment of the present invention;
[0011] [0011]FIG. 3 is a diagram of a host channel adapter in accordance with a preferred embodiment of the present invention;
[0012] [0012]FIG. 4 is a diagram illustrating processing of work requests in accordance with a preferred embodiment of the present invention;
[0013] [0013]FIG. 5 is an illustration of a data packet in accordance with a preferred embodiment of the present invention;
[0014] [0014]FIG. 6 depicts a schematic diagram illustrating memory access through a Protection/Translation Table in accordance with the present invention;
[0015] [0015]FIG. 7 depicts a flowchart illustrating memory access through a Protection/Translation Table in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] The present invention provides a distributed computing system having end nodes, switches, routers, and links interconnecting these components. Each end node uses send and receive queue pairs to transmit and receives messages. The end nodes segment the message into packets and transmit the packets over the links. The switches and routers interconnect the end nodes and route the packets to the appropriate end node. The end nodes reassemble the packets into a message at the destination.
[0017] With reference now to the figures and in particular with reference to FIG. 1, a diagram of a network global change computing system is illustrated in accordance with a preferred embodiment of the present invention. The distributed computer system represented in FIG. 1 takes the form of a system area network (SAN) 100 and is provided merely for illustrative purposes, and the embodiments of the present invention described below can be implemented on computer systems of numerous other types and configurations. For example, computer systems implementing the present invention can range from a small server with one processor and a few input/output (I/O) adapters to massively parallel supercomputer systems with hundreds or thousands of processors and thousands of I/O adapters. Furthermore, the present invention can be implemented in an infrastructure of remote computer systems connected by an internet or intranet.
[0018] SAN 100 is a high-bandwidth, low-latency network interconnecting nodes within the distributed computer system. A node is any component attached to one or more links of a network and forming the origin and/or destination of messages within the network. In the depicted example, SAN 100 includes nodes in the form of host processor node 102 , host processor node 104 , redundant array independent disk (RAID) subsystem node 106 , and I/O chassis node 108 . The nodes illustrated in FIG. 1 are for illustrative purposes only, as SAN 100 can connect any number and any type of independent processor nodes, I/O adapter nodes, and I/O device nodes. Any one of the nodes can function as an endnode, which is herein defined to be a device that originates or finally consumes messages or frames in SAN 100 .
[0019] In one embodiment of the present invention, an error handling mechanism in distributed computer systems is present in which the error handling mechanism allows for reliable connection or reliable datagram communication between end nodes in a distributed computing system, such as SAN 100 .
[0020] A message, as used herein, is an application-defined unit of data exchange, which is a primitive unit of communication between cooperating processes. A packet is one unit of data encapsulated by a networking protocol headers and/or trailer. The headers generally provide control and routing information for directing the frame through SAN. The trailer generally contains control and cyclic redundancy check (CRC) data for ensuring packets are not delivered with corrupted contents.
[0021] SAN 100 contains the communications and management infrastructure supporting both I/O and interprocessor communications (IPC) within a distributed computer system. The SAN 100 shown in FIG. 1 includes a switched communications fabric 116 , which allows many devices to concurrently transfer data with high-bandwidth and low latency in a secure environment. Endnodes can communicate over multiple ports and utilize multiple paths through the SAN fabric. The multiple ports and paths through the SAN shown in FIG. 1 can be employed for fault tolerance and increased bandwidth data transfers.
[0022] The SAN 100 in FIG. 1 includes switch 112 , switch 114 , switch 146 , and router 117 . A switch is a device that connects multiple links together and allows routing of packets from one link to another link within a subnet using a small header Destination Local Identifier (DLID) field. A router is a device that connects multiple subnets together and is capable of routing frames from one link in a first subnet to another link in a second subnet using a large header Destination Globally Unique Identifier (DGUID).
[0023] In one embodiment, a link is a full duplex channel between any two network fabric elements, such as endnodes, switches, or routers. Example of suitable links include, but are not limited to, copper cables, optical cables, and printed circuit copper traces on backplanes and printed circuit boards.
[0024] For reliable service types, endnodes, such as host processor endnodes and I/O adapter endnodes, generate request packets and return acknowledgment packets. Switches and routers pass packets along, from the source to the destination. Except for the variant CRC trailer field which is updated at each stage in the network, switches pass the packets along unmodified. Routers update the variant CRC trailer field and modify other fields in the header as the packet is routed.
[0025] In SAN 100 as illustrated in FIG. 1, host processor node 102 , host processor node 104 , and I/O chassis 108 include at least one channel adapter (CA) to interface to SAN 100 . In one embodiment, each channel adapter is an endpoint that implements the channel adapter interface in sufficient detail to source or sink packets transmitted on SAN fabric 100 . Host processor node 102 contains channel adapters in the form of host channel adapter 118 and host channel adapter 120 . Host processor node 104 contains host channel adapter 122 and host channel adapter 124 . Host processor node 102 also includes central processing units 126 - 130 and a memory 132 interconnected by bus system 134 . Host processor node 104 similarly includes central processing units 136 - 140 and a memory 142 interconnected by a bus system 144 .
[0026] Host channel adapters 118 and 120 provide a connection to switch 112 while host channel adapters 122 and 124 provide a connection to switches 112 and 114 .
[0027] In one embodiment, a host channel adapter is implemented in hardware. In this implementation, the host channel adapter hardware offloads much of central processing unit and I/O adapter communication overhead. This hardware implementation of the host channel adapter also permits multiple concurrent communications over a switched network without the traditional overhead associated with communicating protocols. In one embodiment, the host channel adapters and SAN 100 in FIG. 1 provide the I/O and interprocessor communications (IPC) consumers of the distributed computer system with zero processor-copy data transfers without involving the operating system kernel process, and employs hardware to provide reliable, fault tolerant communications.
[0028] As indicated in FIG. 1, router 116 is coupled to wide area network (WAN) and/or local area network (LAN) connections to other hosts or other routers.
[0029] The I/O chassis 108 in FIG. 1 include an I/O switch 146 and multiple I/O modules 148 - 156 . In these examples, the I/O modules take the form of adapter cards. Example adapter cards illustrated in FIG. 1 include a SCSI adapter card for I/O module 148 ; an adapter card to fiber channel hub and fiber channel-arbitrated loop (FC-AL) devices for I/O module 152 ; an ethernet adapter card for I/O module 150 ; a graphics adapter card for I/O module 154 ; and a video adapter card for I/O module 156 . Any known type of adapter card can be implemented. I/O adapters also include a switch in the I/O adapter backplane to couple the adapter cards to the SAN fabric. These modules contain target channel adapters 158 - 166 .
[0030] In this example, RAID subsystem node 106 in FIG. 1 includes a processor 168 , a memory 170 , a target channel adapter (TCA) 172 , and multiple redundant and/or striped storage disk unit 174 . Target channel adapter 172 can be a fully functional host channel adapter.
[0031] SAN 100 handles data communications for I/O and interprocessor communications. SAN 100 supports high-bandwidth and scalability required for I/O and also supports the extremely low latency and low CPU overhead required for interprocessor communications. User clients can bypass the operating system kernel process and directly access network communication hardware, such as host channel adapters, which enable efficient message passing protocols. SAN 100 is suited to current computing models and is a building block for new forms of I/O and computer cluster communication. Further, SAN 100 in FIG. 1 allows I/O adapter nodes to communicate among themselves or communicate with any or all of the processor nodes in distributed computer system. With an I/O adapter attached to the SAN 100 , the resulting I/O adapter node has substantially the same communication capability as any host processor node in SAN 100 .
[0032] Turning next to FIG. 2, a functional block diagram of a host processor node is depicted in accordance with a preferred embodiment of the present invention. Host processor node 200 is an example of a host processor node, such as host processor node 102 in FIG. 1. In this example, host processor node 200 shown in FIG. 2 includes a set of consumers 202 - 208 , which are processes executing on host processor node 200 . Host processor node 200 also includes channel adapter 210 and channel adapter 212 . Channel adapter 210 contains ports 214 and 216 while channel adapter 212 contains ports 218 and 220 . Each port connects to a link. The ports can connect to one SAN subnet or multiple SAN subnets, such as SAN 100 in FIG. 1. In these examples, the channel adapters take the form of host channel adapters.
[0033] Consumers 202 - 208 transfer messages to the SAN via the verbs interface 222 and message and data service 224 . A verbs interface is essentially an abstract description of the functionality of a host channel adapter. An operating system may expose some or all of the verb functionality through its programming interface. Basically, this interface defines the behavior of the host. Additionally, host processor node 200 includes a message and data service 224 , which is a higher level interface than the verb layer and is used to process messages and data received through channel adapter 210 and channel adapter 212 . Message and data service 224 provides an interface to consumers 202 - 208 to process messages and other data.
[0034] With reference now to FIG. 3, a diagram of a host channel adapter is depicted in accordance with a preferred embodiment of the present invention. Host channel adapter 300 shown in FIG. 3 includes a set of queue pairs (QPs) 302 - 310 , which are used to transfer messages to the host channel adapter ports 312 - 316 . Buffering of data to host channel adapter ports 312 - 316 is channeled through virtual lanes (VL) 318 - 334 where each VL has its own flow control. Subnet manager configures channel adapters with the local addresses for each physical port, i.e., the port's LID. Subnet manager agent (SMA) 336 is the entity that communicates with the subnet manager for the purpose of configuring the channel adapter. Memory translation and protection (MTP) 338 is a mechanism that translates virtual addresses to physical addresses and to validate access rights. Direct memory access (DMA) 340 provides for direct memory access operations using memory 340 with respect to queue pairs 302 - 310 .
[0035] A single channel adapter, such as the host channel adapter 300 shown in FIG. 3, can support thousands of queue pairs. By contrast, a target channel adapter in an I/O adapter typically supports a much smaller number of queue pairs.
[0036] Each queue pair consists of a send work queue (SWQ) and a receive work queue. The send work queue is used to send channel and memory semantic messages. The receive work queue receives channel semantic messages. A consumer calls an operating-system specific programming interface, which is herein referred to as verbs, to place work requests (WRs) onto a work queue.
[0037] With reference now to FIG. 4, a diagram illustrating processing of work requests is depicted in accordance with a preferred embodiment of the present invention. In FIG. 4, a receive work queue 400 , send work queue 402 , and completion queue 404 are present for processing requests from and for consumer 406 . These requests from consumer 406 are eventually sent to hardware 408 . In this example, consumer 406 generates work requests 410 and 412 and receives work completion 414 . As shown in FIG. 4, work requests placed onto a work queue are referred to as work queue elements (WQEs).
[0038] Send work queue 402 contains work queue elements (WQEs) 422 - 428 , describing data to be transmitted on the SAN fabric. Receive work queue 400 contains work queue elements (WQEs) 416 - 420 , describing where to place incoming channel semantic data from the SAN fabric. A work queue element is processed by hardware 408 in the host channel adapter.
[0039] The verbs also provide a mechanism for retrieving completed work from completion queue 404 . As shown in FIG. 4, completion queue 404 contains completion queue elements (CQEs) 430 - 436 . Completion queue elements contain information about previously completed work queue elements. Completion queue 404 is used to create a single point of completion notification for multiple queue pairs. A completion queue element is a data structure on a completion queue. This element describes a completed work queue element. The completion queue element contains sufficient information to determine the queue pair and specific work queue element that completed. A completion queue context is a block of information that contains pointers to, length, and other information needed to manage the individual completion queues.
[0040] Example work requests supported for the send work queue 402 shown in FIG. 4 are as follows. A send work request is a channel semantic operation to push a set of local data segments to the data segments referenced by a remote node's receive work queue element. For example, work queue element 428 contains references to data segment 4 438 , data segment 5 440 , and data segment 6 442 . Each of the send work request's data segments contains a virtually contiguous memory region. The virtual addresses used to reference the local data segments are in the address context of the process that created the local queue pair.
[0041] A remote direct memory access (RDMA) read work request provides a memory semantic operation to read a virtually contiguous memory space on a remote node. A memory space can either be a portion of a memory region or portion of a memory window. A memory region references a previously registered set of virtually contiguous memory addresses defined by a virtual address and length. A memory window references a set of virtually contiguous memory addresses which have been bound to a previously registered region.
[0042] The RDMA Read work request reads a virtually contiguous memory space on a remote endnode and writes the data to a virtually contiguous local memory space. Similar to the send work request, virtual addresses used by the RDMA Read work queue element to reference the local data segments are in the address context of the process that created the local queue pair. For example, work queue element 416 in receive work queue 400 references data segment 1 444 , data segment 2 446 , and data segment 448 . The remote virtual addresses are in the address context of the process owning the remote queue pair targeted by the RDMA Read work queue element.
[0043] A RDMA Write work queue element provides a memory semantic operation to write a virtually contiguous memory space on a remote node. The RDMA Write work queue element contains a scatter list of local virtually contiguous memory spaces and the virtual address of the remote memory space into which the local memory spaces are written.
[0044] An Atomic Operation work queue element provides a memory semantic operation to perform an atomic operation on a remote word. The Atomic Operation work queue element is a combined RDMA Read, Modify, and RDMA Write operation. The Atomic Operation work queue element can support several read-modify-write operations, such as Compare and Swap if equal.
[0045] A bind (unbind) remote access key (R_Key) work queue element provides a command to the host channel adapter hardware to modify (destroy) a memory window by associating (disassociating) the memory window to a memory region. The R_Key is part of each RDMA access and is used to validate that the remote process has permitted access to the buffer.
[0046] In one embodiment, receive work queue 400 shown in FIG. 4 only supports one type of work queue element, which is referred to as a receive work queue element. The receive work queue element provides a channel semantic operation describing a local memory space into which incoming send messages are written. The receive work queue element includes a scatter list describing several virtually contiguous memory spaces. An incoming send message is written to these memory spaces. The virtual addresses are in the address context of the process that created the local queue pair.
[0047] For interprocessor communications, a user-mode software process transfers data through queue pairs directly from where the buffer resides in memory. In one embodiment, the transfer through the queue pairs bypasses the operating system and consumes few host instruction cycles. Queue pairs permit zero processor-copy data transfer with no operating system kernel involvement. The zero processor-copy data transfer provides for efficient support of high-bandwidth and low-latency communication.
[0048] When a queue pair is created, the queue pair is set to provide a selected type of transport service. In one embodiment, a distributed computer system implementing the present invention supports four types of transport services.
[0049] Reliable and Unreliable connected services associate a local queue pair with one and only one remote queue pair. Connected services require a process to create a queue pair for each process which is to communicate over the SAN fabric. Thus, if each of N host processor nodes contain P processes, and all P processes on each node wish to communicate with all the processes on all the other nodes, each host processor node requires P 2 ×(N−1) queue pairs. Moreover, a process can connect a queue pair to another queue pair on the same host channel adapter.
[0050] Reliable datagram service associates a local end-end (EE) context with one and only one remote end-end context. The reliable datagram service permits a client process of one queue pair to communicate with any other queue pair on any other remote node. At a receive work queue, the reliable datagram service permits incoming messages from any send work queue on any other remote node. The reliable datagram service greatly improves scalability because the reliable datagram service is connectionless. Therefore, an endnode with a fixed number of queue pairs can communicate with far more processes and endnodes with a reliable datagram service than with a reliable connection transport service. For example, if each of N host processor nodes contain P processes, and all P processes on each node wish to communicate with all the processes on all the other nodes, the reliable connection service requires P 2 ×(N−1) queue pairs on each node. By comparison, the connectionless reliable datagram service only requires P queue pairs+(N−1) EE contexts on each node for exactly the same communications.
[0051] The unreliable datagram service is connectionless. The unreliable datagram service is employed by management applications to discover and integrate new switches, routers, and endnodes into a given distributed computer system. The unreliable datagram service does not provide the reliability guarantees of the reliable connection service and the reliable datagram service. The unreliable datagram service accordingly operates with less state information maintained at each endnode.
[0052] Turning next to FIG. 5, an illustration of a data packet is depicted in accordance with a preferred embodiment of the present invention. Message data 500 contains data segment 1 502 , data segment 2 504 , and data segment 3 506 , which are similar to the data segments illustrated in FIG. 4. In this example, these data segments form a packet 508 , which is placed into packet payload 510 within data packet 512 . Additionally, data packet 512 contains CRC 514 , which is used for error checking. Additionally, routing header 516 and transport header 518 are present in data packet 512 . Routing header 516 is used to identify source and destination ports for data packet 512 . Transport header 518 in this example specifies the destination queue pair for data packet 512 . Additionally, transport header 518 also provides information such as the operation code, packet sequence number, and partition for data packet 512 . The operating code identifies whether the packet is the first, last, intermediate, or only packet of a message. The operation code also specifies whether the operation is a send RDMA write, read, or atomic. The packet sequence number is initialized when communications is established and increments each time a queue pair creates a new packet. Ports of an endnode may be configured to be members of one or more possibly overlapping sets called partitions.
[0053] Each memory region has an associated Address Translation Table (ATT). The entries in the ATT are real addresses of the pages that make up part of the memory region. The entries are arranged in ascending order corresponding to the incrementing virtual address associated with the memory region. When the HCA hardware translates from a virtual address to a real address, it indexes into the ATT based on the virtual address offset into the memory region.
[0054] Both memory regions and memory windows are accessed through a Protection/Translation Table (PTT). Each memory window belongs to a memory region and defines a portion (or subset) of the region. For memory regions, each PTT Element contains a real address pointer to the beginning of each ATT in main memory. For memory windows, each PTT Element contains a pointer to the associated memory region. Also, each access to main memory includes either a Local Key (L_Key) or a Remote Key (R_Key) that is supplied by the user. The L_Keys and R_Keys are divided into two portions. The first portion is called the index and is used to index into the PTT, and the second portion is a protection key. The user provides the L_Key and R_Key and the HCA hardware uses the keys to find the PTT Element. Within each PTT Element is a protection key, and the HCA hardware compares this protection key to the second portion of the L_Key or R_Key. If the protection keys match, memory access may be given to the user depending on the particular access rights requested (i.e. Read, Write, or Atomic operation).
[0055] Referring to FIG. 6, a schematic diagram illustrating memory access through a Protection/Translation Table is depicted in accordance with the present invention. The hardware structure in FIG. 6 is part of a HCA. The HCA accesses main memory on behalf of its users in two cases. First, local users from the host system (the one to which the HCA is attached) supply work requests that are comprised of virtual addresses and byte counts. Collectively, these addresses and lengths are called scatter/gather lists. All access to main memory for a particular work request must be from the same memory region, and therefore use the same Address Translation Table (ATT). The user supplies a L_Key with each work request.
[0056] A second source for main memory access is from external users who are performing Remote Direct Memory Access (RDMA) and Atomic operations. These accesses may be for either a memory region or a portion of a region (memory window). In either case, the HCA translates these addresses using the same translation mechanisms that are used for local accesses. However, in this case, the external user supplies a R_Key for the incoming packets.
[0057] Referring to FIG. 7, a flowchart illustrating memory access through a Protection/Translation Table is depicted in accordance with the present invention. FIG. 6 shows that the user (internal or external) 604 supplies a Key (L_Key or R_Key) 602 to the HCA hardware when the user wants access to main memory (step 701 ). The Key 602 is divided into two portions: the index portion 602 a and the protection portion 602 b. The HCA hardware has a Base Real Address Register (BRAR) 606 that points to the beginning of the Protection/Translation Table (PTT) 610 which is in either main memory or HCA local memory (depending on the specific implementation). At the beginning of each access to main memory, the HCA shifts the Key index portion 602 a to the left by the number of bits required for each PTT Element 612 (step 702 ). This number is the power of 2 representing the size of the PTT in bytes. For example, if each PTT is 64 bytes, the shift operation would be 6 bits (2 to the 6th power). The HCA then adds this number to the BRAR 606 using adder 608 (step 703 ). The resulting composite address is the base address (the first byte) of the PTT Element 612 in main or local memory for the memory region or window.
[0058] The HCA then uses this address from adder 608 to fetch the PTT Element 612 from memory (step 704 ). Within each PTT Element 612 is a protection key 614 , along with other validity and access rights information.
[0059] The HCA hardware first checks that the index 602 a is valid (step 705 ), meaning the corresponding PTT 610 actually exists. This check is performed because empty, invalid or unused PTT's might be interspersed among the valid ones. If the index 602 a is valid, the HCA then uses the comparator hardware 616 to compare the L_Key protection portion 602 b to the protection key 614 in the PTT Element 612 (step 706 ). If the comparator 616 determines that the protection keys 602 b and 614 match (step 707 ), the access rights are granted to the user (step 708 ). If protection keys 602 b and 614 do not match, access is denied (step 709 ). Finally, the PTT Element 612 also contains specific access rights information describing the types of main memory operation that the user is allowed (i.e. Read, Write, Atomic operations).
[0060] It is important to note that while the present invention has been described in the context of a fully functioning data processing system, those of ordinary skill in the art will appreciate that the processes of the present invention are capable of being distributed in the form of a computer readable medium of instructions and a variety of forms and that the present invention applies equally regardless of the particular type of signal bearing media actually used to carry out the distribution. Examples of computer readable media include recordable-type media, such as a floppy disk, a hard disk drive, a RAM, CD-ROMs, DVD-ROMs, and transmission-type media, such as digital and analog communications links, wired or wireless communications links using transmission forms, such as, for example, radio frequency and light wave transmissions. The computer readable media may take the form of coded formats that are decoded for actual use in a particular data processing system.
[0061] The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
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A method, system and program for controlling access to computer memory are provided. The present invention comprises receiving a work request from a user, wherein the work request comprises an index portion and a protection portion. The index portion of the work request is used to locate an element in an address translation and protection table. The protection portion of the work request is then compared with a protection key in the table element, and access to memory is granted only if the protection portion and protection key match.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of application Ser. No. 10/944,661, now U.S. Pat. No. 7,118,829 to Leising et al., which is continuation-in-part of application Ser. No. 10/004,995, now U.S. Pat. No. 6,797,017 to Leising et al., which claims priority on provisional application Ser. No. 60/254,918, filed Dec. 12, 2000.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to the conversion of chemical energy to electrical energy. More particularly, this invention relates to the preparation of an improved cathode active material for non-aqueous lithium electrochemical cells, and still more particularly, a cathode active ε-phase silver vanadium oxide (SVO, Ag 2 V 4 O 11 ) prepared using a γ-phase silver vanadium oxide (Ag 1.2 V 3 O 8.1 ) starting material. The product cathode active material can be used in an implantable electrochemical cell, for example of the type powering a cardiac defibrillator, where the cell may run under a light load for significant periods interrupted from time to time by high rate pulse discharges.
[0004] The reaction of γ-phase SVO with a source of silver produces ε-phase SVO that possesses a lower surface area than SVO produced from other vanadium-containing starting materials. The relatively low surface area of this new ε-phase SVO material results in greater long-term stability for the cathode active material in comparison to other forms of SVO with higher specific surfaces areas.
[0005] 2. Prior Art
[0006] The prior art discloses many processes for manufacturing SVO; however, they result in a product with greater surface area than the material prepared by the current invention.
[0007] Specifically, U.S. Pat. Nos. 4,310,609 and 4,391,729, both to Liang et al., disclose the preparation of silver vanadium oxide by a thermal decomposition reaction of silver nitrate with vanadium oxide conducted under an air atmosphere. This decomposition reaction is further detailed in the publication: Leising, R. A.; Takeuchi, E. S. Chem. Mater. 1993, 5, 738-742, where the synthesis of SVO from silver nitrates and vanadium oxide under an air atmosphere is presented as a function of temperature. In another reference: Leising, R. A.; Takeuchi, E. S. Chem. Mater. 1994, 6, 489-495, the synthesis of SVO from different silver precursor materials (silver nitrate, silver nitrite, silver oxide, silver vanadate, and silver carbonate) is described. The product active materials of this latter publication are consistent with the formation of a mixture of SVO phases prepared under argon, which is not solely ε-phase Ag 2 V 4 O 11 .
[0008] Also, the preparation of SVO from silver oxide and vanadium oxide is well documented in the literature. In the publications: Fleury, P.; Kohlmuller, R. C. R. Acad. Sci. Paris 1966, 262C, 475-477, and Casalot, A.; Pouchard, M. Bull Soc. Chim. Fr. 1967, 3817-3820, the reaction of silver oxide with vanadium oxide is described. Wenda, E. J. Thermal Anal. 1985, 30, 89-887, present the phase diagram of the V 2 O 5 -Ag 2 O system in which the starting materials are heated under oxygen to form SVO, among other materials. Thus, Fleury and Kohlmuller teach that the heat treatment of starting materials under a non-oxidizing atmosphere (such as argon) results in the formation of SVO with a reduced silver content.
[0009] U.S. Pat. Nos. 5,955,218 and 6,130,005, both to Crespi et al., relate to heat-treating silver vanadium oxide materials, for example, γ-phase SVO to form decomposition-produced SVO (dSVO). In these patents, thermal decomposition SVO prepared according to the previously discussed U.S. Pat. Nos. 4,310,609 and 4,391,729 is heated under an air atmosphere at a somewhat lower temperature of 360° C. However, the '218 and '005 patents to Crespi et al. demonstrate that adding a second heat treatment step increases the crystallinity of the resulting active material. The present invention is concerned with the product active material's surface area, and not necessarily its crystallinity.
[0010] U.S. Pat. No. 5,221,453 to Crespi teaches a method for making an electrochemical cell containing SVO, in which the cathode active material is prepared by a chemical addition reaction of an admixed 2:1 mole ratio of AgVO 3 and V 2 O 5 heated in the range of 300° C. to 700° C. for a period of 5 to 24 hours. Crespi does not discuss γ-phase SVO in the context of this invention. Therefore, this process could not manufacture the ε-phase material described by the current invention.
[0011] Also, U.S. Pat. No. 5,895,733 to Crespi et al. shows a method for synthesizing SVO by using AgO and a vanadium oxide as starting materials. However, the result is not a low surface area ε-phase SVO cathode material, as disclosed in the current invention.
[0012] U.S. Pat. No. 5,545,497 to Takeuchi et al. teaches cathode materials having the general formula of Ag x V 2 O y . Suitable materials comprise a β-phase SVO having in the general formula x=0.35 and y=5.18 and a γ-phase SVO having x=0.74 and y=5.37, or a mixture of the phases thereof. Such SVO materials are produced by the thermal decomposition of a silver salt in the presence of vanadium pentoxide. In addition, U.S. Pat. No. 6,171,729 to Gan et al. shows exemplary alkali metal/solid cathode electrochemical cells in which the cathode may be an SVO of β-, γ- or ε-phase materials. However, none of Gan et al.'s methods are capable of producing a low surface area ε-phase cathode material, as per the current invention.
[0013] Therefore, based on the prior art, there is a need to develop a process for the synthesis of mixed metal oxides, including silver vanadium oxide, having a relatively low surface area. An example is a low surface area SVO prepared using a silver-containing compound and γ-phase SVO as starting materials. The product ε-phase SVO is a cathode active material useful for non-aqueous electrochemical cells having enhanced characteristics, including the high pulse capability necessary for use with cardiac defibrillators.
SUMMARY OF THE INVENTION
[0014] The current invention relates to the preparation of an improved cathode active material for non-aqueous lithium electrochemical cells, and in particular, a cathode active material that contains ε-phase SVO prepared using a γ-phase SVO starting material. The reaction of γ-phase SVO with a source of silver produces ε-phase SVO possessing a lower surface area than ε-phase SVO produced from other vanadium-containing starting materials. The present synthesis technique is not, however, limited to silver salts since salts of copper, magnesium and manganese can be used to produce relatively low surface are metal oxide active materials as well. The relatively low surface area of the ε-phase SVO material provides an advantage in greater long-term stability when used as an active cathode material compared to SVO with a higher specific surface area.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] The current invention discloses that reacting a γ-phase SVO material with a source of silver, or other suitable metal salt, produces pure ε-phase SVO (Ag 2 V 4 O 11 ). This product material possesses a relatively lower surface area in comparison to active materials synthesized by a thermal decomposition reaction under an oxidizing atmosphere. Decreased surface area is an unexpected result.
[0016] The thermal reaction of silver nitrate with vanadium oxide under an air atmosphere is a typical example of the preparation of silver vanadium oxide by a decomposition reaction. This reaction is set forth below in Equation 1:
2AgNO 3 +2V 2 O 5 →Ag 2 V 4 O 11 +2NO x (1)
[0017] The physical characteristics of SVO material (i.e. particle morphology, surface area, crystallinity, etc.) produced by this reaction are dependent on the temperature and time of reaction. In addition, the reaction environment has a dramatic effect on the product material. The same reaction of silver nitrate with vanadium oxide conducted under an argon atmosphere is depicted below in Equation 2:
2AgNO 3 +2V 2 O 5 →AgVO 3 +Ag 1.2 V 3 O 8 +2NO x (2)
[0018] Thus, the synthesis of SVO under an inert atmosphere results in the formation of a mixture of silver vanadate (AgVO 3 ) and γ-phase SVO (Ag 1.2 V 3 O 8 ). This is described in the above-referenced publication by Leising, R. A.; Takeuchi, E. S. Chem. Mater. 1994, 6, 489-495. As reported by Leising et al., a mixture of material phases is less suitable than a single ε-phase SVO (Ag 2 V 4 O 11 ) as a cathode active material for lithium electrochemical cells. For this reason, argon is typically not preferred for synthesis of SVO cathode active material.
[0019] A more benign preparation technique for producing ε-phase SVO from vanadium oxide and silver carbonate (Ag 2 CO 3 ) according to Equation 3 below, results in the release of CO 2 gas, which is a nontoxic byproduct. However, the specific surface area of the product SVO is also higher than the surface area of SVO prepared from silver nitrate. This is shown below in Table 1.
Ag 2 CO 3 +2V 2 O 5 →Ag 2 V 4 O 11 +CO 2 (3)
[0020] Thus, a synthesis technique for SVO using vanadium oxide and either silver oxide or silver carbonate, or other preferred metal salts, while eliminating the formation of toxic NO x byproduct, results in an SVO material with a higher specific surface area than SVO produced from vanadium oxide and silver nitrate.
TABLE 1 Specific Surface Area of ε-Phase SVO Synthesis BET Surface Starting Materials Temperature Area V 2 O 5 + AgNO 3 500° C. 0.42 m 2 /gram V 2 O 5 + 0.5Ag 2 O 500° C. 0.64 m 2 /gram V 2 O 5 + 0.5Ag 2 CO 3 500° C. 0.81 m 2 /gram Ag 1.2 V 3 O 8.1 + 0.15Ag 2 O 500° C. 0.54 m 2 /gram Ag 1.2 V 3 O 8.1 + 0.15Ag 2 CO 3 500° C. 0.44 m 2 /gram
[0021] The present invention is an alternate preparation synthesis that does not produce noxious by-products, such as NO x and, additionally, results in an active material with a desirable relatively low surface area. Benefits attributed to the present synthesis process for the formation of a cathode active material are illustrated in the following examples.
EXAMPLE 1
[0022] In contrast to the prior art syntheses described above, SVO of the present invention is prepared using γ-phase SVO (Ag 1.2 V 3 O 8.1 ) as a starting material instead of V 2 O 5 . In particular, a 12.90-gram sample of Ag 1.2 V 3 O 8.1 was combined with a 1.09-gram sample of Ag 2 O, and heated to 500° C. under a flowing air atmosphere for about 16 hours. The sample was then cooled, mixed and reheated under a flowing air atmosphere at about 500° C. for about 24 hours. At this point, the material was cooled and analyzed by x-ray powder diffraction and BET surface area measurements. The x-ray powder diffraction data confirmed the formation of ε-phase SVO (Ag 2 V 4 O 11 ). The material displayed a BET surface area of 0.54 m 2 /gram.
COMPARATIVE EXAMPLE 1
[0023] As a comparison, SVO was prepared by a prior art combination reaction. In particular, a 9.00-gram sample of V 2 O 5 was combined with a 5.73-gram sample of Ag 2 O, and heated to about 500° C. under a flowing air atmosphere for about 16 hours. The sample was then cooled, mixed and reheated under a flowing air atmosphere at about 500° C. for about 24 hours. At this point the material was cooled and analyzed by x-ray powder diffraction and BET surface area measurements. The material displayed a BET surface area of 0.64 m 2 /gram, which is significantly higher than the specific surface area of the material prepared in Example 1.
EXAMPLE 2
[0024] Epsilon-phase SVO according to the present invention was also prepared using a γ-phase SVO starting material in combination with silver carbonate. In particular, a 5.00-gram sample of Ag 1.2 V 3 O 8.1 was combined with a 0.50-gram sample of Ag 2 CO 3 , and heated to about 500° C. under a flowing air atmosphere for about 16 hours. The sample was then cooled, mixed and reheated under a flowing air atmosphere at about 500° C. for about 24 hours. At this point, the material was cooled and analyzed by x-ray powder diffraction and BET surface area measurements. The x-ray powder diffraction data confirmed the formation of ε-phase SVO (Ag 2 V 4 O 11 ), while the material displayed a BET surface area of 0.44 m 2 /gram.
COMPARATIVE EXAMPLE 2
[0025] As a comparison to Example 2, SVO was prepared using V 2 O 5 and Ag 2 CO 3 . In particular, a 15.00-gram sample of V 2 O 5 was combined with an 11.37-gram sample of Ag 2 CO 3 , and heated to about 450° C. under a flowing air atmosphere for about 16 hours. The sample was then cooled, mixed and reheated under a flowing air atmosphere at about 500° C. for about 24 hours. At this point the material was cooled and analyzed by x-ray powder diffraction and BET surface area measurements. The material displayed a BET surface area of 0.81 m 2 /gram, which is nearly twice the specific surface area of the material prepared in Example 2.
EXAMPLE 3
[0026] Copper silver vanadium oxide or CSVO (Cu 0.2 Ag 0.8 V 2 O 5.6 ) was prepared according to the present invention using γ-phase SVO as a starting material in combination with copper(II) oxide. In particular, a 1.80-gram sample of Ag 1.2 V 3 O 8.1 was combined with a 0.10-gram sample of CuO, and heated to about 450° C. under a flowing air atmosphere for about 16 hours. The sample was then cooled, mixed and reheated under a flowing air atmosphere at about 500° C. for about 24 hours. At this point, the material was cooled and analyzed by BET surface area measurements. The material displayed a BET surface area of 0.31 m 2 /gram.
COMPARATIVE EXAMPLE 3
[0027] As a comparison to the product of Example 3, CSVO was prepared via the prior art decomposition method using V 2 O 5 , Cu(NO 3 ) 2 and AgNO 3 . In particular, a 1.36 gram sample of V 2 O 5 was combined with a 0.99 gram sample of AgNO 3 and a 0.34 gram sample of Cu(NO 3 ) 2 .2.5H 2 O, and heated to about 400° C. under a flowing air atmosphere for about 16 hours. The sample was then cooled, mixed and reheated under a flowing air atmosphere at about 500° C. for about 44 hours. At this point, the product material was cooled and analyzed by BET surface area measurement. The material displayed a BET surface area of 0.45 m 2 /gram, which is significantly higher than the specific surface area of the CSVO material prepared in Example 3. Thus, in addition to the toxic implications of released NO x gas, the preparation of CSVO by the prior art method provides a material with a higher specific surface area than the new preparation technique.
[0028] The above detailed description and examples are intended for the purpose of illustrating the invention, and are not to be construed as limiting. For example, starting materials other than silver oxide and silver carbonate are reacted with γ-phase silver vanadium oxide to form ε-phase silver vanadium compounds. The list includes: silver lactate (AgC 3 H 5 O 3 , T m 120° C.), silver triflate (AgCF 3 SO 3 , T m 286° C.), silver pentafluoropropionate (AgC 3 F 5 O 2 , T m 242° C.), silver laurate (AgC 12 H 23 O 2 , T m 212° C.), silver myristate (AgC 14 H 27 O 2 , T m 211° C.), silver palmitate (AgC 16 H 31 O 2 , T m 209° C.), silver stearate (AgC 18 H 35 O 2 , T m 205° C.), silver vanadate (AgVO 3 , T m 465° C.), copper oxide (CuO, T m 1,446° C.), copper carbonate (Cu 2 Co 3 ), manganese carbonate (MnCO 3 ), manganese oxide (MnO, T m 1,650° C.), magnesium carbonate (MgCO 3 , T d 350° C.), magnesium oxide (MgO, T m 2,826° C.), and combinations and mixtures thereof.
[0029] While the starting materials are described as being heated to a preferred temperature of about 500° C., it is contemplated by the scope of the present invention that suitable heating temperatures range from about 300° C. to about 550° C., depending on the specific starting materials. Also, heating times for both the first and second heating steps range from about 5 hours to about 30 hours. Longer heating times are required for lower heating temperatures. Further, while the present invention has been described in the examples as requiring two heating events with an ambient mixing in between, that is not necessarily imperative. Some synthesis protocols according to the present invention may require one heating step with periodic mixing, or multiple heating events with periodic ambient mixing.
[0030] The product mixed metal oxides according to the present invention include: ε-phase SVO (Ag 2 V 4 O 11 ) CSVO (Cu 0.2 Ag 0.8 V 2 O 5.6 ), MnSVO (Mn 0.2 Ag 0.8 V 2 O 5.8 ), and MgSVO (Mg 0.2 Ag 0.8 V 2 O 5.6 ). The use of the above mixed metal oxides as a cathode active material provides an electrochemical cell that possesses sufficient energy density and discharge capacity required to meet the vigorous requirements of implantable medical devices. These types of cells comprise an anode of a metal selected from Groups IA, IIA and IIIB of the Periodic Table of the Elements. Such anode active materials include lithium, sodium, potassium, etc., and their alloys and intermetallic compounds including, for example, Li—Mg, Li—Si, Li—Al, Li—B and Li—Si—B alloys and intermetallic compounds. The preferred anode comprises lithium. An alternate anode comprises a lithium alloy such as a lithium-aluminum alloy. The greater the amounts of aluminum present by weight in the alloy, however, the lower the energy density of the cell.
[0031] The form of the anode may vary, but preferably the anode is a thin metal sheet or foil of the anode metal, pressed or rolled on a metallic anode current collector, i.e., preferably comprising titanium, titanium alloy or nickel, to form an anode component. Copper, tungsten and tantalum are also suitable materials for the anode current collector. In the exemplary cell of the present invention, the anode component has an extended tab or lead of the same material as the anode current collector, i.e., preferably nickel or titanium, integrally formed therewith such as by welding and contacted by a weld to a cell case of conductive metal in a case-negative electrical configuration. Alternatively, the anode may be formed in some other geometry, such as a bobbin shape, cylinder or pellet to allow an alternate low surface cell design.
[0032] Before the previously described ε-phase active materials are fabrication into a cathode electrode for incorporation into an electrochemical cell, they are preferably mixed with a binder material, such as a powdered fluoro-polymer, more preferably powdered polytetrafluoro-ethylene or powdered polyvinylidene fluoride, present at about 1 to about 5 weight percent of the cathode mixture. Further, up to about 10 weight percent of a conductive diluent is preferably added to the cathode mixture to improve conductivity. Suitable materials for this purpose include acetylene black, carbon black and/or graphite or a metallic powder such as of nickel, aluminum, titanium and stainless steel. The preferred cathode active mixture thus includes a powdered fluoro-polymer binder present at about 3 weight percent, a conductive diluent present at about 3 weight percent and about 94 weight percent of the cathode active material. For example, depending on the application of the electrochemical cell, the range of cathode compositions is from about 99% to about 80%, by weight, ε-phase silver vanadium oxide mixed with carbon graphite and PTFE.
[0033] Cathode components for incorporation into an electrochemical cell according to the present invention may be prepared by rolling, spreading or pressing the cathode active materials onto a suitable current collector selected from the group consisting of stainless steel, titanium, tantalum, platinum, gold, aluminum, cobalt-nickel alloys, nickel-containing alloys, highly alloyed ferritic stainless steel containing molybdenum and chromium, and nickel-, chromium- and molybdenum-containing alloys. The preferred current collector material is titanium and, most preferably, the titanium cathode current collector has a thin layer of graphite/carbon material, iridium, iridium oxide or platinum applied thereto. Cathodes prepared as described above may be in the form of one or more plates operatively associated with at least one or more plates of anode material, or in the form of a strip wound with a corresponding strip of anode material in a structure similar to a “jellyroll”.
[0034] In order to prevent internal short circuit conditions, the cathode is separated from the Group IA, IIA or IIIB anode by a suitable separator material. The separator is of electrically insulative material, and the separator material also is chemically unreactive with the anode and cathode active materials and both chemically unreactive with and insoluble in the electrolyte. In addition, the separator material has a degree of porosity sufficient to allow flow there through of the electrolyte during the electrochemical reaction of the cell. Illustrative separator materials include fabrics woven from fluoropolymeric fibers including polyvinylidine fluoride, polyethylenetetrafluoroethylene, and polyethylenechlorotrifluoroethylene used either alone or laminated with a fluoropolymeric microporous film, non-woven glass, polypropylene, polyethylene, glass fiber materials, ceramics, a polytetrafluoroethylene membrane commercially available under the designation ZITEX (Chemplast Inc.), a polypropylene membrane commercially available under the designation CELGARD (Celanese Plastic Company, Inc.) and a membrane commercially available under the designation DEXIGLAS (C. H. Dexter, Div., Dexter Corp.).
[0035] The electrochemical cell of the present invention further includes a nonaqueous, ionically conductive electrolyte that serves as a medium for migration of ions between the anode and the cathode electrodes during the electrochemical reactions of the cell. The electrochemical reaction at the electrodes involves conversion of ions in atomic or molecular forms that migrate from the anode to the cathode. Thus, nonaqueous electrolytes suitable for the present invention are substantially inert to the anode and cathode materials, and they exhibit those physical properties necessary for ionic transport, namely, low viscosity, low surface tension and wettability.
[0036] A suitable electrolyte has an inorganic, ionically conductive salt dissolved in a nonaqueous solvent, and more preferably, the electrolyte includes an ionizable alkali metal salt dissolved in a mixture of aprotic organic solvents comprising a low viscosity solvent and a high permittivity solvent. The inorganic, ionically conductive salt serves as the vehicle for migration of the anode ions to intercalate or react with the cathode active material. Preferably, the ion forming alkali metal salt is similar to the alkali metal comprising the anode.
[0037] In the case of an anode comprising lithium, the alkali metal salt of the electrolyte is a lithium based salt. Known lithium salts that are useful as a vehicle for transport of alkali metal ions from the anode to the cathode include LiPF 6 , LiBF 4 , LiAsF 6 , LiSbF 6 , LiClO 4 , LiO 2 , LiAlCl 4 , LiGaCl 4 , LiC(SO 2 CF 3 ) 3 , LiN(SO 2 CF 3 ) 2 , LiSCN, LiO 3 SCF 3 , LiC 6 F 5 SO 3 , LiO 2 CCF 3 , LiSO 6 F, LiB(C 6 H 5 ) 4 , LiCF 3 SO 3 , and mixtures thereof.
[0038] Low viscosity solvents useful with the present invention include esters, linear and cyclic ethers and dialkyl carbonates such as tetrahydrofuran (THF), methyl acetate (MA), diglyme, trigylme, tetragylme, dimethyl carbonate (DMC), 1,2-dimethoxyethane (DME), 1,2-diethoxyethane (DEE), 1-ethoxy,2-methoxyethane (EME), ethyl methyl carbonate, methyl propyl carbonate, ethyl propyl carbonate, diethyl carbonate, dipropyl carbonate, and mixtures thereof. Suitable high permittivity solvents include cyclic carbonates, cyclic esters and cyclic amides such as propylene carbonate (PC), ethylene carbonate (EC), butylene carbonate (BC), acetonitrile, dimethyl sulfoxide, dimethyl, formamide, dimethyl acetamide, γ-valerolactone, γ-butyrolactone (GBL), N-methyl-pyrolidinone (NMP), and mixtures thereof. In the present invention, the preferred anode is lithium metal and the preferred electrolyte is 0.8M to 1.5M LiAsF 6 or LiPF 6 dissolved in a 50:50 mixture, by volume, of propylene carbonate as the preferred high permittivity solvent and 1,2-dimethoxyethane as the preferred low viscosity solvent.
[0039] The preferred form of a primary alkali metal/solid cathode electrochemical cell is a case-negative design wherein the anode is in contact with a conductive metal casing and the cathode contacted to a current collector is the positive terminal. The cathode current collector is in contact with a positive terminal pin via a lead of the same material as the current collector. The lead is welded to both the current collector and the positive terminal pin for electrical contact.
[0040] A preferred material for the casing is titanium although stainless steel, mild steel, nickel-plated mild steel and aluminum are also suitable. The casing header comprises a metallic lid having an opening to accommodate the glass-to-metal seal/terminal pin feedthrough for the cathode electrode. The anode electrode is preferably connected to the case or the lid. An additional opening is provided for electrolyte filling. The casing header comprises elements having compatibility with the other components of the electrochemical cell and is resistant to corrosion. The cell is thereafter filled with the electrolyte solution described hereinabove and hermetically sealed such as by close-welding a titanium plug over the fill hole, but not limited thereto. The cell of the present invention can also be constructed in a case-positive design.
[0041] It is appreciated that various modifications to the inventive concepts described herein may be apparent to those of ordinary skill in the art without departing from the spirit and scope of the present invention as defined by the appended claims.
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The current invention relates to the preparation of an improved cathode active material for non-aqueous lithium electrochemical cell. In particular, the cathode active material comprises ε-phase silver vanadium oxide prepared by using a γ-phase silver vanadium oxide starting material. The reaction of γ-phase SVO with a silver salt produces the novel ε-phase SVO possessing a lower surface area than ε-phase SVO produces from vanadium oxide (V 2 O 5 ) and a similar silver salt as starting materials. Consequently, the low surface area ε-phase SVO material provides an advantage in greater long-term stability in pulse dischargeable cells.
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BACKGROUND OF THE INVENTION
This invention relates to user-controlled interactive computer display systems, specifically to a display system and method for constructing and editing a hierarchical arrangement of information.
PRIOR ART
In a user-controlled interactive computer display system it is desirable to insulate the user from the computer and how the computer itself works. The object is to provide a display system and method that relates directly to the work at hand, allowing the user to learn quickly how to operate the display system, then work efficiently words the completion of his or her task. This is especially important for display systems used by people who have minimal computer experience.
Proven display systems and methods exist for constructing and manipulating textual documents, free-form graphics drawings, and tables of numbers. Such is not the case for hierarchical diagrams or representations such as corporate organization charts, work break-down structures, and decision trees.
Traditional display systems and methods for working with hierarchical representations fall into three groups: editors for an indented or subscripted list of items (such a list scheme is described by Donald E. Knuth, Fundamental Algorithms, Addison-Wesley, 1973), prompting systems that query the user for nodes in the representation one at a time (e.g., Diagram-Master (TM) by Decision Resources), and systems that allow the user to construct a purely graphic image of the representation (draw/paint display systems, e.g., PC Paint Plus (TM) by Mouse Systems Corp.).
These display systems and methods of the prior art have the disadvantage of requiring the user to explicity specify the positional information about a node. This is a time consuming step that must be performed repeatedly as the hierarchy is constructed and edited. The resulting error rate is high.
For applications that require a diagrammatic output such as an organization chart, the trend has been to develop display systems that allow the user to draw an image of the diagram on the display device of the computer. This technique has the advantage of being easy for the inexperienced user to understand because he is simply copying on to the display device a representation from his everyday experience. However, the other prior art systems and methods require a user to maintain the overall image of the diagram in his or her head. This is not any easy task, especially when editing the hierarchy.
Unfortunately, the price paid for ease-of-use is very high. Since the costs to process purely graphic image are prohibitively high, the user is forced to do much of the hard work of positioning the nodes, positioning the descriptive information in the nodes, and drawing the connecting lines. Consequently, the overall speed of draw/paint display systems is very slow. Draw/paint systems have other well known disadvantages: they require specialized and more expensive display hardware (which most users do not possess), editing is limited to copying or erasing then redrawing, and the information the user has painstakingly input cannot be used for other tasks. For example, a user doing an organization chart may want the computer to sum the salaries of the individuals represented in the chart. This is not possible with draw/paint systems of the prior art.
Thus, there exists a need for a new method that is intuitive to learn, quick to use, and flexible in its application.
Accordingly, it is the object of this invention to provide an improved method for displaying a hierarchy that overcomes the disadvantages of the prior art.
In particular, it is an object of the invention to accept information about the nodes of the hierarchy in a way that allows it to be stored in a database. The information can then be used for a variety of purposes once it has been entered. Another object is to place minimal demands on the hardware of the computer display system so that the broadest possible cross-section of equipment can support the invention.
Most importantly, it is an object of this invention to eliminate the need for the user to provide explicit positional information about each node. There should not even be a requirement to know that positional information exists, or how to provide it. By eliminating the need for such an expertise in constructing hierarchies, a broader selection of people can build them. By eliminating the steps associated with providing positional information, hierachies can be constructed and changed much more quickly and accurately.
SUMMARY OF THE INVENTION
A computer display system and method is disclosed that has particular application to the construction and manipulation of hierarchical representations. A computer is programmed to provide an area on the display screen where information about a single, superior node in the representation can be entered and remembered by the computer. Adjacent to this area (below in the present embodiment) another area is created where subordinate nodes can be created, identified and stored by the computer. By using a command key or menu selection in the present embodiment, the user can instantly change the contents of the display to that of any other node above, below, or beside the currently displayed node. In other words, the user can navigate around the representation at will. In such a way, a hierarchical representation can quickly be entered into the computer. The user always sees one node and its subordinate nodes. Subsequent processing can modify the nodes and their relationship to one another by editing their contents, changing their order or interconnections, performing calculations on values assigned to them, and formatting their representation for printed output.
The present invention provides such an improvement in speed, that it can be used to perform "what if" analysis not before possible on hierarchical representations. Users can quickly edit their hierarchy to compare one alternative to another.
DESCRIPTION OF THE DRAWING
FIG. 1 is a block schematic diagram of the preferred embodient of the present invention; and
FIG. 2 is a graphic representation of a frame which displays information about a node and its subordinate nodes; and
FIG. 3 is a graphic representation of a frame which displays information about a staff-level node; and
FIG. 4 is a graphic representation of a frame which displays information about a terminal node at the lowest possible level of the hierarchy; and
FIG. 5 is a graphic representation of a frame with sample information in some of its data-entry fields; and
FIG. 6 is a graphic representation of a display of index information about a sample hierarchy; and
FIG. 7 is a graphic representation of a display of a map of a sample hierarchy; and
FIGS. 8, 8A, 8B, and 8C comprise a logic flow diagram illustrating the operation of the preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For clarity of description only, the invention will be described as embodied to produce common office organization charts. Of course it should be understood changes to the data entry field(s) such as, but not limited to, their: identification label, type (text, numeric only, multiple choice, date only, etc.), size or length, position relative to one another within their area, and quantity can make the invention appropriate for entirely different applications such as work breakdown structures, decision trees, and outlines, etc. The performance of different kinds of operations (such as statistical or arithmetic operations) on the contents of the data entry fields can also make the invention appropriate for entirely different applications.
The following definitions are applicable to the description:
Node
An element that has two types of information associated with it. Positional information that describes its spatial relationship to other nodes and descriptive information that allows it to represent something to an observer.
Hierarchy
A single topmost or root node which has no superior and an indefinite plurality (which can be zero) of subordinate nodes such that each node has one and only one immediate superior node and such that each subordinate node is in some way ordered relative to its sibling nodes (those nodes with the same immediate superior). Thus, the positional information for each node includes, at a minimum, two pieces: superior node and position relative to siblings. This type of hierarchy represents an ordered or plane tree.
Branch
A sub-hierarchy including a node and all of the directly or indirectly connected nodes below it, if any.
Frest
A plurality of hierarchies.
Referring now to FIG. 1, there is shown a schematic diagram of the preferred embodiment of the present invention that includes a central processing unit 11 which is connected to and controls the display device 13 in response to inputs supplied to the CPU 11 via the user's manipulation of the keyboard (or mouse or other input device) 15.
The CPU accesses addresses memory 18 which contains information that is supplied via the keyboard 15, mass storage 27, or network 29 and instructions for manipulation of that information in accordance with the operating sequences of the present invention. These operating sequences are directed toward developing a specific database 17 of hierarchical information under command of the hierarchy processor 19 (described in detail later herein). The hierarchy processor 19 interacts with the CPU 11 to display an image 21 on the display device 13 that can allow a hierarchy to be constructed and changed under control of the user. The image 21 that is displayed includes one or more primary representations of the data as shown in FIG. 2.
This representation is referred to as a frame 74. Each frame is uniquely identified by the positional information of the node whose descriptive information is displayed in the superior node box 40. In this embodiment the frame represents a work group. The term work group refers to an individual manager and the people reporting directly to him or her.
The subordinate nodes box 42 is the lower box in a frame 74. It contains an ordered list (according to the position in which they were entered) of the subordinate nodes (as identified by a subset of the information contained about them in the database) whose superior node identifies the current frame, herein referred to as the current superior node. (It is described below how indirectly connected nodes are in certain conditions listed.) The user can enter as many subordinate nodes as the current superior node has (up to 16 in the present embodiment although the number can be indefinitely large by providing means to scroll or page through additional entries). The subordinate nodes box 42 expands and contracts depending on the number of subordinate nodes. The nodes will appear in a corresponding order on the printed chart as they appear top-to-bottom in the subordinate nodes box 42 on the screen.
The fields for descriptive information, i.e., superior node name field 44, superior node title field 46, and superior node comment field 48, have self explanatory labels such as Name 45, Title 47, and Comment 49. However, they may be used for other information.
The fields for descriptive information, i.e., superior node name abbreviation field 50a, superior node title abbreviation field 50b, and superior node comment abbreviation field 50c (labeled Abbrev 51a, 51b, 51c) are for abbreviations of the information the user enters in the corresponding fields 44, 46, 48. The invention may use these abbreviations when printing the chart if there is difficulty making the chart fit on the page size requested. Entering abbreviations is entirely optional. Once the node has been created, changes to the descriptive information fields only change the descriptive information stored in the database 17 of FIG. 1.
The superior node level field 52, labeled Chart Level 53 contains positional information about a node indicating the node's level in the hierarchy. The top level is defined as 1. The topmost node's immediate subordinate nodes are at level 2 and so on. The superior node level field 52 defaults to a value one greater than the chart level for the current superior node. If the node is to be placed at an even lower level the user can specify a larger number. The user is disallowed from entering a number less than or equal to the level of the node's superior node. The specification of a number different than the default or previous value always involves creation or destruction of nodes. In the present embodiment, nodes invisible to the user (they are never displayed) are created to hold a place at each level of the hierarchy between the superior node and the actual (real-world) subordinate. Correspondingly, said invisible nodes are destroyed if the user reduces the number of intervening levels.
The invention also provides for staff level nodes, i.e., employees. A staff level node is a terminal node that cannot have subordinate nodes, consequently, the staff frame as shown in FIG. 3 is displayed differently on the display device 13. Staff level nodes are identified with an S in the node's level field 71 or 58a. Arbitrarily, the current embodiment has a limit of 99 levels. A node at the 99th level is also a terminal node displayed as shown in FIG. 4.
The value in the superior node line type field 54 of FIG. 2, labeled Line Type 55, indicates whether the current superior node is connected to its superior (in the final printed output) with a solid line (S), a dotted line (D), or no line at all (N). The present embodiment of the invention defaults to a solid line. Display of the superior node line type field 54, and label 55 is suppressed if the hierarchy's topmost node is the current superior node since that node has no node to be connected to. This field is highly peculiar to the application of the present embodiment.
In accordance with the present invention, the subordinate node name field 56a and label 57a, subordinate node level field 58a and label 59a, and subordinate node line type field 60a and label 61a contain a subset of the information describing the subordinate node. The ordinal of the subordinate node 64a shows the subordinate node's order from top-to-bottom starting with 1.
FIG. 5 shows a frame as displayed with sample information in the fields. The potential subordinate node row 62 is the bottom-most row of fields in the subordinate nodes box 42. It is not associated with any existing node and serves as a means as described below to add new nodes. It is displayed unless the maximum number of subordinate nodes is already assigned to the current superior node.
With reference to FIG. 2, the scale 66 allows the user to estimate the length in characters of the information entered into superior node fields 44, 46, and 48. The length of these fields has an impact on the printed size of the chart. The top connecting line 68 is shown if the current superior node has a superior of its own and if the line type of the current superior node is not "None". The top connecting line 68 is dotted if the line type of the current superior node is "Dotted". Staff frames have a side connecting line 69 in place of a top connecting line 68. The side connecting line 69 in FIG. 3 behaves like the top connecting line 68. The box connector 70 graphically connects the superior nodes box 40 and the subordinate nodes box 42. One bottom connecting line 72a is displayed for each subordinate node in the subordinate nodes box 42 that has at least one subordinate node of its own. Lines 68, 69, 70, and 72a help the user reference the frame to a diagram of a hierarchy such as an office organization chart.
Referring now to FIGS. 8A and 8B, there is shown the overall flow through the display system. When the system is loaded into addressable memory 18, it is in the "Main Menu" state. From the "Main Menu" the user can do such things as access the mass storage 27, exit the system, or choose to work on a hierarchy. Under receiving a request from the user to work on a hierarchy there is first a test 81 to ascertain whether a hierarchy exists. If no hierarchy exists, a hierarchy is established by creating a topmost node 83. A topmost node has positional information indicating that it has no superior.
There are a large number of ways to consistently specify the positional information about this topmost node and the other nodes in a hierarchy which, in the present invention, is an ordered or plane tree. The preferred embodiment is a triply-linked data structure wherein pointers are established to a node's superior, leftmost subordinate, and adjacent right sibling. With a triply-linked data structure, a change in the positional information of one node changes the positional information of other nodes. For example, to add a rightmost node to a group of existing siblings, the new node will have null pointers to leftmost subordinate and adjacent right sibling; the pointer to the node's superior will hold the address of the current superior node. Additionally, the new node's left sibling must have its adjacent right sibling pointer changed from null to the address of the new node as entered in the database 17. This approach provides extremely high speed when polling the database 17 (even to find the left adjacent sibling for which there is no pointer is a quick calculation) with some speed penalties when changing the positional information. The trade-off is favorable because polling is an extremely frequent activity while changing the positional information is rare and generally performed when speed is not an issue.
Manipulation of a triply-linked data structure is well covered by the literature (see for example, Knuth, Fundamental Algorithms).
Alternatively, a four-way-linked data structure could be used to describe the positional information of each node. To the three links described above we would add a link to the left adjacent sibling. This would speed operations where the finding the left adjacent sibling was important, but the additional storage overhead and added complexity in changing the positional information may make this alternative data structure less attractive than the embodiment described above. On the other hand, a doubly-linked structure would be sufficient to define our hierarchy (we would give up from the triply-linked structure the pointer to leftmost subordinate), but it is believed the processing burden for many common operations would result in unacceptable performance. Though not favored, these and other data structures can be used to implement the invention.
A memory allocation scheme is used in developing the database 17 according to the present invention. A fixed array of C-language structures which include positional and descriptive information (name, title, comment, etc.) is defined and allocated. Pointers to the elements of this array are used to initialize a stack. A pop routine indicates the next available structure when a node is created. A push routine returns the memory space from a destroyed node back to the available pool of memory space. The C-language function malloc could alternatively be used to allocate and assign memory for the information.
Node creation in the database 17 refers to obtaining a pointer to an available block of memory from the stack and storing the proper positional information at that location. Node destruction refers to erasing the contents of the memory block and pushing the pointer to the block back on the stack. Updating the database, as later discussed, is a more generic operation which includes updating both the positional and descriptive information about the node as required.
Referring again to the flow chart of FIGS. 8A and 8B, at this time, the topmost node has no subordinate nodes or descriptive information about itself (other than default values of information as applicable). The topmost node is designated as the current superior node.
In all cases, a hierarchy 81 now exists and a current superior node has been designated. System flow proceeds to the functional block that generates the screen image of a frame 84. Specifically, the database 17 is polled for descriptive information about the current superior node and that information is displayed in the appropriate fields on display device 13. Then the database is polled for the subordinate nodes of the current superior node (if any) and the required descriptive information about them. This information is displayed in the subordinate nodes box 42. A potential subordinate node row 62 is also displayed in the subordinate nodes box 42 if the current superior node has fewer than the maximum number of subordinate nodes. This row has only default descriptive information in its fields; it is not associated with a node. Other background information that may be desired to complete the image of a frame is generated and displayed.
If the current superior node has just been changed, the cursor is placed in the superior node name field, else its position depends on the previous history of the system.
User input and editing within a given field is handled with a buffered editor that waits for and responds to user edits, but does not update the database until the field is exited. System behavior depends on the field in which the editor is called as described below.
If the cursor 86 is in the superior node box 40, the editor is called for the appropriate field and the system awaits user input. If the edits make a legal change 96 in the superior node level field 52, then the appropriate number of nodes will be created or destroyed 102 and the subordinate node level field(s) 58a values will be updated 106. Edits to other fields will result in simple updates 100 to the database 17. If the cursor 88 is in the potential subordinate node row when the field editor is called 92, any change or addition 98 results in the creation/addition of at least one node 104, more if the subordinate node level field 58a is legally changed. The database 17 will be updated 100 if information is added to the subordinate node name field 56a. If the cursor 88 is elsewhere in the subordinate nodes box 42, the editor 94 is called for the appropriate field. If the edits make a legal change 96 in the subordinate node level field 58a, then the appropriate number of nodes will be created or destroyed 102. Edits to other fields will result in simple updates 100 to the database 17.
If the user exits field editing 180, 110 with a keystroke that moves the cursor to another field in either the superior node box 40 or the subordinate nodes box 42, then a small loop is made to resume editing at the chosen field. Otherwise all possible paths of flow rejoin and a test is performed 112 to establish whether the user wants to invoke a command. If the test fails, the flow returns to the "Main Menu" operating state. If the user has chosen to invoke a command 112, flow passes through a series of tests 114, 118, 130, 138, 154, 170 to identify the particular command. A description of each command follows:
The user can navigate from one frame 74 to another. The navigation operations 116 are several in number. At the user's direction, they can show the frame of the node at the same level to the left or right of the current superior node, to the frame of the current node's superior, to the frame of the topmost node of the hierarchy, or to the frame of one of the current node's subordinate nodes. If the current frame is already at the extreme of the selected navigation direction, the display image remains unchanged.
If the cursor is in the superior node's box 40 when the command to navigate down is invoked, the frame of the superior node's leftmost subordinate node (at the highest level of subordinate nodes) will be displayed. If the node identified in the superior node's box 40 has no subordinate nodes, the leftmost frame of the next lower level will be displayed. These conventions for navigating down in the hierarchy are arbitrary and could be modified as desired to establish different conventions. In the present embodiment, animation is used to slide portions of the new frame images into place from the appropriate direction. This enhances the users illusion that he is actually moving about a hierarchy.
The user can also navigate directly to another frame by making a randomly chosen node the current superior node. In the present embodiment this is possible by choosing a navigation command to display a list of the nodes alphabetized by the first field of descriptive test FIG. 6. The invention will navigate directly to the node selected by the user.
All of the navigation commands operate by changing the value 116 of the memory address (a pointer in the C-language) that identifies the node known as the current superior node. The system loops to the display frame step 84 and places the cursor in the top, leftmost field 44 of the new current superior node's frame 74. The user has the impression that the representaiton of the entire hierarchy can move at his command while at any one time he views a portion (the frame 74) through a window.
The command to insert 118, the creation of a new node at the cursor location, has a behavior that depends on the box in which the cursor is currently located. If the cursor 102 is anywhere in the superior node box 40 when the insert command is invoked, a node will be created above the current superior node 122 with appropriate changes to the positional information of attached nodes. The new node becomes the current superior node 124 and the screen is updated. The new image of the superior node's box 40 will of course be empty of descriptive information other than defaults peculiar to the application of the present embodiment. All nodes directly or indirectly subordinate to the new node will be moved down in the hierarchy one level. If the cursor 120 is anywhere in the subordinate nodes box 42 when the insert command 118 is invoked, a node will be created 128 between the node the cursor is on (or the potential subordinate node row 62) and the one above it (if one exists). The cursor will stay on the new node which will have no descriptive information other than defaults peculiar to the application of the present embodiment. The positional information of the new node's siblings will be adjusted appropriately.
The present invention allows hierarchies to be merged in a manner similar to insertion of a new node. Another hierarchy selected by name 132 (from the mass storage 27 in the current embodiment) is merged by inserting 136 it's topmost node at the current cursor location. This process follows the conventions of the insertion operation except that the sursor 134 must be in the subordinate nodes box 42 (as an arbitrary restriction according to the preferred embodiment).
The delete command 138 destroys the existence of the node the cursor is on. If the node the cursor is on has subordinate nodes 140, the user is asked to specify 144 whether the subordinate nodes are also to be deleted. If the user requests that subordinate nodes be deleted, the node the cursor is on defines the top of a branch which is deleted 146. If the user does not want to delete the subordinates, the subordinate nodes are inserted in order as subordinate nodes of the deleted node's superior 152. In all cases, the positional information of previously attached and still existing nodes is updated 146, 152. The current superior node is unchanged if the cursor 150 was located in the subordinate nodes box 42. If the cursor was in the superior node box 40, the topmost deleted node's superior becomes the current superior node 148. There must be one and only one topmost node in each hierarchy. The preferred embodiment of the invention cannot handle a forest of hierarchies at one time. For that reason the topmost node in the hierarchy can be deleted only if it has exactly one subordinate node connected directly 142. In contrast, if the topmost node, having several subordinate nodes, were deleted as an individual, that would result in those subordinate nodes being topmost nodes in several independent hierarchies.
The move command 154 is a two step process in the preferred embodiment. The user first invokes the move command 156 when the cursor is on the topmost node of the branch to be moved 158. Then the user moves the cursor to the location where the topmost node of the branch previously identified is to be inserted and invokes the move command once more. If the branch to be moved has move than one node 162 and the cursor 164 is not in the same subordinate nodes box 42 as that of the topmost node of the branch to be moved, the user is asked whether to move the entire branch or just the topmost node 166. If the user requests to move just the topmost node, a negative choice at 166, that action is performed 160. The convention in the current embodiment is to leave a node without descriptive information in the moved node's place to which the moved node's previous subordinates are connected. Otherwise, the entire branch is moved 168. The positional information of all affected nodes on both ends of the operation is updated 160 and 168 (the conventions used to update the positional information of the moved node are the same as for inserting a new node). If the cursor is in the superior node box 169, then the moved node becomes the current superior node 171.
The Show Entire Chart command 170 displays a map of the hierarchy in the form illustrated in FIG. 7. It is very useful for viewing where the current superior node is with regard to the rest of the hierarchy. A window is made to appear over a part of the current frame. Each regular node will appear as a small square 190. Each staff node will appear as a dash 192. The current superior node may be made to blink on and off.
Other conventional operations may be included such as saving the hierarchy to mass storage 27, retrieving a hierarchy from mass storage 27, erasing the entire hierarchy, or processing the data 17 constructed according to the invention (for example, to format and print an organization chart). It is also possible in the current embodiment to perform most of these operations on part of the hierarchy by identifying the topmost node to be processed and by indicating how many levels down from that node to process.
As an additional disclosure, the User's Guide for the present embodiment of the invention is included below as an appendix. It should be noted that the User's guide uses slightly different terminology for its description because it was written for a non-technical individual. Nodes are referred to as employees, persons, or positions and superior nodes are referred to as managers. Navigation is referred to as "moving between work groups" and the merging of two charts is referred to as appending.
The present invention as configured may be used to build an office organization chart. During operation, the user is presented with a manageable piece of what can be an indefinitely large hierarchy. The user can make changes to this piece without having to consider the effect of these changes on other parts of the hierarchy. In fact, the user does not even need to known that his changes will have an effect. The system stores information about the entire hierarchy and makes changes as necessary, based on the user's modifications. Once the user has established the structure of the hierarchy, global operations such as formatting and printing an organization chart can be performed as if the user was operating on a single node.
In particular, the user can add a node simply by typing a name into the potential subordinate node row 62 under the appropriate manager. This is intuitive to the user because the frame displayd to him effectively represents an organization chart even though it is not. The most important point is that the user's intended action is unambiguous to the system; the system knows that the current superior node defines the superior node pointer and the system can calculate the sibling pointers since it is known that the additional node is the rightmost of the existing subordinates. Therefore, the positional information about the node is implicitly extracted from the user and automatically recorded by the system. The user is not even required to known that a node has positional information, nor is the user required to know the rules of constructing a hierarchy from nodes. The expertise in these arcane matters is subsumed by the system and method, freeing the user to concentrate on the task at hand.
In addition, configuring such a hierarchical chart requires fewer steps than in the prior art wherein the position information must be explicity stated by the user. Thus the prior art requires more steps that must be learned and repeated for every iteration.
Similar advantages are obtained when inserting, merging, or moving nodes. It is intuitive to the user that a request to perform a node insertion when the cursor is in the superior node box 40 of the frame 74 will result in a new node being placed above the superior node. On the other hand, if the cursor is in the subordinate nodes box 42 of the frame 74, it is intuitive to the user that a request to perform a node insertion will result in a new node between the existing adjacent nodes. The system has all the information it requires since the cursor location on the display device 13 uniquely defines the nodes affected by the insertion. In the prior draw/paint art, wherein an actual graphic image of the hierarchy is being worked on, it would be ambiquous to the user and to the system which type of insertion was to occur because these prior art systems don't distinguish between the two types of nodes (current superior node or subordinate node) at any one time. Additional commands are required, lengthening the learning process and/or the time to perform the operation. In fact, it is common that an insertion in the draw/paint prior art requires the user to manually move or erase and redraw portions of the hierarchy to make room for a new node. ##SPC1##
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A user-controlled interactive computer display system and method is disclosed for manipulating a hierarchy of information (a topmost node and a number of subordinate nodes, each with only one superior node). This display system and method allows a hierarchical arrangement of information to be constructed and changed with a minimum of steps and errors because positional information about each node is handled implicitly by the system.
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CROSS-REFERENCE TO RELATED APPLICATION—CLAIM OF PRIORITY
This Application is related to and claims priority U.S. Patent Application No. 61/398,495 entitled NOVEL DEVELOPER PLATFORM which was filed on Jun. 25, 2010, which names at least Daniel Knoodle as a common inventor.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to Application Development commonly called “App Development,” and more particularly to software programming tools that enable Developers of Apps to tie into Application Programming Interfaces (“APIs”).
PROBLEM STATEMENT
Interpretation Considerations
This section describes the technical field in more detail, and discusses problems encountered in the technical field. This section does not describe prior art as defined for purposes of anticipation or obviousness under 35 U.S.C. section 102 or 35 U.S.C. section 103. Thus, nothing stated in the Problem Statement is to be construed as prior art.
Discussion
Apps are proliferating at unbelievably rapid rates, particularly since smart phones incorporated powerful processors and quality batteries. The advent of “App Stores” only quickened this pace. Soon thereafter everyone thought that “there's an app for that.” However, this clever piece of marketing led to unintended consequences. First, people believed this message, and concluded that Apps must be amazingly simple to “build” (or program). Second, marketing departments and executives almost instantly felt ashamed and behind the curve. The first result is that literally hundreds of thousands of businesses and individuals (hereinafter just “businesses”) with neat ideas sought out “App Development Shops” such as X-CUBED LABS®. The second result is that only then did these businesses learn of the chasm between App development marketing and reality, namely that App development is much more costly, difficult, and time consuming than the marketing messages led them to believe. The result is that the businesses either: 1) walked away frustrated, 2) put up the time and money to build the App they wanted, or 3) cut back on the type of App they wanted, and that their customers would enjoy. As a result of this, millions of Apps were downloaded with minimal “no frills” functionality—and then used only once or twice. This “App remorse” has even spun off one marketing campaign that asks, “Does your App suck?” Even industry followers such as GARTNER®'s Eric Knip have coined the phrase “Rich Context Aware” to differentiate Apps that meaningfully engage the end customer from those that are no-frills.
Accordingly, what is needed are system architectures, devices and methods (including business methods) for enabling developers to build Apps that meaningfully engage end customers faster and less expensively, the present invention provides such an invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Various aspects of the invention, as well as an embodiment, are better understood by reference to the following detailed description. To better understand the invention, the detailed description should be read in conjunction with the drawings and tables, in which:
FIG. 1 illustrates one system architecture according to the invention.
FIG. 2 is a flow chart of a process for providing an end-point third-party API data or function through a middleware platform API to an App.
DETAILED DESCRIPTION OF THE INVENTION
Interpretation Considerations
When reading this section (which describes an exemplary embodiment of the best mode of the invention, hereinafter “exemplary embodiment”), one should keep in mind several points. First, the following exemplary embodiment is what the inventor believes to be the best mode for practicing the invention at the time this patent was filed. Thus, since one of ordinary skill in the art may recognize from the following exemplary embodiment that substantially equivalent structures or substantially equivalent acts may be used to achieve the same results in exactly the same way, or to achieve the same results in a not dissimilar way, the following exemplary embodiment should not be interpreted as limiting the invention to one embodiment.
Likewise, individual aspects (sometimes called species) of the invention are provided as examples, and, accordingly, one of ordinary skill in the art may recognize from a following exemplary structure (or a following exemplary act) that a substantially equivalent structure or substantially equivalent act may be used to either achieve the same results in substantially the same way, or to achieve the same results in a not dissimilar way.
Accordingly, the discussion of a species (or a specific item) invokes the genus (the class of items) to which that species belongs as well as related species in that genus. Likewise, the recitation of a genus invokes the species known in the art. Furthermore, it is recognized that as technology develops, a number of additional alternatives to achieve an aspect of the invention may arise. Such advances are hereby incorporated within their respective genus, and should be recognized as being functionally equivalent or structurally equivalent to the aspect shown or described.
Second, the only essential aspects of the invention are identified by the claims. Thus, aspects of the invention, including elements, acts, functions, and relationships (shown or described) should not be interpreted as being essential unless they are explicitly described and identified as being essential. Third, a function or an act should be interpreted as incorporating all modes of doing that function or act, unless otherwise explicitly stated (for example, one recognizes that “tacking” may be done by nailing, stapling, gluing, hot gunning, riveting, etc., and so a use of the word tacking invokes stapling, gluing, etc., and all other modes of that word and similar words, such as “attaching”).
Fourth, unless explicitly stated otherwise, conjunctive words (such as “or”, “and”, “including”, or “comprising” for example) should be interpreted in the inclusive, not the exclusive, sense. Fifth, the words “means” and “step” are provided to facilitate the reader's understanding of the invention and do not mean “means” or “step” as defined in §112, paragraph 6 of 35 U.S.C., unless used as “means for -functioning-” or “step for -functioning-” in the Claims section. Sixth, the invention is also described in view of the Festo decisions, and, in that regard, the claims and the invention incorporate equivalents known, unknown, foreseeable, and unforeseeable. Seventh, the language and each word used in the invention should be given the ordinary interpretation of the language and the word, unless indicated otherwise.
Additionally, some systems and methods of the invention may be practiced by placing the invention on a computer-readable medium, particularly control and detection/feedback methodologies. Computer-readable mediums include passive data storage, such as a random access memory (RAM) as well as semi-permanent data storage. In addition, the invention may be embodied in the RAM of a computer and effectively transform a standard computer into a new specific computing machine, including (and preferably) machines incorporating “cloud” computing system.
Data elements are organizations of data. One data element could be a simple electric signal placed on a data cable. One common and more sophisticated data element is called a packet. Other data elements could include packets with additional headers/footers/flags. Data signals comprise data, and are carried across transmission mediums and store and transport various data structures, and, thus, may be used to operate the methods of the invention. It should be noted in the following discussion that acts with like names are performed in like manners, unless otherwise stated. Of course, the foregoing discussions and definitions are provided for clarification purposes and are not limiting. Words and phrases are to be given their ordinary plain meaning unless indicated otherwise. The numerous innovative teachings of present application are described with particular reference to presently preferred embodiments.
GENERAL DESCRIPTION OF THE INVENTION
Automated Scalability
Scalability is the concept that a grouping of servers handles the load for the users of the applications in the system. The platform needs to be able to scale up and down dynamically based on usage and load, so that the system does not have huge load spikes taking over the service. Developers that build their application on the inventive platform will give their application the ability to scale automatically.
User Management
The user management functionality in one sense is a tool that a developer can use to give the end users of the application the ability to manage the preferences, interests from relationships and other user functionality.
User management functionality also includes control of preferences, account management, interests, relationships and status updates, invites, and whether to ignore, approve and/or delete relationships, among other user functionality.
Additionally, developers that develop applications on the inventive platform need to mange users of their applications. Developers need to mange those users preferences, those users settings and configurations. For example, if a user wants to get notifications to a cell phone, or email the their cell phone, and email details; at the same time the user has friends and other relationships to other individuals on that application, and those relationships between those individuals needs to be managed; the inventive enables this. Other examples of user management include friending relationships and un-friending, relationships between those individuals, ignores from one individual to the other, approvals in relationships and things of that nature known to those of skill in the art.
Activity Management Functionality
Developers want users to be able to interact with one another. Those interactions are done through activities. For example, if you have a sports activity for two individuals, and assume that they want to schedule something, such as an activity such as a racket ball game. For this or any sorts where they are going to come together at a specific location, at a particular times, and they are going to have a specific number of people that are going to come to that activity. Those people are going to have to be able to request invitations, and be sent invitations, for that activity. In addition, developers must manage different details about the users and their relationships with each other. For example, an activity may be based on the distance from one another, their friendship, relationships, or their geo-spatial relationship to one another, for example. Activities also take into account user preferences, and other user details. The inventive platform provides tool kits that enable developers to provide this feature set to the end users of that application. Additionally, activity management functionality includes managing invites, attendance, locations, events based on locations, distance, date, creator, friends, audio spatial, requests, indication, events and other data known to those of skill in the art, all surrounding a particular activity, for example.
Geo Location Functionality
One concept of the proprietary platform is location. Location aware information pulls the location data discussed above from desperate sources. Geo-coding is the concept of taking and address and encoding that address to a latitude and longitude point on the physical surface of the earth. Reverse geo-coding is the opposite—taking the latitude and longitude and turning it into a physical mailing address at some location. Geo IP (Internet Protocol) takes the user's IP address for their computer (the user's IP addresses can be used to identify their location). Exemplary geo location functionality includes geo coding, reverse field coding, geo IP, geo spatial, geo referencing, location, and points of interest.
Specifically, the IP address for that user can be traced back to an internet service provider and subsequently back to a location and point on the earth. Geo IP gives us the latitude and longitude of that user browsing through their web browser to a particular web sight or application.
Geo-spatial is the concept of a proximity area around some point. So, if a system knows a specific latitude and longitude point on the earth, Geo-spatial gives you the details about what's within a typical radius around that location.
Geo-fencing is semi related to Geo-spatial in that it is a literal spatial area of interest. Geo-fencing operates as a perimeter “drawn” around some location, for example, that wraps around a building or behind/surrounds a playground or a group of buildings. So, the fenced off area is a location grouping. As someone enters a fence their mobile device passes across the boundary of that fence, and the mobile device sends off some kind of signal. In one example, the signal is to a server somewhere on the proprietary platform that then allows the system to determine that this user just entered this area and that information can then be pushed out to other applications and other devices on the platform. For example, a program running on the platform may notify a user that a friend that as entered into that area—or a business partner, or an alumni, and things of this nature. So, that person, the user, is walking into that fenced off area, and sending off a notification.
Locations and Points of Interest
A point of interest is basically a listing of specific locations of a particular place or business. So, if one identifies all of the LA Fitness' in a geographic area, each one of those locations is point of interest. A point of interest can also be a park or somebody's landmark, such as somebody's home. Any kind of landmark, or a particular point, or business, or identifiable entity as it's marked on a physical map can be a point of interest. So as you are looking for information given a current point location where that user is standing with their hand held device, points of interest provide details about what is around that person, what are the businesses, and the restaurants, parks and the other points of interest that are around them.
Thus, the Geo-location functionality of the proprietary platform allows a developer to select which one or ones of these functionalities, or functionally categories that they want to employ on their applications.
The proprietary platform also matches that data back to a user's preferences in the context of the application that he/she is working in. For example, for an application that is specific to sports, then information related to restaurants is likely irrelevant and should be excluded.
Social Network Functionality
The social networks have proliferated in the past decade, and provide an wide assortment of interesting data through their APIs. The proprietary platform gives developers the ability for those application developers to provide social network functionality, avoiding the need to learn how to interface with each one of those social networks, learning the application programming interface and the building blocks and layers for each one of those individually. The proprietary platform consolidates the interfaces into one programming platform/interface, so that the application developers make one call to the platform and the platform makes the call then to Face book or Twitter, some other social network. The platform can simultaneously pull back all the relevant information for a particular query.
For social networks, the platform brings in details about a user's friends, their groups, relationships, and associations, among other data. The platform also allows for authentication, and single sign on (so when users come into the platform or into the platform's developers' applications, the developers don't have to manage and maintain users log-in credentials). The login credentials can be authenticated and validated through any of those social networks, Face book, Twitter, Linked-In, My Space, or any others. It off-loads the burden of user authentication and the authentication in the trust relationship management for the user to the application.
Trust management relationships of friend groups can be separated into friends, acquaintances, and professional associates, open to everybody or other peers of trust. Also a user can select which data is available, if any, to the platform or between friend groups, from whichever program or other platform that they are using or choosing to make available to your proprietary system. In one embodiment, the platform shares social relevant information, book marking pieces of information and then tagging those pieces of information.
Notification Functionality
Notification functionality is provided to developers so that then can allow their applications' users to notify each other or the system can notify users about various events and other things.
As activities occur as users invite someone to an activity, as users interact with other friends, groups, relationships they have an interaction on the platform. Various types of notifications are sent for those events. The notifications that the platform sends and receives are typically email-based, so the platform sends email notifications to the users in cases where we the platform is verifying their email address(es). In SMS (Simple Message System), which is how common everyday text messages are sent/received on a cell phone, the platform gives developers the ability to send text messages to their users, and for users to send messages through the platform that come out as text messages to other users. In one embodiment, we provide a multi-media messaging system that can be used for sending graphical content, video, images, and things of that nature, to a mobile device. iPhone provides a “push” ability as a proprietary system from Apple so that a developer can send push notifications to an iPhone directly. The platform can do this, also. Within the notifications, the platform can send a status up-date to friends. The messaging can be sent either from the application level, platform level, or from an individual level.
Accomplishment Sharing Functionality
Accomplishment sharing comes into play where there is a competition between users. This allows a developer to store who won a particular competition or sporting event or activity. Then an application can compare and rank those users based on those accomplishments, and based on their comparison to other users on that application platform. Users can accomplish tasks or gain some type of medal or award of some sort based on some accomplishment. So, if a user has visited “these four cities” they can get an accomplishment badge related to the visits. Other applications may use that functionality to determine how many Starbucks a user had, and compare this to other users of the application. Then, the user may get a coupon if they visit a restaurant frequently. This encourages users to check in every time they are at the restaurant, and incentivizes businesses/locations to provide “accomplishments” to users for having registered a visit a certain number of times. The businesses/locations can then use that data to turn offer discounts, for example.
Data Market Place
The data market place is for sharing user profile information between applications, developers, advertisers, and marketers. As a developer builds an application on the platform they build up a specific set of data around the users of that platform, including their preferences, their friends and their networks. So, that data can be licensed by other application developers, or marketers and advertisers to utilize that information to target users or enhance the experience of those users on other applications. It also can be used to predict applications that may be needed but have yet-to-be developed. It can also be used to predict user's habits and preferences, things of that nature and even having location sharing. In one embodiment, it contemplates the sharing of user location data between applications so those users' location preferences even can be shared across applications.
So, when a developer starts out with the platform, they begin with base functionalities that the platform provides for them to build out an application. They start with things like user authentication into that application, so they are going to build up some code on their end so they can facilitate communication with the device and the platform.
From there the developer may move to user profile development, user preferences, user details, things of that nature and get into perhaps locations for that user, their home address, work address, for example, to build up the location type data for that user. Next, a developer can build-out some event management functionality for their application. Next, a developer can develop functionality around some type of social information or specific activity types. For example, this could be implemented in an application for bar hopping. A user could select their bar, they could select the people they prefer to bar hop with, and if they met some sleazy guy on those bars they could make some note to the effect of “Don't go to bar x because there's some sleazy guy that hangs out there.”
Conceivably, there could be facial recognition software so that the platform could use a picture, perhaps taken with an iPhone, to identify that “sleazy dude.” And, then if Mr. Sleazy is identified in another photograph in another bar, Mr. Sleazy is recognition followed.
So, from the activity and event management, a developer starts to build a geo-location profile for an application. The user's geo spatial data and geo fencing starts to get built up and comes into play regarding the areas where there users are going frequently, fro example. User want to know what the things are that are around them—things that they can interact with that are related to their application(s). For example, in a bar application, perhaps they want to get some food, restaurant information, point of interest data, or the like; this lets the developer(s) of the application easily provide the functionality. Specifically, if a user goes to a bar, that bar could detect that they are present at their location and spontaneously make a menu available to them. They could also offer the user VIP services or offer them any other type of offer that that location might have available for users of this application to users of “that type.” Perhaps it suggests playing pool if pool tables are not occupied.
If a user is open to sharing data, the bar could send/receive information about the user's likes, dislikes and habits. So, perhaps that user likes Shirley Temples so they are offered a discount on Shirley Temples, or Stella on tap but not Stella in a bottle. In other words, a user can begin an experience with an application with a context that enhances the user experience.
At the same time, notifications are going out to the system so that the system registers each user at that location. The bar/restaurant/location may register that the user has entered the building, and they can start the whole sequence of offering things and catering to that individual user. Developers can also control how they want to limit their cost for a user, so that they can limit the amount of information going back and forth, or they limit the number of SMS or internet messages, or other information, are going back and forth to limit their cost (based on any factor). This is a cost containment feature for the developer.
Also, as the inventive platform scales up and down for the user-load, a developer may want max limit how much they want to get charged for user load on the system so they scale things like that and set the preferences so there not incurring charges that they wouldn't expect. The application management interface allows them to access billing information, and access all these settings and configurations for that application. In one embodiment, there's a mail server the platform interfaces with, and that configuration for that mail server and the log-in credentials are provided when they tie into geo-location data they can either utilize the 's log-in credentials for that geo-location information, and utilize the 's billing plan, or they can choose to get billed separately from that geo-location provider so that they can pawn that information from the other provider and pay them directly.
Email server enables the platform to tie into the developer's email server. So, the email address that an email is sent from shows up as an application, or a company that is making that application, so that the whole application is being branded as a particular company or trade name rather than being identified as the actual data-source, so that the entity underwriting an application can use the in a manner consistent with marketing and branding strategies. Via application management, a developer can manage meta data and the details about what's being stored for their users, and the types of information being stored for the users. In this light, a data market place is created, so that developers and/or the platform can re-sell, share and license that information between applications and developers and companies/entities.
Shared Context
The goal of shared context is to intelligently match a need, want, or desire expressed by an individual user to the resources (person, substance, knowledge, or other container of value) made available by members of their social graph (explicitly trusted) or members of an application at large (implicitly trusted).
Shared context is needed because as the user-base of networks such as Twitter climbs, and the number of social graph connections increases between users, an alarmingly disproportionate amount of status updates deemed irrelevant by each user (“noise”) obscures items of genuine interest (“signal”). Noise damages user perceptions of a network's utility, which in turn threatens the long-term viability of that network, such as MySpace is experiencing. The system facilitates intelligent social messaging queuing. Most users have tangible objectives in mind when they approach social media. They inherently want to share their knowledge, experiences, and skills with people interested in what they have to say. Likewise, they wish to receive only messages they personally consider valuable that meet their own needs, interests, and tastes.
The system facilitates shared context by seamlessly distributing messages to dynamically-aggregated audiences (microcosms within a social graph that share a common bond meeting the objective of the need in question) that would deem that message relevant to themselves at a personal level. Components would include an automated relevance filter seeking obvious connections that are easily identifiable, and a human-centered curation process to validate connections being proposed.
The sources of shared context are any type of content produced by an individual that can be reduced to unstructured text (whether embedded in the content itself or available as associated metadata) for direct analysis by the Shared Context system and ability to associate metadata to the content via crowd-sourced or trusted human input into the Curation (meaning that users of a site could look at a picture of a yellow parrot, and associate “bird”, “parrot”, “yellow”, and “beak” as meta data associated with the image). In addition, users may provide information about themselves through applications designed to format responses in a way that is inherently understandable to the Shared Context system, removing the need for unstructured text analysis.
A user initiates the process of sharing context by opting-in to pushing their data into the system by a) linking their social accounts, and b) providing direct information to questions on tastes and behaviors in order to build an online persona within the system that matches their real-world persona as closely as possible. The user sets privacy controls on who can be considered as a potential match only within a certain network, such as FaceBook friends, or perhaps a subset of a network, like FaceBook friends who live in Dallas.
The system pre-qualifies potentially valuable connections between users that are a) connected tangentially or b) unconnected to one another: as the system builds more profiles on members of a user's social graph, it is better able to facilitate the propagation of shared context. When two users provide the same or similar response to a given question or scenario (“what's your favorite sports?”), then the system is able to pre-qualify a connection. Different types of data with different similarities between users will allow messages to be ranked from most potentially relevant to least potentially relevant (meaning that someone who shares the same tastes and geo-location of a user might be better able to answer their question on a given subject in a certain nearby location).
The container of shared context is any type of social media content (tweet, audio clip, video clip, image) that is found to match the profiles of two users within pre-defined trust networks. The platform can pass the message from the sender (one with an objective) to vetted recipients (one or more users who could directly or indirectly meet the sender's objective).
Icon/Drag-and-Drop/Pull-Down Programming
In one embodiment the system allows for a developer/designer to choose an icon or other indicia to designate a functionality to apply to a program/application. For example, a developer/designer may select a social media functionality (as discussed above) to provide pre-designated functions to the developer's application. When a limited set of functionalities are provided, these may be selected by a developer in a “drop-down” menu format. Accordingly, a potential user may become a potential developer/designer whereby they can select from a variety of functions, and also assign a number of indicias, such as a cub scout troop number, to identify activates and functions associated with that troop. Ultimately, one with no developer, designer, or coding experience may generate a unique application.
For example, perhaps a Den Mom wants to create an application for her son's Cub Scout Troop. She may open up the system, and first select an icon associated with “create a closed social network.” Next, she will select from a pull-down menu “administrator approved acceptance only” so that she, or another application administrator, can control who joins the application's network. She may choose to provide for two categories of members via a pull down menu, and then name one group “Scouts” and another group “Parents” via standard data entry. Then, she may select an icon associated with “create geo-location ability” so that “members” can see where each other are when they are using the application. Next, she may add SMS text messaging capabilities by selecting an “enable messaging” icon for each group type. She may also choose to enable broadcast text messaging via a “enable broadcast messaging,” in this case, just for the group called Parents. Then, by selecting a “create profile type” icon, the Den Mom determines via radio buttons the types of information each user of the app should either provide, or import from another source (in which case the mom would use a “social networking” icon to create interfaces with respective popular social networks). Now, the mom can upload images, including an “app image”, and associate it with the application she just created. Now, the Den mom can use templates to generate the form for user data entry. Other functions can be added and customized, as well as web and native code enablement, in a similar manner. Finally, the application is submitted to application distributors, such as Apple, for approval and distribution.
DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates one system architecture (“architecture”) 100 according to the invention. The architecture generally comprises an App having an App front end (“front end”) 110 and an App back end (“back end”) 120 . Although only one App is shown, it should be understood that the inventive middleware platform can service and support any number of Apps. The front end 110 is known in the App Design and App Developments arts and generally comprises a user interface, and manages what the user sees and perhaps interacts with on a smart phone screen or in some cases a desktop computer screen. The back end 120 is also generally known in the same arts and generally comprises the code needed to access functions and information (some of which were discussed above) from APIs. For example, one function (“F(a)”) that could be accessed by an API could be a regulated poker shuffle provided by an independent API 130 . A back end 120 will sometimes access and store data independently using their own preferred data storage systems, illustrated here as a database 140 .
In invention includes cloud computing, which practically eliminates the need to plan to scale a database or hardware on an Apps's back-end, as a cloud computing layer (“cloud”) 160 , such as MICROSOFT®'s AZURE® database. Additionally, a middleware platform layer (“middleware platform”) 150 sits on top of the cloud 160 .
The middleware platform 150 is a back-end facing API, such as a REST (or “restful”) API, that provides distinct advantages for an App Developer. The middleware platform 150 allows App developers to access desired app functions 152 , 154 , 156 where N is the number of App functions available through the middleware platform. These App functions are made available to developers by the middleware layer separately and independently accessing that information from third-party APIs. In other words, the developer only needs to access one API (the middleware platform 150 ) rather than develop code into multiple end-point APIs 172 , 174 , and 176 where Z is the number of end-point APIs the middleware platform 150 ties into. Further, this shifts the burden of maintaining the tie-in into the end-point APIs 172 - 176 on the middleware platform 150 rather than on the developer of the App back end 120 or its owner.
Additionally, in a preferred embodiment, the middleware platform 150 not only ties into the end point APIs 172 - 176 , it also cross-integrates the data that is obtained from these APIs, and normalizes the way in which the data or functions obtained from the end point APIs 172 - 176 is presented to the back end developer in a simplified conceptual methodology via the middleware platform 150 API. Of course, it will be appreciated that some endpoint features may be written directly into the middleware platform 150 and not access a third-party API at all without departing from the scope or understanding of the invention.
FIG. 2 is a flow chart of a process algorithm 200 for providing an end-point third-party API data or function through a middleware platform API to an App. Although this data request is illustrated as to a call, it will be appreciated by those of ordinary skill in the art upon reading this specification that this process can be applied to analogous App functions. The algorithm starts in a App Call act 210 , in which a middleware platform such as the middleware platform 150 receives a request for a particular piece of data, such as the location of a business. Then, in a middleware convolution act 220 , the middleware layer performs a number of acts directed to the App Call act 210 . For one, the middleware layer takes advantage of data previously stored on a cloud (such as the cloud 160 )—for example an authentication token or security details. Then, the middleware layer uses the information provided in the call to construct a properly formatted call for a third-party API data provider, such as GOOGLE MAPS®. Next, in a present call act 230 , the middleware platform makes call to the third party API (or more precisely, the proper API endpoint), which may be using a restful or SOAP standard. Although not illustrated, if an error message is received, it is treated in a manner similar to receiving data, discussed next.
Properly formatted data is received responsive to the call in a receive data act 240 ; continuing with our example, the location of a business. Then, in a middleware reconvolution act 250 , the data is disambiguated to match the format the App expects, as per our example, the data associated with the location of the business. Additionally, the data may be stored for later use and retrieval by the middleware platform as provided by each end point API's terms of service or equivalent license. Further, the middleware reconvolution act 250 may also incorporate other data stored on the cloud, and may also “strip out” certain data provided by the end point API prior to presenting the data to the App in a present data to app act 260 .
Though the invention has been described with respect to specific preferred embodiments, many variations and modifications will become apparent to those skilled in the art upon reading the present application. Specifically, the invention may be altered in ways readily apparent to those of ordinary skill in the art upon reading the present disclosure. It is therefore the intention that the appended claims and their equivalents be interpreted as broadly as possible in view of the prior art to include all such variations and modifications.
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The invention is a novel developer platform that facilitates software application development, by consolidating common programming tasks into independently usable functional objects. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).
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BACKGROUND OF THE INVENTION The present invention is concerned with a pressure-controlled readjusting device for a vehicle brake, in particular, a disc brake.
Readjusting devices of the afore-described type are needed in brake calipers intended to perform, in addition to the hydraulic function of the operating brake, the function of a mechanical parking brake. The brake pad wear is compensated by a readjusting device as the operating distance of the mechanical parking brake would otherwise increase by the amount of the pad wear. During operation of such a readjusting device, the brake must be prevented from automatically readjusting by an excessive amount, i.e., the operating clearance between brake pad and brake disc must be maintained. The pad compression and the caliper expansion at elevated hydraulic pressures also must be compensated. Moreover, the readjusting device must be insensitive to high hydraulic pressure and pressure fluctuations, temperature influences, and vibration and must insure operating safety throughout an extended period of time.
To prevent the readjusting device from readjusting at a high brake pressure and, hence, at a resilient deformation of the caliper and of the pad, measures have already been suggested (see German Patents No. 38 00 734, No. 38 00 735, and No. 38 03 564) which prevent adjustment above a predetermined brake pressure. Devices of this type are of a relatively complex design and require a very careful setting of the components involved in switching off the readjusting device. These prior art readjusting devices are limited in that pad wear resulting from a high brake pressure be readjusted during the braking operation.
German Patent No. 26 15 404 teaches switching off the readjusting device at a relatively low pressure and, subsequently, at a decreasing pressure, readjusting the distance no longer covered by the piston because the pad has worn. The disadvantage of the state-of-the-art readjusting device is that it requires a cylinder of a substantially complex design composed of a plurality of individual components. The friction cone of the rotating readjusting device undercuts a part of the cylinder so that the cylinder must be substantially dissembled for repairing or replacing individual components. This problem applies especially to the replacement of the sealant required for initiating the pressure control.
U.S. Pat. No. 3,920,103 displaceably arranges the rotatable readjusting element within the piston in a spring-loaded manner. A sealant is provided on the rotatable element to seal the pad-sided piston cavity against the remaining space of the brake cylinder. However, the readjusting device described therein is of a design such that the spring loading of the rotatable readjusting member tends to keep the friction cone disengaged permanently, resulting, with respect to the hand brake, in comparatively extended readjusting distances.
SUMMARY OF THE INVENTION
It is the object of the present invention, therefore, to provide a readjusting device of the aforedescribed type having a simple and low-cost design, involving comparatively small space requirements, and being able to reliably adjust the necessary amount to assure proper clearance.
The present invention locates, in the readjusting device, the friction cone of the rotatable readjusting member in the piston. At the same time, the rotatable readjusting member is prestressed, through the non-rotating readjusting member, toward the auxiliary actuator. Consequently, the comparatively strong first spring can be displaced into the area of the auxiliary actuator, where relatively ample space is available.
According to one embodiment of the present invention, a second spring, supported on the piston, acts upon the rotatable readjusting member toward the pressure applied to the sealant upon actuation of the brake. That feature assures that, upon commencement of the hydraulic braking operation, the friction cone is safely closed and readjustment in the closing direction of the friction cone, also in a decreased brake pressure, is reliably executed against the existing mechanical friction. Through this feature, the rotatable readjusting member is prestressed toward the friction cone, thereby enabling friction losses, if any, likely to impede readjustment following the braking operation, to be overcome. The spring force will act in the same direction as the sealant to which the brake pressure is applied.
A particularly simple design of the readjusting device is attained when the sealant is configured as a sleeve. Such a configuration allows the second spring to directly engage the sealing sleeve and act upon the rotatable readjusting member, so that intermediate rings or the like are unnecessary.
A particularly favorable enhancement of the on/off effect of the readjusting device caused by the pressure is attained when the rotatable readjusting member protrudes into the interior of the piston and the chamber formed between the closed piston end and the sealant communicates with the atmosphere through a hole within the piston. In such a design, the area of the piston interior behind the sealant is brought to atmospheric (ambient) pressure, thereby enhancing the effect of the brake pressure on the sealant so that the friction cone is safely held closed even at very low brake pressures. This prevents readjustment during the pressure build-up until the pressure is finally decreased.
The rotatable readjusting member is rendered rotatable with respect to the piston by supporting the sealant on the piston and locating a roller bearing between the sealant and the readjusting member acting in the axial direction. This embodiment of the present invention substantially improves the rotating movement of the rotatable readjusting member, thereby further decreasing the potential friction values and enhancing the precision of the readjusting pattern of the readjusting device.
If the rotatable readjusting member is made of a soft material suitable for extrusion processes, the roller bearing is configured as a ball bearing or, preferably, as a needle bearing and a support plate is provided between the roller bearing and the sealant.
To prevent the anti-friction bearing from sliding on the material of the sealant, a support disc is inserted between the bearing and sealant.
The end of the second spring can be locked in a retaining groove within the cylindrical surface of the piston. This embodiment of the present invention provides for a particularly low-cost locking device on the piston. Moreover, the embodiment provides a safety device which, upon disengaging the second spring, will permit a braking movement of the piston even if such braking would otherwise be impossible in view of the limited spring deflection.
According to still another embodiment of the present invention, the rotatable readjusting member is formed as a nut having an internal thread with a conical shoulder at the end facing the piston bottom. A corresponding frictional cone, incorporated into the pistion bottom, is associated with the shoulder. This particularly simple design makes good use of the available construction length. Moreover, the nut, because its diameter exceeds that of the spindle, is particularly suitable for accommodating the friction cone; in that instance, larger diameters of the cone and, hence, an enhanced friction effect, are easily attainable.
In a further embodiment of the inventon, the nut has a continuous, longitudinal orifice which permits a low-cost manufacture of the internal thread. The nut is preformed by extrusion and an internal thread can be easily molded into the orifice for accommodating a spindle.
The end of the orifice in the nut facing the piston bottom is sealed, in a pressure-tight manner, by forcing a ball into that end. To the extent that the part provided behind the sealant in the interior of the piston is under ambient pressure, this embodiment of the invention isolates the brake pressure away from the pressure-free space within the piston.
According to another embodiment of the present invention, the hole within the piston is a bore emerging from an annular groove provided within the outer cylindrical surface of the piston. The hole serves to mount the protective sleeve and extends in a direction oblique to the longitudinal axis fo the piston. This embodiment seals the pressure-free interior of the piston against the ingress of dirt and the hole at a large distance from the heated brake plate.
The first spring is supported on the cylinder through a spring cup and can be locked in position by causing the mount of the first spring to engage the housing. The spring cup has, at its open end, a radially outwardly directed rim and slots extending in the longitudinal direction. The locking arms, which are formed by the rim and slots, extend in a direction oblique to the longitudinal axis of the cup.
The non-rotatable readjusting member, as a rule, is locked against rotation by a lug of that member which protrudes into a corresponding groove in the cylinder incorporated into the brake housing. According to another embodiment of the present invention, a mounting socket open toward the spring cup is provided. The spring cup, first spring, and non-rotating spindle are disposed in the mounting socket to form a pre-mounted unit. The mounting socket is held in the cylinder in a non-rotating manner.
It is important that the friction of the rotatable readjusting device be as low as possible. At the same time, a sound sealing effect must be achieved even at a low brake pressure. Consequently, a centering sleeve is provided to improve the orientation of the sealing sleeve between the second spring and the sealant. That design allows the sealing faces of the sealing sleeve to abut the counter faces with minimal friction.
An additional decrease in friction losses can be attained by providing at least one of the sealing faces of the sealant with a sliding material. This embodiment makes it possible to use a wider sliding ring in abutment with one or both sealing faces.
A plurality of narrow sliding rings in parallel with one another can be buttoned to one sealing face or to both sealing faces. The sliding ring, preferably, may be provided only on the sliding face in abutment with the rotatable readjusting member. Alternatively, the sliding ring can be deleted entirely so that, in a non-pressurized condition, a cavity is formed. The cavity is sealed by the sealing lip and friction resistance to the rotatable readjusting member is avoided except for the abutting sealing lip.
To facilitate easy assembly, however, it is also possible for internal and external sliding rings to be interconnected through bridges.
According to another embodiment of the present invention, the non-rotating readjusting member is a spindle held in the cylinder. The spindle is preferably manufactured by extrusion, does not rotate, and is subject to longitudinal displacement.
The invention, in particular, provides external access to the non-pressurized interior of the piston with no escape of brake fluid. Hence, through a corresponding opening, there is access to the rotatable readjusting member so that the readjusted piston can be more easily restored during replacement of the brake pads. The piston has a continuous front opening aligned with the longitudinal axis of the piston. The rotating readjusting member has a recess, which accommodates a threaded tool, aligned with the front opening. The recess is molded either into the rotatable readjusting member or into a closure member.
Importantly, the front opening also vents the pressure-free interior of the piston, thereby avoiding the need for a special hole of the type discussed above. The clearance between the closure member and the front opening prevents friction between the rotatable readjusting member and the piston face and enables the readjusting member to be guided.
The front opening is closed by a lid, which may be detached, or by a detachable pin which protrudes into the recess. The sealant permits access between the interior of the piston and the atmosphere. These features provide an improved mounting surface for the piston on the carrier plate of the brake pad.
The support of the second spring may be modified over that described above. The second spring is placed within a piston sleeve forced into the piston orifice and the roller bearing is supported toward the open side of the piston. The piston sleeve is longitudinally displaced with respect to the inner wall of the piston once a predetermined force is applied. Such a construction enables the force at which the support of the second spring on the piston interior is overcome to be better fixed and readjusted.
It should be noted that the second spring is not required. The effect of the spring can be replaced by the effect of the brake pressure on the sealant. Hence, it is not necessary for the rotatable readjusting member to be readjusted by the second spring; the low pressure which exists during the decrease of the brake pressure will be adequate to unload the first spring, thereby providing a minor gap in the friction cone which is readjusted by the remainder of the brake pressure. In this manner, another simplification of the readjusting device according to the present invention is possible: the second spring is deleted.
The roller bearing can also be supported, on one side, on the piston sleeve through the second spring and in the direction facing away from the piston bottom. On the opposite side, the roller bearing can be supported on the rotatable readjusting member through a racer for the ball bearing or through a support ring and the sealant. That construction provides a clear cut and simple embodiment for the rear face of the sealant.
BRIEF DESCRIPTION OF THE DRAWING
Several embodiments of the present invention will now be described, along with a number of modifications, with reference to the drawing, wherein:
FIG. 1 is a sectional view of a simplified form of one embodiment of the readjusting device according to the present invention;
FIG. 2 shows a modified sealing unit of the readjusting device according to FIG. 1;
FIG. 3 shows a sealing unit modified over FIG. 2;
FIG. 4 is an exploded view of individual elements of the sealing unit according to FIG. 2;
FIGS. 5 and 6 show a readjusting spindle employed in the illustration according to FIG. 13;
FIGS. 7 and 8 show a readjusting spindle disposed in a mounting socket;
FIGS. 9 and 10 show a readjusting spindle along with a locking plate for locking against twisting;
FIGS. 11 and 12 show a readjusting spindle along with a locking plate and a locking bolt for locking against twisting;
FIG. 13 shows a second embodiment of a readjusting device modified over FIG. 1;
FIG. 14 shows a modified form of the second embodiment of a readjusting device according to FIG. 13 with a spindle support modified according to FIGS. 7 and 8 being inserted;
FIG. 15 shows a modified readjusting device according to FIG. 13 with a modified sealing unit;
FIG. 16 shows a readjusting device with a sealing unit modified over FIG. 3;
FIG. 17 shows a modified sealing for the readjusting nut and a readjusting nut modified over FIG. 17;
FIG. 18 shows a modification of the closure member.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an actuator 1 for a disc brake provided with a hydraulic actuator 2 and a mechanical actuator 3. The mechanical actuator comprises an actuating shaft 6 rotatably disposed by anti-friction bearings 4 within a brake housing 5. The rotation of the actuating shaft 6 causes a push member 7 to be displaced in a substantially axial direction.
The hydraulic actuating means 2 comprises a step cylinder 8 incorporated into the brake housing 5. A piston 9 is axially displaced within the step cylinder 8 in view of the brake pressure exerted. The piston 9 is sealed against the cylinder 8 by a cylinder sealant 10 which exerts the conventional roll-back effect for restoring the piston 9 after the braking operation. The ends of a dirt-collecting sleeve 11 are held in an annular groove 12 of the piston 9 and within a corresponding groove in the brake housing 5.
The force transmission between the mechanical actuator 3 and the piston 9 is effected through a readjusting device 13. Readjusting device 13 automatically readjusts its length to the position of the piston 9 within the cylinder 8, which varies with pad wear, thereby minimizing the distance for the mechanical actuator 3.
The readjusting device 13, basically, is composed of a spindle 14, forming the non-rotatable readjusting member, and a nut 15, forming the rotatable readjusting member.
The nut, through a sealing unit 16 (described below in greater detail), is sealed against the inner cylindrical surface of the hollow piston 9 and is rotatably disposed. The spindle 14, by a radially extending lug 17 engaging a locking groove 18 within the brake housing 5 or by other measures described below, is locked against rotation but is axially displaceable. A conical lug 19 on the nut 15 forms a friction surface which, together with a corresponding friction surface, forms a friction cone 20 on the bottom of the piston 9 through which the rotating movement of the nut 15 is locked against the piston in a pressure-controlled manner, thereby allowing the rotating movement to be nearly stopped.
One end of a first spring 22 is supported through a spring cup 21 engaging a corresponding circumferential groove within the cylinder 8 of the housing 5. Through a collar 23 of the spindle 14, first spring 22 tends to force the collar 23 against the push member 7. The spring cup 21, at its open end has circumferentially distributed slots 24 confining locking arms formed thereby, through which the cup can be locked into a corresponding groove within the housing 5.
It is of utmost importance to the function of the readjusting device according to the present invention that the interior of the piston 9, through the sealing unit 16, be subdivided into two parts. As shown in FIG. 1, the left-hand part forms an ambient pressure chamber 25. Through a hole 26, pressure chamber 25 is in communication with the environment of the piston 9. In this manner, the effect of the brake force which controls the friction cone and, hence, the rotation of the nut, is enhanced in the hole (or brake pressure chamber) 26 as it no longer works against the remainder of the pressure in the chamber 25 but rather against the atmospheric pressure.
The nut 15, preferably, is configured as an extruded part and is provided with an orifice 28 molded into which is the nut thread 29. This insures a relatively low-cost manufacture of the nut 15. In the event that the hole 26 is provided, it will be necessary for the orifice 28 to be sealed in a pressure-tight manner in order to separate the chambers 25 and 26 in a pressure-tight manner. This, preferably, is effected by a sealing ball 30 forced into the orifice 28.
As to the effect of the sealing unit 16, it is desired that, on the one hand, the nut 15 rotates, friction-free, vis-a-vis the inner face of the piston and, on the other hand, even at a very low brake pressure, a full sealing of the chamber 25 against the chamber 26 is attained. Hence, a low friction is insured during rotation of the sealing unit vis-a-vis the nut and, optionally, vis-a-vis the interior wall of the piston while, at the same time, even at a very low brake pressure, the sealant should respond and seal reliably.
This is achieved, in the embodiment according to FIG. 1, by a sleeve sealant 31 and an anti-friction bearing 32 designed as a needle bearing, with an annular support disc 33 inserted between the sleeve sealant 31 and the anti-friction bearing 32. By substituting a needle bearing 32 for a ball bearing and by providing the support disc ahead of the sleeve sealant and behind the bearing, the force exerted on the sleeve sealant and the conical lug 19 through the substantial brake pressure is reduced. The operation of the sealing unit 16 is thereby assured.
The operation of the sleeve sealant 31 can be further enhanced by inserting a sliding ring 34 at least on the sealing face adjacent the nut 15. Alternatively, the corresponding chamber may be formed through a separating joint so that, substantially, only the sealing lip 35 abuts the nut. Consequently, the friction is considerably reduced as nut 15 substantially rotates away from underneath the sleeve sealant 31 and essentially does not exert any movement vis-a-vis the inner wall of the piston, thereby causing the friction losses to considerably decrease in view of the greater distance.
The sealing unit 16, through a second spring 36, supported on the piston 9, is slightly prestressed against the conical lug 19. Although second spring 36 facilitates operation of the readjusting device according to the invention, it is not absolutely necessary. The end of the second spring 36 disposed toward the open piston side is locked within a retaining groove 37 provided in piston 9. In case of danger, unlocked from the retaining groove 37 once the compressive force acting upon the second spring becomes excessive. Thus, it is insured that, given the readjustment effect, the movement of the piston due to the brake pressure and, hence, the braking operation, can never be seriously impeded.
Shaft 39 of spindle 14, through a sealant 38, is sealed to create a force exerted by the brake pressure on the cross sectional face AS of shaft 39 tending to readjust the spindle 14 toward the push member 7.
The operation of the readjusting device according to the invention will now be described with reference to FIG. 1.
After assembly of the brake, the initial situation is as follows: the friction cone 20 between the nut 15 and the friction face of piston 9 is closed. The shaft 39 of the spindle 14 is in abutment with the push member 7. Provided between the pad (not shown in FIG. 1) before the piston 9 and the brake disc is a clearance. A pad readjusting measurement is required to provide the space needed for assembly of the brake. Subsequently, the piston, by one movement or by a small number of movements, after assembly of the brake, is restored to its initial position. The piston along with the pad, through a hydraulic pressure increase, moves toward the brake disc (not shown), thereby overcoming the pad adjusting measurement and, hence, readjusting the differential distance, optionally, in one movement.
Starting from the afore-described initial position, during the hydraulic actuation, the following operations take part with no pad wear: The friction cone 20 is closed by the effect of the second spring 36. If the readjusting device according to the invention is not provided with a second spring 36, then, in the initial position (at least after the brake has been previously applied), the friction cone 20 will be closed. Friction cone 20 is closed by the remaining pressure, upon termination of the braking operation, and by the restoring effect of the cylindrical sealant 10, which place the conical lug 19 against the friction face of the piston 9. Ambient pressure (differential pressure principle) prevails in the ambient pressure chamber 25. The rising hydraulic brake pressure is exerted on a differential face A d being the difference between the piston face A A and A S .
The rising brake pressure and the force of second spring 36 will cause engagement of friction cone 20, thereby preventing rotation of the nut 15 and, hence, readjustment.
Once the brake pressure has reached an adequate value, the piston along with the nut 15 forced against the interior of the piston in FIG. 1, are moved to the left against the pad and the brake disc. Because the friction cone 20 prevents the nut 15 from rotating, nut 15 will pull, through the thread 29, after the clearance has been overcome, the spindle 14 locked against rotation, to the left. This will compress the first spring 22 held on the housing 5. The shaft 39 of the spindle 14 is lifted from the mechanical actuator 3, creating a corresponding gap between the push member 7 and the associated end of the spindle 14. The gap occurs at point S and is not shown in FIG. 1. Because all rotatable parts are now locked against rotation, under a growing hydraulic pressure, regardless of the magnitude of that pressure, no readjustment can be effected; readjustment would require the rotation of nut 15. This will apply upon caliper deformation, pad compression, or other flexible deformation resulting only in a corresponding enlargement of the gap S. The gap simulates a memory function for the distance covered by piston 9 in FIG. 1 to the left but not readjusted yet.
During the pressure decrease, the brake caliper expands and the piston 9 is withdrawn through the cylindrical sealant 10 into its initial position. A further movement of the piston to the right is not possible, because the cylinder sealant cannot return beyond the previous movement of the piston from its initial position to the left. Under the criterion that no pad wear occurred, the spindle will again abut the mechanical actuator 3 because the return movement of the piston completely closed the previously formed gap. The position of the mechanical actuator compared to the position of the spindle 14, hence, simulates a memory function regarding the distance to be readjusted at that moment. The actual readjustment will be effected only when the gap exists after the pressure decrease, indicating that the return movement of the piston 9 has not completely restored it to its initial position. Then--as described below--the readjusting device is readjusted by the force of the springs.
Now, the operation of the readjusting device according to the invention when pad wear occurs will be considered. The processes which occur are compared to the one-movement adjustment.
During the pressure increase, the same operations occur as the ones described above. However, in view of the pad wear or the pad readjusting measurement required for the assembly of the brake, the piston travel exceeds the maximum return travel due to the roll-back effect of the cylinder sealant 10.
During the pressure decrease, the roll-back pattern of the cylindrical sealing ring 10, therefore, is not adequate to place the piston 9 in its initial position held before the pressure build-up. A remaining gap S (e.g., S x ) is left between spindle 14 and the mechanical actuator 3, especially the push member 7. In the non-pressurized condition of the brake pressure chamber 26, the retracting force of the first spring 22 now exceeds the oppositely directed cone-closing force of the second spring 36 serving to close the cone, including the sleeve friction force FRM and the friction force of the thread 29. Consequently, the first spring 22 forces the spindle 14 to the right until the gap S is closed toward the mechanical actuator 3 (with S X =0).
The spindle 14 moving to the right, through thread 29, pulls nut 15, thereby disengaging friction cone 20 so that the nut can rotate on the thread 29. The second spring 36, by overcoming the sleeve friction force (including the thread friction force), through the sealing unit 16, is forced against the conical lug 19 of the nut 15, thereby causing the nut to rotate. The nut rotates until the friction force in the friction cone 20 has increased to such an extent that a further rotation is prevented. This will terminate the readjustment and restore the initial situation for the succeeding braking operation.
Now, the operations occurring with the mechanical application of the brake (parking brake) will be described. By rotating the actuating shaft 6, the push member 7 is forced onto the shaft 39 of the spindle 14, with the spindle, in FIG. 1, being moved to the left until the clearance of the thread 29 has been closed. The spindle 14 is forced onto the nut 15, thereby forcing the conical lug 19 against the friction face of the piston 9. The friction cone 20, already initially closed (as described above) is sealed even more firmly. Further movement of the spindle 14 to the left will exert pressure on the piston, thereby moving the piston in the same direction against the pad and brake disc. The thread driving torque, tending to rotate the nut in view of the force exerted on the spindle, will be overcome by the friction torque of the friction cone 20, i.e. the nut is unable to rotate despite the clamping force of the mechanical actuator 3. Hence, no adjustment will be possible. During the mechanical brake actuation, the first spring 22 will be compressed by the spindle movement.
Upon termination of the mechanical actuation, i.e., once the parking brake is released, the actuator 3 will return. Due to the roll-back effect of the cylindrical sealant 10, the piston will be withdrawn. The first spring 22 pulls the spindle 14 to the right. The friction cone 20, due to the friction force of the sleeve sealant 31 and the effect of the second spring 36, will remain closed, i.e., the nut 15 is unable to rotate. The first spring 22 overcomes the thread clearance until the spindle returns to its end position, restoring the initial position existing before the mechanical actuation. However, the thread play must exceed the aggregate of venting clearance, pad compression, and caliper expansion.
A number of advantageous modifications of the adjusting device according to the invention will now be described with reference to FIGS. 2 to 18.
FIG. 2 Shows a sealing unit 16 modified over FIG. 1. For cost saving purposes, the needle bearing 32 of FIG. 1 has been replaced by a ball bearing 40 as shown in FIG. 2; however, this is advisable only if the increased spot-type pressure exerted by the balls can be withstood by the material selected for the nut. To increase the slidability of the sealing unit 16, the sleeve sealant 31 has been surrounded by a one-piece sliding ring 41 as shown in FIG. 2, top. However, the one-piece sliding ring also may be replaced by two sliding rings 42,43 as shown in FIG. 2, bottom. The slidability of the sealing unit 16 can be substantially increased by such rings. An improved sealant and an improved force transmission of the second spring 36 to the ball bearing 40 is attainable by a centered sleeve 44 supporting, in suitable manner, the sealing lips 35.
FIG. 3 shows another sealing unit modified over the one according to FIG. 1, in which the one-piece or two-piece sliding ring of FIG. 2 is replaced by two narrow sliding rings 45. Otherwise, the sealing unit 16 according to FIG. 3 is identical with the one according to FIG. 2. The sliding ring or rings may be omitted on the inner or outer sealing face of the sleeve sealant 31. The sliding rings 45 may be buttoned into corresponding recesses of the sleeve sealant 31.
FIG. 4 shows, in an exploded illustration, a sealing unit 16 substantially corresponding to the one shown in FIG. 2, wherein the two sliding rings 42, 43 are interconnected through webs. The rest of the components shown in FIG. 4 correspond to the parts shown in FIG. 2 under the same reference numeral.
FIGS. 5 to 12 refer, in sectional side views and in plan views, to various modifications of the non-rotatable, axially displaceable mounting of the spindle 14. As opposed to the spindle 14 according to FIG. 1, the spindle 14 of FIG. 5 comprises two, oppositely arranged, substantially semi-circular, radially extending lugs 17 protruding into corresponding locking grooves 18 (shown in FIG. 1) and insuring non-rotatability and axial displaceability. FIGS. 7 and 8 show a mounting socket 46 for mounting the spindle 14, with the mounting socket 46 in the housing and the spindle 14 being locked against rotation by four lugs oppositely arranged in pairs over the mounting socket 46. A locking groove permits the spring cup 21 according to FIG. 1 to be locked into the mounting socket 46. The first spring 22 is supported on a support plate 48. The unit composed of spring cup 21, first spring 22, mounting socket 46, spindle 17, and support plate 48 may be premounted and inserted as a unit into the cylinder 8 according to FIG. 1.
FIGS. 9 and 10 show the spindle 14 locked against rotation and axially displaceable by a retaining plate 49. The edges of the spindle 14 protrude through a hole within the retaining plate 49 such that the spindle cannot rotate in those holes with respect to the retaining plate. The retaining plate 49 can be prevented from rotating with respect to the brake housing (FIG. 1) by providing, for example, a nose 50 (corresponding to lugs 17 in FIGS. 5 through 8) or a retaining pin 51 penetrating through a corresponding bore within the retaining plate 49 and protruding into a corresponding bore extending parallel to the cylindrical longitudinal axis within the lug of cylinder 8.
FIG. 13 shows a second embodiment of the readjusting device according to the present invention modified over FIG. 1. Some of the modifications described above have been incorporated. An additional modification exchanges the retaining groove 37 according to FIG. 1 by a piston sleeve 52. Piston sleeve 52 serves as a lock in case the brake movement of the piston 9 is impeded by the second spring 36 because, in that case, given a predetermined force, the piston sleeve 52 will be forced out of the piston. The configuration of the sliding rings substantially corresponds to the one according to FIG. 2 (bottom), with the bottom of the sleeve sealant 31 not mounted on the support disc 33 but rather on webs (not shown) according to FIG. 4.
FIG. 14 shows a modification corresponding to the features described in connection with FIGS. 7 and 8, with the mounting socket 46 given a slightly more solid configuration. FIG. 14, moreover, shows a plug 53. If the plug, in FIG. 14, is pressed to the right, the friction cone 20 can be detached, thereby enabling the piston 9, in the event of repair requirements (such as replacement of pads), to be inserted to the right into the cylinder. The plug 53 is disposed, with play, within a corresponding hole on the bottom of the piston 9, thereby avoiding the hole 26 shown in FIG. 1.
FIG. 15, as distinguished from FIG. 13, shows a modified embodiment of the sealing unit 16. The parts of the actuator left unchanged over FIG. 13 have, therefore, been omitted in FIG. 15 (righthand side of FIG. 13). The anti-friction bearing 40 is disposed between a racer 54 and a support ring 55 so that the anti-friction members of the anti-friction bearing 40 contact a material of suitable hardness. The support ring maintains the racing surface for the anti-friction bearing 40 at an adequate distance from the bottom of the sleeve sealant 31.
FIG. 16 shows an embodiment of the readjusting device according to the present invention which is not provided with a second spring 36. The support member 56 performs the function of the second spring, acting as an anti-friction bearing according to FIG. 1. The operation 29 of the readjusting device has been adequately described above. Other forms of the embodiment of the sealing unit 16 deviating from FIG. 16 will, of course, be possible without departing from the spirit of the invention. An anti-friction bearing 40, according to FIG. 16, contacts a support member 56. However, the sealing unit 16 also can be designed in accordance with FIG. 1.
The deviations from FIG. 1, as shown in FIG. 17 replace the sealing ball 30 with a substantially cylindrical closure member 57. A recess 58 is provided in closure member 57 to accommodate a tool, thereby enabling, for example, with the aid of a hexagonal spanner, the nut both to be forced away from the friction cone and to be screwed, according to FIG. 17, to the right by a rotating movement on the spindle, thereby detaching the readjusting device and enabling the piston to be easily inserted. The recess 58 is provided with a plug 53 sealing the recess 58 and protecting the recess against the ingress of dirt.
FIG. 17, in addition, shows the brake shoe 59 actuated by the piston along with a section of the brake disc 60 which is acted upon by the brake shoe 59. If, according to FIG. 17, the chamber 25 of FIG. 1 is under ambient pressure, the closure member 57 is required to protrude, with corresponding play, through the continuous front hole 61 within the piston.
FIG. 18 shows a modification of the closure member 57 which, however, also is provided with a recess 58 for the accommodation of a tool. A lid 62 protects the piston interior against the ingress of dirt. The lid is detachable so that the closure member 57 can be screwed, through the recess 58, to the right. Also, it will, of course, be possible for the closure member 57 to be integrally formed with the nut 15.
To improve slidability, the sealing unit may have sliding rings made of highly slidable and flexible Teflon. The exchange of the nut-sided slide rings as described in FIG. 13 with a recess will permit a sealing effect in two pressure stages. First, only the sealing lips will seal at a lower friction resistance, while, at an elevated pressure, the recess 34 is filled by the material of the sleeve sealant, thereby increasing the sealing effect. The centering sleeve 44 is so configured that--while easily vented--it transmits the spring force through the rubber diaphragm to the support ring and, hence, to the axial bearing and the friction cone. At elevated hydraulic pressures, the expanding sleeve forces the Teflon rings against the sealing faces, thus enhancing the sealing effect of the resilient lips (two-phase sealing), thereby increasing, in a side effect, the friction forces and increasingly preventing the nut from rotating.
In addition, the position of the sealing unit 16, axially, is remote from the hot brake disc to such an extent that the temperature problem, which is likely to arise with prior art readjusting devices, is avoided. The plug 53 enables the piston to be set back for replacing the pad, without rotation of the piston, especially if the thread 29 is a trapezoidal thread. The second spring 36, at the same time, forms a stop for the movement of the piston 9, thereby limiting the possible movement of the piston. This is of advantage, for example, in misassemblies (inadvertent omission of the brake pad) or in the first hydraulic movement, because, in that instance, the piston tries to cover a distance which can exceed the aggregate of the normal actuating distance inclusive of the normal brake pad wear. This internal stop will insure that the spindle cannot move out to a further degree than is permitted by the spindle sealant (O-ring 38). The brake, hence, also in cases of faulty operations or misassemblies, will remain pressure-tight. As the axial movement of the spindle is confined by this stop, a high piston force results from the hydraulic pressure.
In addition to the retaining groove 37 as described above, another locking element is provided, namely the piston sleeve 52. The length of piston sleeve 52 is dimensioned so that, in view of the piston force, the spring sleeve in the piston can slide a distance approximately equal to the thickness of the brake pad. The piston sleeve does not lose its guidance and, upon insertion of the piston into the housing, the piston sleeve can be brought flush against the piston, thereby enabling the brake to retain its full serviceability.
The support member 56 according to FIG. 16 not only can cause an internally directed resilient effect but also may be provided with play vis-a-vis the ball bearing 40. The minimum gap permits easy opening of the friction cone and enables readjustment in accordance with the above descriptions.
The lid 62 is forced at a space from the piston 9 onto the nut 15, thereby permitting an adequate axial movement of the nut 15. An improvement allowing a greater freedom of movement of the nut 15 is attained if the outer annular cylindrical surface of the lid 62 is pressed onto the annular inner wall of the recess of the piston 9 accommodating the lid 62.
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A readjusting device wherein the readjusting process is pressure-controlled and is readjusted upon a decreasing brake pressure.
The frictional cone is placed in the piston and the sealant is provided between the rotatable readjusting member and the interior wall of the piston. Advantageous embodiments of the readjusting control are disclosed which employ a differential pressure process and improvements in the restoring pattern of the adjusting device.
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BACKGROUND OF THE INVENTION
The invention relates to a device that can be walked on and/or driven on, for example for bridging under bridges requiring renovation or for bridging over streets, made of a web that can be walked on, which is connected to handrails via transverse struts.
In many applications nowadays, webs are needed which can be walked on by persons. Mention should be made here, only by way of example, of pedestrian crossways over streets, which are primarily erected to be removable once more when they are provided only in the short term. This often occurs in the case of building works on the actual pedestrian crossways or in the case of the re-equipment of subways.
Reference should be made, as a further example, to bridging under bridges requiring renovation, in which a web, which can be walked on by the appropriate workers, is led along under the bridge but is suspended at the top on the bridge. A means of bridging under in this way must not only be easy to put together but primarily also mobile, since this under-bridging means has to be displaced between two bridge pillars.
As mentioned above, these two examples are intended only to indicate the possible applications, and do not constitute any exhaustive enumeration. What is disadvantageous in the case of all these applications is that these devices that can be walked on and/or driven on are mostly produced from steel elements and are therefore very heavy. In addition, their assembly is extremely complicated and requires a great deal of time.
SUMMARY OF THE INVENTION
The present invention is based on the object of developing a device that can be walked on of the abovementioned type, which is relatively light in weight, easy to produce and very versatile.
The achievement of this object leads to the fact that the web that can be walked on and/or the transverse struts and/or the handrails comprises or comprise extruded aluminum profiles.
Extruded aluminum profiles have the advantage that they are significantly lighter in comparison with, for example, steel profiles. It is therefore possible, for example, to produce under-bridging means of considerable length without the weight being too high.
Furthermore, it is possible in the extrusion process to produce aluminum profiles in such a way that they have a very high stiffness. This means that such devices that can be walked on and/or driven on can be classified in terms of their safety exactly as highly as the devices made of steel.
A particular advantage of the use of extruded aluminum profiles resides in the fact that a device that can be walked on and driven on of this type may be produced in an extraordinarily versatile manner. It is possible to produce the device in any desired length and width, without complicated efforts having to be exerted in addition.
The appropriate aluminum profiles are laid together at their extruded length, joined together and connected to one another. It is then possible in each case to cut a series of boards or of transverse struts off from this structure made of a plurality of extruded aluminum profiles. It is also possible for sections of a desired length to be cut off from an extruded profile and joined to make the boards or used as transverse struts. This is an extremely cost-effective and rapid production process and allows the production of boards and transverse struts of any desired length and width.
It may be sufficient if the same structure made of appropriate extruded aluminum strips is used for boards and transverse struts, but in practice fewer aluminum profiles might be adequate for the transverse struts than for the boards. In any case, however, at least one profiled strip is provided, which is adjoined on both sides by hinge profiles. The hinge profiles have the function that an arbitrary number of boards and transverse struts can be coupled together, in order to produce a device that can be walked on in the desired length.
In a simple exemplary embodiment, the hinge profiles of adjacent boards or transverse struts are configured in such a way that they engage in each other like teeth. That is to say, fork-like lugs project from a board or from a transverse strut, between which in each case tongues from the other board or transverse strut are pushed. The connection is then preferably performed via appropriate transverse rods or transverse pins, which are pushed into the lugs or tongues through appropriate eyes. It is then only necessary to carry out securing of these transverse rods or transverse pins in order that they do not inadvertently slide out of the eyes.
In a simple exemplary embodiment, a securing of this type may comprise appropriate bolts. However, bolts have to be secured in turn, in order that they do not loosen inadvertently. For this reason, annular channels are preferably molded on a transverse rod or a transverse pin on both sides in each case, into which channels a clamping bracket similar to a snap ring is inserted. For example, this clamping bracket may have opposed latching knobs, so that the clamping bracket is, so to speak, clipped into the annular channel.
In a further, preferred exemplary embodiment, the boards and the transverse struts are configured in such a way that they can be exposed to considerable lateral loads. For this purpose it is necessary to support the transverse struts at the boards in a physically separated manner. Therefore, here the hinge profile of a board is enlarged, for example designed in a triangular shape. The articulation point of the transverse struts is then no longer located close to the walk-on plane of the boards but spatially separated therefrom. Provided above and beneath the articulation point are supporting strips or abutments, against which the ends of the transverse struts are pressed. The transverse struts are prevented from bending out by this means.
As mentioned above, the handrail also comprises an extruded aluminum profile. This may, for example, be a U-shaped profile, the handrail then being simply pushed over the ends of the transverse struts and likewise secured by means of the transverse pin.
In a particularly preferred exemplary embodiment, the handrail is also used for holding a facing, by means of which the spaces between the transverse struts are made safe. The facing may be, for example, a textile tarpaulin, which may also be printed. By this means, this facing may also serve at the same time to carry advertisements. The facing preferably has an edge trim, which can be pushed into an appropriate groove in the handrail. At the other end, the facing is then fixed via another fastening element, for example a piece of elastic or the like. The facing also offers a safeguard for the people who walk on the device.
Since the handrail is also intended to be produced from an extruded aluminum profile, this may comprise an outer tube from which two angle strips project on either side, onto which in turn the groove to accommodate the edge trim is integrally molded. In order to connect successive handrail sections, an inner tube is provided which is pushed into the outer tube. By means of appropriate transverse pins, successive handrails can be fixed via the inner tube.
In some cases there is also the desire to "house" a device that can be walked on and/or driven on. In the modular system, this can also be carried out with the proposed cutoff extruded profiles. The transverse pin, which secures the handrail with respect to the transverse struts, is extended, for example, so that further transverse struts can be pushed onto the extension, these further struts being directed upward. At the other end, these transverse struts are in turn connected by means of a corresponding handrail, a roofing sheet being laid over these opposite handrails.
In order to secure and to maintain a specific distance between these additional transverse struts, a transverse bar is provided, which connects the opposite transverse struts to each other and at the same time spaces them apart. Floorboards can also be laid onto the transverse bars, which possibly, if desired, can in turn be walked on.
The present invention produces a device that can be walked on and/or driven on which is very easy to erect and to remove once more, which can be varied arbitrarily in its length and which has a relatively low weight with adequate stiffness. The whole takes place in a modular system, a few profiles being sufficient to produce a bridge or the like of desired length.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages, features and details of the invention emerge from the following description of preferred exemplary embodiments, and with reference to the drawing:
FIG. 1 shows a side view of a device that can be walked on according to the invention;
FIG. 2 shows a plan view of the device according to FIG. 1;
FIG. 3 shows a side view, shown enlarged, of a transverse strut according to the invention;
FIG. 4 shows a plan view of the transverse strut according to FIG. 3;
FIG. 5 shows a cross section, shown enlarged, through a part of the device that can be walked on according to FIG. 1, along the line V--V;
FIG. 6 shows a cross section through a part of FIG. 5 along the line VI--VI;
FIG. 7 shows a side view of a further region of the handrail according to FIG. 1;
FIG. 8 shows a plan view of the region of the handrail according to FIG. 7;
FIG. 9 shows a detail, broken open and partially in cross section, from the device that can be walked on according to FIG. 1 in the region of the connection of transverse struts to a web;
FIG. 10 shows a detail, shown enlarged, of a further exemplary embodiment of a possible connection between the individual elements of the device that can be walked on according to FIG. 1;
FIG. 11 shows a cross section through FIG. 10 along the line XI--XI;
FIG. 12 shows a side view of a board according to the invention for a further exemplary embodiment of a device that can be walked on;
FIG. 13 shows a cross section through a part of the device that can be walked on in the region of the connecting point of two boards according to FIG. 12;
FIG. 14 shows a plan view of a further exemplary embodiment of a transverse strut;
FIG. 15 shows a detail from a connecting region of two boards similar to FIG. 13, with fixed transverse struts;
FIG. 16 shows a cross section through the connecting point of the boards according to FIG. 15 with inserted transverse struts;
FIG. 17 shows a perspective view of a subregion of a device that can be walked on;
FIG. 18 shows a perspective view of a further exemplary embodiment of a handrail on transverse struts;
FIG. 19 shows a side view of a connecting point with a further exemplary embodiment of a handrail according to the invention on transverse struts;
FIG. 20 shows a schematic illustration of a further exemplary embodiment of a device that can be walked on according to the invention;
FIG. 21 shows a schematic illustration of a further exemplary embodiment of a device that can be walked on, corresponding to FIG. 1.
DETAILED DESCRIPTION
According to FIG. 1, a device that can be walked on according to the invention has a web 1, which is connected to handrails 3.1 and 3.2 on both sides via transverse struts 2. In this case, the web comprises individual boards 4, which are connected to one another in the manner of a hinge. In this way, a web 1 of any desired length can be produced. Each board 4 in turn comprises a plurality of profiled strips 5, which are produced from aluminum in the extrusion process. By way of example, it is indicated in FIGS. 3 and 4 how boards 4 of this type made of profiled strips 5 may be composed. In this case, however, it is also indicated at the same time in FIGS. 3 and 4 that the transverse struts 2 can be produced in the same way.
It can be seen that each board 4 and/or each transverse strut 2 begins with a hinge profile 6 and ends with a hinge profile 7. Between these there are various profiled strips 5.1 and 5.2, which may be of any desired configuration. Preference is given to a sandwich-like structure, which gives the overall board 4 and/or the transverse strut 2 an adequate stiffness. On the surface of the profiled strips 5 and the hinge profiles 6 and 7 there are ribs 8, which increase the resistance to slipping. The individual profiled strips 5 are connected to one another and to the hinge profile 6 or 7 by appropriate welded seams 9.
It can be seen in FIG. 2 that the hinge profiles 6 and 7 are configured in such a way that successive hinge profiles 6 and 7 engage in one another like teeth. The connection is then carried out by means of a transverse rod 10, illustrated in FIG. 9, which is pushed through appropriate eyes 11 and 12 in the hinge profiles 6 and 7. The securing of the transverse rod 10 on each side can be carried out by means of a bolt 13 screwed in at the end, with the interposition of an appropriate washer 14. Another possibility is described further below.
As mentioned above, the transverse struts 2 are also intended to be composed of individual profiles 5, the upper hinge profiles 7.1 and 7.2 of two cooperating transverse struts 2.1 and 2.2 being able to be seen in FIG. 6. The opposite hinge profile of each transverse strut 2.1 or 2.2 is connected in an articulated manner to the transverse rod 10, as indicated in FIG. 9.
The connection of the two cooperating transverse struts 2.1 and 2.2 together and to the handrail 3 is performed in accordance with FIG. 5 via a further transverse pin 15, into which on both sides bolts 16 and 17 are screwed at the ends, with the interposition of washers 18 and clamping pieces 19. By this means, an articulated fastening of the transverse struts 2 is performed, but the zig-zag arrangement imparts considerable stability to the overall device that can be walked on.
It can be seen in FIGS. 7 and 8 that the handrail 3 is also composed of individual sections 20.1 and 20.2. In this case, a joint 21 remains open between the sections 20.1 and 20.2, and is bridged over by a strip 22, which is only fixed on one section 20.1 by, for example, welding. The connection to the other section 20.2 is performed via a push-in pin 23, which secures the two sections 20.1 and 20.2 in relation to each other.
Instead of bolts 13, 16 or 17, another, easily detachable fixing of the corresponding transverse rods 10 or transverse pins 15 may be carried out, as is indicated in FIGS. 10 and 11. For this purpose, annular channels 23 are turned at the ends into the transverse rod 10 or transverse pin 15, into which channels snap-ring-like clamping brackets 24 can be inserted. Each clamping bracket 24 is shaped like a horseshoe or U-shaped and has inwardly directed latching knobs 25.1 and 25.2, which engage behind the transverse rod 10 or the transverse pin 15. By this means, the fixing of the transverse rod 10 or the transverse pin 15 in the clamping bracket 24 is secured. Additional securing may further be performed, for example, by means of a cotter pin, bolt or else by a simple piece of wire, which is threaded through two opposite drilled holes 26.1 and 26.2 in the clamping bracket 24, the two ends of the piece of wire being twisted together. In order that the clamping bracket 24 may be pushed more easily over the transverse rod 10 or the transverse pin 15 in the region of the annular channel 23, that is to say that the clamping bracket 24 opens more easily, a slight weakening 27 is provided in its vertex area.
The production of the device that can be walked on according to the invention takes place as follows:
Using the extrusion process, profiled strips 5 and hinge profiles 6 and 7 are produced. In order to form the boards 4, a number of profiled strips 5 are connected to one another by welding, any arbitrary amount of intermeshing between the individual profiled strips being able to take place here, such as for example tongue and groove connections or the like. However, the connection is as a rule always performed via a welded seam. However, the invention is not restricted to this; provided it is suitable, the connection may also be performed via a mechanical or chemical bonding means.
The hinge profiles are incised like teeth, so that a good tooth-like or hinge-like connection between the individual boards can take place at a later time.
Since as a rule the extruded profiles have a considerable length, this process also produces a structure which is significantly longer than the width of a desired board. However, this means that a plurality of boards can be cut off from such a structure.
Provided the boards 4 have a length which corresponds to that of the transverse strut 2, it is now possible for a plurality of transverse struts 2 to be cut off from a board 4, like wafers, in the longitudinal direction. When doing this, care should be taken that here, too, the opposite hinge moldings alternate, as is clarified in FIG. 4 and also in FIG. 2.
As a rule, however, the boards should have a greater length than the transverse struts 2. For this reason, it proves to be advisable to produce the transverse struts 2 from a number of dedicated profiled strips or hinge profiles. Production takes place in the same way as the production of the boards 4, but using a reduced number of profiled strips.
Depending on the desired length of the web 1, boards are now connected to one another, in each case a hinge profile 6 cooperating with a hinge profile 7 of the following board. After this, the transverse rod 10 is pushed through the eyes 11 and 12. On both sides, a transverse strut 2 is pushed onto each transverse rod 10 and secured by means of the bolt 13 and/or the clamping bracket 24.
At the other end, the transverse strut 2 is fixed on the handrail 3, a connection here of two adjacent transverse struts 2.1 and 2.2 being performed by means of the transverse pin 15 and the corresponding bolts 16, 17 and/or the clamping bracket 24.
As a rule, further transverse struts might be necessary between two board ends in each case, as can be seen in FIG. 1. The fixing of these transverse struts to the web 1 can be performed either via a short pin or via a further transverse rod, which is pushed through the sandwich-like structure of the profiled strips 5 and shows out of the profiled strips 5 on both sides. Two ends of adjacent transverse struts, which in turn engage in each other like teeth, can also be pushed onto this transverse rod. Securing is carried out once more via a bolt or the abovementioned clamping bracket 24.
Shown in FIG. 12 is a further exemplary embodiment of a board 4.1. Like the board 4, the board 4.1 is also produced from a plurality of profiled strips 5.3 and 5.4. These profiled strips 5 are preferably produced from aluminum in the extrusion process, appropriate strips of the desired width being cut off from this extruded profile.
Whereas the profiled strips 5.4 are designed as simple box profiles, the hinge profiles 6.1 and 7.1 have a dedicated shape, which primarily serves the strength or the lateral load bearing ability of the board 4.1. The hinge profiles 6.1 and 7.1 are overall approximately triangular-shaped in their contour, there being provided in the plane that can be walked on of the board 4 a supporting strip 28, below this supporting strip 28 a sleeve section 29, and below the latter an abutment 30. In this case, the sleeve sections 29 project approximately half way beyond the supporting strips 28 and the abutment 30, each hinge profile 6.1 and 7.1 being provided with a plurality of sleeve sections 29 arranged in an offset manner, which when the boards 4.1 are placed together with further boards 4.1, cooperate like teeth with sleeve sections arranged there. This is indicated in FIG. 13, the transverse rod 10 being pushed through the sleeve sections 29 in order to connect a hinge profile 6.1 to a hinge profile 7.1 of the adjacent board. In the region of the connection to transverse struts 31.1 and 31.2, the hinge profiles 6.1 and 7.1 have an incision 32, into which the transverse struts 31.1 and 31.2 can be inserted, as is illustrated in FIGS. 15 and 17. The transverse struts 31.1 and 31.2 are then likewise passed through by the transverse rod 10 and thus connected to the boards 4.1.
The advantage of arranging the transverse rod 10 deeper underneath the walk-on level of the board 4.1 and of the triangular configuration of the hinge profiles 6.1 and 7.1 with the supporting strips 28 and abutment 30 resides in the fact that the corresponding ends of the transverse struts 31.1 and 31.2 can be supported against these supporting strips 28 and abutment 30, which can then intercept the appropriate forces in the event of lateral loading of the transverse struts 31.1 and 31.2. The bending out of the transverse struts 31 is effectively prevented by this means.
In order that the transverse struts 31.1 and 31.2 can cooperate with the abutments 30, as is indicated in FIG. 15, the corresponding transverse strut 31.1 or 31.2 in each case has an integrally-molded supporting lug 33, which presses onto the abutment 30. A corresponding transverse strut 31 of this type is shown in FIG. 14.
In order that the transverse struts 31.1 and 31.2 can also have an appropriately distributed pressure applied to them from the outside, the transverse rod 10 has pushed onto it a U-shaped clamp 34, which presses onto the transverse struts 31.1 and 31.2 with its limbs remote from the transverse rod 10. A nut 35 is provided for fixing the clamp 34.
FIGS. 18 and 19 primarily show a further exemplary embodiment of a handrail 3.1. The latter likewise comprises preferably extruded aluminum profiled sections, an outer tube 36 being provided which has grooving 37 on its surface. This grooving 37 improves the possible grip.
Spaced angle strips 38.1 and 38.2 project from the outer tube 36, and in the position of use engage over the transverse struts 31.1 and 31.2. Integrally molded in each case at the end of each angle strip 38.1 and 38.2 is a groove 39.1 and 39.2, which serves to accommodate an edge trim 40, as is described in relation to FIG. 20.
A connection of the handrail 3.1 to the two transverse struts 31.1 and 31.2 is performed via a transverse pin 15.1, which is secured by cotter pins 41.
Successive handrail sections 3.1 are preferably connected to one another by an inner tube 42, which is pushed into adjacent ends of outer tubes 36. Here, too, securing of the inner tube 42 is performed via a securing pin 43, which is secured by a cotter pin.
Illustrated in FIG. 20 is a device that can be walked on which is "housed". It is possible to see boards 4.1, from which transverse struts 31.1 and 31.2 project. The handrail 3.1 is fitted on these transverse struts 31.1 and 31.2. Cladding the areas between the transverse struts is performed by a facing 44. The facing 44 preferably comprises a suitable textile material which has the edge trim 40 at the edge. This edge trim 40 is pushed into a groove 39 in the handrail 3.1. The lower end of the facing 44 is fixed in any desired manner. For example, a piece of elastic 45 is conceivable, which engages via an appropriate hook into corresponding holes in the underside of the board 4.1. However, other possibilities are also conceivable here.
In order to stiffen the facing 44, pockets 46 are further provided, into which it is possible to push reinforcing strips, not shown in more detail.
For the purpose of housing, the transverse pin 15.1 is replaced by a transverse rod 47, which projects somewhat beyond the transverse strut 31.1. Further transverse struts 31.3 and 31.4 are pushed onto this transverse rod 47 and fastened by means of cotter pins or the like. Fitted onto these transverse struts 31.3 and 31.4 is a further handrail 3.1, on which a roofing sheet 48 rests firmly. This roofing sheet 48 extends from the handrail 3.1 to the opposite handrail 3.1 and is fastened there in any desired way. This preferably takes place there once more via a piece of elastic or the like, not shown in more detail.
In order to improve the stability and, in particular, to secure the spacing, there is provided between the opposite transverse struts 31.3/31.4 a transverse bar 49, which simultaneously also replaces the transverse pin 15.1 connecting the handrail 3.1 to the transverse struts 31.3/31.4.
FIG. 21 indicates that it is also possible for downwardly projecting lower struts 50 to be provided. The connecting of these lower struts 50 to the boards 4 or 4.1 is performed via the transverse rods 10. At the other end, the lower struts 50 can be connected to one another by handrail elements 3/3.1. This mirror-image arrangement in relation to the transverse struts 3/31 gives the overall device enormous strength and is primarily suitable for relatively long bridges.
It is inherently self-evident that hinge profiles 6/7 at the beginning of a web 1 may be replaced by an appropriate drive-on profile, which is of wedge-shaped design. In this way, a bridge of this type may also be suitable for vehicles.
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In a device that can be walked on or driven on, for example for bridging under bridges requiring renovation or for bridging over streets, a web that can be walked on is connected to handrails via transverse struts. In this case, the web that can be walked on and/or the transverse struts and/or the handrails comprise extruded aluminum profiles.
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BACKGROUND OF THE INVENTION
Field of the Invention
Portable grinding tools are customarily hand-held units and for this reason have limited torque and speed capability necessitated by the maximum weight that can conveniently be held in an operator's hands. A recent patent, U.S. Pat. No. 3,214,869, discloses a portable grinding apparatus in which the motor is mounted within a wheeled canister and connected through a flexible shaft to a hand-held grinding tool. While this structure is an improvement over the prior devices in that drive motors of higher torque and speed capability can be used than used in previous hand-held tools, the device is still limited since the canister-housed motor is cumbersome and limits freedom of movement of the operator.
SUMMARY OF THE INVENTION
This invention comprises a portable grinding apparatus in which the drive motor is mounted on a back-pack support frame and connected to a hand-held abrading tool by a flexible shaft. The back-pack frame comprises a pair of parallel standards interconnected by crossbars and bears harness means permitting its detachable mounting to the back of an operator. The frame has a support plate that rotatably carries a base plate on which the drive motor is attached. The base plate and drive motor are covered by an enclosure and lock means are provided on the frame to secure the base plate and enclosure against free rotation. The enclosure is provided with an exhaust fan to provide air circulation through the enclosed chamber, to provide a cooling air flow for the drive motor.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the preferred embodiment shown in the figures of which:
FIG. 1 is a side elevational view of the grinding apparatus;
FIG. 2 is an elevational view of the back of the apparatus;
FIG. 3 is a back elevational view of the apparatus with the dome enclosure removed;
FIG. 4 is a view of the inside of the dome enclosure;
FIG. 5 is a sectional, elevational view of the apparatus;
FIG. 6 is a view along the lines 6--6 of FIG. 5; and
FIG. 7 is a schematic of the control circuit of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the invention is illustrated as a housing 10 formed by a dome enclosure 12 which is attached to a support plate 14 that has a peripheral edge 16 and that is carried on a frame formed of a pair of parallel standards 18 which have a forwardly inclined lower end 20, as conventional in back-packs. The frame also includes an auxiliary frame 22 formed of a lowermost crossbar and upright parallel arms 26 which extend to an upper tubular crossbar 28 of the main frame. The main frame has a plurality of tubular posts 30 to which is attached the support plate 14 for the portable grinding apparatus. A crossbar 13 (see FIGS. 3 and 5) is provided at the lower portion of plate 14 and is secured to the main frame.
The support frame also has interconnectable strap means to permit securing the frame to the back of an operator. The interconnectable strap means includes an over-the-shoulder strap 32 carried at each side of the apparatus and secured to the upper tubular crossbar 28 with a dependent strap 34 extends to the lower portion of each parallel standard 20. The strap means also includes a wallet securing member defined by strap 36 which is attached to fabric band 38 of cushioning material designed to fit the small of the operator's back.
Referring now to FIG. 2, the apparatus is illustrated from the back side of the operator. The power supply for the grinding apparatus comprises an electrical cord 40 which enters the domed enclosure 12 through grommet 42. The dome 12 bares a peripheral, radial slot 44 which provides for exit of flexible shaft 46 from the drive motor contained within dome 12. The flexible shaft 46 extends to a hand grip 48 that is distally carried thereon and a grinding means such as grinding wheel 50 that is attached to the flexible shaft with a retaining nut 52. The hand grip 48 also bears remote switch 54 for operation of the motor.
The dome enclosure 12 is provided with ventilating means and has a ventilating port 58 which is covered by a grid or screen 60 to provide for discharge of the air circulated through the dome enclosure 12 during operation.
Referring now to FIG. 3, the apparatus is shown with the dome 12 removed. As there illustrated, the support plate 14 has a plurality of apertures 15 that are spaced about the plate to permit a circulating flow of air through the enclosure. The drive motor 62 is mounted on the support plate 14 at a central position and a relay 64 is provided for controlling the operation of the motor. The electrical cord 40 is provided with a disconnecting plug attachment 67 and 66; these elements are shown in FIGS. 4 and 3, respectively. A short length of the cord 68 extends to the relay box 64. A lead 60 also extends to relay box 64 and this lead is coextensive with the flexible shaft, extending to remote switch 54.
The flexible shaft 46 is provided with a support carried by the motor casing. This support comprises bearing and sleeve shaft support 59 which is distally carried by brackets 57 on opposite sides of the motor casing. Brackets 57 are secured by bands 53 and 55 which encircle the motor casing.
Referring to FIG. 4, the dome enclosure carries a ventilating means 70 in the form of an exhaust fan, and the like, having its own drive motor and connected through the relay box 64 by electrical lead 69 having a disconnectable plug 71 for connection in relay box 64.
The dome enclosure also supports a plurality of switch means 72 and 74 which are restart and reversing switches, respectively, and redundant switches 72' and 74', connected in parallel therewith. These switches are interconnected by conductor 73 and, through lead 75 and connector plug 77, are detachably connected to mating plug 79 on the end of conductor 81 which leads to relay box 64.
Referring now to FIG. 5, the portable grinding apparatus is shown in a sectional view with the dome 12 secured to a base plate 80 which is carried on a central plate 82 that is secured to hub 84. The latter is rotatably mounted on auxilliary plate 86 which is attached to the support plate 14 with fasteners, such as rivets, machine screws 88 and the like. The motor 62 is mounted in a support cradle 90 of a generally U-shaped bracket having apertures to receive the mounting fasteners 92 which secure cradle 90, base plate 80 and central plate 82 in assembly. The frame also bears interlocking means to restrain or detent the rotational movement of the base plate 80 and associated dome 12. This comprises a pin 94 which is biased by spring 96 into a detenting position to seat in aperture 98 of the base plate 80. Pin 94 extends through an elongated aperture or slot 100 in the support plate 12 and through an aperture in the standard 18. A hand grip 102 can be provided on the end of pin 94.
Referring now to FIG. 6, the elongated slot 100 is illustrated with pin 94 rotated 90° from the view shown in the FIG. 5 to reveal, in the hidden object lines, a crosspin 104 that is carried by pin 94 and that functions to serve as a key to restrain the detenting position of pin 94 when retrieved and rotated in the illustrated manner; the crosspin bearing against the support plate 14 and preventing further inward movement of pin 94.
Referring now to FIG. 7, the electrical schematic of the grinding apparatus is illustrated. As there shown, electrical supply lead 40 is connected through mating connector plug 66 and 67 to lead 68 that extends to the relay box 64. The output of the relay box comprises conducting leads 61 and 63 which extend to motor 62. The conductor 60 which extends to remote switch 54, illustrated, and the interconnecting leads 69 and 65 are shown between the exhaust fan 70 and relay box 64. Also shown is the interconnecting lead 75 and 79 which extend between the reset switch means 72 and reversing switch means 74 and relay box 64.
The operation of the grinding apparatus of the invention is fairly apparent from the preceding description. The apparatus is intended for mounting on the back of an operator where it is removed from any possible obstruction with the work or hindrance of the free movement of the operator. The drive motor is mounted on a rotatable base plate thereby permitting the operator to freely shift the grinding tool assembly to either hand without requiring that the flexible shaft be passed in front of the operator. This is accomplished by the operator by disengaging the interlocking pin 94 that restrains free rotation of the domed enclosure, thereafter, rotating the flexible shaft and attached assembly from one side to the other and securing the assembly in the final desired position by seating the locking pin 94 in the appropriate aperture 97 or 98. The operator starts and stops the device using remote switch 54. When it is desired to reverse the rotation, the operator can reach behind his back and move the reset switch 74 or 74'. Since the switches are in parallel and are symmetrically positioned, the switch will be in the proper position regardless of the orientation of the motor and drive shaft on the support frame. A similar convenience is provided with the redundant parallel restart switch means 72.
The invention has been described with reference to the presently illustrated and preferred embodiment. It is not intended that the invention be unduly limited by this description of the preferred embodiment. Instead, it is intended that the invention be defined by the means, and their obvious equivalents, set forth in the following claims.
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There is disclosed a portable grinding apparatus which includes a frame with straps and the like for mounting on the back of an operator. The frame supports a base plate carrying an electric motor which is connected through a flexible shaft to a hand-held abrating device, such as a grinding wheel and the like. The base plate, which supports the grinding motor, is rotatably mounted on the frame to permit shifting the abrating device between the operator's hands and the motor is covered with a housing which includes an exhaust fan for circulating a flow of air across the motor to provide comfort to the operator.
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BACKGROUND OF THE INVENTION
This invention relates to automatic vehicular transmissions utilizing planetary gear sets and controllable clutches to obtain a suitable set of speed ratios.
In a front wheel drive vehicle, the axial space available for the transmission is limited by the width of the engine compartment and the length of the engine. In addition, the trend to increase the number of ratios available generally increases the number of components required. For these reasons, it is desirable to position components concentrically with each other in order to minimize axial length. The ability to position components concentrically is limited, however, by the need to connect particular components to each other and to the transmission case.
Furthermore, it is desirable for the output element to be located near the center of the vehicle, which corresponds to the input end of the gear box. An output element located toward the outside of the vehicle may require additional support structure and add length on the transfer axis. With some kinematic arrangements, however, the need to connect certain elements to the transmission case requires that the output element be so located.
BRIEF SUMMARY OF THE INVENTION
The claimed invention is a family of six and eight speed kinematic arrangements that are amenable to coaxial placement of components and also amenable to placing the output shaft near the front of the transmission. The arrangements include an epicyclic gearing assembly with four elements, a front planetary gear set with a stationary carrier, and a set of clutches and brakes. These arrangements are in the family of dual input kinematic arrangements as described in U.S. Pat. Nos. 5,106,352 and 7,699,744. One of the brakes is located internally and operates by releasably connecting one element of the epicyclic gearing assembly to the fixed carrier of the front gear set. As a result of this placement, this brake and two of the clutches may be positioned co-axially with each other and also with the epicyclic gearing assembly. Furthermore, this placement does not interfere with locating the output member at the front of the gear box. The epicyclic gearing assembly may take a number of forms, some of which would not be possible with a traditional placement of the aforementioned brake.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a transmission according to the present invention wherein the epicyclic gearing assembly is a Simpson gear set.
FIG. 2 is a table showing the proposed tooth numbers for the gears of the transmission illustrated in FIG. 1 .
FIG. 3 is a table indicating the clutch state and resulting speed ratio of the transmission in FIG. 1 when the gears have the numbers of teeth indicated in FIG. 2 .
FIG. 4 is a schematic diagram of a transmission according to the present invention wherein the epicyclic gearing assembly is a crossed ring carrier gear set.
FIG. 5 is a table showing the proposed tooth numbers for the gears of the transmission illustrated in FIG. 4 .
FIG. 6 is a table indicating the clutch state and resulting speed ratio of the transmission in FIG. 4 when the gears have the numbers of teeth indicated in FIG. 5 .
FIG. 7 is a schematic diagram of a transmission according to the present invention wherein the epicyclic gearing assembly is a Ravigneaux gear set.
FIG. 8 is a table showing the proposed tooth numbers for the gears of the transmission illustrated in FIG. 7 .
FIG. 9 is a table indicating the clutch state and resulting speed ratio of the transmission in FIG. 7 when the gears have the numbers of teeth indicated in FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
A transmission according to a first embodiment of the invention is illustrated in FIG. 1 . A transmission housing 14 is fixed to the vehicle structure. An input shaft 10 is driven by the vehicle's engine, preferably via a launch device such as a torque converter with a lockup clutch, or via a dedicated launch clutch. Alternatively, the input shaft may be driven directly by the vehicle's engine. An output element 12 is driveably connected to the vehicle's wheels, preferably via a differential and either a set of transfer gears or a transfer chain. Output element 12 is supported by front support 52 which is fixed to the transmission housing.
Front gear set 40 is a double pinion planetary gear set. Carrier 46 is fixed to the front support 52 . Sun gear 42 is fixed to input shaft 10 . A set of inner planet gears 48 is supported for rotation on carrier 46 and meshes with sun gear 42 . A set of outer planet gears 50 is also supported for rotation on carrier 46 such that each outer planet gear meshes with a corresponding inner planet gear 48 . A ring gear 44 with internal teeth meshes with each of the outer planet gears 50 . As a result of this gearing, ring gear 44 rotates in the same direction as input shaft 10 but at a reduced speed.
Rear gear set 20 and middle gear set 30 are simple planetary gear sets. A set of planet gears 28 is supported for rotation on carrier 26 and meshes with both sun gear 22 and ring gear 24 . Similarly, a set of planet gears 38 is supported for rotation on carrier 36 and meshes with both sun gear 32 and ring gear 34 . Sun gear 22 and sun gear 32 are fixed to each other and to shell 56 . Carrier 26 is fixed to shell 80 . Carrier 36 and ring gear 24 are fixed to each other and to output element 12 through shell 90 . Ring gear 34 is fixed to shell 68 .
Front cylinder assembly 62 is fixed to ring gear 44 . Clutch pack 70 is comprised of plates splined to cylinder assembly 62 alternating with plates splined to shell 68 . When hydraulic pressure is applied to piston 72 , the plates are forced together and torque is transferred between ring gear 44 and ring gear 34 . When the hydraulic pressure is released, ring gear 44 and ring gear 34 may rotate at different speeds with low parasitic drag. Similarly, clutch pack 64 is comprised of plates splined to cylinder assembly 62 alternating with plates splined to shell 56 . When hydraulic pressure is applied to piston 66 , torque is transferred between ring gear 44 and sun gears 22 and 32 . Pressurized fluid is routed from the control body, through front support 52 , into front cylinder assembly 62 between rotating seals.
Middle cylinder assembly 54 is fixed to carrier 46 . Clutch pack 58 is comprised of plates splined to cylinder assembly 54 alternating with plates splined to shell 56 . When hydraulic pressure is applied to piston 60 , sun gear 22 and sun gear 32 are held against rotation. Pressurized fluid is routed from the control body, through front support 52 , between planet gears, into middle cylinder assembly 54 . A more traditional placement of this brake would preclude routing shell 90 to the front of the gear box and therefore require that the output be located near the center of the gear box. As a result of this placement of clutch pack 58 , output element 12 is located in the more favorable position near the front of the gear box.
Rear cylinder assembly 74 is fixed to input shaft 10 . When hydraulic pressure is applied to piston 84 , clutch pack 82 transfers torque between input shaft 10 and carrier 26 . Similarly, when hydraulic pressure is applied to piston 78 , clutch pack 76 transfers torque between input shaft 10 and sun gears 22 and 32 . Clutch pack 76 and piston 78 are required for an eight speed transmission, but may be omitted in a six speed transmission. Pressurized fluid is routed from the control body, through housing 14 , into rear cylinder assembly 74 between rotating seals.
When hydraulic pressure is applied to piston 88 , clutch pack 86 holds carrier 26 against rotation. One way clutch 92 passively prevents carrier 26 from rotating in the negative direction, but allows carrier 26 to rotate in the forward direction. One way clutch 92 may optionally be omitted and its function performed by actively controlling clutch 86 .
This arrangement permits clutch packs 58 , 64 , and 70 to be positioned concentrically and outside of the planetary gear sets such that they do not add to the axial length of the gearbox. Similarly, clutch packs 76 , 82 , and 86 may be positioned concentrically with each other and outside the planetary gearing.
Although clutches 64 , 70 , 76 , and 82 and brakes 58 and 86 have all been illustrated and described as hydraulically actuated multi-plate clutches or brakes, the invention may be practiced with alternate types of releasable connections including but not limited to dog clutches, controllable one way clutches, magnetically actuated clutches, or electrically actuated clutches. Components being fixed to one another means that the components are attached in a fashion that transfers torque and forces the components to rotate at the same speed for anticipated torque levels. Acceptable methods of fixing components to one another include but are not limited to machining from common stock, welds, spline joints, and interference fits. Some lash or torsional compliance between fixed components is permissible.
If the transmission of FIG. 1 is equipped with a launch device, then it is prepared for forward vehicle motion by engaging clutch 70 . If one way clutch 92 is omitted, then brake 86 must also be engaged. If the launch device is a torque converter, the vehicle will accelerate as soon as the brakes are released. The torque converter lock up clutch should be engaged soon after the vehicle attains a sufficient speed. On the other hand, if the launch device is a dedicated launch clutch, forward motion is effectuated by gradually engaging the dedicated launch clutch.
If input shaft 10 is directly driven by the engine, then the only preparation required for forward vehicle motion is engaging brake 86 if one way clutch 92 is omitted. Forward motion is effectuated by gradually engaging clutch 70 . The remaining steps in operating the transmission are independent of the type of launch device.
Once the vehicle reaches a sufficient forward speed, a shift into second gear is accomplished by gradually engaging brake 58 . As brake 58 is engaged, one way clutch 92 will over run. If one way clutch 92 is omitted, brake 86 must be gradually released while brake 58 is engaged. All remaining shifts between adjacent gears are accomplished by the coordinated engagement of one clutch or brake and release of another clutch or brake while maintaining a third clutch or brake according to the table in FIG. 3 . In addition to these shifts, all two step shifts may be accomplished by releasing a single element, engaging another element, and maintaining one element in an engaged state.
If the transmission is equipped with a launch device, then it is prepared for reverse vehicle motion by engaging clutch 64 and brake 86 . As with forward motion, if the launch device is a torque converter, the vehicle will accelerate as soon as the brakes are released. If the launch device is a dedicated launch clutch, reverse motion is effectuated by gradually engaging the dedicated launch clutch. On the other hand, if input shaft 10 is directly driven by the engine, then the transmission is prepared for reverse vehicle motion by engaging brake 86 and reverse motion is effectuated by gradually engaging clutch 64 .
A transmission according to this invention comprises an epicyclic gearing assembly with four members that rotate around a common axis with speeds that are linearly related. Specifically, the second and third elements each have speeds that are a weighted average of the speed of the first and fourth elements. The speed of the second element is between the speed of the first and third elements. The speed of the third element is between the speed of the second and fourth elements. The weighting factors are determined by the configuration of the epicyclic gearing assembly and the ratios of the numbers of gear teeth.
In the transmission of FIG. 1 , the epicyclic gearing assembly corresponds to planetary gear sets 20 and 30 . The first member corresponds to ring gear 34 . The second member corresponds to the combination of carrier 36 and ring gear 24 . The third member corresponds to carrier 26 . Finally, the fourth member corresponds to the combination of sun gear 22 and sun gear 32 .
FIG. 4 illustrates a transmission according to the present invention in which the epicyclic gearing assembly comprises two simple planetary gear sets 120 and 130 in a crossed ring carrier configuration. Carrier 136 is fixed to ring gear 124 and also to output element 12 through shell 90 . Carrier 126 is fixed to ring gear 134 and shell 80 . The first member corresponds to sun gear 132 which is fixed to shell 68 . The second member corresponds to the combination of carrier 136 and ring gear 124 . The third member corresponds to the combination of carrier 126 and ring gear 134 . Finally, the fourth member corresponds to sun gear 122 which is fixed to shell 56 . FIG. 5 shows suggested tooth numbers for this embodiment and FIG. 6 shows the resulting speed ratios. The operation of this embodiment is identical to the operation of the embodiment of FIG. 1 .
FIG. 7 illustrates a transmission according to the present invention in which the epicyclic gearing assembly is a Ravigneaux gear set 140 . A set of long planet gears 152 is supported for rotation on carrier 148 and meshes with both sun gear 142 and ring gear 146 . A set of short planet gears 150 is also supported for rotation on carrier 148 such that each short planet gear meshes with a corresponding long planet gear and with sun gear 144 . The first member corresponds to sun gear 144 which is fixed to shell 68 . The second member corresponds to ring gear 146 which is fixed to output element 12 through shell 90 . The third member corresponds to carrier 148 which is fixed to shell 80 . Finally, the fourth member corresponds to sun gear 142 which is fixed to shell 56 . FIG. 8 shows suggested tooth numbers for this embodiment and FIG. 9 shows the resulting speed ratios. The operation of this embodiment is identical to the operation of the embodiment of FIG. 1 .
Other types of epicyclic gearing assemblies are known and may be substituted without departing from the present invention. These other known types include but are not limited to planetary gear sets with stepped planet gears and other combinations of two simple or double pinion planetary gear sets with two connections between elements.
In accordance with the provisions of the patent statutes, the preferred embodiment has been described. However, it should be noted that alternate embodiments can be practiced otherwise than as specifically illustrated and described.
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A multiple speed power transmission comprises: an epicyclic gearing assembly comprising first, second, third, and fourth rotating members with linearly related speeds; a double pinion planetary gear set with grounded carrier and input driven sun gear; two brakes; four clutches; and specified interconnections. The brakes and clutches are operated in combinations of two to produce eight forward speed ratios and at least one reverse speed ratio.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority under 35 U.S.C. §119 to Japanese Patent Application No. 2007-116095, filed Apr. 25, 2007, entitled “ELECTROPHOTOGRAPHIC PHOTORECEPTOR, METHOD FOR MANUFACTURING THE SAME, AND IMAGE-FORMING APPARATUS” The contents of this application are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electrophotographic photoreceptor, a method for manufacturing the electrophotographic photoreceptor, and an image-forming apparatus that includes the electrophotographic photoreceptor.
2. Description of the Related Art
The production of electrophotographic photoreceptors that include an amorphous silicon (hereinafter referred to as “a-Si”) photosensitive layer is increasing year by year because of their high abrasion resistance, high heat resistance, high photosensitivity, and nonpolluting characteristics.
One of such electrophotographic photoreceptors includes an a-Si photosensitive layer that is formed on a cylindrical aluminum alloy substrate by a thin-film forming method (for example, a glow discharge decomposition method). This a-Si photosensitive layer includes an a-Si photoconductive layer and a surface layer formed thereon. The a-Si photosensitive layer may include a carrier injection preventing layer between the cylindrical substrate and the photoconductive layer.
However, in electrophotographic photoreceptors having such a structure, the photosensitive layer may have a protrusion.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a schematic view of an image-forming apparatus according to an embodiment of the present invention;
FIG. 2A is a schematic cross-sectional view of an electrophotographic photoreceptor according to an embodiment of the present invention, and FIG. 2B is an enlarged view of a principal part thereof;
FIG. 3 is a schematic cross-sectional view of a plasma chemical vapor deposition (CVD) apparatus for forming a photosensitive layer in the electrophotographic photoreceptor illustrated in FIG. 2A ;
FIG. 4 is a schematic cross-sectional view of a principal part of an electrophotographic photoreceptor to illustrate a protrusion disposed on a photosensitive layer;
FIGS. 5A to 5C are schematic cross-sectional views of a principal part of an electrophotographic photoreceptor to illustrate a resin portion that partly ( 5 A, 5 B) or entirely ( 5 C) covers a protrusion disposed on a photosensitive layer;
FIG. 6 is a schematic view of an apparatus for forming a resin portion;
FIG. 7 is a schematic cross-sectional view illustrating how a protrusion disposed on a photosensitive layer scrapes resin off a resin film;
FIGS. 8A to 8C are schematic cross-sectional views of a principal part of an electrophotographic photoreceptor to illustrate a resin portion that partly ( 8 A, 8 B) or entirely ( 8 C) covers a protrusion disposed on a photosensitive layer;
FIG. 9 is a schematic cross-sectional view of a principal part of a lapping sheet for grinding a resin portion; and
FIG. 10 is a schematic view of another apparatus for forming a resin portion upon a electrophotographic photoreceptor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to an aspect of the present invention, an electrophotographic photoreceptor includes a substrate, a photosensitive layer and a resin portion. The photosensitive layer is disposed on the substrate and has a protrusion thereon. The resin portion partly or entirely covers the protrusion.
According to another aspect of the present invention, a method for manufacturing an electrophotographic photoreceptor includes the steps of: forming a photosensitive layer on the outer surface of a cylindrical substrate; and partly or entirely covering a protrusion disposed on the photosensitive layer with a resin.
According to further aspect of the present invention, an image-forming apparatus includes the electrophotographic photoreceptor.
Some embodiments of the invention will now be described with reference to the accompanying drawings, wherein like reference numerals designate corresponding or identical elements throughout the various drawings.
As illustrated in FIG. 1 , an image-forming apparatus 1 utilizes a Carlson process as an image-forming method. The image-forming apparatus 1 includes an electrophotographic photoreceptor 2 , a charger 41 , an exposure unit 42 , a developing unit 43 , a transfer unit 44 , a fixing unit 45 , a cleaning unit 46 , and a static eliminator 47 .
The charger 41 is of a non-contact type. The charger 41 includes a housing 41 B having an opening 41 A facing the electrophotographic photoreceptor 2 , the grid electrode 41 C disposed at the opening 41 A, and a charging wire 41 D disposed inside the housing 41 B.
The charger may be a contact charger in place of the non-contact charger 41 . The contact charger may have a charging roller. For example, the charging roller includes an electroconductive rubber roller and a metal shaft disposed at the center of the electroconductive rubber roller. A direct-current (DC) voltage or a voltage of DC and alternating current (AC) is applied to the metal shaft to charge the electrophotographic photoreceptor 2 directly.
The exposure unit 42 can emit light having a particular wavelength (for example, in the range of 650 to 780 nm) and forms an electrostatic latent image on the electrophotographic photoreceptor 2 . The exposure unit 42 can irradiate the electrophotographic photoreceptor 2 with light corresponding to a picture signal to reduce the electric potential at the irradiated portion, thus forming an electrostatic latent image as a voltage contrast. The exposure unit 42 may include a light-emitting diode (LED) head including a plurality of LED devices (wavelength: about 680 nm). Alternatively, in place of the LED head, the exposure unit 42 may include an optical system that includes a laser beam and a polygonal mirror, or an optical system that includes a lens and a mirror each transmitting light reflected from an object to be printed.
The developing unit 43 develops an electrostatic latent image of the electrophotographic photoreceptor 2 to form a toner image. The developing unit 43 includes a developing roller 43 A for retaining a developing agent (toner), and a wheel (not shown) for maintaining a substantially constant gap between the developing unit 43 and the electrophotographic photoreceptor 2 . The developing agent composes a toner image that is formed on the electrophotographic photoreceptor 2 . The developing agent may be a one-component system containing a toner or a two-component system containing a toner and a carrier.
The developing roller 43 A conveys a developing agent to the surface (particularly to an area to be developed) of the electrophotographic photoreceptor 2 . The developing roller 43 A is charged at a predetermined electric potential with a predetermined polarity upon the application of a direct-current voltage or an alternating voltage.
In the developing unit 43 , the developing agent conveyed by the developing roller 43 A adheres to an area to be developed on the electrophotographic photoreceptor 2 by the electrostatic attraction force between the developing agent and an electrostatic latent image, thus visualizing the latent image. When a toner image is formed by normal development, the charge polarity of the toner image is opposite to the charge polarity of the surface of the electrophotographic photoreceptor 2 . When a toner image is formed by reversal development, the charge polarity of the toner image is the same as the charge polarity of the surface of the electrophotographic photoreceptor 2 .
The transfer unit 44 transfers a toner image formed on the electrophotographic photoreceptor 2 to a recording medium P supplied to a transfer area between the electrophotographic photoreceptor 2 and the transfer unit 44 . The transfer unit 44 includes a transfer charger 44 A and a detach charger 44 B. In the transfer unit 44 , the back (non-recording surface) of the recording medium P is charged oppositely to the toner image by the transfer charger 44 A. The electrostatic attraction force between the charged electricity and the toner image allows the toner image to be transferred to the recording medium P. In the transfer unit 44 , synchronously with the transfer of the toner image, the back of the recording medium P is charged by an alternating current by the detach charger 44 B. Consequently, the recording medium P is immediately separated from the surface of the electrophotographic photoreceptor 2 .
The transfer unit 44 may be a transfer roller, which is disposed facing to the electrophotographic photoreceptor 2 with a minute gap (typically 0.5 mm or less) therebetween. The transfer roller is designed to apply a transfer voltage to the recording medium P, for example, with a direct-current power source to attract a toner image formed on the electrophotographic photoreceptor 2 to the recording medium P. The use of the transfer roller can eliminate a detach apparatus, such as the detach charger 44 B.
The fixing unit 45 includes a pair of fixing rollers 45 A and 45 B, and fixes a transferred toner image on the recording medium P. The fixing rollers 45 A and 45 B may be a metal roller coated with Teflon (registered trademark). The fixing unit 45 fixes a toner image, for example, by heating the recording medium P and applying pressure on the recording medium P when the recording medium P passes between the pair of fixing rollers 45 A and 45 B.
The cleaning unit 46 includes a cleaning blade 46 A, a spring 46 B, and a case 46 C, and removes a developing agent that remains on the electrophotographic photoreceptor 2 . The cleaning blade 46 A scrapes a residual toner off the surface of a surface layer 29 of the electrophotographic photoreceptor 2 . The cleaning blade 46 A is supported by the case 46 C via an urging means, such as the spring 46 B, such that the front-end of the cleaning blade 46 A is pressed against the outer surface (surface layer 29 in FIG. 2B ) of the electrophotographic photoreceptor 2 . The cleaning blade 46 A may be formed of a rubber material mainly composed of a polyurethane resin. The front-end of the cleaning blade 46 A in contact with the surface layer 29 typically has a thickness in the range of 1.0 to 1.2 mm. The linear pressure of the cleaning blade 46 A against the surface layer 29 may be 0.14 gf/cm (typically in the range of 0.05 to 0.3 gf/cm). The cleaning blade 46 A may have a hardness of 74 (suitably in the range of 67 to 84) according to JIS K 6253 (ISO 7619).
The static eliminator 47 removes surface charges (a remaining electrostatic latent image) of the electrophotographic photoreceptor 2 . The static eliminator 47 irradiates the outer surface (surface layer 29 in FIG. 2B ) of the electrophotographic photoreceptor 2 with light from a light source, such as an LED, thus removing surface charges of the electrophotographic photoreceptor 2 .
An electrostatic latent image and a toner image are formed on the electrophotographic photoreceptor in response to a picture signal. The electrophotographic photoreceptor can rotate in the direction of arrow A in FIG. 1 . As illustrated in FIG. 2A , the electrophotographic photoreceptor 2 includes a photosensitive layer 21 formed on a cylindrical substrate 20 .
The cylindrical substrate 20 is a base body of the electrophotographic photoreceptor 2 . At least the surface of the cylindrical substrate 20 is electrically conductive. More specifically, the cylindrical substrate 20 may be formed entirely of an electroconductive material, or may be an insulating cylindrical body having an electroconductive film thereon. Examples of the electroconductive material that forms the cylindrical substrate 20 include metals, such as Al, stainless steel (SUS), Zn, Cu, Fe, Ti, Ni, Cr, Ta, Sn, Au, and Ag, and alloys thereof. Examples of an insulating material that forms the cylindrical substrate 20 include resins, glasses, and ceramics. Examples of a material that forms the electroconductive film of the cylindrical substrate 20 include the same metals as the electroconductive material that forms the cylindrical substrate 20 and transparent electroconductive materials, such as indium tin oxide (ITO) and SnO 2 . Preferably, the cylindrical substrate 20 is formed entirely of an Al alloy material. An Al alloy material can reduce the weight and the cost of the electrophotographic photoreceptor 2 . In addition, when a charge injection preventing layer 27 and a photoconductive layer 28 of the photosensitive layer 21 described below are formed of an amorphous silicon (a-Si) material, the adhesiveness between the electrophotographic photoreceptor 2 and the charge injection preventing layer 27 or the photoconductive layer 28 increases. This also increases the reliability.
The photosensitive layer 21 may be composed of the charge injection preventing layer 27 , the photoconductive layer 28 , and the surface layer 29 .
The charge injection preventing layer 27 prevents electrons and/or holes of the cylindrical substrate 20 from being injected into the photoconductive layer 28 . A material of the charge injection preventing layer 27 depends on the material of the photoconductive layer 28 , and may be an inorganic material, such as an a-Si material. The charge injection preventing layer 27 may be omitted. Furthermore, the charge injection preventing layer 27 may be replaced with a layer absorbing long-wavelength light. The layer absorbing long-wavelength light can prevent incident light having a long wavelength of at least 0.8 μm from being reflected from the cylindrical substrate 20 and forming interference fringes on a recorded image during exposure.
In the photoconductive layer 28 , exposure to a laser beam from the exposure unit 42 excites electrons and generates carriers, such as free electrons or holes. The thickness of the photoconductive layer 28 depends on the photoconductive material and desired electrophotographic characteristics, and may be in the range of 5 to 100 μm (suitably in the range of 15 to 80 μm).
The photoconductive layer 28 is formed of an a-Si material. Examples of the a-Si material include a-Si, amorphous silicon carbide (a-SiC), amorphous silicon nitride (a-SiN), amorphous silicon oxide (a-SiO), amorphous silicon germanium (a-SiGe), amorphous silicon carbonitride (a-SiCN), amorphous silicon oxynitride (a-SiNO), amorphous silicon oxycarbide (a-SiCO), and amorphous silicon oxycarbonitride (a-SiCNO). In particular, a photoconductive layer 28 formed of a-Si or an a-Si alloy material composed of an a-Si and an element, such as C, N, or O, consistently has excellent electrophotographic characteristics, such as high photosensitivity, high responsivity, good repetition stability, good heat resistance, and high durability. In addition, this photoconductive layer 28 has high compatibility with a surface layer 29 formed of hydrogenated a-SiC (hereinafter referred to as a-SiC:H). The photoconductive layer 28 may contain particles of the a-Si material described above dispersed in a resin, or may be an organic photo conductor (OPC) layer.
When the photoconductive layer 28 is formed entirely of an inorganic substance, the photoconductive layer 28 may be formed by a known method, such as glow discharge decomposition, sputtering, vapor deposition, electron cyclotron resonance (ECR), photo-CVD, catalytic CVD, or reactive evaporation.
The photoconductive layer 28 may be formed with a plasma CVD apparatus 5 illustrated in FIG. 3 . The plasma CVD apparatus 5 includes a substrate support 51 at the center of a cylindrical vacuum vessel 50 . An a-Si film is formed by glow discharge plasma on a cylindrical substrate 20 supported by the substrate support 51 . The vacuum vessel 50 is coupled to a high-frequency power source 52 . A high-frequency power is applied between the vacuum vessel 50 and the substrate support 51 (cylindrical substrate 20 ) which is grounded. The substrate support 51 can be rotated by a rotation mechanism 53 , and is heated by a heater 54 disposed in the substrate support 51 . The plasma CVD apparatus 5 further includes a plurality of gas-inlet pipes 55 surrounding the substrate support 51 (cylindrical substrate 20 ). Each of the gas-inlet pipes 55 includes a plurality of gas inlets 56 disposed in the axial direction. The gas inlets 56 face the cylindrical substrate 20 so that a reaction gas blows out from the gas inlets 56 toward the cylindrical substrate 20 .
In the formation of an a-Si film on the cylindrical substrate 20 with the plasma CVD apparatus 5 , a reaction gas having a predetermined composition is blown on the cylindrical substrate 20 at a predetermined flow rate from the gas-inlet pipes 55 via the gas inlets 56 , while the cylindrical substrate 20 , together with the substrate support 51 , is rotated by the rotation mechanism 53 . The high-frequency power source 52 applies a high-frequency power between the vacuum vessel 50 and the substrate support 51 (cylindrical substrate 20 ) to decompose the reaction gas by glow discharge, thereby forming an a-Si film on the cylindrical substrate 20 , which is maintained at a desired temperature.
As illustrated in FIG. 2B , the surface layer 29 , which is formed on the photoconductive layer 28 , protects the photoconductive layer 28 from friction and abrasion. The surface layer 29 is formed of an inorganic material, such as an a-Si material. The thickness of the surface layer 29 is in the range of 0.2 to 1.5 μm (suitably in the range of 0.5 to 1.0 μm). The surface layer 29 having a thickness of at least 0.2 μm can reduce image flaws and inconsistencies in image density due to impression durability. The surface layer 29 having a thickness of 1.5 μm or less improves initial properties (for example, image defects due to residual potential).
A surface layer 29 formed of a-SiC:H can be formed with the plasma CVD apparatus 5 illustrated in FIG. 3 , in the same way as the photoconductive layer 28 formed of an a-Si material. When an a-Si photosensitive layer 21 is formed with the plasma CVD apparatus 5 , a protrusion 22 may be formed at the surface of the photosensitive layer 21 , as illustrated in FIG. 4 . This protrusion 22 may be formed by abnormal growth of a foreign particle 23 deposited on the surface of the cylindrical substrate 20 or during the formation of the photosensitive layer 21 . The protrusion 22 may cause an image defect, as described above.
In the electrophotographic photoreceptor 2 , as illustrated in FIGS. 5A to 5C , resin portion 6 a , 6 b , or 6 c partly or entirely covers a protrusion 22 .
As illustrated in FIG. 5A , the resin portion 6 a is formed on the front side of the protrusion 22 in the rotation direction of the electrophotographic photoreceptor 2 so that the resin portion 6 a reduces a difference in level between the protrusion 22 and a normal surface 24 .
As illustrated in FIG. 5B , the resin portion 6 b is formed on the front and rear sides of the protrusion 22 in the rotation direction of the electrophotographic photoreceptor 2 so that the resin portion 6 b reduces a difference in level between the protrusion 22 and the normal surface 24 .
As illustrated in FIG. 5C , a resin portion 6 c entirely covers the protrusion 22 . More specifically, the resin portion 6 c covers the top 22 A of the protrusion 22 , as well as the front and rear sides of the protrusion 22 in the rotation direction of the electrophotographic photoreceptor 2 .
As illustrated in FIG. 6 , the resin portions 6 a , 6 b , and 6 c illustrated in FIGS. 5A to 5C can be formed by making a resin sheet 60 contact with the photosensitive layer 21 (see FIG. 2A ) disposed on the cylindrical substrate 20 , which is rotatably supported, for example, by an umbrella-shaped center pin (not shown) for use in a lathe. The resin sheet 60 supplied from a resin roller 61 is pressed against the photosensitive layer 21 by a rear roller 62 . The rear roller 62 generally rotates in the different direction as the cylindrical substrate 20 . The resin sheet 60 is wound around a recovery roller 63 .
The nip width between the photosensitive layer 21 and the resin sheet 60 is controlled by the hardness of the resin sheet 60 and the pressing force of the rear roller 62 against the photosensitive layer 21 via the resin sheet 60 . The resin sheet 60 may be a monolayer of a resin material of the resin portion 6 a , 6 b , or 6 c , or a multilayer composed of the resin materials on a base sheet. Examples of the resin material include “fluorocarbon resins” (which include at least one fluorine atom and may include other halogen atoms), polystyrene resins, and polyethylene resins. Fluorocarbon resins are preferred in terms of the prevention of toner deposition. Examples of the fluorocarbon resins include polytetrafluoroethylene, polychlorotrifluoroethylene, polyvinylidene fluoride, polyvinyl fluoride, perfluoroalkoxy fluorocarbons, tetrafluoroethylene-hexafluoropropylene copolymers, ethylene-tetrafluoroethylene copolymers, and ethylene-chlorotrifluoroethylene copolymers. The pressing force of the rear roller 62 against the photosensitive layer 21 via the resin sheet 60 may be in the range of 0.01 to 0.2 kgf/cm 2 (9.806×10 to 1.961×10 Pa) per unit axial length. The nip width may be in the range of 0.01 to 2 mm.
As illustrated in FIG. 7 , when the resin sheet 60 moves relative to the cylindrical substrate 20 while the resin sheet 60 is in contact with the photosensitive layer 21 , the protrusion 22 scrapes a resin 64 off the resin sheet 60 . The resin 64 adheres to the photosensitive layer 21 to reduce a difference in level between the protrusion 22 and the normal surface 24 . The nip width between the photosensitive layer 21 and the resin sheet 60 , the hardness of the resin sheet 60 (the composition of the resin material), or the moving speed of the resin sheet 60 is appropriately controlled to apply the resin portion 6 a , 6 b , or 6 c to the side and/or the top of the protrusion 22 while the resin adhering to the normal surface 24 is minimized, as illustrated in FIGS. 5A to 5C .
In the electrophotographic photoreceptor 2 , at least part of the side of the protrusion 22 disposed on the photosensitive layer 21 is covered with the resin portion 6 a , 6 b , or 6 c . This can reduce the toner deposition at a stepped portion 25 between the protrusion 22 and the normal surface 24 , and allows toner around the protrusion 22 to be removed easily with the cleaning blade 46 A. Furthermore, the reduction in toner deposition around the protrusion 22 can reduce toner adherence to the photosensitive layer 21 .
Thus, in the electrophotographic photoreceptor 2 and the image-forming apparatus 1 including the electrophotographic photoreceptor 2 , image defects caused by the toner deposition around the protrusion 22 , as well as insufficient cleaning and black-striped image defects, can be reduced.
Other examples of the resin portion are described below with reference to FIGS. 8A to 8C and FIG. 9 .
As illustrated in FIGS. 8A to 8C , a resin portion 7 a , 7 b , or 7 c partly or entirely covers the side of the protrusion 22 , or entirely covers the protrusion 22 having a flat top 70 .
As illustrated in FIG. 8A , the resin portion 7 a corresponds to a truncated form of the protrusion 22 illustrated in FIG. 5A . As illustrated in FIG. 8B , the resin portion 7 b corresponds to a truncated form of the protrusion 22 illustrated in FIG. 5B . As illustrated in FIG. 8C , the resin portion 7 c corresponds to a truncated form of the protrusion 22 illustrated in FIG. 5C .
The resin portions 7 a , 7 b , and 7 c can be formed in the same way as the resin portions 6 a , 6 b , and 6 c illustrated in FIGS. 5A to 5C , except that the protrusion 22 is truncated.
The protrusion 22 may be truncated using a lapping sheet in place of the resin sheet 60 of the apparatus illustrated in FIG. 6 . The direction of movement of the lapping sheet may follow the rotation direction of the cylindrical substrate 20 , or may be the opposite direction thereof.
As illustrated in FIG. 9 , a lapping sheet 71 includes a base sheet 72 and a polymer resin binder 74 containing abrasive particles 73 . Preferably, the base sheet 72 is a polyester that does not expand and contract significantly and has a uniform thickness. Examples of the abrasive particles 73 include silicon carbide, iron oxide, chromium oxide, aluminum oxide, and diamond particles. The size of the abrasive particles 73 may be in the range of 0.3 to 20 μm.
The protrusion 22 is ground with the lapping sheet 71 to form a truncated protrusion 22 . The height of the truncated protrusion 22 is appropriately determined in a manner that depends on the size of the protrusion 22 . For example, when the protrusion 22 has a diameter of 0.3 mm or less and a height of 60 μm or less, the height of the truncated protrusion 22 may be in the range of about 0.1 to 1 μm.
After the protrusion 22 is ground, the lapping sheet 71 of the apparatus is replaced with the resin sheet 60 . In the same way as the resin portions 6 a , 6 b , and 6 c illustrated in FIGS. 5A to 5C , the resin portion 7 a , 7 b , or 7 c is formed to reduce a difference in level between the protrusion 22 (flat top 70 ) and the normal surface 24 .
Grinding of the protrusion 22 and the formation of the resin portion 7 a , 7 b , or 7 c may be performed in a single step by controlling the type of the lapping sheet 71 (the type and the particle size of abrasive particles, the type of a binder, etc.), the nip width between the photosensitive layer 21 and the lapping sheet 71 , and the moving speed of the lapping sheet 71 relative to the cylindrical substrate 20 .
Thus, in the electrophotographic photoreceptor 2 having the resin portion 7 a , 7 b , or 7 c and the image-forming apparatus 1 including the electrophotographic photoreceptor 2 , image defects caused by the toner deposition around the protrusion 22 , as well as insufficient cleaning and black-striped image defects, can be reduced.
Furthermore, even when the protrusion 22 comes into contact with the cleaning blade 46 A, a reduction in height of the protrusion 22 can reduce frictional heat and damage to the cleaning blade 46 A. This can further reduce adhesion of toner to the photosensitive layer 21 , and further reduce the occurrence of insufficient cleaning and black-striped image defects.
The resin portions 6 a , 6 b , 6 c , 7 a , 7 b , and 7 c may be formed not only by the methods described above, but also using a liquid material containing a resin material.
For example, as illustrated in FIG. 10 , a liquid material (resin coating material) is applied to the photosensitive layer 21 with a spray coater 80 , while the electrophotographic photoreceptor 2 is rotated. After the resin coating material is heat-treated with a heat treatment apparatus 81 , an excessive resin coating material is removed with a blade 82 and a finishing roller 83 .
The present invention will be further described with Examples. The present invention is not limited to the Examples.
Example 1
Toner deposition was observed after image forming in both cases where a protrusion disposed on an electrophotographic photoreceptor is or is not covered with a resin portion.
(Production of Electrophotographic Photoreceptor)
Electrophotographic photoreceptors A and B according to Comparative Examples and electrophotographic photoreceptors C1, C2, D1 and D2 according to Examples were produced.
The electrophotographic photoreceptor A was produced as follows. A cylindrical substrate was mirror-finished and washed. A photosensitive layer was formed on the cylindrical substrate with a plasma CVD apparatus 5 illustrated in FIG. 3 . The cylindrical substrate was an aluminum cylindrical substrate having a diameter of 84 mm and a length of 370 mm. The photosensitive layer had a three-layered structure composed of a p-type charge injection preventing layer, an a-Si photoconductive layer, and an a-Si surface layer. The p-type charge injection preventing layer was formed using SiH 4 , B 2 H 6 , H 2 , and NO as reaction gases, and had a thickness of 4 μm. The a-Si photoconductive layer was formed using SiH 4 , H 2 , and B 2 H 6 as reaction gases, and had a thickness of 27 μm. The a-Si surface layer was formed using SiH 4 and CH 4 as reaction gases, and had a thickness of 0.7 μm.
The electrophotographic photoreceptor B was produced as follows. A photoreceptor produced in the same way as the electrophotographic photoreceptor A was attached to a umbrella-shaped center pin, and was installed in a rotator. The photoreceptor was rotated at 60 revolutions per minute (rpm) to grind a protrusion disposed on the photoreceptor with a lapping sheet (planarization), thus producing the electrophotographic photoreceptor B.
The electrophotographic photoreceptors C were produced as follows: a photoreceptor subjected to the planarization as in the electrophotographic photoreceptor B was brought into contact with a resin-coated sheet to cover the protrusion and its periphery with a resin portion (see FIG. 8C ). The resin portion was formed of a fluorocarbon resin (C2) or a polystyrene resin (C1).
The electrophotographic photoreceptors D were produced as follows: a photoreceptor (not subjected to planarization) produced in the same way as the electrophotographic photoreceptor A was brought into contact with a resin-coated sheet to cover the protrusion and its periphery with a resin portion (see FIG. 5C ). The resin portion was formed of a fluorocarbon resin (D2) or a polystyrene resin (D1).
(Evaluation of Toner Deposition)
The electrophotographic photoreceptor A, B, C, or D was installed in an image-forming apparatus (KM-8030, Kyocera Mita Corporation). After a plate wear test of 10,000 sheets, the electrophotographic photoreceptor was visually inspected. This test was performed in quintuplicate for each of the electrophotographic photoreceptors A, B, C, and D. The toner deposition was evaluated as the incidence of the toner deposition. The incidence of the toner deposition was defined by the ratio of the number of protrusions to which toner adhered to the total number of protrusions.
TABLE 1
Resin portion
None
Polystyrene resin
Fluorocarbon resin
A
25%
—
—
B
5%
—
—
C
—
0% (C1)
0% (C2)
D
—
8% (D1)
2% (D2)
Table 1 shows that, in a comparison of the electrophotographic photoreceptors A and D1 in which the protrusion was not truncated, the presence of the polystyrene resin portion reduced the incidence of the toner deposition from 25% to 8%, and the presence of the fluorocarbon resin portion (Example D2) reduced the incidence of the toner deposition to 2%. In a comparison of the electrophotographic photoreceptors B, C1 and C2 in which the protrusion was truncated, the presence of the polystyrene (C1) or fluorocarbon (C2) resin portion reduced the incidence of the toner deposition from 5% to 0%.
These results demonstrate that the formation of a resin portion can reduce the toner deposition.
Furthermore, the incidence of the toner deposition was lower in the electrophotographic photoreceptors C1 and C2, in which the truncated protrusion was covered with the resin portion, than in the electrophotographic photoreceptors D1 and D2, in which the full protrusion was covered with the resin portion.
This result demonstrates that the formation of a resin portion covering a truncated protrusion can further reduce the toner deposition.
Furthermore, the incidence of the toner deposition was lower in the electrophotographic photoreceptor D2 having the fluorocarbon resin portion than in the electrophotographic photoreceptor D1 having the polystyrene resin portion.
This result demonstrates that the fluorocarbon resin portion is preferred to the polystyrene resin portion.
Example 2
The surfaces of the photosensitive layers of the electrophotographic photoreceptors A and D1 in Example 1 were observed. Images after a plate wear test were evaluated.
Surface observation of the electrophotographic photoreceptor A before use showed that there were 20 protrusions having a diameter in the range of 0.1 to 0.2 mm and a height in the range of 15 to 50 μm.
The electrophotographic photoreceptor A was installed in an image-forming apparatus (KM-8030, Kyocera Mita Corporation). After a plate wear test of 10,000 sheets, surface observation of the photosensitive layer showed that there was discharge breakdown of one protrusion and that five of the 20 protrusions had toner deposition. Inspection of images after the plate wear test showed that there were two black spots in a white solid portion and six white spots in a gray image formed by performing an intermediate exposure (exposure at an intermediate point of the light decay from the dark voltage) to a black solid portion. The term “white solid portion”, as used herein, refers to a printed portion corresponding to an unexposed portion of an electrophotographic photoreceptor.
Surface observation of the electrophotographic photoreceptor D1 before use showed that there were 25 protrusions having a diameter in the range of 0.1 to 0.2 mm and a height in the range of 15 to 50 μm.
The electrophotographic photoreceptor D1 was installed in the image-forming apparatus (KM-8030, Kyocera Mita Corporation). After a plate wear test of 10,000 sheets, two of the 25 protrusions had toner deposition, and the discharge breakdown of the protrusions was not observed. Inspection of images after the plate wear test showed that there was no black spot in a white solid portion and two white spots in a gray image formed by performing an intermediate exposure to a black solid portion.
Example 3
Surface observation of a photosensitive layer of an electrophotographic photoreceptor E and the evaluation of images after a plate wear test were performed as in Example 2. In the electrophotographic photoreceptor E, grinding of a protrusion and the formation of a resin portion were performed in a single step.
A photoreceptor (not subjected to planarization) produced in the same way as the electrophotographic photoreceptor A was treated with a lapping sheet to produce the electrophotographic photoreceptor E. The lapping sheet was composed of a polyethylene terephthalate base sheet and a fluorocarbon resin binder containing abrasive particles.
The lapping sheet was brought into contact with a photosensitive layer with an apparatus illustrated in FIG. 6 . Grinding of a protrusion with the abrasive particles and the formation of a fluorocarbon resin portion were performed in a single step. The pressing force of the lapping sheet against the photosensitive layer was appropriately controlled to selectively cover a protrusion with a resin portion (see FIG. 8C ).
Surface observation of the electrophotographic photoreceptor E before use showed that there was no protrusion having a diameter in the range of 0.1 to 0.2 mm and a height in the range of 15 to 50 μm.
The electrophotographic photoreceptor E was installed in an image-forming apparatus (KM-8030, Kyocera Mita Corporation). After a plate wear test of 10,000 sheets, surface observation of the photosensitive layer showed that there was no discharge breakdown and no substantial toner deposition. Inspection of images after the plate wear test showed that there was no black spot in a white solid portion and no white spot in a gray image formed by performing an intermediate exposure to a black solid portion.
Example 4
Surface observation of a photosensitive layer of an electrophotographic photoreceptor F and the evaluation of images after a plate wear test were performed as in Example 2. In the electrophotographic photoreceptor F, a resin portion was formed with an apparatus illustrated in FIG. 10 .
The electrophotographic photoreceptor F was produced as follows. A photoreceptor produced in the same way as the electrophotographic photoreceptor A was attached to a umbrella-shaped center pin, and was installed in an rotator. A resin coating material was applied to a photosensitive layer with a spray coater, while the electrophotographic photoreceptor F was rotated. A rubber blade was then brought into contact with the rotated photoreceptor to scrape the resin coating material off a normal surface. A finishing roller was then brought into contact with the rotated photoreceptor to further scrape the resin coating material off the normal surface. Thus, a protrusion disposed on the electrophotographic photoreceptor F was selectively covered with the resin coating material (see FIG. 5C ).
Surface observation of the electrophotographic photoreceptor F before use showed that there were 20 protrusions having a diameter in the range of 0.1 to 0.2 mm and a height in the range of 15 to 50 μm.
The electrophotographic photoreceptor F was installed in an image-forming apparatus (KM-8030, Kyocera Mita Corporation). After a plate wear test of 10,000 sheets, surface observation of the photosensitive layer showed that there was no discharge breakdown and that two of the 20 protrusions had toner deposition. Inspection of images after the plate wear test showed that there was one black spot in a white solid portion and two white spots in a gray image formed by performing an intermediate exposure to a black solid portion.
Table 2 summarizes the results of Examples 2, 3, and 4.
TABLE 2
Comparative
Example
Example 2
Example 3
Example 4
Electrophotographic
Electrophotographic
Electrophotographic
Electrophotographic
photoreceptor A
photoreceptor D1
photoreceptor E
photoreceptor F
Toner
25%
8%
0%
10%
deposition
Discharge
0%
0%
0%
0%
breakdown
Black spot
10%
4%
0%
5%
Evaluation
Poor
Fair
Good
Fair
Table 2 shows that toner deposition, discharge breakdown, and black spots were reduced in the electrophotographic photoreceptors D1, E, and F according to the present embodiments, as compared with the conventional electrophotographic photoreceptor A having no resin portion. Thus, the present invention can provide an electrophotographic photoreceptor exhibiting less toner deposition and fewer black spots than before without deterioration of discharge breakdown. Furthermore, according to the present invention, damage to a cleaning blade by a protrusion, insufficient cleaning, and black-striped image defects can be reduced.
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The invention relates to an electrophotographic photoreceptor in which protrusions from the surface of the photoreceptor are partly or completely covered by a resin. The effect of such resin covering is to reduce toner deposition, thereby reducing or eliminating spotting defects in images formed using the electrophotographic photoreceptor. The invention further relates to an image-forming apparatus incorporating such an electrophotographic photoreceptor.
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CROSS REFERENCE TO RELATED PATENTS
[0001] Reference is made to U.S. Pat. No. 5,974,706 and to U.S. Pat. No. 5,983,535 both of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a swivel connection for use between a quick attachment mounting frame and a quick attachment bracket to permit a bucket or other attachment coupled to a boom to be pivoted about a generally horizontal axis during use for cutting a grade slope or working at an angle, and still have the benefit of a quick attachment bracket for engaging a frame on the bucket.
[0003] Quick attachment units have been utilized for excavator buckets and other attachments. For example U.S. Pat. No. 5,974,706 illustrates such a quick attachment system, where a bracket can be used for mounting frames that are attached to various tools so the tools can quickly be mounted to an excavator or backhoe boom. Also, U.S. Pat. No. 5,983,535 shows a quick attachment bracket and frame which are held in assembly with a bolt on connection.
[0004] Excavator or backhoe booms pivot about generally horizontal axes, and these horizontal pivots are fixed. However, it is desired from time to time to cut a slope with the bucket, or use an attachment such as a powered earth auger at an angle other than vertical. The present devices do not provide a low cost positive holding angular displacement swivel for use with a quick attachment bracket on a bucket or a tool.
SUMMARY OF THE INVENTION
[0005] The present invention relates to a hydraulically controlled swivel connected between a backhoe or excavator boom and an attachment tool implement. The swivel has a frame on one end that attaches to a quick coupler bracket on the boom. A second bracket that will couple to a similar frame is pivotally mounted to the frame of the swivel. The second bracket is for connection to a frame on a bucket or other attachment or implement. The swivel frame and bracket are held together with a pivot pin which, is substantially horizontal when the excavator bucket is moved to a position with the bucket cutting blade or edge lowered. A linear hydraulic cylinder is mounted between the swivel frame and the second bracket for pivoting the second bracket about the axis of the pivot pin so that the bucket cutting blade or other implement or tool can be positioned at an angle or slope during use.
[0006] The linear hydraulic cylinder used can be mounted on end pivot pins, as shown, or on trunnions at a desired location along the cylinder. While one linear cylinder is shown, two linear cylinders, one on each side of the pivot pin could be used.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a perspective view of an excavator having a bucket mounted on a swivel made according to the present invention;
[0008] [0008]FIG. 2 is an enlarged fragmentary view of the end of the excavator boom and the swivel in place;
[0009] [0009]FIG. 3 is a side view of the swivel;
[0010] [0010]FIG. 4 is an end view of the swivel taken generally along line 4 - 4 in FIG. 3, with a boom mounted bracket removed;
[0011] [0011]FIG. 5 is a fragmentary schematic view of a quick attachment frame mounted on an excavator bucket; and
[0012] [0012]FIG. 6 is a detail of the retainer between the swivel bracket and a frame on a bucket or blade.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] [0013]FIG. 1 illustrates an excavator 10 of typical configuration, to show an implement or machine on which the present control arrangement is mounted. The excavator 10 includes a frame 12 , mounting an engine in a compartment 12 A. The excavator drive tracks 13 A and 13 B are mounted on suitable sprockets and axles, and are driven by hydraulic motors 15 , shown schematically. The motors 15 could also be electric, and controlled by a switch assembly. The tracks 13 A and 13 B on opposite sides of the excavator are used for driving the excavator along the ground and for steering. The excavator can be turned right and left, by selectively driving the tracks, which can be driven in forward and rearward directions.
[0014] The engine in the engine compartment 12 A is used for driving various components, including a hydraulic pump 15 C that will provide hydraulic pressure for the drive motors 15 for tracks 13 A and 13 B, and also for operating actuators such as the actuator or cylinder 14 A for a main or base boom arm 14 , and an actuator or cylinder 14 B for controlling a dipper arm 16 that is pivoted to the end of base arm 14 . The actuator boom, dipper arm and a bucket 20 are operated in a normal manner. These actuators may be controlled by a conventional joystick control 17 comprising a handle movable to control the various functions of the boom, dipper arm and bucket.
[0015] The base arm 14 is pivoted to a bracket on the frame 12 about a horizontal pivot. The pivot of the dipper arm 16 to the base arm is parallel to the base arm pivot. The outer end of the dipper arm 16 includes a folding link assembly 18 that is used for controlling pivoting of a tool such as the bucket 20 . The link is actuated by double acting hydraulic actuator shown schematically at 22 and operated through controls 17 . The actuator 22 extends and retracts an actuator rod 22 A (FIG. 2) under power and controls the tool pivoting about a horizontal axis. The link assembly 18 connects to a quick attachment bracket 24 that is pivotally mounted on a pin 26 to the outer end of the arm 16 , again about a pivot parallel to the base arm or boom pivot. The actuator 22 acting through the linkage 18 controls the pivoting of the quick attachment bracket 24 about the axis of the pin 26 .
[0016] The bracket 24 is a quick attachment bracket that can have an automatic latch such as shown in U.S. Pat. No. 5,974,706, that will support a swivel assembly 34 . The bracket 24 is not shown in detail. The swivel assembly includes a frame 35 comprising a pair of side plates 36 and 38 , that will straddle the bracket 24 , and will permit a nose end 32 of the bracket 24 to fit underneath a crossbar 40 . In addition, the frame 35 has a cross member 42 that fits into a mating saddle 24 A on the bracket 24 . A releasably spring-loaded latch dog 43 on the bracket engage a latch surface 24 C on the frame 35 to hold the frame 35 on the bracket 24 until the latch dog 43 is released.
[0017] The frame 35 is not directly attached to an implement, as it is in U.S. Pat. Nos. 5,974,706 and 5,983,535, but forms part of the swivel 34 . The frame 35 carries a swivel support bracket 50 that has spaced end bracket plates 52 and 54 , respectively, that are held together with one or more panels 56 . The panel 56 and bracket plates 52 and 54 are all welded into place on a quick attachment frame base plate 58 that also supports the frame side plates 36 and 38 on an opposite side of the base plate from the bracket 50 .
[0018] The panels 56 are perpendicular to the base plate 58 and support the spaced end bracket plates 52 and 54 . Laterally and outwardly extending arms 60 A and 60 B that are parallel to each other are fixed to the bracket 50 . The arms 60 A and 60 B extend back toward and beyond the quick attachment frame side plates 36 and 38 , and extend alongside dipper arm 16 . When the swivel frame 50 is in a position shown in FIGS. 3 and 4 the arms 60 A and 60 B, extend upwardly. The arm 60 A and 60 B are spaced so they support a hydraulic cylinder 62 between them. The cylinder end is pinned to the outer ends of the arms.
[0019] A pivot hub 64 is mounted between the outer end portions 52 A and 54 A of the end bracket plates 52 and 54 . The arm 60 B is an integral part of the plate 54 , as shown, but can be welded in place if desired. The arm 60 A is welded to the panel 56 and extends laterally therefrom.
[0020] A second attachment bracket 68 (FIGS. 3 and 4) is mounted to the swivel support bracket 50 for pivotal movement about the axis of hub 64 . The second quick attachment bracket 68 has a pair of plates 72 and 74 extending therefrom that overlap the ends 52 A and 54 A of the frame plates 52 and 54 . A pin 70 passes through the sleeve 64 and the ends of the plates 72 and 74 SO the bracket 68 is mounted on swivel bracket 50 , and thus on frame 35 and forms a part of swivel 34 . Additionally, the bracket 68 has an ear 76 mounted thereon, with a bore which aligns with a bore on plate 74 that carries a pin 77 that holds a rod end 78 on the rod of the double acting, linear hydraulic actuator 62 . The actuator 62 will control the angle of the second bracket 68 about the axis 71 of the pin 70 .
[0021] In FIG. 3, the swiveling second bracket 68 is shown without a bucket or blade attached for sake of clarity. It can be seen that the swiveling second bracket 68 has a saddle 80 that is open in direction facing toward a nose portion 82 that is formed by a pair of side plates 84 . The side plates 84 are held together with a cross plate 86 from which the saddle 80 is made. The details of the saddle, side plates and cross plate of bracket 68 are shown in the prior mentioned U.S. Pat. No. 5,983,535. The bracket 24 on the end of the arm 16 has a saddle constructed in the same manner, but includes the automatic latch arrangement shown in U.S. Pat. No. 5,974,706.
[0022] The swiveling second bracket 68 receives and supports a quick attachment frame 90 of the excavator bucket or other implement 20 . Frame 90 includes a pair of side plates 93 , and an end cross member 94 that fits into the saddle 80 . The side plates 93 are spaced sufficiently so they fit on the outer sides of the side plates 84 and cross plate 86 of the swiveling second bracket 68 . The nose member 82 fits beneath a retainer bar 92 on the frame 90 on the bucket 20 as shown in FIG. 6. A cross bar 94 is positioned to extend between and rest on outer ends of both of the side plates 93 on the frame 90 . The bar 94 is held against the edges of the side members 93 of the frame 90 and the nose member 82 of the bracket 68 is pulled into place and held with cap screws 98 , also as shown in FIG. 3 of U.S. Pat. 5,983,535. When the bucket 20 or other tool or implement and frame 90 are positioned substantially as shown in FIGS. 1 and 3, and the swivel assembly is mounted on the boom dipper arm 16 , it can be seen that by extending and retracting the rod of linear actuator or cylinder 62 , the angle of the blade 100 of the bucket 20 relative to a horizontal plane can be changed, since the bracket 68 swivels about the axis 71 of pin 70 . The second frame can be attached to a bulldozer blade or larger bucket if desired, or can support a tool such as an earth auger or hydraulic breaker.
[0023] The cylinder 62 is controlled by a double lock pilot operated valve 106 of conventional design to prevent leakdown of the cylinder 62 when it is under load. Hydraulic pressure from the valve 106 to either of the outlets from the valve connected to lines 106 A or 106 B serves as pilot pressure to open check valves to permit flow into and out of cylinder 62 . The check valves normally prevent flow out of either end of the cylinder to insure that the cylinder 62 remains in a fixed position. Thus, there is no unwanted change in angular position because of valve leakage.
[0024] The use of a direct acting linear hydraulic cylinder or actuator 62 provides for a very rugged and controllable positioning of the angle of the bucket blade or other tool under boom loading. A set angle of slope on a ditch or the like can be obtained. The dipper arm of the excavator used for moving the bucket toward or away from the excavator body to form an angle cut. The slope angle of a ditch or channel can be maintained as the angled blade 100 moves along the ditch. Augers and hammers can be held at an angle during use as well.
[0025] A total swiveling or pivoting movement about pin 70 of approximately 30° in each direction can be obtained using the hydraulic cylinder 62 . In FIG. 4, angle indicator marks 104 are shown schematically. Also, a dotted position of the plate 74 is shown in FIG. 4. It should be noted that the pin axis 71 extends in fore and aft direction of the excavator, perpendicular to the axis of pivoting of the excavator backhoe boom, so that the angle can be maintained to provide a slope relative to the pivot axis of the boom, and thus relative to a horizontal plane.
[0026] As stated, while one linear cylinder is shown, two cylinders, one on each side of the pivot pin, can be used. The cylinders also can be mounted as desired. The linear cylinder swivel can be used with any type of quick attachment bracket arrangement.
[0027] Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
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A swivel connection for quick attachment bracket equipped excavator booms. The swivel connection has a frame that mounts onto a quick attachment bracket on an excavator or backhoe boom, and the frame pivotally mounts a second attachment bracket about a swivel axis. The second attachment bracket is adapted to fit into a frame on an implement that also is connectable to the bracket on the boom. An implement attached to the second bracket this can be pivoted relative to the frame of the swivel connection. A linear hydraulic actuator is used for controlling the pivoting movement of the second bracket relative to the frame.
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FIELD
[0001] A stuffing box for a wellhead that is temperature conditioned.
BACKGROUND
[0002] A stuffing box is a packing gland chamber used to hold packing material compressed around a moving pump rod to reduce the escape of fluids from a well. Instead, the well fluids are directed to a production line. In cold temperatures, stuffing boxes may begin to leak well fluids, the grease or oil may become more viscous, and the well head may freeze. In warm temperatures, the lubricant is less viscous and therefore more difficult to control, which may result in the packing becoming brittle and fatigue more rapidly.
SUMMARY
[0003] There is provided a temperature conditioned stuffing box, comprising a housing having an outer surface, an inner surface defining a packing-receiving bore, a lower surface for attaching to a wellhead and an upper surface. A flow passage through the housing for passes temperature-conditioned fluid through the housing, the flow passage having an input and an output.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] These and other features will become more apparent from the following description in which reference is made to the appended drawings, the drawings are for the purpose of illustration only and are not intended to be in any way limiting, wherein:
[0005] FIG. 1 is a side elevation view in section of a temperature conditioned stuffing box with containment.
[0006] FIG. 2 is a side elevation view in section of a temperature conditioned stuffing box attached to a wellhead.
[0007] FIG. 3 is a side elevation view in section of a temperature conditioned stuffing box without containment.
[0008] FIG. 4 is a top plan view of a temperature conditioned stuffing box showing the containment cavity and vertical passages for the temperature conditioned housing.
[0009] FIG. 5 is a partially transparent bottom plan view showing a passage of the temperature conditioned housing connecting two vertical passages.
[0010] FIG. 6 is a perspective view of a flow path.
DETAILED DESCRIPTION
[0011] A temperature conditioned stuffing box generally identified by reference numeral 10 , will now be described with reference to FIG. 1 through 6 .
[0012] Structure and Relationship of Parts:
[0013] In cold temperatures, the stuffing boxes 10 tend to leak well fluids. Referring to FIG. 2 , it has been found that one of the causes of this leakage is that, as the packing gland 12 in a stuffing box 10 becomes cold, it does not compress around the polish rod 14 . In addition, in cold temperatures, the lubricant, such as grease or oil, may also be come stiff and less effective. Furthermore, most wells in cold weather will freeze at the wellhead 16 , including the stuffing box 10 . By using a temperature conditioned stuffing box 10 as described herein, this effect can be prevented, or at least reduced, resulting in less spillage and torn packing glands 12 in the stuffing box 10 . In warm temperatures, the stuffing boxes 10 also risk leaking as the lubricant becomes more difficult to control, resulting in more brittle packing that fatigues more rapidly. In both situations, a more moderate temperature may reduce the risk of leakage.
[0014] FIG. 2 shows the temperature conditioned stuffing box housing 18 on a typical wellhead 16 , flanged above a flow-tee 22 of the wellhead 16 and the radigan blowout preventer 24 . Below that is the wellhead tubing bonnet 28 . Above the stuffing box 10 is a driver 30 that drives the polish rod 14 . While the driver 30 is shown to be a hydraulic cylinder, it will be understood that the stuffing box 10 may be adapted to be used with polish rods 14 that rotate or that reciprocate, and that the driver 30 may therefore be a drive head that rotates the polish rod 14 , or a pumping jack the reciprocates the rod vertically.
[0015] As the drive head 30 or jack causes fluids to be pumped from the well, the fluids come up the well into the wellhead 16 , and exit through the flow-tee 22 . The packing glands 12 of the stuffing box 10 seal against the polish rod 14 to prevent fluid from flowing up through the stuffing box 10 . The stuffing box 10 is preferably provided with a lantern spring 32 to compress the packing 12 as it wears. A plate 36 is bolted over the spring 32 and the packing gland cavity 38 to enclose the packing. A cavity 38 is located at the top of the stuffing box 10 above the plate 36 that contains the packing 12 and where the polish rod 14 exits the packing glands 12 . The driver 30 or another plate 40 may be bolted on top to form a containment chamber 42 with the cavity 44 to contain any fluids that leak through the packing glands 12 . As the chamber 42 fills with fluid, it may be piped to a holding system 45 through a test cock 46 .
[0016] Referring to FIG. 1 and FIG. 3 , the housing 18 of the stuffing box 10 is formed to have a “temperature conditioned housing”, with an input 48 and an output 50 for temperature conditioned fluid to flow through. Examples of heated fluids that are generally available on a well site include heated water, steam, hydraulic oil, engine coolant, etc. Examples of generally available cooling fluids include water, such as pumping water through the passages, etc. It will be understood that any suitable fluid may be used to heat or cool the housing 18 . The temperature-conditioned fluid may be used to maintain the packing gland 12 at a constant temperature or within a preferred temperature range. The housing 18 may be formed by casting, machining, or a combination of methods. Referring to FIG. 4 and FIG. 5 , the passages 52 in the housing are preferably made by machining, and connect the various passages 52 to create a flow path that flows around the packing glands 12 (not shown in these figures) in the body. This may be done by having a series of inputs 48 and outputs 50 that connect the passages 52 externally, or preferably, by sealing the holes at the surface of the housing 18 while leaving the adjacent channels 52 connected inside the housing 18 . The channels 52 may be formed vertically as well as horizontally to achieve a higher coverage. FIG. 5 shows a series of horizontal and vertical passages 52 that pass around the stuffing box 10 . Since the passages 52 are preferably made by machining from the surface, the outside of these passages 52 are filled or plugged to prevent fluid from escaping. An example of a completed flow path between input 48 and output 50 made up of various passages 52 is shown in FIG. 6 . It will be understood that other flow paths may be made using the principles discussed herein, which may or may not involve 90 degree corners as shown.
[0017] There are different ways of controlling the temperature of the stuffing box 10 . Since the stuffing box 10 is able to operate in a range of temperatures, it is not always necessary to maintain a specific temperature, such as by using a thermostat, although it is possible to do so. Two main ways of controlling the temperature of stuffing box 10 are to control the temperature of the fluid entering housing 18 , and to control the flow rate of the fluid through housing 18 . For example, heated coolant from an engine, or heated hydraulic oil are readily available sources of heated fluid. However, it is generally easier to provide a flow control that restricts the amount of fluid that enters the housing than to control the temperature of the coolant or oil.
[0018] In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one of the elements.
[0019] The following claims are to understood to include what is specifically illustrated and described above, what is conceptually equivalent, and what can be obviously substituted. Those skilled in the art will appreciate that various adaptations and modifications of the described embodiments can be configured without departing from the scope of the claims. The illustrated embodiments have been set forth only as examples and should not be taken as limiting the invention. It is to be understood that, within the scope of the following claims, the invention may be practiced other than as specifically illustrated and described.
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A temperature conditioned stuffing box includes a housing having an outer surface, an inner surface defining a packing-receiving bore, a lower surface for attaching to a wellhead and an upper surface. A flow passage through the housing for passing temperature-conditioned fluid through the housing has an input and an output.
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This application is a continuation of U.S. patent application Ser. No. 11/850,213, filed Sep. 5, 2007, now U.S. Pat. No. 9,406,196 which is a divisional of U.S. patent application Ser. No. 10/410,197, filed Apr. 10, 2003, now U.S. Pat. No. 7,341,517 which is incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
The present invention relates to real-time interactive wagering on event outcomes. Event outcomes may be based on, for example, financial markets and indices, sporting and entertainment events, political events, games of chance, and natural phenomena such as weather and earthquakes. Wagers can be of a fixed-odds type or a spread-bet type (both described further below). Wagers can be placed on, for example, the change in the Consumer Price Index for a given month; a nation's Gross Domestic Product (GDP); a casino's payout or winnings at blackjack over a given period; the team that will win baseball's World Series; the actor that will win an Academy Award; and the price movement of individual stocks, gold, commodities, or any real-time index. Events on which wagers can be placed include both those with known and unknown outcome probabilities. The present invention does not, however, involve trading of financial instruments.
Current wagering systems are often slow and inefficient, and thus do not offer clients real-time wagering. Many known systems conduct wagering manually by telephone. Even known online wagering systems do not offer real-time wagering. Processing delays are commonly incurred between initially placing a wager and receiving confirmation of that wager. For example, after a client places a wager, the client's available credit is usually checked before the wager is accepted and confirmed. During such processing delays, the price of a desired wager can and often does change. Thus clients may not at times get the prices originally presented. Moreover, presented wager prices are typically not current, but often may lag actual prices by as much as 5-10 minutes. Another disadvantage of known wagering systems is their limited selection of events on which to wager. Known systems and methods generally cannot easily establish wagering on customized or client-requested events, such as, for example, the snowfall in New York's Central Park next Christmas Day.
In view of the foregoing, it would be desirable to provide real-time interactive wagering on event outcomes.
It would also be desirable to provide real-time interactive wagering on event outcomes with real-time transaction confirmation.
It would further be desirable to provide real-time interactive wagering on event outcomes with real-time management of client-wagering credit.
It would still further be desirable to provide real-time interactive wagering on event outcomes with automatic wager-tracking indices.
It would yet further be desirable to provide real-time interactive wagering on event outcomes with automatic dealer hedging.
It would also be desirable to provide real-time interactive wagering on event outcomes with automatic price-spread adjustment
It would further be desirable to provide real-time interactive wagering on event outcomes with automatic forward price setting.
It would further be desirable to provide real-time interactive wagering on event outcomes with selectable foreign or domestic currencies.
It would further be desirable to provide real-time interactive remote participation in casino events.
It would further be desirable to provide real-time interactive remote wagering on event outcomes with a cap and collar for spread-bet wagering.
SUMMARY OF THE INVENTION
It is an object of this invention to provide real-time interactive wagering on event outcomes.
It is also an object of this invention to provide real-time interactive wagering on event outcomes with real-time transaction confirmation.
It is further an object of this invention to provide real-time interactive wagering on event outcomes with real-time management of client-wagering credit.
It is still further an object of this invention to provide real-time interactive wagering on event outcomes with automatic wager-tracking indices.
It is yet further an object of this invention to provide real-time interactive wagering on event outcomes with automatic dealer hedging.
It is another object of this invention to provide real-time interactive wagering on event outcomes with automatic price-spread adjustments.
It is still another object of this invention to provide real-time interactive wagering on event outcomes with automatic forward price setting.
It is still another object of this invention to provide real-time interactive wagering on event outcomes with selectable foreign or domestic currencies.
It is still another object of this invention to provide real-time interactive remote participation in casino events.
It is yet another object of this invention to provide real-time interactive remote wagering on event outcomes with a cap and collar for spread-bet wagering.
In accordance with this invention, a data processing computer and a plurality of client workstations are provided that communicate interactively via a network. The workstations can be, for example, personal computers, laptop computers, mainframe computers, dumb terminals, personal digital assistants (PDAs), cellular phones, or other portable devices having network capabilities. The network can be, for example, the Internet, an Ethernet, a token ring, a token bus, or any other suitable communications medium or configuration that links the workstations with the data processing computer. The present invention operates interactively with online clients preferably via an Internet Web site.
The present invention preferably provides automatic real-time client credit management, real-time online corroborated wager prices, real-time interactive transaction confirmation, automatic price-spread adjustments, automatic setting of forward pricing, automatic wager-tracking indices, automatic dealer hedging, automatic client and dealer defined wagering limits, and multiple-price wagering. Other features of the present invention include choice of currencies for buying and selling, and provisions for evaluating and establishing wagering on events requested by clients. The present invention can be deployed in a dealer environment in which clients wager with the “house,” which acts as dealer, or in a brokerage environment in which clients wager with other clients or combinations of other houses, one or more of the houses acting as broker or another dealer.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages of the invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
FIG. 1 is a block diagram of a system for real-time interactive wagering in accordance with the present invention;
FIG. 2 is a flow diagram of a client qualification process in accordance with the present invention;
FIG. 3 is a flow diagram of a client credit management process in accordance with the present invention;
FIGS. 4-8 are a series of screen displays illustrating an interactive wager transaction in accordance with the present invention; and
FIG. 9 is a flow diagram of an automatic hedging process in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to systems and methods for real-time interactive wagering on event outcomes. The systems and methods of the present invention may be implemented using a data processing computer and a plurality of client workstations that communicate interactively with the computer via a network.
FIG. 1 illustrates a real-time interactive wagering system 100 according to the present invention. The system includes a house wagering processor 102 and a plurality of client workstations 104 - 107 , all of which are linked together via network 108 . Wagering processor 102 can be, for example, a data processing computer having appropriate processing speed and memory capacity. Client workstations 104 - 107 can be directly or remotely connected to processor 102 and can be, for example, personal computers, dumb terminals, personal digital assistants (PDAs), laptop computers, mainframe computers, cellular telephones with Internet capabilities, or other devices capable of communicating with processor 102 via network 108 . Network 108 can be, for example, the Internet, an Ethernet, a token ring, a token bus, or any other suitable communication medium or configuration that links the workstations with processor 102 to provide real-time interaction. In a preferred embodiment, clients preferably interact with the system via an Internet Web site.
Wagering system 100 also includes electronic feeds 110 and 112 each coupled to processor 102 and to respective preferably independent market data sources 114 and 116 . As described further below, market data sources 114 and 116 each provide pricing and other information regarding known markets, indices and the like (e.g, S&P 500, stock prices, etc.). Electronic feeds 110 and 112 can be any communication medium that transmits available market data and changes thereof substantially immediately.
An account with “house” is first opened by establishing credit in any known or appropriate manner. For example, credit may be established by submitting a financial statement or credit report, by authorizing the house to charge a credit card, or by depositing cash or securities with the house. The house is likely to then further qualify a client in accordance with either conventional standards of the financial industry, proprietary standards of the house, or a combination of both. Qualification standards may be further based on wagering in either a dealer environment, a brokerage environment, or both.
FIG. 2 shows an embodiment of a client qualification process according to the present invention. Qualification process 200 begins at qualification state 202 after a client has opened an account and has established a line-of-credit as described above. At 204 , the client logs in to the wagering system by entering an identifier (ID) and a password at one of client workstations 104 - 107 . At 206 , house wagering processor 102 applies a predetermined house qualification test on the client's line-of-credit and other financial information as deemed appropriate by the house. This test determines whether the client is currently qualified to wager on currently available event outcomes or particular subsets thereof. At 208 , the house wagering system preferably applies a third-party qualification test for wagering in one or more brokerage environments. After applying the house and third-party qualification tests, wagering parameters are assigned to the client at 210 . These wagering parameters can include, for example, the types of available event outcomes, available third-parties, and associated wagering minimums. At 212 , the wagering system determines whether the client qualifies to participate in wagering based on the assigned wagering parameters and the client's current financial situation. If qualified, the client can proceed to wager on selected event outcomes. If the client does not qualify, the system performs a risk notification function at 214 . The client may then be informed of the non-qualification. Additionally or alternatively, the risk notification function may alert the house that further scrutiny of that client's credentials is required. The system then returns to host qualification test 206 where, if any deficiencies had been corrected by the client or modifications made by the house, the qualification tests are reapplied.
Once credit is established and the client is qualified to wager, the system automatically manages that credit in real time, and presents to a client—before any wagers are placed—only an amount the client is currently authorized to wager. For example, if a client is authorized to wager $1000 and wagers $1000 that the Dow Jones Industrial Average (DJIA) will rise to a certain value by a certain date, and then on another event collects $1500 from a matured wager, the system automatically updates the client's credit in real time to authorize the client to wager another $500. The system will not permit a client to wager more than that client's authorized amount.
Moreover, the system preferably presents to a client only those events whose minimum wagering amounts are within the client's authorized credit. As a client places wagers, the system not only automatically updates the client's credit in real time, but also updates the displayed list of events on which that client has sufficient authorized credit to wager. Thus, as a client's credit increases, more events on which to wager may be shown. Conversely, as a client's credit decreases, less events on which to wager may be shown. Alternatively, the system can also display other wagers regardless of whether the client's authorized credit meets their minimum wagering amounts. Such other wagers may include the most popular one, a reference set of wagers (e.g., the DJIA and the FTSE with respect to a wager on the price of IBM stock at the end of the month), a wager that is being promoted, wagers likely to be of interest to the client in view of the client's past wagering activity, or wagers in accordance with a client's customized display (described further below).
FIG. 3 shows an embodiment of a client credit management process 300 according to the present invention. The system determines a client's current available credit at 302 . If the client's credit is based upon securities or other variable assets, the current market values of those securities or other assets are ascertained to determine the client's available credit. At 304 , the system selects wagerable event outcomes whose minimum wagering amounts do not exceed the client's current available credit. If the client has provided instructions customizing the selection of wagerable event outcomes, at 306 , those wagerable event outcomes not in accordance with the client's instructions are removed from the selection of event outcomes. At 308 , the system calculates a preferably maximum amount that the client is authorized to wager for each of the selected wagerable event outcomes. At 310 , the selected wagerable event outcomes and their respective authorized wager amounts are displayed to the client. At 312 , if a request to wager is not received within a predetermined time period, the system returns to 302 . If a request to wager is received, at 314 acceptance of the wager is confirmed and the client's available credit is substantially immediately adjusted. The system then returns to 302 .
The system preferably also includes a reward feature that in accordance with house criteria rewards clients with either additional credit or other types of gifts. House criteria for distributing rewards may include, for example, placing a certain number of wagers within a specified period of time, placing wagers on certain events, or wagering or winning certain amounts. The house may also wish to console clients who have recently lost a wager by increasing their credit or providing some other reward.
The system displays wagerable events, current wager prices, and preferably other market data. The displayed information is preferably customizable. For example, a client may wish to see only wagerable events of interest (e.g., basketball events) or only those events upon which that client has placed wagers. For clients who have not customized their display, the house can initially set and then later modify display defaults in accordance with house policies and objectives. Moreover, the house can optionally override a client's display defaults either temporarily or permanently to notify a client of, for example, new wagerable events or special wagering prices of events not displayed by that client.
Displayed wager prices are updated in real time as price changes occur. To ensure that displayed pricing information and market data based on existing markets are accurate, the system corroborates displayed data with preferably multiple electronic feeds from at least two sources where possible. Because data from multiple sources are not likely synchronized with respect to time, the system preferably performs such synchronization. If prices from multiple sources do not agree with each other after synchronization, the system may widen the spread, cancel bids/offers, or not accept any further wagering. This feature can advantageously avoid potentially costly errors.
The system provides each client with a customizable preferably single display that shows, for example, various wagerable events on which that client can wager, prices for those events, applicable maturity (e.g., end of day, end of quarter, etc.), and authorized funds with which that client can wager. The maturity of an event outcome is the time, date, or time and date on which a wager on that event outcome concludes. For example, an event outcome may be a casino's slot machine payouts and its maturity may be every hour on the hour each day. The status of an event outcome at it's maturity determines the outcome of wagers placed on that event.
Wagers can be of at least two types—a fixed-odds wager or a spread-bet wager. A fixed-odds wager involves a fixed amount wagered on an event outcome that matures on a predetermined future date and time. For example, the house acting as a dealer, or another wagerer with the house acting as a broker, may offer 10:1 odds that the S&P 500 index will not exceed a certain level as of 4:00 p.m. on a certain day. A client may then wager a fixed amount that the S&P will exceed that level. At the maturity date and time, the client will either lose the wagered amount or win 10 times the wagered amount. Thus, in this type of wager, the client's stake (i.e., the wagered amount) is fixed, and the risk to both the client and the dealer or other wagerer is known.
A spread-bet wager involves a fixed amount wagered on each incremental movement of a continuous event (e.g., a stock price, the S&P 500 index, etc.) until a predetermined maturity (e.g., end of day, week, or quarter). For example, assume the wagerable event is the movement of Index X until the end of the current quarter. The current price of Index X is $1500. The house may set an offer price of $1505 and a bid price of $1495, and the wager may be $100 per tick (a tick is the smallest incremental movement of an event). To wager that Index X will rise, a client “takes” the $1505 offer. For each tick rise in Index X, the client's stake increases $100; for each tick drop in Index X, the client's stake decreases $100. To wager that Index X will drop, a client “hits” the $1495 bid. Accordingly, for each tick drop in Index X, the client's stake increases $100; for each tick rise in Index X, the client's stake decreases $100. Potential winnings are for the most part unlimited, subject only to the amount of favorable movement of the continuous event until maturity, while losses are generally limited to the client's maximum credit.
To hedge a spread-bet wager before maturity (e.g., because a client is losing too much), the client can place an opposite wager. For example, if the original wager involved the price rise of XYZ stock by the end of the quarter, but after the first week, the price drops precipitously, the client can hedge that wager by placing (quickly) another wager that the price of XYZ will drop by the end of the quarter. Thus, any additional losses incurred in the original wager will be substantially offset by gains made on the hedged wager. Similarly, however, should XYZ stock reverse direction before the end of the quarter, any gains made on the original wager will also be substantially offset by losses incurred in the hedged wager.
In another embodiment of the invention, a cap and collar system could be offered to clients as another way to hedge a spread-bet wager. With the cap and collar system, a client would agree to a limit on potential gains, (i.e., a cap), in exchange for a limit on potential losses (i.e., a collar). The cap would be calculated based on a number of elements (i.e., the spread, the collar, the predetermined risk criteria, the client, and the market volatility).
While the cap and collar system places a limit on potential gains, it has certain advantages over other methods of hedging spread-bet wagers. For example, the cap and collar system is not as subject to the risks of a volatile market. If a market drops in price rapidly, an opposite wager might not be transacted quickly enough to prevent a sizeable loss. However, since the collar is established at a set amount, the maximum size of a potential loss is guaranteed. Additionally, in the case of a market that drops in price and then recovers, placing an opposite wager would result in an overall loss for the wager, whereas hedging via the cap and collar system would result in an overall gain. Finally, the cap and collar system is simply the most straightforward way to limit risk for multiple spread-bet wagers.
After a client enters one or more wagers on one or more selected events, the transaction is confirmed in real time. Substantially no processing delays are incurred primarily because the client has already been qualified and the selected events and wagered amounts have already been authorized.
If a wager price should change as a client places a wager, the system will prompt the client to confirm acceptance of the price change. This price retention feature is implemented substantially as described in U.S. patent application Ser. No. 09/553,423, filed Apr. 19, 2000, entitled “SYSTEMS AND METHODS FOR TRADING”, now U.S. Pat. No. 7,392,214, which is hereby incorporated by reference, but in the context of online interactive wagering.
FIGS. 4-8 show embodiments of interactive display screens according to the present invention as a wager is being placed.
FIG. 4 illustrates a representative login screen 400 according to the invention. A client logs in to the system before placing wagers. The client enters a user name in data entry field 402 and a password in data entry field 404 . The client then selects login button 406 to submit the user name and password to the wagering system. Alternatively, the client can select cancel button 408 to exit login screen 400 without logging in to the system.
FIG. 5 illustrates a representative screen display 500 according to the invention shown after a client has logged in to the system. Pop-up screen 502 contains a scrollable list 504 of wagerable event outcomes on which the client is authorized to wager. The client may select a check box 506 next to a corresponding wagerable event outcome that the client wishes to add to a list 508 of previously selected wagerable event outcomes currently being monitored on screen 500 . To place a wager on an event, the client may, for example, double-click on a wagerable event outcome from list 508 to enter wagered amounts and other information as required.
FIG. 6 illustrates a representative screen display 600 according to the invention shown after a client has double-clicked on a wagerable event outcome on list 508 . A pop-up screen 602 displays the following: the name of the double-clicked wagerable event outcome in display field 604 , a series of buttons 606 representing preset wager amounts, a drop-down list 608 for selecting a desired currency in which to wager, a stake data entry field 610 where the client can enter a wager amount 612 as an alternative to selecting one of wagering amount buttons 606 , a sell button 614 and a corresponding sell price 616 , and a buy button 618 and a corresponding buy price 620 .
FIG. 7 illustrates a representative screen display 700 according to the invention showing pop-up window 602 after a client has entered an amount of “25” into stake data entry field 610 and selected buy button 618 . After the client clicks on buy button 618 , buy price 620 is indicated in field 722 and transmit button 724 is enabled.
FIG. 8 illustrates a representative screen display 800 according to the invention shown after a client clicks on transmit button 724 of FIG. 7 . Pop-up window 802 advantageously provides in real time a confirmation message 804 that wager 806 has been accepted. Wager 806 is displayed in session history display 808 .
Note that in each of the above screen displays, alternatives to the pop-up windows can be used to display and enter the information shown.
To help manage both clients' and dealer's risk, the system preferably includes index processing capabilities that provide numerous automatic wager-tracking indices to monitor wagering activity and market or event performances. For example, the system can indicate how many wagers have been placed, how much has been placed, and on what they have been placed. Historical and current results of placed wagers (e.g., how much has been won and lost) along with any other data related to wagered events can also be indexed and displayed. Moreover, clients can create customized indices and customized displays of indices. For example, a client can customize and display an index showing the client's win-loss ratio over the last 20 wagers or the last month. Advantageously, displayed indices are updated in real time as new information is entered or received by the system. As a default, the house determines what indices are available to clients.
The system also preferably provides automatic verbal language translations of displayed indices and other information (e.g., “Clients are buying event #1,” or “1000 wagers placed on event #2”). Text versions of displayed indices are preferably automatically provided in a client selected language.
The system preferably hedges automatically in response to client wagering. FIG. 9 illustrates a hedging process 900 according to the invention. Generally, hedging is a strategy used to offset investment risk. For example, if clients are wagering heavily that the price of oil will increase to a particular level, the house may buy one or more options or futures contracts to hedge the positions taken by clients. The system initially sets hedging parameters at 902 in accordance with the amount of risk the house is willing to take. As wagers are placed at 904 , the system at 906 automatically analyzes wagering data and applicable market conditions and determines whether the house should hedge and, if so, by how much and in what markets. Preferably, the system's hedging analysis also takes into account the skill of particular clients (e.g., via past performance) and the size of their wagers. For example, if a known client wagers a large amount, and that client is more likely to win than lose based on that client's past performance, the house may hedge sooner or more substantially than if that client were more likely to lose.
If the system at 908 determines that the house should hedge, it may go to one or more preferably correlated markets and automatically complete one or more transactions. If no market is available or appropriate to sufficiently hedge client positions, the system may hedge by increasing the price spread or by choosing to show only bids or only offers. If the system determines that hedging is not necessary, no hedging transactions will be executed. However, hedging variables will be updated at 912 to reflect current client positions, and hedging orders may be readied for immediate execution should client positions move such that hedging becomes necessary.
For each event in which wagers can be placed, the system initially sets a spread (i.e., sets bid and offer prices) and then dynamically resets and skews the spread where appropriate in accordance with the house's policies and objectives as wagers are placed. System 100 preferably includes a neural network (i.e., a learned algorithm; not shown in FIG. 1 ) that bases a spread on market conditions, past performance, and other data, such as, for example, current market volatility, current direction of the market, underlying position of the house, amount and direction of the most recent wagers, liquidity of market, and liquidity of hedging markets. Accordingly, spreads can be increased, decreased, or skewed (i.e., shifted such that the actual wager price is no longer in the center of the spread). The neural network balances the need to ensure an adequate profit, thus preferably avoiding too narrow a spread, versus the need to attract clients, thus preferably avoiding too wide a spread. For example, an initial spread for a particular event outcome may be set at a bid of 5 below and an offer of 5 above the actual price. Thus, if the actual price is $105, the bid price is $100 and the offer price is $110. If the market for that event outcome moves rapidly upward (e.g., because many are bullish), the system may skew the spread upward, setting the bid price at 1 below and the offer price at 9 above the actual price. Alternatively, because wagerers tend to be contrarians, the system may skew wager prices contrary to the direction of the underlying market.
The house can also use this feature to offset either its own or its clients' performance in one market by dynamically adjusting the spread in other markets. Thus, this feature gives the house an opportunity to control profit.
Additionally, the system preferably offers multiple pricing of wagerable events. That is, the system can customize the price spread of an event to individual clients or groups of clients in accordance with, for example, credit quality, number of wagers placed, size of wagers, or wager performance. For example, the system may discount wager prices to a client who has recently suffered several losses. Similarly, the system may discount prices or add a premium to clients who wager large amounts.
The system of the present invention preferably operates 24 hours/day, 7 days/week. This allows clients to wager at their convenience. However, many of the existing markets upon which wagerable events may be based are operated at only certain times on certain days. Clients interested in obtaining prices from those markets for specific current or future dates may not be able to get those prices either because the particular market is closed at the time of the inquiry or because that market did not quote prices for that specific date.
Advantageously, the system automatically calculates a value for the requested wager price for the requested date using established prices from known market dates and other market information. In particular, the system preferably calculates wager prices by correlating prices of different, but preferably related, markets where possible. This helps to forecast the direction of the closed market and thus determine a reasonable requested wager price. For example, if a client requests a price from the FTSE market, but that market is currently closed, the system may calculate a price based on a currently open market, such as, for example, the DJIA, and its correlation with the FTSE. Other data such as the placement of the most recent wagers and known carrying-costs (e.g., interest, dividends, commodity storage charges, etc.) are also preferably included in the calculation of unavailable wager prices.
The system preferably automatically helps clients control risk. The house, a client, or both can enter instructions (e.g., criteria) into the system defining, for example, when too much has been wagered or lost. If the criteria is met during wagering, the system can warn or prevent the client from wagering further. For example, the house may have the system warn a client when the client loses over 40% of his credit in 4 hours. A client may decide that the system should halt the client's wagering when the client loses 50% of his credit in 1 hour. Moreover, should the client's criteria be met, the system will not only prevent the client from continued wagering, but preferably will take the client out of the online wagering environment and provide the client with a pre-selected non-wagering environment. For example, clients may indicate that when a wagering limit is reached, they would like to see a display of a specific picture (e.g., of their family). Or, they may want to play video games or be put in an online chat-room, etc. This change of atmosphere away from the wagering environment provides clients with a cooling off period in which they can reassess their wagering activity and results.
The system preferably also includes an automatic stop-loss feature in which clients can enter specific criteria into the system that will invoke stop-loss wagering. Upon invocation, this feature automatically places offsetting wagers to offset, for example, a client's losses from previously placed spread-bet wagers. Preferably, an automatic readjustment mechanism regulates in real time combinations of stop-loss features (e.g., raising one and lowering another in a two wager client profile).
The system preferably allows clients to select particular currencies when placing wagers and when receiving proceeds from successful wagers. Clients can thus additionally take on currency exchange risk. The currency chosen by a client when placing a wager may be different than the currency chosen at pay-out. For example, a wager can be placed in euros and paid out in U.S. dollars. The currency to be paid-out and place of payment can be selected at any time during the wager or at time of payment.
At a specified time (e.g., every hour, every day, after the outcome of a specific event, etc.), the system determines settlement prices based on predetermined criteria. This “marking to market” process fixes a price for a wagerable event outcome or ends a wager. Final wager prices can be based on, for example, event market conditions, which in turn may be based on the number of wagers placed, the amounts of the wagers, the win-loss ratio of placed wagers, and the potential amounts that stand to be won or lost.
To facilitate wagering at remote workstations, clients can be optionally issued a universal wagering debit-type card that contains identification and financial information, including authorized credit. A client preferably initiates a wager by first inserting the card into a card reader at a workstation, which then preferably establishes communication between the client and the house. This can be done instead of or subsequent to the login process described above. Each time a client transacts a wager, the master financial information files maintained by the system are updated. When the client is finished wagering, the financial information on the client's card is updated and the card is ejected from the card reader. Alternatively, the card can be swiped once to establish communication with the house and swiped again to debit the card with each contemplated wager before that wager is submitted. Upon winning a wager, the card can be swiped to credit all or part of the amount won. As another alternative, the card can be fabricated with an electronic transmitter/receiver circuit that automatically initiates communication with the house and receives transmitted updated financial information at an appropriately equipped workstation.
Other features of the wagering card according to the invention preferably include issuing the card anonymously with prepaid credit (e.g., to be given as a gift). Upon the prepaid card's first use by a client (after preferably logging in as described with respect to FIG. 4 ), the system's master financial files are updated. The card can be preferably used at banks to obtain cash (e.g., up to the authorized credit amount), and used in traditional financial transactions (e.g., to buy shares of stock at a conventional brokerage firm). The card can also be preferably independently updated with an increase in credit at, for example, a financial institution that may have a relationship with the house. The newly updated credit encoded on the card can later be transmitted (e.g., upon insertion into a card reader at a workstation) to the system's master financial files, or the credit can be maintained on the card and debited or credited on a transactional basis. The card can further be preferably used to wager even though access to the system's master financial files is currently unavailable (e.g., because of some technical reason).
The system preferably evaluates client requests for wagering on events that may not be based on an existing market, such as, for example, a particular athlete's likelihood of winning a gold medal at the next Olympics or a casino's likelihood of paying out more than particular amount at roulette over a certain period. If the house approves wagering on a client requested event, the system will establish that event as wagerable by, among other things, determining spreads, establishing customizable indices, and notifying all or selected clients of the new event.
The system preferably includes quantification processing capabilities that establish wagers for various events. For example, a client may request a wager that damage from a particular hurricane will exceed $5 billion dollars. Before establishing the $5 billion in hurricane damage as a wagerable event, the system preferably analyzes available data to determine whether the $5 billion is a feasible amount on which to accept wagers (i.e., within the risk tolerance of the house). The available data that may be analyzed may include, for example, the hurricane's current strength, current location, and targeted onshore arrival location, and amounts of damage caused by past hurricanes of similar strength and circumstances. This feature can be used, for example, by the insurance industry to hedge potential losses from such an event.
In another embodiment of the present invention, the house may not only act as a dealer to one-sided wagers (i.e., wagers between clients and the house), but may also act as a broker to two-sided wagers (e.g., wagers between clients, between clients and other houses, and between other houses). In this environment (also known as an exchange environment), the system allows qualified clients or dealers (other houses) to enter bids and offers to be displayed to other clients or dealers, and enables each house to control dealer risk.
The brokerage environment of the present invention preferably includes the following features: a participant qualification state, an instrument creation state, a bid/offer state, a “when” state, a qualified workup state, a price retention state, a price improvement state, a request for market state, a restore state, a price generation state, a position conversion state, and a marking-to-market state. These features are implemented substantially as described in the aforementioned U.S. patent application Ser. No. 09/553,423, but in the context of online interactive wagering.
Moreover, the brokerage environment of the present invention also preferably includes the following features: an order gathering state, a marketing making state, a trade order allocation state, a multiple wagering state, and a request for size state. These features are implemented substantially as described in U.S. patent application Ser. No. 09/593,554 entitled “SYSTEMS AND METHODS FOR ELECTRONIC TRADING THAT PROVIDE INCENTIVES AND LINKED AUCTIONS,” filed on Jun. 14, 2000, now U.S. Pat. No. 7,401,044, which is hereby incorporated by reference, but in the context of online interactive wagering.
In another embodiment of the present invention, the house may allow clients the option of remotely participating in live casino games. A client connecting to the system through a workstation or other suitable hardware would be able to participate remotely in a live casino game.
This system and method could allow a client to remotely participate in casino games in any available casino, but preferably this system would be a closed system that would operate strictly within a particular casino. According to this embodiment, each hotel room (as well as other areas of the hotel and resort) would have a workstation or a television properly equipped to interface with the system. A client would then be able to participate remotely in real-time interactive casino games without actually being present in the casino.
For example, if a client wanted to participate in a craps game, the client would logon to the system from the hotel room. The client could then establish a new credit account or use an existing credit account. According to one embodiment the client's credit account could be linked to the bill for the client's room. According to another embodiment the client's credit account could be associated with an anonymous pre-paid card. Once the client has fully initiated the session and has selected a specific table or table type, the client may begin to place wagers on the craps game. By preferably viewing a live video of the craps table or alternatively a live description of the action on the table, the client would place bets which would be tracked by the system. The action of the game would also be tracked by the system and all money won and lost would be reflected by the client's account.
Advantages of this system for the house include the ability to automatically monitor and track the performance of clients participating in casino games. Additionally this system would provide more opportunities for clients to participate in casino games.
Advantages of this system for the client include the ability to participate in casino games when it is inconvenient or undesirable to leave the room. Additionally the current system would allow the client abilities not available within the actual casino, such as the ability to participate in several different games at once. Certain types of rewards and benefits may also apply when remotely participating in casino games that may or may not be the same as the rewards offered on the casino floor. These rewards may include such things as: increased credit, free rooms, free room upgrades, free gifts, free wagers, credits towards the room bill, free event tickets, free transportation, free access to clubs, free meals, or any other type of similar reward or incentive.
Thus it is seen that real-time interactive wagering on event outcomes is presented. One skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments, which are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims which follow.
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Systems and methods for real-time interactive wagering on event outcomes are presented. Clients are first qualified and given wagering limits before being allowed to interactively wager on event outcomes. Event outcomes may be based on, for example, financial markets and indices, sporting and entertainment events, casino games, casino performances, and natural phenomena such as weather and earthquakes. Events on which wagers can be placed include both those with known and unknown outcome probabilities, and wagers can be a fixed-odds type or a spread-bet type. Wager transactions, including acceptances and confirmations, are executed in real time. Clients can customize displays of events on which they are authorized to wager. Real-time client credit management, automatic dealer hedging, automatic price-spread adjustments, and automatic client and dealer defined wagering limits are also provided.
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This application is a continuation of U.S. application Ser. No. 08/887,366, filed Jul. 2, 1997, now U.S. Pat. No. 5,990,845.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to antennas. More specifically, the present invention relates to a fan shaped conical antenna that is suitable for use in a direction finding array used in a direction finding system. Instead of using a full circular cone, the antenna includes only a sector of a complete circular cone. The antenna is used in a direction finding array of antennas that operates in the VHF/UHF/SHF bands.
2. Description of the Related Art
Conical antennas, which include a single inverted cone over a ground plane, and biconical antennas, which include a pair of cones oriented with their apexes pointing toward each other are used as broadband antennas for various applications, including direction finding. FIG. 1 is a schematic diagram illustrating two such antennas. A biconical antenna 100 includes a top inverted cone 101 a and a bottom cone 101 b. An electronic coupler 102 provides a connection to a feeding circuit (not shown) that provides an electrical signal that feeds the antenna. It should be noted that the antenna is symmetric about the cone axis and that each of the cones is a full cone, spanning 360°. Similarly, a single cone antenna 110 includes a single antenna cone 111 that also spans 360° and is symmetric about the cone axis. Single antenna cone 111 is connected to an electronic coupler 114 that provides a connection to a feeding circuit (not shown) that provides an electrical signal that feeds the antenna. The single cone antenna is located over a ground plane 112 .
Antennas such as the ones shown above may be included in an array of antennas used for direction finding. Direction finding antenna arrays determine direction by comparing the phase or strength of signals received at different antennas. According to the principle of reciprocity, signals may likewise be sent from an array in a particular direction by altering the phase or strength of the electric signals feeding each of the antennas. Hereinafter, antenna surfaces such as top inverted cone 101 a and bottom cone 101 b are referred to as radiators and it should be understood that the antenna surfaces may be used to either radiate or receive a signal.
Because the conical antennas shown in FIG. 1 are symmetric about the cone axis, the radiation pattern from the antenna is omniazimuthal or isotropic with respect to the azimuth angle. As a result, the radiation patterns from such antennas tend to interfere with each other when a group of such antennas are included in an array. This complicates direction finding and may reduce the accuracy that may be achieved. Furthermore, each of the antennas take up a relatively large amount of space and must be spaced apart in an array to ensure that they do not physically interfere with each other.
What is needed is a direction finding antenna and a direction finding array made up of broadband antennas that do not radiate isotropically with respect to the azimuth angle and which occupy less physical space than the full conical antennas shown in FIG. 1 .
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a broadband antenna suitable for use in a direction finding array. In one embodiment, the antenna is designed for use over a 16:1 frequency bandwidth. The antenna uses only a sector of a circular cone and therefore occupies less space than a full cone. In a circular DF array, the antenna reduces the interactions between elements compared to typical omnidirectional elements. Asymmetries in the azimuthal antenna pattern of the antennas located along the perimeter of the array enables direction information to be determined from the amplitude of the signals detected by the antennas in the array. This provides more accurate and reliable direction finding.
It should be appreciated that the present invention can be implemented in numerous ways, including as a process, an apparatus, a system, a device, a method, or a computer readable medium. Several inventive embodiments of the present invention are described below.
In one embodiment, a broadband partial fan cone direction finding antenna and array disclosed. The antenna includes a radiator having a partial cone shape. The radiator substantially occupies a spatial area defined by a portion of a cone and the cone is defined by a cone axis, a cone height, and a cone angle. The cone has a base and an apex, and the portion of the cone is defined by a cone sweep angle. The cone sweep angle is determined as the angle subtended by a projection of the portion of the cone projected onto a plane that is perpendicular to the cone axis. The cone sweep angle is less than 360° so that the portion of the cone is bounded on its sides by edges which extend radially from the apex of the cone outward to the base of the cone.
In another embodiment, a flat fan antenna is disclosed that includes a flat metal radiator. The flat metal radiator is formed in the shape of a sector of a flat disc. The sector is defined by a sector angle, an inner radius and an outer radius. The sector angle determines the angle subtended by the sector; the inner radius determines the inner edge of the sector; and the outer radius determines the outer edge of the sector. The flat metal radiator is tilted from the vertical by a tilt angle. The flat fan antenna has a radiation pattern and performance similar to the pattern and performance of a partial fan cone antenna.
In another embodiment, an antenna direction finding array includes a plurality of direction finding antennas approximately spaced around the circumference of a circle. Each direction finding antenna is pointed outward from the center of the circle, and each of the direction finding antennas has an amplitude response that is greater in the azimuthal direction that the antenna is pointed. A central reference antenna has an amplitude response that is substantially omniazimuthal so that the central reference antenna is suitable to be connected to a reference receiver and a signal from the central reference antenna is suitable for use as a reference for measuring the phase of the signals from the plurality of direction finding antennas.
These and other features and advantages of the present invention will be presented in more detail in the following specification of the invention and the accompanying figures which illustrate by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:
FIG. 1 is a schematic diagram illustrating two such antennas.
FIG. 2 is a schematic diagram of a biconical antenna constructed according to one embodiment of the present invention.
FIG. 3 a is a schematic diagram of single fan conical antenna that is used in certain embodiments over a ground plane.
FIG. 3 b is a schematic diagram illustrating single fan conical antenna that includes a metal disc at approximately the apex of an inverted cone that is perpendicular to the cone axis.
FIG. 3 c is a schematic diagram illustrating single fan conical antenna that is made up of a series of rods that are used in place of a curved metal sheet.
FIG. 3 d is a schematic diagram of a top view of a flat fan conical antenna surface. The antenna surface is flat and pie shaped.
FIG. 4 a is a graph showing the measured VSWR for a typical biconical fan antenna such as the one shown in FIG. 2 for a 50Ω antenna feed.
FIG. 4 b is a graph showing the measured VSWR for a typical singe cone fan antenna over a ground plane.
FIG. 5 a shows the elevation pattern at 166 MHz.
FIG. 5 b shows the elevation pattern at 500 MHz.
FIG. 5 c shows the elevation pattern at 1000 MHz.
FIG. 5 d shows the elevation pattern at 1500 MHz.
FIG. 5 e shows the elevation pattern at 2000 MHz.
FIG. 5 f shows the elevation pattern at 2700 MHz.
FIG. 5 g shows the azimuth pattern at 166 MHz at an elevation angle of 0°.
FIG. 5 h shows the azimuth pattern at 500 MHz.
FIG. 5 i shows the azimuth pattern at 1000 MHz.
FIG. 5 j shows the azimuth pattern at 1500 MHz.
FIG. 5 k shows the azimuth pattern at 2000 MHz.
FIG. 5 l shows the azimuth pattern at 2700 MHz.
FIG. 6 is a schematic diagram of a direction finding antenna array that includes a fixed reference biconical antenna at the center and 13 120° conical fan antennas that are equally spaced along the circumference of a circle around the center antenna.
FIG. 7 is a schematic diagram of a combined high and low frequency direction finding array that includes a 7 element low frequency array that is used for frequencies between about 20 MHz and 175 MHz and a 13 element high frequency array that is used for frequencies between about 175 MHz and 2700 MHz.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiment of the invention. An example of the preferred embodiment is illustrated in the accompanying drawings. While the invention will be described in conjunction with that preferred embodiment, it will be understood that it is not intended to limit the invention to one preferred embodiment. On the contrary, it is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. The present invention may be practiced without some or all of these specific details. In other instances, well known process operations have not been described in detail in order not to unnecessarily obscure the present invention.
FIG. 2 is a schematic diagram of a biconical antenna 200 constructed according to one embodiment of the present invention. A top fan 202 is constructed of a metal sheet that is formed in the shape of a partial cone. Instead of sweeping 360 the fan sweeps out only 120°. Therefore the fan is in the shape of ⅓ of a complete cone. It is preferred that the fan sweep out between 80° and 180°. More preferably, the fan sweeps out between 105° and 135° and most preferably the fan sweeps out 120° plus or minus a few degrees. A bottom fan 204 sweeps out substantially the same angle as top fan 202 . The size of the fans may be scaled according to the wavelength of radiation that is being transmitted or received. When scaling an antenna, all the antenna dimensions are scaled proportionally to wavelength; i.e. if the wavelength is doubled, all the antenna dimensions are doubled. In some embodiments, a dielectric spacer 206 is provided to mechanically stabilize the fans. This is especially important when the antenna is mounted in a windy environment. In other embodiments, reinforced metal veins are provided along the inner surface or outer surface of the partial cone to provide structural strength. So long as the veins have a relatively low profile to the cone surface, the electrical performance is not significantly degraded.
In addition, in some embodiments, the two axes of the upper and lower cones need not be vertical or parallel as shown. The axes are shown parallel in FIG. 2 with the apex of the lower cone pointing straight up and the apex of the lower cone pointing straight down. Both axes could be tilted the same amount or by different amounts from the vertical. In one embodiment, the axes are tilted toward each other along the center line of the fan cone by up to 45° so that the fan cone surfaces are closer together than if the axes were not tilted.
An insulating spacer 208 is provided between the upper and lower fans. The fans are attached to the insulating spacer using a set of dielectric screws 210 . In a preferred embodiment, the screws and the insulating spacer are made of nylon. Insulating spacer 208 is physically attached to a metal support pipe 212 that is supported by a metal base 214 . A coaxial cable 218 runs through metal support pipe 212 . It should be noted that the cone shaped fans do not extend all the way to the apex of the cone but are truncated before the apex in some embodiments. Coaxial cable 218 is connected at one end to a connector 219 that is suitable for connecting to a transmitter that generates an electrical signal or to a receiver that processes a signal received by the antenna. The support pipe may be dielectric and ferrite beads may be placed around the coaxial cable in order to choke off currents. In one embodiment, the connector is a standard 50Ω connector and the cable is a 50Ω cable. Other impedences are used in other embodiments. At the other end, coaxial cable 218 is electrically coupled to the two antenna fans via a circuit board 220 that provides a lightning protection circuit to protect the transmitter or receiver from surges caused by lightning striking the antenna.
Preferably, the cone shaped fan extends almost completely to a point at the apex of the cone and is truncated by a very small amount. In one embodiment, the width of the inner edge of the fan cone near the apex is about 0.25 inch or about 0.5 cm. When the size of the inner edge of the fan cone is very small, electrical discontinuities are avoided when the signal is fed to the antenna. This keeps the impedance constant over a larger frequency range and keeps the VSWR relatively low. In one embodiment, a small hole is drilled near the inner edge of the fan cone and the center conductor of coaxial cable 218 is extended through the hole and soldered to the fan cone. In some embodiments, a washer is used to reinforce the hole and help hold the wire in place. Similarly, in the flat fan antenna embodiment described below, it is preferable to extend the inner edge of the flat fan to as close to a point as possible to minimize discontinuities.
In one embodiment, the length along a radial of the fan cone surface is about 0.20 wavelengths at the lowest frequency of operation. The length in one preferred embodiment is approximately 12 inches. The interior angle between the two fan cone surfaces is preferably between 50° and 80°. Thus, when the two cone axes are vertical and the two cones have the same cone angle so the cone angles will be between 50 and 65 degrees. In some embodiments, the cone angles used may be as small as 20° and as large as 80° and in some embodiments the upper and lower cone angles may differ. Most preferably, the interior angle between the fan cone surfaces is about 60°.
The curved surfaces of the partial cone shaped fans which function as the radiators for the biconical antenna help provide a substantially constant input impedance for the antenna across a large frequency bandwidth. In another embodiment, the fans are made of a flat metal sheet formed into a pie shaped portion of a flat disc. Instead of defining a sector of a cone, a flat fan is shaped to define a portion or sector of a circle. The angle that defines the size of the sector, referred to as the sector angle, roughly corresponds to the sweep angle of the fan cone antenna. Typically, the flat fan is tilted from the vertical at a tilt angle that roughly corresponds to the cone angle used for a fan cone. Like the fan cone antenna, the flat fan antenna may be implemented as a double fan or as a single fan over a ground plane. When implemented as a double flat fan, the tilt angles of the two fans determine an interior opening angle that is the angle defined by the two surfaces.
As shown below, the VSWR for flat fans is similar to the VSWR for curved fans over a broad frequency range. A flat embodiment is very useful since manufacturing flat cone fan sectors is considerably easier than manufacturing curved fans that define a portion of a conical surface. The sector angle used for the flat fan antennas preferably sweeps out between 60° and 180°. More preferably, the fan sweeps out between 70° and 130° and most preferably the fan sweeps out 80° plus or minus a few degrees. The interior opening angle between the fans is between about 20° and 140°. More preferably, the interior opening angle is between about 40° and 80°. Most preferably, the interior opening angle is about 60° plus or minus a few degrees.
FIG. 3 a is a schematic diagram of single fan conical antenna 300 that is used in certain embodiments over a ground plane 301 . Similar to a biconical antenna, a partial cone radiator 302 is a curved surface that includes only about 120° of a 360° full cone. The impedance characteristics of the single fan conical antennas are similar to the impedance characteristics of the biconical fan antenna. It is preferred that the fan sweep out between 80° and 180°. More preferably, the fan sweeps out between 105° and 135° and most preferably the fan sweeps out 120° plus or minus a few degrees.
FIG. 3 b is a schematic diagram illustrating single fan conical antenna that includes a metal disc 310 at approximately the apex of an inverted cone 312 that is perpendicular to the cone axis. The metal disc is used in applications where a ground plane is not present. In other embodiments, the metal disc is not parallel to the cone axis. The impedance is not as constant as the biconical antenna, but the performance is satisfactory for applications that do not require constant impedance over the broadest possible bandwidth.
FIG. 3 c is a schematic diagram illustrating single fan conical antenna that is made up of a series of rods 330 that are used in place of a curved metal sheet. The rods are angled such that they occupy a conical path subtending approximately 120°, similar to the biconical fan and the single fan antennas described above. The rods are generally less susceptible to deformation or damage as a result of wind than the metal sheets. In the antenna shown, 13 metal rods are used to define a 120° sweep. It is preferred that the fan sweep out between 80° and 180°. More preferably, the fan sweeps out between 105° and 135° and most preferably the fan sweeps out 120° plus or minus a few degrees. The number of rods used is preferably between 10 and 30 and more preferably between 10 and 20. In some embodiments, an even greater number of rods is used. Performance of such an antenna compared to an antenna with a cone portion made of a curved metal sheet is not significantly different. It should also be noted that a biconical antenna may also be similarly constructed with fans that include rods instead of metal sheets in accordance with the present invention.
FIG. 3 d is a schematic diagram of a top view of a flat fan conical antenna surface. The antenna surface is flat and pie shaped. The surface is characterized by a sector angle 340 and by an inner edge radius 344 and an outer edge radius 342 that determine the size of the surface. As noted above, the size of the inner edge is preferably very small so that electrical discontinuities are minimized. Preferably the inner edge radius is made small so that the inner edge is almost a point. In one embodiment, the inner edge radius is less than an inch. It should be noted that in some embodiments, the inner and outer arcs may be squared off into straight edges. The length along a radial for the flat fan is scaled according to the wavelength being sent or received. In one embodiment, the length is about 12 inches long.
FIG. 4 a is a graph showing the measured VSWR for a typical biconical fan antenna such as the one shown in FIG. 2 for a 50Ω antenna feed. The VSWR is a measure of how much energy is reflected back toward the transmitter when a signal is applied to the antenna with a given input impedance. It can be seen from the graph that the VSWR is close to 2:1 across a large bandwidth from about 180 MHz to 3000 Mhz for about a 16:1 range in bandwidth. This is because the impedance of the antenna is nearly constant across the band, between approximately 80 and 100Ω. Thus, the antenna can be used with a simple 50Ω feed with no need for an active amplifier over a large bandwidth. In some embodiments, an active amplifier is used to further extend the bandwidth.
Similarly, FIG. 4 b is a graph showing the measured VSWR for a typical single cone fan antenna over a ground plane. The VSWR is similar to that shown in FIG. 4 a. FIG. 4 c is a graph showing the measured VSWR for a typical double flat fan antenna for a 50Ω antenna feed. The particular double flat fan antenna measured had two flat fans 12 inches long with 80° fan sectors. The top fan was tilted downward away from vertical by about 59.5° and the bottom fan was tilted upward from the vertical by the same amount so that the two fans together defined an interior angle of about 61°. As can be see, the VSWR remains close to 2 over a large bandwidth and is less than 5 from 175 MHz to 3000 MHz. The impedance of the antenna is nearly constant across the band, between approximately 80 and 100Ω.
For the above described antennas, the angle of the cone fan surface relative to the vertical cone axis, referred to as the cone angle, or the angle of the flat fan surface relative to vertical, referred to as the tilt angle, determines the impedance of the antenna. (Note that the cone angle should be distinguished from the sweep angle which determines the portion of a cone included in the fan, e.g. 360° for a full cone and 120° in the ⅓ fan cone examples above. Likewise, the tilt angle should be distinguished from the sector angle which determines the portion of a disc included in the fan, e.g. 360° for a full disc and less than 360° for a sector of a disc.) The above data was taken for cone angles and tilt angles of about 60°, leaving an interior opening between the surfaces of about 60° which is most preferred. In the case of a single fan antenna, the angle between the fan surface and a ground plane is preferably about 30°.
As noted above, Cone angles between 20° and 80° and tilt angles between 20° and 80° may also be used. For a biconical antenna, as the cone angle is increased and the cones are moved closer together, the impedance decreases and the antenna may radiate less at low frequencies. Likewise, as the cone angle is increased for a single cone the impedance is also decreased. Generally, the separation between the cone surfaces or between a single cone surface and a virtual reflected surface below the ground plane must be at least about one half a wavelength at the outer edge of the surfaces in order for the antenna to radiate efficiently.
FIGS. 5 a through 51 show calculated antenna patterns in azimuth and elevation for a single 120° fan cone made up of 13 wires over a ground plane as shown in FIG. 3 c. As mentioned above, the antenna pattern of the wire antenna tracing out the fan cone shape is similar to the pattern for a fan cone made up of a curved metal sheet. FIG. 5 a shows the elevation pattern at 166 MHz. At such a low frequency, the radiation pattern is the same in the forward and backward directions and is nearly isotropic. FIG. 5 b shows the elevation pattern at 500 MHz; FIG. 5 c shows the elevation pattern at 1000 MHz; FIG. 5 d shows the elevation pattern at 1500 MHz; FIG. 5 e shows the elevation pattern at 2000 MHz; and FIG. 5 f shows the elevation pattern at 2700 MHz. As the frequency of the radiation increases, the amount of radiation radiated in a backward direction decreases and the gain of the forward radiation increases. At 2700 MHz, back lobe is significantly reduced and the gain at low angles in the forward direction is more than 10 dBi and is over 5 dB greater than it is at 500 MHz. In different embodiments, preferably the gain varies between about 3 dBi and 15 dBi. Most preferably, the gain varies between about 5 dBi and about 10 dBi.
FIG. 5 g shows the azimuth pattern at 166 MHz at an elevation angle of 0°. At such a low frequency, the radiation pattern is the same in the forward and backward directions and is nearly isotropic. The forward azimuthal direction is defined as the direction pointing from the center of the fan cone radiator surface toward the cone axis. It should be noted that in other embodiments, the forward direction is similarly defined. For example, in the flat fan embodiment, the forward direction is defined as the direction toward which the flat fan is tilted. FIG. 5 h shows the azimuth pattern at 500 MHz; FIG. 5 i shows the azimuth pattern at 1000 MHz; FIG. 5 j shows the azimuth pattern at 1500 MHz; FIG. 5 k shows the azimuth pattern at 2000 MHz; and FIG. 5 l shows the azimuth pattern at 2700 MHz. As the frequency of the radiation increases, the amount of radiation radiated in a backward direction decreases and the gain of the forward radiation increases. At 2700 MHz, the back lobe is significantly reduced and the gain at low angles in the forward direction is over 10 dBi and is more than 5 dB greater than it is at 500 MHz.
Thus, the biconical fan cone, the single fan cone antennas and the flat fan antennas are broadband antennas in the VHF/UHF/SHF bands. The antenna patterns are similar, providing a gain of greater than 5 dBi and up to over 10 dBi. The VSWR of the antenna for a 50Ω feed is most preferably approximately 2 across a large bandwidth of at least about 16:1. In other embodiments, the VSWR is less than 5 across a bandwidth of at least 15:1 or less than 8 across a bandwidth of 15:1. Above about 1000 MHz, the antenna provides about 5 dB more gain in the forward direction than a corresponding full cone antenna with a symmetric pattern. It should be noted that the minimum frequency at which the 5 dB gain increase is realized varies according to the physical size of the antenna and so the 5 dB gain can be realized at a desired frequency by scaling the antenna accordingly.
As mentioned above, the flat fan antennas and the biconical fan antennas described above are particularly suited for inclusion in an array of antennas used for direction finding. Specifically, the asymmetrical antenna patterns shown above are useful in direction finding arrays. The attenuated back lobes of the antennas help to generally reduce interference between the antennas in a circular array with the antennas located about the circumference of the circle and pointing outward from the circle. As noted above, direction finding arrays generally operate by comparing the phase of the signals received by antennas arranged in an array. Information about direction may also be derived from the amplitude of the signals received from antennas facing different directions in an array when the antennas have asymmetric patterns as shown above. The information obtained may be used to make a rough approximation of direction which is used to resolve ambiguities in the phase information or to detect and correct errors in the phased derived direction. In one embodiment, a check is made that the phase derived direction and an amplitude derived direction are within 90° or else the phase derived direction is flipped 180° so that the phase derived direction and the amplitude derived direction are within 90°.
FIG. 6 is a schematic diagram of a direction finding antenna array 600 that includes a fixed reference biconical antenna 610 at the center and 13 120° conical fan antennas 620 that are equally spaced along the circumference of a circle around the center antenna. The fans are pointed outward, away from the center of the circle. This particular array is compact and particularly suitable for a mobile application where the array is mounted on the top of a van, for example. In other embodiments, different numbers of conical fan antennas are used, including 4 through 24. More elements may be used if required. It is preferred that odd numbers of antennas are used since fewer ambiguities result when the array is used for direction finding. Note that the fan shape of the 13 conical fan antennas enables them to be spaced together more closely without physically interfering with each other than would be possible if the antennas were full 360° cones.
The use of the fan shaped antennas reduces electrical interference among the elements because the back lobes of the radiation are reduced for the fans as shown above. The fixed reference antenna is a biconical antenna that includes two full cones and is elevated above a ground plane. The 13 conical fan antennas are single cone portions mounted over a ground plane. Each of the antennas include a series of wires which trace out the cone or partial cone shape. In an embodiment utilizing a mobile antenna array, the antennas operate at frequencies between 20 and 2700 MHz.
In another embodiment, a 9 element array of 80 degree flat fan antennas provides a particularly compact array that is useful for mobile applications. In such mobile embodiments, it is preferred to cover the array with a radome for protection.
The use of a central reference antenna is a particularly useful feature of certain embodiments of the present invention. In order to reliably measure the amplitude and phase of the signal received by each antenna in the array for the purpose of direction finding, the signal received by each antenna is compared to a reference signal. It is important that the reference signal be a sufficiently strong signal. In circular antenna arrays that do not have a central reference antenna, one of the other antennas on the circle that has a strong signal is used as a reference for the signal measured at a measured antenna. A disadvantage of this approach is that an n by 1 switch is required to select the antenna to be used as a reference. At high frequencies such switches can be expensive.
In certain embodiments, a central reference antenna that is a full cone and is omniazimuthal is directly wired to a reference receiver and used as a reference for all of the elements of a circular array so that no switch is required to select the reference antenna for input to the reference receiver. Thus, a full 360° omniazimuthal conical antenna is used as a central reference and fan cones which provide a directional pattern with gain in the forward direction are used as outwardly directed elements on the circle. The central reference antenna has similar radial length and cone angle to the fan cones used as the elements on the circle.
FIG. 7 is a schematic diagram of a combined high and low frequency direction finding array 700 that includes a 7 element low frequency array that is used for frequencies between about 20 MHz and 175 MHz and a 13 element high frequency array that is used for frequencies between about 175 MHz and 2700 MHz. The 13 element high frequency element array uses a central reference antenna 725 that is elevated above the 13 element high frequency array. Central reference antenna 725 is a full 360° sweep biconical antenna. The 7 element low frequency array does not use a central reference antenna. This is because the other antennas in the array may be used as references . This is practical because low frequency n×1 switches are relatively inexpensive. High frequency switches, on the other hand, are more expensive and so it is more cost effective to use a central reference antenna.
Both the 7 element low frequency array and the 13 element high frequency array use biconical partial cone antennas constructed of wires that trace out the partial cone shape. Alternatively, curved metal sheets could be used to define the partial cone shape or flat fan antennas could be used. The use of 120° cones allows the array to be compact. Other partial cone angles are used in other embodiments. Biconical antennas are used since the entire array is shown elevated above the ground. In other embodiments, one or both of the arrays are mounted on a ground plane and single cones are used. In certain other embodiments, metal sheets instead of wires are used to trace the cone path. The combined high and low frequency direction finding array provides service over an extremely wide bandwidth.
Thus, a wide band fan antenna with gain in a forward direction has been disclosed for use in a direction finding array. The direction finding array includes a number of such antennas arranged around the circumference of a circle and, in some embodiments, a central omniazimuthal pattern antenna is included as a reference antenna.
Although the foregoing invention has been described in some detail for purposes of clarity of understanding, it will be apparent that certain changes and modifications may be practiced within the scope of the appended claims. It should be noted that there are may alternative ways of implementing both the process and apparatus of the present invention. Accordingly, the present embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalents of the appended claims.
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A broadband partial fan cone direction finding antenna and array disclosed. The antenna includes a radiator having a partial cone shape. The radiator substantially occupies a spatial area defined by a portion of a cone and the cone is defined by a cone axis, a cone height, and a cone angle. The cone has a base and an apex, and the portion of the cone is defined by a cone sweep angle. The cone sweep angle is determined as the angle subtended by a projection of the portion of the cone projected onto a plane that is perpendicular to the cone axis. The cone sweep angle is less than 360° so that the portion of the cone is bounded on its sides by edges which extend radially from the apex of the cone outward to the base of the cone.
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BACKGROUND OF THE INVENTION
The present invention relates to a fuel injection pump for internal combustion engines, of the type in which the rate of fuel delivery is adjusted by rotating a plunger within a plunger barrel. More particularly, the invention is concerned with an improvement in the device for rotating the plunger in the fuel injection pump of the type mentioned above.
A fuel injection pump called "Bosch" type fuel injection pump has been known. This fuel injection pump has a plunger adapted to be moved reciprocatingly in a plunger barrel (referred to simply as "barrel", hereinafter) to pressurize and deliver a fuel. The rate of delivery of the fuel is adjusted by changing the timing at which the fuel pressurizing chamber in the barrel is brought into communication with a fuel relief port formed in the wall of the barrel, through changing the relative rotational position relatively to each other. In this fuel injection pump, in order to cause the rotation of the plunger, there is provided a plunger rotating member which engaged in the circumferential direction with a projection provided at an intermediate portion of the plunger, and a rack gear disposed at one side of the plunger rotating member and meshing with the gear teeth formed on the outer periphery of the plunger rotating member. In operation, the rack gear is pulled and pushed to rotate the plunger rotating member, thereby to cause the rotation of the plunger.
Thus, this known fuel injection pump requires a combination of a plunger rotating member and a rack for rotating the plunger, resulting in a complicated construction and uneconomically raised cost of production of the fuel injection pump.
SUMMARY OF THE INVENTION
Under these circumstances, the present invention aims as its major object to provide a fuel injection pump having a single barrel, in which the plunger is rotated solely by a plunger rotating member, thereby to simplify the construction of the fuel injection pump and to reduce the cost of production of the same through the reduction of number of parts.
The present invention provides in its another aspect to provide a fuel injection pump having a multiplicity of barrels, in which the plungers are rotated by a combination of respective plunger rotating members and a fuel adjusting rod, thereby to simplify the construction of the fuel injection pump and to reduce the cost of production of the same through the reduction of the number of parts.
To this end, according to the invention, there is provided a fuel injection pump for internal combustion engines of the type having a plunger adapted to be reciprocatingly moved in a barrel to pressurize and deliver a fuel before the establishment of communication between a fuel pressurizing chamber and a fuel relief bore formed in the wall of the barrel, said plunger being adapted to be rotated relatively to the barrel to change the timing of establishment of the communication thereby to adjust the rate of delivery of said fuel, characterized by comprising a plunger rotating member coupled to said plunger for rotation together with the plunger, whereby the plunger is rotated as the plunger rotating member is rotated.
The foregoing and still other advantages of the invention will be made more apparent from the following detailed explanation of the preferred embodiments taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view of a conventional fuel injection pump;
FIG. 2 is a vertical sectional view of a fuel injection pump constructed in accordance with a first embodiment of the present invention;
FIG. 3 is an exploded perspective view of an essential part of the fuel injection pump shown in FIG. 2;
FIG. 4 is a vertical sectional view of a fuel injection pump constructed in accordance with a second embodiment of the invention;
FIG. 5 is a sectional view taken along the line V--V of FIG. 4;
FIG. 6 is a sectional view taken along the line VI--VI of FIG. 4;
FIG. 7 is a vertical sectional view of a fuel injection pump constructed in accordance with a third embodiment of the invention;
FIG. 8 is a view taken in the direction of arrow lines VIII--VIII of FIG. 7;
FIG. 9 is a vertical sectional view of a fourth embodiment of the invention;
FIG. 10 is a view taken in the direction of arrow line X of FIG. 9;
FIG. 11 is a vertical sectional view showing the structure for connecting the plunger barrel unit to a mounting flange;
FIG. 12 is an enlarged view of the portion marked at XII of FIG. 11;
FIG. 13 is a vertical sectional view of a fuel injection pump constructed in accordance with a fifth embodiment of the invention;
FIG. 14 shows a pump mounting hole formed in an internal combustion engine;
FIG. 15 is a sectional view taken along the line XV--XV of FIG. 13;
FIG. 16 is a front elevational view of a fuel injection pump constructed in accordance with a sixth embodiment of the invention;
FIG. 17 is a sectional view taken along the line XVII--XVII of FIG. 16;
FIG. 18 is an exploded perspective view of a plunger rotating device;
FIG. 19 is an enlarged view of a portion marked at XIX in FIG. 17;
FIG. 20 is an enlarged sectional view of an essential part of a fuel injection pump constructed in accordance with a seventh embodiment of the invention;
FIG. 21 is an enlarged sectional view of an essential part of a fuel injection pump constructed in accordance with an eighth embodiment of the invention;
FIG. 22 is an enlarged sectional view of an essential part of a fuel injection pump constructed in accordance with a ninth embodiment of the invention;
FIG. 23 is a sectional front elevational view of a tenth embodiment of the invention; and
FIG. 24 is a sectional view taken along the line XXIV--XXIV of FIG. 23.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1 showing a conventional Bosch type fuel injection pump, a pump casing 2 mounts a barrel 3 which reciprocatably and slidably receives a plunger 4 provided at its top with an inclined lead 6. The wall of the barrel 3 has a fuel relief port 5 of a small diameter. A plunger rotating member rotatably fitted around the barrel 3 has, at its lower part, a groove 8 which engages with a projection 9 formed at an intermediate portion of the plunger 4. The plunger rotating member 7 is provided on its outer peripheral surface with gear teeth 10 meshing with a rack gear 11 disposed at one side of the plunger rotating member 7. In FIG. 1, a reference numeral 3a denotes a fuel pressurizing chamber. A cam roller 13 connected to the lower end of the plunger 4 is adapted to be pressed against a fuel cam 14 by means of a plunger spring 12. A reference numeral 15 designates a delivery valve held by a delivery valve holder 16.
The conventional fuel injection pump having the construction outlined as above operates in a manner explained hereinbelow.
As the engine on which the fuel injection pump starts to run, the fuel cam 14 is rotated to reciprocatingly move the plunger 4 within the barrel 3 through the medium of the cam roller 13, thereby to pressurize the fuel sucked into the fuel pressurizing chamber. For adjusting the rate of delivery of the fuel from the pump, the rack gear 11 is moved in one and the other direction to rotate the plunger 4 through the action of the plunger rotating member 7, thereby to change the timing at which the inclined lead 6 is brought into communication with the fuel relief port 5. The fuel thus metered is delivered at a high pressure to a fuel injection valve (not shown) through a delivery valve 15.
Thus, in the fuel injection pump, it is necessary to incorporate a combination of a plunger rotating member 7 and a rack gear 11 for rotating the plunger. Accordingly, the construction of the fuel pump itself is complicated and the cost of production of the same is uneconomically raised due to a large number of parts.
The above-described problems of the prior art is fairly overcome by the fuel injection pump of the present invention.
FIGS. 2 and 3 show a fuel injection pump constructed in accordance with a first embodiment of the invention. Referring to FIG. 2, a plunger 24 is reciprocatingly received by a barrel 23 which also serves as a pump casing. The reciprocating motion of the plunger 24 is caused by a fuel cam 34 which cooperates with a cam roller 33 attached to the lower end of the plunger 24. This fuel injection pump as a whole is generally designated at a reference numeral 21. A fuel relief port 25 having a circular or elliptic shape and acting also as a fuel suction port is formed in the wall of the barrel 23. On the other hand, the plunger 24 has a fuel relief bore 26 opening at the top and side surfaces thereof. The rate of delivery of the fuel from this pump is adjusted by varying the timing at which the fuel relief bore 26, i.e. the pressurizing chamber 23a, is brought into communication with the fuel relief port 25, through rotating the plunger 24 relatively to the barrel 23. Thus, the fuel injection pump of this first embodiment is of the type so-called "Bosch" type fuel injection pump.
At an intermediate portion 24c of the plunger 24, formed is a pin bore 29a extending from the outer peripheral surface toward the axis of the plunger 24, as will be understood from FIG. 3. Furthermore, a pin 29 of a suitable length is forcibly fitted into the pin bore 29a, so that the portion of the pin 29 projected out of the outer peripheral surface of the plunger constitutes a projection 29b. The projection 29b has flattened two vertical side surfaces which are extended in parallel with the axis of the plunger and acting as sliding surfaces. The projection 29b engages with a later-mentioned groove 28 formed in a plunger rotating member 27.
On the other hand, a plunger rotating member having a cylindrical form is fitted around an intermediate portion 24c of the plunger 24 in such a manner as to cover or conceal the projection 29. The plunger rotating member 27 is provided in its inner peripheral surface with a groove 28 adapted for receiving the projection 29b in such a manner as to permit the projection 29b to slidingly move in the axial direction within the groove 28. Thus, the plunger 24 is slidable in the axial direction of the plunger rotating member 27 but is prevented from rotating relatively to the latter due to the mutual engagement of the projection 29b and the groove 28.
The plunger rotating member 27 is provided at its one side with a lever member 30 projected unitarily therewith. An engaging pin 31 attached to the end of the lever member 30 engages one end 39a of an adjusting lever 39 the other end 39b of which is connected to a centrifugal governor 38. The adjusting lever 39 is mounted on a pin 40 and is rotatively biased by a spring 41 such that its end 39b is pressed against an operating member 38a of the centrifugal governor 38.
Therefore, the plunger rotating member 27 is rotatively movable in the direction of arrows A-B in accordance with the displacement of the operating member 38a of the centrifugal governor 38. In FIG. 2, a reference numeral 32 designates a plunger spring adapted for pressing a cam roller 33 against a fuel cam 34, while a reference numeral 35 designates a delivery valve held by a delivery valve holder 36. The fuel is sucked through a fuel suction pipe denoted by a reference numeral 37.
The fuel injection pump 21 of the first embodiment described heretofore operates in a manner explained hereinbelow.
The plunger 24 is moved reciprocatingly up and down within the barrel 23, by the cam action of the fuel cam, so that the fuel sucked through the fuel suction/relief port 25 of the barrel into the fuel pressurizing chamber 23a is pressurized and delivered to the fuel injection valve (not shown) through a fuel delivery valve 35. During the reciprocating motion of the plunger 24, the projection 29b on an intermediate portion of the plunger is reciprocatingly slided in the axial direction along the groove 28 of the plunger rotating member 27.
During the operation of the fuel injection pump 21, the rate of delivery of the fuel is adjusted in a manner explained below. As the load imposed on the engine is changed, the centrifugal governor 38 operates correspondingly to displace the operation member 38a thereof. As a result of the displacement of the operating member 38a, the adjusting lever 39 is swung around the pin 40. Consequently, the plunger rotating member 27 is rotated in the direction of the arrows A, B because it is connected through the pin 31 to one end 30a of the adjusting lever 30, so that the plunger 24, having the projection 29b received by the groove 28 of the plunger rotating member 27 in such a manner as to be able to slide in the axial direction but not to rotate relatively to the plunger rotating member, is rotated together with the plunger rotating member 27. In consequence, the timing at which the fuel relief port 25 in the barrel 23 is communicated with the fuel relief bore 26 opening in the top 24a of the plunger 24 and in the peripheral surface of the same is changed to vary the effective stroke length of the plunger 24 and, hence, the rate of delivery of the fuel.
The invention is applicable not only to the fuel injection pump of the type having a fuel metering mechanism constituted by a circular or elliptical fuel relief port 25 of a substantial diameter and a circular fuel relief bore 26 of the small diameter as in the case of illustrated embodiment, but also to fuel injection pump of the type having, as shown in FIG. 1, a fuel metering mechanism constituted by a fuel relief port 5 of small diameter formed in the barrel 3 and an inclined lead 6 provided in the plunger.
As will be understood from the foregoing description, in the fuel injection pump of the first embodiment, the projection provided on the peripheral surface of the plunger is engaged in the circumferential direction by the plunger rotating member directly fitting the plunger, and the plunger rotating member is rotated by an external governor mechanism thereby to rotate the plunger relatively to the barrel. Therefore, the number of parts is reduced to lower the production cost and the construction is simplified to facilitate the disassembling and assembling of the fuel injection pump.
FIGS. 4 thru 6 in combination show a second embodiment of the invention having a specific mechanism for supporting the plunger rotating member, in which a plunger rotating member similar to that of the first embodiment is supported by a cylindrical member detachably secured to the pump body acting also as the barrel, so that the disassembling and assembling of the fuel injection pump is very much facilitated.
Another feature of this second embodiment resides in that the barrel constituting the pump body and a mounting flange for mounting the barrel on the engine are formed in separate bodies. The flange member is clamped between the barrel and the delivery valve holder screwed to the barrel thereby to further facilitate the disassembling and assembling, as well as the manufacturing, of the fuel injection pump.
Referring to FIG. 4, there is shown the fuel injection pump of the second embodiment of the invention designated generally at a reference numeral 51. In this embodiment, a plunger 54 is moved reciprocatingly in a plunger receiving bore 53a formed in a barrel 53 serving also as a pump body, thereby to pressurize and deliver the fuel. The rate of fuel delivery is adjusted by varying the timing at which a fuel relief port 55 formed in the barrel 53 is brought into communication with a fuel relief bore 56 formed in the plunger 54 and opening in the top surface 54a of the plunger. Thus, the fuel injection pump of this embodiment is also of the type generally referred to as "Bosch" type fuel injection pump.
The barrel 53 has a cylindrical form of a suitable length with the plunger receiving bore 53a formed axially in the latter. At an intermediate of the barrel 53, formed is the aforementioned fuel relief port so as to open at its one side in the outer peripheral surface of the barrel as at 55a and to the inner peripheral surface of the same at its other end as at 55b. The fuel relief port 55 serves also as a fuel suction port and has a circular or elliptic form.
The barrel 53 is provided with a screw thread portion 75 for screwing a delivery valve holder 66 for holding the delivery valve 65, as well as a flange portion 76 of a diameter greater than that of the intermediate portion 74 of the barrel 53. The delivery valve holder 66 and the flange 76 are formed at the upper side and lower side of the intermediate portion 74 of the barrel 53, respectively. Also, a tabular mounting flange member 77 for mounting the fuel injection pump is fitted around the intermediate portion between the flange 76 and the thread portion 75. The mounting flange member 77 is provided with a radial through bore 78 of the same diameter as the fuel relief port 55.
The through bore 78 of this mounting flange 77 is located to be aligned and communicated with the fuel relief port 55 of the barrel 53, and is closed at its one end with a plugging pin 79 while the other end is connected to a fuel suction pipe 67. The delivery valve holder 66 is screwed to a threaded portion 75 formed at the upper end of the barrel 53 so that the mounting flange member 77 is clamped between the upper end surface 76a of the flange 76 of the barrel 53 and the lower end surface 66a of the delivery valve holder 66, so that it is unitarily and detachably fixed to the barrel 53. Reference numerals 80 and 81 denote sealing members.
On the other hand, a radial pin bore 59a is formed at an intermediate portion 54c of the plunger 54 so as to penetrate the plunger 54 in the radial direction thereof. At the same time, a head-equipped pin 59 of a suitable length is forcibly fitted into the pin bore 59a such that the head of the pin 59 projects outward from the outer peripheral surface of the plunger to form a projection 59b. This projection 59b has flattened side surfaces extending in the axial direction of the plunger, and is slidably received by a vertical groove 58 formed in the inner peripheral surface of a cylindrical plunger rotating member 57 rotatably fitting around the lower end portion of the barrel 53, so as to be able to slide up and down within the vertical groove 58 as the plunger 54 moves up and down reciprocatingly but to prevent relative rotation between the plunger rotating member 57 and the plunger 54.
A reference numeral 60 designates a lever member fixed to the plunger rotating member 57. This lever member is connected, through an engaging pin 61 fixed thereto, to a governor (not shown), so as to rotate the plunger 54 through the medium of the plunger rotating member 57, in accordance with the displacement of an operation member of the governor. The plunger rotating member 57 is supported by a cylindrical member 82 which fits the outer peripheral surface of the flange 76 of a barrel 53 form the lower side in such a manner as to cover the flange 57b formed at an upper end of the plunger rotating member 57.
More specifically, the upper end 82a of the cylindrical member 82 fits around the outer peripheral surface of the flange 76 of the barrel 53, in such a state that the upper end surface of an annular projection 83 acting also as a spring retainer and formed at the lower end 82b of inner peripheral surface engages with the lower end surface of the flange 57b of the plunger rotating member 57. At the same time, as shown in FIG. 5, a C-shaped stopper ring 85 fits in a stopper ring groove 84 formed in the outer peripheral surface of the upper end portion 82a of the cylindrical member 82 and having a suitable depth. The stopper ring 85 has a bent end 85a which is inserted into a pin bore 86 formed to extend radially from the bottom of the ring groove 84 and further into a pin bore 87 which is formed in the flange 76 of the barrel 53 in such a manner as to be aligned and communicated with the pin bore 86. Thus, the cylindrical member 82 is detachably connected to the barrel 53 and rotatably supports the plunger rotating member 57.
In this state, the lever member 60 of the plunger rotating member 57 is projected outwardly from a sector-shaped window hole 88 formed in the peripheral wall of the cylindrical member 82 opposing to the pin bore 86. A plunger spring 62 acts between the annular projection 83 of the cylindrical member 82 and a spring retainer 63 provided at the lower end portion 54b of the plunger 54, so as to always bias the plunger 54 downwardly.
The fuel injection pump having the described construction is mounted on the engine with its mounting flange 77 resting on a pump mount 89 formed on the engine. The mounting flange 77 is tightly fixed to the pump mount 89 by means of bolts 90, as will be seen from FIG. 6.
The fuel injection pump of this embodiment operates in the following manner. As the fuel cam (not shown) is rotated, the plunger 54 is reciprocatingly moved in the plunger receiving bore 53a of the barrel 53 up and down, so that the fuel sucked into the bore 53a through the fuel suction/relief port 56 of the barrel is pressurized by the plunger 54 and delivered to a fuel injection valve (not shown) through a delivery valve 65. The rate of delivery of the fuel is adjusted by varying the timing of establishment of communication between the relief port 56 in the plunger 54 and the fuel relief bore 55 of the barrel, through rotation of the plunger 54 through the medium of the lever 60 of the plunger rotating member 57.
The fuel injection pump 51 of this embodiment offers an advantage that, since the plunger rotating member 57 rotatably fitting around the lower end of the barrel 53 is supported by the cylindrical member 82 detachably secured to the barrel 53 by means of the C-shaped stopper ring 85, it is possible to easily attach and detach the plunger rotating member to and from the barrel 53 simply by attaching and detaching the C-shaped stopper ring 85, so that the disassembling and assembling of the fuel injection pump 51 is considerably facilitated.
As a modification, it is possible to use a pin in place of the C-shaped stopper ring 85. By so doing, it is possible to reduce the number of steps of the manufacturing process as compared with the case where the C-shaped stopper ring is used, because it is not necessary to form the ring groove 84 in the cylindrical member 82.
In addition, since the barrel constituting the pump body is formed separately from the mounting flange and since the mounting flange is clamped between the flange formed on the periphery of the barrel and the delivery valve holder which is screwed to the barrel, it is possible to easily connect and disconnect the barrel and the mounting flange by attaching and detaching the delivery valve holder to and from the barrel, so that the disassembling and assembling of the fuel pump is facilitated considerably. It is possible to prevent the barrel from being dropped accidentally from the mounting flange during the attaching and detaching of the delivery valve holder, by arranging such that the plugging pin fitting in one end of the through bore in the mounting flange is projected into the fuel relief bore of the barrel.
In addition, since the barrel is formed separately from the mounting flange, the size of the barrel is reduced and the shape of the same is simplified, followed by an advantage that, when the barrel is heat-treated (quenched), it is possible to uniformly treat the whole portion of the barrel, particularly the inner peripheral surface thereof. Another advantage resides in that it is possible to make a suitable selection of the materials. For instance, it is possible to form the barrel, which generally requires a high resistance to wear, from a chromium-molybdenum steel or the like high-class alloy, while forming the mounting flange, which generally requires not so high strength and wear resistance, from a light alloy such as an aluminum alloy. Such a suitable selection of the materials contributes to the reduction of the cost of production of the fuel injection pump.
FIGS. 7 and 8 designate a third embodiment of the invention in which the number of parts is reduced to lower the production cost of the fuel injection pump by arranging such that the mounting flange for fixing the barrel constituting the pump body to the pump mount of the engine function also as the cover for closing the lever receiving bore in the pump mount and as a member providing a fuel passage.
Referring to FIG. 7, a fuel injection pump of this embodiment, generally designated at a reference numeral 101, has a plunger 104 adapted to reciprocatingly move in a plunger receiving bore 103a formed in a barrel 103 so as to pressurize and deliver the fuel through a delivery valve 115. The rate of delivery of the fuel is changed by changing the timing of establishment of the communication between a fuel relief port 105 formed in the barrel 103 and a fuel relief bore 106 formed in the plunger 104, through rotating the plunger 104 relatively to the barrel 103. Thus, the fuel injection pump of this embodiment is also of the type called "Bosch" type fuel injection pump. This fuel injection pump 101 is mounted on the engine body 122 by means of a pump mount 121.
The barrel 103 is constituted by a cylindrical member of a suitable length and having the axially-extending plunger receiving bore 103a. At an intermediate portion of the barrel 103, formed is a fuel relief port 105 so as to penetrate the wall of the barrel 103 in the radial direction. The fuel relief port 105 acts also as a fuel suction port. A flange 123 and a screw thread 124 are formed at the upper and lower sides of the intermediate portion of the barrel 103 where the fuel relief port 105 is formed. A later-mentioned mounting flange 125 is fitted to the portion between the flange 123 and the thread 124.
As will be seen from FIGS. 7 and 8, the mounting flange 125 is a substantially pentagonal flat member of a suitable thickness. A pump receiving bore 126 for receiving the barrel 103 is formed at a portion of the mounting flange 125 offset by a suitable distance from the center of the mounting flange 125. The mounting fange 125 is provided with a fuel passage 127 of a suitable length extending radially through the pump receiving bore along a straight line l 1 which interconnects the center of the mounting flange 125 and the center of the pump receiving bore 126. The mounting flange 125 is placed between the flange 123 and the threaded portion 124 of the barrel, with its fuel passage 127 aligned and communicated with the fuel relief port 105 of the barrel 103, and is detachably fastened to the barrel 103 by means of a delivery valve holder 116 which is screwed to the threaded portion 124 of the barrel. A plugging pin 128 of a suitable length is press-fitted into the offset-side end of the pump receiving bore of the fuel passage 127 to close the end 127b. The end 128a of the plugging pin 128 projects into the fuel relief port 105 of the barrel 103 to prevent the barrel from being accidentally dropped from the mounting flange 125 when the delivery valve holder 116 is detached from the barrel 103.
A fuel suction pipe 117 is secured to the other end of the fuel passage 127. Furthermore, a circular protrusion 129 of a suitable outside diameter is formed on the lower end surface 125b of the mounting flange 125. The protrusion 129 is formed on the aforementioned straight line l 1 at a suitable offset from the pump receiving bore 126. This circular protrusion 129 functions as a locating member for locating the mounting flange 125 when the latter is attached to the pump mount 121. The size of the mounting flange 125 is suitably selected such that, when the mounting flange 125 is secured to the pump mount 121, the lower side 125b of the mounting flange 125 covers the lever receiving bore 130 formed in the pump mount.
On the other hand, a plunger rotating member 107, having a vertical groove 118 engaging a projection 119 formed on an intermediate portion of the plunger 104, is slidably fitted around the lower end portion of the barrel 103. A lever 110 is attached to the upper end of the plunger rotating member 107. The arrangement is such that the plunger 104 is rotated relatively to the barrel 103 by means of the plunger rotating member 107, through the engagement between the vertical groove 118 and the projection 119, as the lever 110 is rotated. The plunger rotating member is rotatably supported by a cylindrical member 132 which in turn is detachably secured to the outer peripheral surface of the flange 123 of the barrel 103 by means of a pin 131. The lever 110 is projected outwardly from the opening 133 formed in the cylindrical member 132, in the same direction as the direction of projection of the fuel suction pipe 117 secured to the mounting flange 125.
The rotation lever 110 is connected by means of a pin 111 to a governor (not shown) so as to be able to rotatively drive the plunger 104 in accordance with the operation of the governor.
A reference numeral 113 designates a spring retainer attached to the lower end of the plunger 104. A plunger spring 112 interposed between the spring retainer 113 and the lower end of the cylindrical member 132 acts to normally bias the spring retainer 113 downwardly.
The fuel injection pump 101 having the described construction is secured to the engine body 122 through the pump mount 121. As will be understood from FIGS. 7 and 8, the pump mount 121 is constituted by a flange portion 121a having a substantially rectangular form and a cylindrical portion 121b projected downwardly from the flange portion 121a. The peripheral wall of the cylindrical portion 121b is suitably cut at its upper end portion to provide an opening 121c which permits the aforementioned lever 110 to project outwardly therethrough. The inner peripheral surface 121d, which constitutes a bore for receiving the spring retainer, has a constant diameter from the lower end thereof up to the upper face of the flange portion 121a. A circular recess 134 of a suitable depth, mating with the aforementioned circular protrusion 129 of the mounting flange 125, is formed on the upper surface of the flange portion 121a, at a suitable offset from the bore 121d for receiving the spring retainer. A lever receiving bore 130 is formed at one side of the receiving bore 121 d so as to extend along the aforementioned straight line l 1 and in communication with the receiving bore 121d.
For mounting the fuel injection pump 101 on the pump mount 121, the fuel injection pump 101 is inserted into the bore 121d from the end of the latter adjacent to the flange 121a to make the circular protrusion 129 of the mounting flange 125 be seated in the circular recess 134 of the pump mount 121. At the same time, the mounting flange 125 is tightened to the flange portion 121a of the pump mount 121 by means of bolts 135.
Since the circular protrusion 129 of the mounting flange 125 and the circular recess 134 of the pump mount 121 are offset, respectively, from the bore 126 of the barrel 103 and the bore 121d of the pump mount 121, the circular protrusion 129 and the circular recess 134 act as locating members for locating the fuel injection pump 101 with respect to the pump mount 121. Thus, the fuel injection pump 101 is correctly positioned in relation to the pump mount 121 in both of horizontal and rotational directions, simply by aligning the circular protrusion 129 with the circular recess 134. In FIG. 7, a reference numeral 114 denotes a cam roller, while a numeral 136 denote bolts. The operation of the fuel injection pump of this embodiment is not described here because it is materially identical to that of the preceding embodiments.
In this embodiment, the fuel passage for supplying the fuel into the barrel is formed in the mounting flange for mounting the barrel on the pump mount. At the same time, the shape and size of the mounting flange are so selected suitably that the lever receiving bore formed in the pump mount is covered by the mounting flange. Thus, the mounting flange plays not only the role of the flange for fixing the barrel but also the roles of the member for providing the fuel passage and the member for closing the lever receiving bore. Consequently, it becomes not necessary to provide specific members for providing the fuel passage and the member for closing the lever receiving bore. Accordingly, the number of parts is reduced to contribute to the reduction of cost of production of the fuel injection pump.
In addition, the circular protrusion formed on the lower side of the mounting flange at an offset from the axis of the pump axis and a circular recess formed in the pump mount fit with each other to function as locating members for correctly locating the fuel injection pump with respect to the pump mount in both of horizontal direction and rotational direction, when the fuel pump is attached to the pump mount. As a result, the work for attaching and detaching the fuel injection pump to and from the pump mount is facilitated to improve the efficiency of the work for disassembling and assembling the fuel injection pump.
FIGS. 9 thru 12 in combination show a fourth embodiment of the invention. In the preceding embodiments 1 to 3, the plunger rotating member is operatively connected to the plunger through an engagement between the projection provided at an intermediate portion of the plunger and the vertical groove formed in the inner peripheral surface of the plunger rotating member so that the plunger is rotated together with the plunger rotating member. This fourth embodiment differs from these preceding embodiments in that the plunger rotating member is directly fixed to the lower end of the plunger.
More specifically, this fourth embodiment is characterized in that the mounting flange for fixing the pump barrel to the engine is unitarily secured to the barrel, by plastically deforming a part of the mounting flange and fitting the deformed portion of the mounting flange into a peripheral groove formed in the outer peripheral surface of the barrel, thereby to obtain a uniform quenching effect of the pump barrel and to facilitate the processing and assembling works.
Referring to FIG. 9, the fuel injection pump 171 of the fourth embodiment has a plunger 174 adapted to be reciprocatingly moved in a plunger receiving bore 173a formed in a barrel 173 constituting the pump body, so as to pressurize and deliver the fuel. The rate of delivery of the fuel is adjusted by varying the timing of establishment of communication between a fuel relief port 175 formed in the barrel 173 and a fuel relief bore 176 opening in the top of the plunger 174, through rotating the plunger 174 relatively to the barrel 173. Thus, the fuel injection pump of this fourth embodiment is also of the type so-called "Bosch" type fuel injection pump. A delivery valve 185 is attached to the upper end portion of the barrel 173, while a spring retainer 183 on which the plunger spring 182 acts is secured to the lower end of the barrel 173. The spring retainer 183 is made to engage with the lower end 174b of the plunger 174 to which the plunger rotating member 177 is fixed. The plunger 174 is adapted to be moved up and down reciprocatingly by a tappet 184 cooperating with a fuel cam (not shown), so as to pressurize the fuel sucked into a fuel pressurizing chamber 173b and deliver the same through the delivery valve 185 to a fuel injection valve (not shown). The rate of delivery of the fuel is adjusted as the plunger rotating member is rotated by means of a lever 180 which in turn is connected to the governor (not shown) through an engaging pin 181. The spring retainer 183 is seated in a recess 184a formed in the upper end of the tappet 184. The tappet 184 is provided also with an arcuate window 184b adapted to permit the lever 180 to be rotated. In the drawings, reference numerals 186 and 187 denote, respectively, a delivery valve holder and a fuel suction pipe.
Hereinunder, an explanation will be made as to the shape of the barrel 173 and as to the connection between the barrel 173 and the mounting flange 190, with specific reference to FIGS. 11 and 12. The barrel 173 is quench-hardened and has a shape constituted by a plurality of cylinders 191, 192, 193, 194 superposed one on the other in the axial direction. Only the cylinder 192 of the second stage is offset by a distance S from the axis l 1 of the barrel. The cylinder 191 of the uppermost stage 191 has an external thread to which the aforementioned delivery valve holder 186 is screwed. The cylinder 193 of the third stage has an outside diameter greater than that of the cylinder of the second stage, and acts as a portion fitting the pump mounting hole 196 of the engine body 195. Namely, the outer peripheral surface 193a of the cylinder 193 fits in the pump mounting hole 196 formed in the engine body. Thus, the cylinder of the third stage will be referred to as "fitting portion", hereinafter. The cylinder 192 of the second stage, interposed between the uppermost cylinder 191 and the fitting portion 193, constitutes a portion to which the aforementioned mounting flange 190 is attached. A step 197 is formed between the cylinder 192 of the second stage and the fitting portion 193 having the larger diameter. The cylinder 192 of the second stage will be referred to as "flange-attaching portion", hereinafter. Thus, the outer peripheral surface 192a of the cylinder 192 of the second stage presents a fitting surface adapted to fit in a pump fitting bore 190a formed in the mounting flange 190. Thus, this outer peripheral surface will be referred to as flange-bore fitting surface. A peripheral groove 198 of a suitable width and depth are formed at an intermediate portion of the flange-bore fitting surface 192a. This peripheral groove 198 is adapted to receive a plastically deformed portion of the mounting flange 190 fitting around the flange-bore fitting surface 192a, and is formed at a position spaced upwardly from the step 197 by a distance corresponding to the thickness h of the flange 190. A reference numeral 199 designates a sealing ring fitting groove formed at a portion of the flange attaching portion near the lower end of the latter. This sealing ring groove 199 receives an "O" ring 200.
Around the flange-bore fitting surface 192a of the flange attaching portion 192, fitted is the above-mentioned mounting flange 190 with its lower side 190b contacting the step 197, as shown in FIG. 11. In this state, as will be seen from FIG. 12, the peripheral groove 198 of the flange attaching portion 192 is opposed by the peripheral edge 190d of the barrel fitting bore 190a adjacent to the upper face 190c of the flange. At the same time, the degree of fitting of the flange-bore fitting surface 192a of the flange attaching portion 192 to the pump fitting bore 190a of the mounting flange 190 is suitably selected to diminish the play therebetween, as much as possible.
The barrel 173 to which the flange member 190 is fitted in a manner stated above is placed on a suitable chisel bed 201 as shown in FIG. 11. On the other hand, a tubular chisel 202 having an annular cutting edge 203 is placed at the outside of the flange attaching portion 192. The annular cutting edge 203 has a diameter which is greater than the inside diameter of the pump fitting bore 190a, and is positioned in contact with the peripheral edge 190d of the barrel fitting bore 190a. The annular cutting edge 203 has a wedge-shaped cross-section constituted by a vertical outer peripheral surface 203a and an inclined surface 203b inclined outwardly and downwardly.
With the annular cutting edge 203 contacting the peripheral edge 190d of the pump fitting bore 190a of the mounting flange 190, the tubular chisel 202 is hit or pressed downwardly by means of a hammer or a press, so that the annular cutting edge 203 of the tubular chisel 202 is driven into the peripheral edge 190d of the pump fitting bore. In consequence, the peripheral edge 190d of the pump fitting bore is plastically deformed outwardly toward the center of the pump fitting bore 190a by the action of the inclined surface 203b of the annular cutting edge 203. The plastically deformed portion is then forced into the aforementioned peripheral groove 198 positioned to oppose to the peripheral edge 190d of the pump fitting bore, as will be seen from FIG. 15.
This plastically deformed portion 204 filling the peripheral groove 198 effectively prevents the mounting flange 190 from being moved in the axial direction of the barrel. Thus, the mounting flange 190 is unitarily fixed to the pump barrel 173. It will be seen that, in the fuel injection pump of this embodiment, it is possible to unit the barrel 173 and the mounting flange 190, simply by plastically deforming the peripheral edge of the pump fitting bore 190a of the mounting flange 190 into the peripheral groove 190 formed in the flange-bore fitting surface 192a.
As will be understood from the foregoing description, in this fourth embodiment of the invention, the mounting flange and the pump barrel are united with each other simply by fitting the flat mounting flange around the barrel and plastically deforming, by means of a chisel or the like, a portion of the mounting flange into the peripheral groove formed in the outer peripheral surface of the pump body. Therefore, the processing and assembling works are simplified to lower the cost of the production of the fuel injection pump as a whole.
In addition, since the connection between the barrel and the mounting flange is achieved by making use of a plastic deformation of the mounting flange, it is not necessary to use specific connecting members such as bolts, so that the number of parts is reduced to lower the cost of production of the fuel injection pump as a whole.
Furthermore, since the barrel and the mounting flange are formed as separate bodies, it is possible to form the barrel and the mounting flange by suitable materials matching the conditions of use. The cost of production is lowered by a suitable selection of the materials.
It is also to be pointed out that, in the event that the barrel is quench-hardened, it is possible to obtain a more uniform quenching effect as compared with the conventional one having a mounting flange formed integrally with the barrel. In the case where the barrel constitutes the pump body as is the case of the illustrated embodiment, it is possible to uniformly heat-treat the plunger receiving bore.
FIGS. 13 to 15 show a fifth embodiment of the invention in which an eccentric fitting surface formed on the periphery of the barrel constituting the pump body is utilized as the locating member for mounting the pump body to the engine and as a member for securing a fuel suction pipe, thereby to facilitate the mounting of the fuel injection pump on the engine and to reduce the size of the pump body.
This embodiment is materially identical to the fourth embodiment, excepting the construction for mounting the pump body on the engine. Therefore, in FIGS. 13 to 15, the same reference numerals with a suffix ' are used to denote the same or corresponding members as those of the fourth embodiment, and the detailed description of these members are omitted.
In the fourth embodiment, the cylinder 193 of the third stage, i.e. the fitting portion 193, is formed to have a diameter greater than the cylinder of the second stage, i.e. the flange attaching portion 192, and a step 197 is formed between the fitting portion 193 and the flange attaching portion 192. The lower side of the mounting flange 190 is made to contact with the upper face of the step 197.
In contrast, in the fifth embodiment, the flange attaching portion 192' corresponding to the flange attaching portion 192 of the fourth embodiment is made to have a greater diameter than the third cylinder 193' constituting the fitting portion 193' corresponding to that 193 of the fourth embodiment. In addition, the flange attaching portion 192' of the fifth embodiment differs from the flange attaching portion 192 of the fourth embodiment in that it has a portion 192'b projecting downward below the mounting flange 190'.
A pump mounting bore 196' for tightly receiving the fitting portion 193' is formed in the engine body 195'. At the same time, a pump mounting seat 205 for closely receiving and holding the downward projection 192'b of the flange attaching portion 192' of the pump body 173' is formed just above the pump mounting bore 196'.
As will be seen from FIG. 14, the peripheral wall 205a of the pump mounting seat 205 is offset by a distance S from the axis of the pump mounting bore 196' and envelopes the latter.
For mounting the fuel injection pump 171' on the engine body 195', the downward projection 192'b of the eccentric flange attaching portion 192' is tightly fitted to the pump mounting seat 205, so that the latter functions as the member for locating the fuel injection pump 171' and as the member for preventing the rotation of the same. The downward projection 192'b has a thickness corresponding to the depth of the pump mounting seat 205, so that, when the mounting flange 190' is caulked and fixed to the flange attaching portion 192', the mounting flange 190' is spaced upward from the lower end surface 192'c of the lower projection 192'b by a distance corresponding to the depth of the pump mounting seat 205.
On the other hand, the fuel suction pipe 187' is fitted in a suction pipe attaching bore 206 formed in the thick-walled portion 192' of the eccentric flange attaching portion 192', immediately above the mounting flange 190', and is communicated with the plunger receiving bore 173'a through the aforementioned fuel relief port 175' formed in the barrel 173'a. The fuel injection pump of this embodiment is mounted on and fixed to the engine body 195' in such a state that the fitting portion 193' of the barrel 173' fits in the pump mounting bore 196' of the engine body 195' and that the downward projection 192'b of the flange attaching portion 192' is seated on the pump mounting seat 205. In this state, the mounting flange 190' is fastened to the engine body 195' by means of bolts which are not shown, thereby to fix the fuel injection pump 171' to the engine body 195'. In this embodiment, the flange attaching portion 192' which is offset by a suitable distance S from the axis of the barrel serves, in cooperation with the pump mounting bore fitting portion 193' formed on the barrel axis, as the member for locating the fuel injection pump in the rotational direction and as the member for preventing the rotation of the same. It is, therefore, possible to easily mount the fuel injection pump 171' on the engine body 195'.
In the described embodiment, the eccentric flange attaching portion 192' acting as locating and rotation-prevention member plays an additional role of a member for securing the fuel suction pipe. Namely, the fuel suction pipe 187' is directly attached to the thick-walled portion of the flange attaching portion 192', so that it is possible to obtain a sufficiently large thickness for holding the fuel suction pipe. At the same time, positioning the fuel suction pipe 187' as close as possible to the axis of the fuel injection pump 171', it is possible to reduce the maximum diameter of the fuel injection pump 171' to obtain a compact construction of the latter.
The first to fifth embodiments described heretofore are single barrel type fuel injection pump having only one barrel. The invention, however, is applicable also to multi-barrel type fuel injection pumps. A typical example of such an application, as a sixth embodiment of the invention, will be described hereinafter with reference to FIGS. 16 to 19.
FIGS. 16 and 17 in combination show a fuel injection pump 211 having three fuel injection pump units each having one barrel.
Each pump unit has a plunger 214 adapted to be reciprocatingly moved in a plunger receiving bore 213b of the barrel 213, by the operation of a fuel cam 224, thereby to suck the fuel into a fuel pressurizing chamber 213a through a fuel suction pipe 227 and to pressurize the thus sucked fuel in the fuel pressurizing chamber 213a. The pressurized fuel is delivered to a fuel injection valve (not shown) through the delivery valve 225. The rate of delivery of the fuel is controlled by varying the timing of establishment of communication between a fuel relief port 215 formed in the wall of the barrel 213 and a fuel relief bore 216 opening in the top surface 214a of the plunger and the side surface of the same, through rotating the plunger in the circumferential direction relatively to the barrel 213 within the latter, by means of a plunger rotating mechanism 230 provided at the lower end portion of the barrel 213. Thus, the fuel injection pump of this embodiment also is of the type so-called "Bosch" type fuel injection pump. The fuel injection pump of this embodiment is constituted by three fuel injection pump units 211A arranged in a side-by-side relation at a suitable pitch within a common pump casing 212. A cam roller 223 attached to the lower end 214b of each plunger 214 is biased toward the fuel cam 224 by means of a plunger spring 222. The plunger 214 is adapted to be moved reciprocatingly by the action of rotary fuel cam 224 and the resilient biasing force exerted by the plunger spring 222.
A radial through bore 219a is formed at an intermediate portion 214c of the plunger 214. A pin 219 is inserted into the through bore 219a from one side of the latter, such that one end thereof project outward from the outer peripheral surface of the plunger 214 by a suitable length. The projecting portion of this pin 219 constitutes a projection 219b which is adapted to engage with a plunger rotating member 217 of a later-mentioned plunger rotating mechanism 230. Both side surfaces of the projection 219b are flattened to present sliding surfaces extending in the axial direction of the plunger.
As will be understood from FIG. 18, the plunger rotating mechanism 230 includes a plunger rotating member 217 fitting around each plunger 214, a fuel adjusting rod 228 for rotating the plunger rotating members and eccentric pins 221 by means of which the fuel adjusting rod 228 is connected to respective plunger rotating members 217.
Each plunger rotating member 217 has a cylindrical body of a suitable length, with its inner peripheral surface slidably fitting around the plunger 214. At one side of the lower portion of the plunger rotating member 217, formed is a vertical groove 218 of a suitable length opening in the lower end surface 217b of the plunger rotating member. The aforementioned projection 219b formed on one side of the plunger 214 is received by the vertical groove 218 in such a manner as to be able to slide in the axial direction of the plunger. The height or length of this vertical groove is selected to be slightly greater than the stroke of the vertical reciprocating movement of the plunger 214. The vertical groove 218 and the projection 219b engage with each other in the circumferential direction, so that the plunger 214 is rotated as a unit with the plunger rotating member 217 as the latter is rotated. A reference numeral 220 designates a lever member inserted into an intermediate portion of the plunger rotating member 217. The lever member 220 is unitarily fixed to the plunger rotating member 217. A bolt hole 231 for attaching a later-mentioned eccentric pin 221 is formed in the free end of the lever member 220.
The eccentric pin 221 is constituted by an upper pin member 232 and a lower pin member 233 which are offset suitably from each other, and a flange portion 234 by means of which the upper and lower pin members 232 and 233 are connected to each other. The lower pin member 233 has an outside diameter suitable for fitting in the bolt hole 231 formed in the lever member 220 of the plunger rotating member 217, and is threaded externally. The upper pin member 232 has a diameter smaller than that of the lower member and constitutes an engaging portion for engaging a later-mentioned fuel adjusting lever 228. In assembling, the lower pin member 233 is inserted into the bolt hole 231 of the lever member 220 from the upper side of the latter, and a nut 235 is screwed to the end of the lower pin member 233 projecting from the lower surface of the lever member 220 to connect the eccentric pin 221 to the lever member 220. The eccentric pin 221 is allowed to be rotated in the direction of arrows M-N as the nut 235 is loosened.
The fuel adjusting lever 228 is constituted by a rod member of a suitable length, and is provided three peripheral grooves 229 formed in the peripheral surface thereof at a suitable pitch in the axial direction thereof. Each of these peripheral grooves 229 is adapted to receive the upper pin member 232 of the eccentric pin 221 of the corresponding pump unit 211A to make the eccentric pins 221 engage with the fuel adjusting rod 228 in the axial direction of the latter. The width and depth of the peripheral groove 229 are suitably selected in accordance with the size of the upper pin member 232. The pitch of the peripheral grooves 229 in the axial direction of the fuel adjusting lever is determined to match the pitch of the axes of the plungers of the pump units 211A.
As will be seen from FIG. 19, the positions of the fuel adjusting rod 228 and the eccentric pins 221 are so determined that, when the upper pin member 232 is received by the corresponding peripheral groove 229, the upper end surface 232a of the upper pin member 232 is positioned below the lower end 229b of the bottom 229a of the peripheral groove 229. This fuel adjusting rod 228 is slidably received by a rod receiving portion 236 provided in the pump casing 212, in such a manner as to be able to slide in the axial direction thereof, and is adapted to be moved back and forth in the directions of the arrows P-Q, by means of a governor (not shown) through the medium of an operating pin 237 which projects radially from the fuel adjusting rod 228.
The fuel injection pump of the described embodiment operates in a manner explained hereinbelow. As the fuel cam 224 is rotated, the plunger 214 is reciprocatingly moved in the plunger receiving bore 213b of the barrel 213 so as to pressurize the fuel in the fuel pressurizing chamber 213a and to deliver the pressurized fuel to a fuel injection valve through the delivery valve 225. As the engine speed is changed for any reason, the governor operates to move the fuel adjusting rod 228 in the axial direction (direction of arrow P-Q). Consequently, in each fuel injection pump unit 211A, the plunger rotating member 217 is rotated in the direction of arrows R-L through the medium of the eccentric pin 221, in accordance with the axial displacement of the fuel adjusting rod 228. As a result, the plungers 214 of all units 211A are simultaneously rotated in the same direction, because of mutual engagement between the vertical groove 218 in the plunger rotating member 217 and the projection 219b of the plunger 214 in each pump unit.
In consequence, the timing of establishment of communication between the fuel relief bore 216 of the plunger 214 and the fuel relief port 215 of the barrel 213 is changed because of a change in the relative rotational position between the barrel and the plunger, so that the rate of delivery of the fuel is increased or decreased to recover the set engine speed.
In this fuel injection pump, for adjusting the fuel delivery rate of each pump unit to uniformalize the rate of fuel delivery of all pump units 211A, the nut 235 associated with the eccentric pin 221 of one of the pump units 211A is loosened and the eccentric pin 221 is rotated in the direction of arrows M-N by a suitable angle. As a result, the relative position of the plunger rotating member 217, relatively to the peripheral groove 229 of the fuel adjusting rod 228, in the direction of arrows P-Q, is changed because the lower pin member 233 is offset from the upper pin member 232. In this state, one pump unit 211A can be adjusted independently of the other pump units. By effecting this adjustment to other pump units, the fuel delivery rates of all pump units can be uniformalized.
In addition, since the eccentric pin 221 is positioned relatively to the peripheral groove 229 of the fuel adjusting rod 228 such that the upper end surface 232a of the upper pin member 232 is positioned below the lower end portion 229b of groove bottom of the peripheral groove 229, the upper end surface 232a is never interferred by the bottom 229b of the peripheral groove 229 however the eccentric pin 221 may be rotated. This arrangement permits a wide range of adjustment of fuel delivery rate for each pump unit.
As has been described, in the fuel injection pump of this embodiment, the pins of the plunger rotating lever members are received by the peripheral grooves formed in the fuel adjusting lever, so that the axial displacement of the fuel adjusting rod is converted into the rotational displacement of the plunger. Therefore, the construction of the plunger rotating mechanism is much simplified as compared with the conventional one employing a combination of a rack and pinion.
In addition, since the upper pin member of the plunger rotating lever member is positioned such that its upper end is positioned below the lower end of the groove bottom of the peripheral groove formed in the fuel adjusting rod, the eccentric pin is never interferred by the groove bottom when it is rotated however the rotation angle may be large, so that it is possible to preserve a wide range of adjustment of the fuel delivery rate.
FIG. 20 shows a seventh embodiment of the invention which relates to an improvement in the construction of the fuel adjusting rod of the multi-barrel type fuel injection pump of the sixth embodiment. More specifically, in this seventh embodiment, the operating pin of the fuel adjusting rod is arranged to freely come into and out of the pump casing to realize the compact construction of the fuel injection pump to facilitate the packaging, while avoiding the breakage of the operating pins during disassembling, assembling and packaging of the fuel injection pump.
The fuel injection pump of this embodiment is materially identical to the sixth embodiment shown in FIGS. 16 through 19, except the construction of the operating pin. The explanation of the same portions as the sixth embodiment, therefore, is omitted. In FIG. 20, the parts same as those of the sixth embodiments are denoted by the same reference numerals having a suffix '. A reference numeral 228' denotes a fuel adjusting rod similar to that of the sixth embodiment. An operating pin 237' is attached to the fuel adjusting rod between two adjacent peripheral grooves so as to extend radially outwardly. This operating pin is forcibly fitted in an attaching bore 238 formed in the fuel adjusting rod 228'. The operating pin 237' is allowed to rotate together with the fuel adjusting rod 228' between a first position (showed by full line) at which it intersects the axis of the plunger at a right angle and a second position (shown by chain line) at which it extends in parallel with the axis of the plunger, as designated at arrows V-W. When the fuel injection pump is mounted on the engine, the operatling pin 237' is rotated to the full-line position to make its end 237'a project outwardly from the opening 212'a of the pump casing 212' to permit the same end to be connected to the link mechanism of a governor. However, when the fuel injection pump is packaged for a transportation or the like purpose, the operating pin 217' is rotated to the position of chain line and concealed behind the opening 212'a of the pump casing 212'.
Since the fuel adjusting rod 228' is allowed to roate to make it possible to accomodate the operating pin 237' in the pump casing 212', there is no fear that the operating pin 237' collides with or be caught by another object during the disassembling/assembling and transportation of the fuel injection pump. In addition, the operating pin is retracted into the pump casing so that the package as a whole is made compact considerably.
Hereinafter, an explanation will be made as to an eighth embodiment of the invention with specific reference to FIG. 21.
In the case where the fuel adjusting rod of the fuel injection pump has a round bar-like form as in the case of the sixth embodiment, the fuel adjusting rod is made to slide as smoothly as possible to provide the control of fuel at a high sensitivity to the condition of operation of the engine. If there is no means for preventing the axial dropping of the fuel adjusting rod in the assembled state, the fuel adjusting rod may be accidentally dropped to be damaged, resulting in an increased resistance against the sliding motion and, hence, a deterioration in the sensitivity of the fuel adjustment. To the contrary, if any means are employed for preventing the accidental dropping of the fuel adjusting rod, the number of parts is increased correspondingly to increase the number of steps of the production process resulting in a raised cost of production.
Under this circumstance, this embodiment is arranged to make use of a part of the pump casing as a member for preventing the dropping of the fuel adjusting rod during disassembling/assembling of the fuel injection pump, thereby to prevent the dropping of the fuel adjusting rod to avoid any damage of the latter, without being accompanied by an increase of the number of parts.
The fuel injection pump of the eighth embodiment is materially identical to the sixth embodiment excepting the construction shown in FIG. 21. Namely, FIG. 21 shows in section a plunger rotating mechanism, in which the same reference numerals with suffix " are used to denote the same parts as the sixth embodiment.
In order to make use of a part of the pump casing 212" as a drop prevention member for preventing the accidental dropping of the fuel adjustment rod during the assembling/disassembling of the fuel injection pump, the distance L between the axis l 1 of the fuel adjusting rod and the common axis line l 2 of the pump units 211A" is determined as follows. Namely, the distance L is selected such that, when the lever member 220" is fully swung by a full angular stroke (rotation angle α) between the outer extreme positions at which respective sides 220"a of the lever member 220 abut corresponding edges 239a of the plunger rotating member insertion opening 239 formed in the pump casing, the engagement between the upper pin member 232" of the eccentric pin 221" attached to the end of the lever member 220" and the side wall 229"c of the peripheral groove 229" of the fuel adjusting rod 228" is maintained safely. By so doing, the fuel adjusting rod 228" is allowed to move only within the axial distance l corresponding to the axial displacement of the fuel adjusting rod which in turn is determined by the range of angular displacement of the lever member 220". A further displacement is limited by the upper pin member 232", because the rotation of the lever member 220" is restricted by the edges 239a of the plunger rotating member receiving bore 239. That is, the edges 239a of the opening 239 act as stoppers for preventing accidental dropping of the fuel adjusting rod 228".
For information, the lever member 220" is swung by an angle β which is smaller than the aforementioned angle α, during the operation of the fuel injection pump.
Thus, in the fuel injection pump of this embodiment, the pin attached to the end of the lever member, whose rotation angle is limited by the edges of the plunger rotating member receiving bore, is ensured to maintain its engagement with the peripheral groove wall of the fuel adjusting rod even when the lever member is swung fully, so that the fuel adjusting rod is prevented from being dropped accidentally during the disassembling/assembling of the fuel injection pump. Accordingly, the necessity for the specific drop-prevention member is eliminated to permit a reduction of number of parts, so that the cost of the fuel injection pump as a whole is remarkably reduced while effectively preventing the accidental dropping of the fuel adjusting rod to ensure a safe fuel adjusting operation of the fuel injection pump over a long period of time.
FIG. 22 shows a nineth embodiment of the invention which is materially identical to the sixth embodiment except the construction shown in FIG. 22. FIG. 22 shows in section the plunger rotating mechanism of the nineth embodiment, in which the same reference numerals with suffix "' are used to denote the same parts as those of the sixth embodiment.
More specifically, this embodiment is concerned with a multi-barrel type fuel injection pump and, more particularly, with an improvement in the fuel metering mechanism for metering the fuel to be injected by the fuel injection pump of the kind described. The characteristic feature of this embodiment resides in that the fuel metering mechanism is simplified without being accompanied by a substantial deterioration of the rigidity of the pump casing.
As will be seen from FIG. 22, the width Z of the bore 239' for receiving the plunger rotating member 217"' is selected to be smaller than the outside size D of the sliding surface 240 of the plunger rotating member 217"', the circumferential edges 239'a of the bore 239' for receiving the plunger rotating member 217"' serve as guiding surfaces for guiding the plunger rotating member and as a member for preventing dropping toward the opening 241, during the assembling of the fuel injection pump. In addition, during the operation of the fuel injection pump, it is possible to stably operate and rotate the plunger rotating member 217"' within the bore 239'. It is possible to suitably select the angle α of opening of the bore 239' such that the circumferential edges 239'a of the bore 239 receiving the plunger rotating member serve as stoppers for limiting the maximum angle of rotation of the lever member 220"'. By so doing, the maximum rate of fuel delivery is limited by the edges 239'a so that it becomes not necessary to employ any specific member for limiting the maximum fuel delivery rate to permit a reduction of number of parts.
As has been described, in this embodiment, the width of opening formed in the side wall of the plunger rotating member receiving bore is selected to permit the lever member of the plunger rotating member to rotate within a predetermined rotation angle, so that the edges of the opening acts as stoppers for preventing excessive rotation of the lever member. In addition, since the width of the opening is reduced to the minimum required size, the rate of area of the opening to the whole pump casing is minimized to ensure a sufficiently high rigidity of the pump casing.
FIGS. 23 and 24 show a tenth embodiment of the invention relating to an improvement in the construction of fuel passage device in the multi-barrel type fuel injection pump of the sixth embodiment. More specifically, this embodiment has a fuel passage device which is arranged permit the voids or air bubbles in the fuel system to be removed by the buoyancy of these bubbles.
Other portions than this fuel passage device are identical to those of the sixth embodiment, so that the detailed description thereof is omitted. In FIGS. 23 and 24, the same reference numerals with suffix "e" are used to denote the same parts or members as those of the sixth embodiment.
A fuel passage device 250 is formed at one side of the barrel 213e of each pump unit 211Ae. The fuel passage device 250 is constituted by three branch fuel passages 252 formed from the outer surface of the pump casing 212e toward the fuel relief ports 215e of respective barrels vertically at an inclination and a main fuel passage 251 extending laterally from the branch fuel passage 252 of one end to the branch fuel passage 252 of the other end to provide mutual communications of all branch fuel passages. The main fuel passage 251 is inclined upwardly at a slight inclination angle from one closed end 251b to the other opened end 251a. The opened end 251a of the main fuel passage 251 is plugged by a priming plug 253. The fuel suction pipe 227e is connected to the opened end of one of the branch fuel passage closer to the opened end 251a of the main fuel passage, while the opened ends of the other branch fuel passages are closed by plugs 254. Therefore, the fuel supplied from the fuel suction pipe into the fuel passage device 250 flows into the fuel pressurizing chambers 213ae through the main fuel passage 251, branch fuel passages 252 and fuel relief ports 215e of respective pump units 211A.
In this fuel injection pump 211e, since the main fuel passage 251 is formed at an upward inclination from the closed end 251b toward the opened end 251a thereof, the air separated from the fuel in the fuel system in the pump casing 212e naturally moves due to buoyancy toward the highest portion of the fuel passage device 250, i.e. toward the opened end 215a of the main fuel passage, and stays at this end. Therefore, by loosening the priming plug 253 fitting the opened end 251a of the main fuel passage, it is possible to easily relief the air from the fuel system. Thus, this embodiment offers an advantage that the priming is achieved easily.
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A fuel injection pump for internal combustion engines of the type having a plunger adapted to be reciprocatingly moved within a barrel to pressurize and deliver a fuel before the establishment of communication between a fuel relief bore formed in the wall of said barrel and a fuel pressurizing chamber, said plunger being adapted to be rotated relatively to said barrel to change the timing of establishment of said communication thereby to adjust the amount of the fuel delivered per stroke of said plunger.
Said fuel injection pump is provided with a plunger rotating member coupled to said plunger for rotation therewith.
Whereby said plunger can be rotated by merely rotating said plunger rotating member.
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BACKGROUND
[0001] The invention relates to a tympanic thermometer.
[0002] The present invention relates to the field of medical thermometers. In particular, it is aimed at the tympanic thermometers intended to measure the temperature of a body, for example of a human body, accurately, notably in difficult climatic conditions and environments.
[0003] It is known practice to measure the temperature of a human body, for example, at the tympanum, because it substantially agrees with the real “core” internal temperature of a body compared with the temperatures read in other, conventional bodily areas (armpit, oral cavity, etc.).
[0004] A tympanic thermometer is known for example from the document EP 0,461,068 that is designed for emergency rescues, for example, in cold, in mountains, at sea, in order to diagnose possible hypothermia. This thermometer comprises a tympanic probe provided with a foam ring and a support limiting its penetration into the external auditory meatus. A flexible cord links the probe to a housing comprising a shell equipped on its first face with means for displaying the measured temperature and with an ear insulating foam fixed onto its second face. Furthermore, a band is used to tighten the housing, covering the ear, on the head of a patient.
[0005] However, it is not possible to decontaminate and disinfect this tympanic thermometer which comprises parts made of foam in contact with bodily areas of a patient, in particular with the external auditory meatus and the auricle of the ear, which can transfer microorganisms from one patient to another, infecting them. Furthermore, the thermal insulation of the external auditory meatus from the ambient environment that this foam offers is insufficient, which can adversely affect the quality of the measurements. In practice, the foam fixed onto the shell is an open-cell foam resulting in the absorption of liquid and the penetration of micro-organisms. To this is added the fact that this thermometer is not sealed, does not withstand the fluids used in medical environments and has numerous constraints on its use.
[0006] The objective of the invention is notably to mitigate all or some of the drawbacks of the prior art.
[0007] More specifically, one object of the invention is to provide a tympanic thermometer that is easy to clean and decontaminate.
SUMMARY
[0008] These objectives are achieved by virtue of a device for measuring the internal temperature of a patient, the device comprising a tympanic thermometer comprising:
[0009] a means for measuring the temperature of a patient consisting of a flexible tube capable of being introduced into an external auditory meatus and comprising an end to which a sensor is fixed;
[0010] a housing comprising a shell to which means for displaying the measured temperature are fixed;
[0011] a first blocking means for blocking the external auditory meatus;
[0012] a second blocking means for insulating the external auditory meatus from the ambient environment.
[0013] The invention is noteworthy in that the measurement means, the housing and the first and second blocking means are sealed and can be cleaned.
[0014] Thus, the tympanic thermometer can be cleaned, disinfected and decontaminated by means as used for example in the medical services to avoid the transfer of microorganisms such as bacteria, viruses or fungi that can infect the patients.
[0015] According to a particular embodiment, the second blocking means is a separate element from the housing of the tympanic thermometer.
[0016] This makes it possible for the measurement device to be manipulated easily and in particular for the reading of the displayed measured temperature to be easily accessible. Obviously, the separation of the two elements means that the second blocking means can easily be cleaned and decontaminated.
[0017] According to a second embodiment, the second blocking means is fixed to the housing, forming a sealed assembly. Such an arrangement will have the advantage of avoiding use of the thermometer without the second blocking means.
[0018] Advantageously, the second blocking means comprises a thermally insulating foam formed in a sealed, impermeable and removable jacket.
[0019] This means that the foam used to insulate the external auditory meatus of an ear from the ambient environment is not in contact with some of the bodily areas of the patient, or with other contaminable elements, which avoids the spread of infections. The sealed, impermeable and removable jacket is an inexpensive and reliable solution, and facilitates the replacement of the foam.
[0020] According to an important feature, the second blocking means has a covering surface area of between 400 mm 2 and 5000 mm 2 .
[0021] This means that the second blocking means can be adapted to all categories of patients and makes it possible to insulate the inside of the ear but also beyond the auricle of the ear.
[0022] Provision is made for the jacket to have a height of between 10 and 70 mm so as to contain any thickness, in particular thermally insulating foams that have a great thickness for a better insulation of the external auditory meatus.
[0023] According to another embodiment, the first blocking means comprises at least a part which substantially forms an angle of between 35 and 90° with an axis, this axis being wholly or partly concentric with a wall of this part to block the external auditory meatus and limit the penetration of the tube into said meatus.
[0024] According to a preferred aspect, the tympanic thermometer and/or the second blocking means are made of polymer materials in order to withstand the hostile environments and improve the seal-tightness.
[0025] To increase the thermal insulation capability, the foam is made of a closed-cell polymer material.
[0026] Advantageously, provision is made for the measurement device to exhibit a positive buoyancy in a fluid depending on the materials and its dimensions to avoid the risk of it sinking for example, in an intervention at sea for example.
[0027] For reasons of hygiene or adaptability of the measurement means to different patients, provision is made for the measurement means to be removable.
[0028] Advantageously, the housing can comprise at least one unit for storing the measured temperature. That should allow for the different temperatures read to be tracked.
[0029] Provision is also made for the link between the housing and the measurement means to be of wireless type. This arrangement avoids the bulk of the measurement device and favors the ergonomics, handleability and convenience in data exchange.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Other innovative features and advantages will emerge from the following description, given by way of indication and without limitation, with reference to the attached drawings, in which:
[0031] FIG. 1 is a perspective view of a measurement device according to a first embodiment of the invention;
[0032] FIG. 2 is a side view of another embodiment of the measurement device in a situation of use on a patient;
[0033] FIG. 3 is a perspective view of another embodiment of the measurement device with the second blocking means fixed onto the housing of the tympanic thermometer;
[0034] FIG. 4 represents a perspective and front view of the measurement device according to FIG. 3 ;
[0035] FIG. 5 is a perspective view of a thermally insulating foam formed in a jacket;
[0036] FIG. 6 is a detailed view of an embodiment of the first blocking means according to the invention;
[0037] FIG. 7 illustrates a measurement means in the ear of a patient;
[0038] FIG. 8 illustrates another embodiment of the invention with the removable measurement means;
[0039] FIG. 9 is a block diagram of the measurement device;
[0040] FIG. 10 is a view of another embodiment of the invention;
[0041] FIG. 11 is a perspective view of another embodiment of the measurement device according to the invention; and
[0042] FIG. 12 is a side view of the measurement device according to FIG. 11 .
DETAILED DESCRIPTION
[0043] The device 1 for measuring the internal temperature of a patient according to the invention is designed for medical personnel to take a measurement of the tympanic temperature of the patient. This temperature measurement device is particularly suited to a hostile environment, such as mountains, sea, etc.
[0044] FIG. 1 illustrates, in a perspective view, an embodiment of the invention in which the device 1 for measuring the internal temperature of the patient comprises a tympanic 2 or auricular thermometer.
[0045] The tympanic thermometer 2 comprises a measurement means 3 . The latter can consist of a flexible tube 4 capable of being introduced into the external auditory meatus C of the patient and comprising an end 5 to which a sensor 6 is fixed. The sensor 6 , well known to those skilled in the art, is intended to pick up the heat radiated by the tympanum. A first blocking means 7 , which is in contact with a bodily area of the patient, in particular with the elastic cartilage of the ear O, is mounted at the other end 5 ′ of the flexible tube 4 . The first blocking means 7 is for blocking the external auditory meatus C of the ear O. The flexible tube 4 has a diameter of between 2 and 15 mm. It can have a length of between 4 and 20 mm.
[0046] The tympanic thermometer 2 also comprises a housing 8 provided with a shell 9 to which means 10 for displaying the temperature measured by the sensor 6 are fixed. More specifically, the display means 10 are fixed onto a front face 11 of the shell 9 . The display means 10 can comprise a frame 13 supporting, for example, an LCD (Liquid Crystal Display) screen. Control or indication buttons 14 (on/off, battery readout, etc.) can be provided, for example, on the frame 13 or the shell 9 of the housing 8 (see FIGS. 4 , 11 and 12 ). The shell 9 also has a rear face 12 in which a housing can be formed, intended to receive at least one battery (not represented). The housing will be closed by a removable cover (also not represented). The housing 8 can be linked with the measurement means 3 by a flexible cord 23 . The housing 8 can have a height H of between, for example, 5 and 20 mm.
[0047] The tympanic thermometer 2 also comprises a second blocking means 15 which is in contact with a bodily area of the patient, in particular with the auricle O. The second blocking means 15 makes it possible to insulate the external auditory meatus of the ear of the patient from the ambient environment as illustrated in FIG. 2 .
[0048] According to the invention, the measurement means 3 , the housing 8 , the first 7 and second 15 means for blocking the external auditory meatus C of the patient are sealed and can be cleaned.
[0049] In the context of the present invention, the term “sealed” should be understood to mean that no fluid is allowed to pass and that it is capable of being cleaned, disinfected, decontaminated by a disinfectant liquid solution, such as, but not limited to, the solutions used for medical devices.
[0050] As can be seen in FIGS. 1 and 2 , the second blocking means 15 is a separate element from the housing 8 of the tympanic thermometer 2 . Each of the separate elements is sealed.
[0051] In FIG. 3 , it can be seen that the second blocking means 15 is fixed to the housing 8 . In this case, the housing 8 and the second blocking means 15 form a sealed assembly. To perfect the seal-tightness and the fixing, a plate 16 can be interposed between the second blocking means 15 and the housing 8 of the tympanic thermometer 2 . The fixing can be carried out by gluing, welding or another sealed element.
[0052] A strap 17 for holding the second blocking means 15 pressed onto the ear O of the patient can be provided. The strap 17 can be secured to the plate 16 which is provided with two openings 18 for this purpose ( FIGS. 3 and 4 ). The strap 17 can also be fixed to the second insulating means 15 ( FIG. 1 ). The strap 17 can comprise tightening loops 19 and/or closure loops 20 . However, it is possible to envisage having the second blocking means 15 mounted on an arc in the configuration of an audio headset for example, or similar. Similarly, an elastic band (not represented) may be sufficient to press the second blocking means 15 onto the ear O of the patient.
[0053] As illustrated in FIG. 5 , the second blocking means 15 is made of a thermally insulating foam 21 which is formed in a sealed and impermeable jacket 22 . The jacket 22 can also be removable.
[0054] Advantageously, the tympanic thermometer 2 and/or the second blocking means 15 are made of polymer materials.
[0055] To make the measurement device as sealed as possible, a transparent sealing film can be provided, either mounted on the front face 11 and/or on the rear face 12 of the housing 8 . The sealing film can be made of polyethylene for example. It can be fixed by gluing or welding, seal-tight fixing screws or other means.
[0056] The thermally insulating foam 21 can be made of a closed-cell polymer material. Preferably, the foam 21 is made of polyurethane. Other materials can of course be used. The thickness of the foam 21 can be between 20 and 60 mm. It also has a density of between 20 and 45 kg/m 3 . Through its composition and its thickness, the foam 21 allows for an excellent insulation of the external auditory meatus from the ambient environment.
[0057] The jacket 22 can be made of a flexible polymer. Preferably, the jacket 22 can be made of silicone or polyurethane. It can have a height of between 10 and 70 mm so that it matches the thickness of the insulating foam 21 . The jacket 22 can be provided with a sealed closure 24 of slider type making it possible to open or close the jacket 22 in order to introduce the foam 21 therein or remove it therefrom. However, the jacket 22 can be completely closed for example by welding or gluing.
[0058] The second blocking means 15 can have any shape, circular, rectangular or other. Provision is made for the second blocking means 15 to have a covering surface area 25 of between 400 mm 2 and 5000 mm 2 .
[0059] The first blocking means 7 represented in FIG. 6 can be fixed or overmolded or mounted removably on the flexible tube 4 . More specifically, the first blocking means 7 comprises at least a part 26 which substantially forms an angle a of between 35 and 90° with an axis A. This axis A is wholly or partly concentric with the wall presented by the part 26 of the first blocking means 7 . The wall of the part 26 can be in the form of a collar or substantially circular. Preferably, this angle a is substantially 90°. This configuration makes it possible on the one hand to block the external auditory meatus and on the other hand to limit the penetration of the measurement means 3 , notably the flexible tube 4 , into this duct, and limit the heat losses. Also, the sensor 6 and/or flexible tube 4 has a rounded end to avoid any risk of pain in the event of contact with the wall of the auditory meatus or with the tympanum. The first blocking means 7 can take the form of an (intra-auricular) earflap or of an earphone.
[0060] According to an advantageous feature, the measurement device 1 exhibits a positive buoyancy in a fluid depending on the material and on its dimensions. More specifically, the seal-tightness of the tympanic thermometer 2 and of the second blocking means prevents, on the one hand, any ingress of liquid. On the other hand, the material used, in this case polyurethane for the foam 21 and/or the jacket 2 , is a highly buoyant material. The measurement device 1 has a weight of between 60 and 500 g, the weight of the measurement device 1 being less than the buoyancy which corresponds to the density of the fluid multiplied by the volume of the fluid. The measurement device 1 can thus float in sea or river water for example.
[0061] Provision can be made for the measurement means 3 to be removable ( FIG. 7 ), in particular, for example, from the flexible cord 23 or from the first blocking means 7 . The flexible tube 4 can be disconnected at its other end 5 ′ (situated before or after the first blocking means 7 ) from the flexile cord 23 or from the first blocking means 7 . The flexible cord 23 can comprise, at one of its ends 27 , a female-type connection plug 28 making it possible to connect the second end 5 ′ of the flexible tube 4 comprising a male connection plug 28 ′ for example. Obviously, any type of connection means can be considered. This configuration makes it possible for the measurement means 3 to be unique and disposable, or makes it possible for the measurement means 3 to be interchangeable for the latter to be adapted to different patients, such as new-born babies, children and adults.
[0062] According to a feature that can be envisaged (see FIG. 10 ), the link between the housing 8 and the measurement means 3 is of wireless type. The housing 8 and the measurement means can each be equipped with a transmitter and a receiver (not represented) to ensure the transmission T of the information from the housing 8 or from the measurement means 3 . The wireless link can use Wi-Fi, infrared, and other such systems. Preferably, the wireless system uses the Bluetooth® configuration according to the well-known standards IEEE 802.15.1 to IEEE 802.15.4. The housing 8 can also communicate wirelessly with other terminals containing a medical file of the patient for example.
[0063] According to another feature that can be envisaged, the housing 8 can comprise at least one unit 31 for storing the measured temperature. In FIG. 9 representing a block diagram of the measurement device 1 , the latter can comprise a CPU processing unit 29 . This processing unit 29 is connected to a temperature measurement unit 30 , a storage unit 31 for storing the measurements read and other program data, a unit 32 for displaying the information processed by the processing unit 29 and a communication interface unit 33 . The storage unit 31 is intended to receive data in analog and/or digital format. Preferably, the storage unit 31 can comprise an electronic integrated circuit mounted on a printed circuit which is housed in the housing of the tympanic thermometer 2 . The memory can be of RAM and/or ROM and/or EPROM type.
[0064] The measurement device I is used as follows: a user introduces the measurement means 3 comprising the flexible tube 4 and the sensor 6 into the external auditory meatus C of the ear O of the patient or of the accident victim. The first blocking means 7 blocks the external auditory meatus by means of a part 26 of this first blocking means 7 which abuts with the entry of the auditory meatus for a first insulation. The user presses the second insulation means 15 onto the auricle so as to hold, on the one hand, the measurement means 3 inside the auditory meatus, and, on the other hand, totally insulate said meatus from the ambient environment. A small volume of air located inside the meatus then reaches the temperature of the blood in the internal carotid artery. The user can then view the temperature by virtue of the display means 10 . The user can then grip the head of the patient on which the second blocking means 15 is placed. The user can keep the housing 8 between the hands or position it on the head of the patient by means of the strap 17 . The thermometer does not need to be calibrated. Reliable measurements concerning the core temperature of the patient can thus be obtained, non-invasively.
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A device for the non-invasive measurement of the core temperature of a patient that includes a tympanic thermometer with a means for measuring the temperature of the patient is described. The device includes a flexible tube capable of being inserted into an external auditory meatus and including an end to which a sensor is connected; a housing including a shell to which a display for displaying the measured temperature is attached; a first blocking means for blocking the external auditory meatus; and a second blocking means for isolating the external auditory meatus from the ambient environment. According to the invention, the measuring means, the housing and the first and second blocking means are sealed and washable.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a National Phase application of International Application No. PCT/CN2010/072933, filed May 19, 2010, which claims the benefit of Chinese Patent Application No. 200910092368.4, filed Sep. 7, 2009, both of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to the protection field of ring networks, in particular to an ethernet switch ring (ESR) protection method and transit node for the multiple points failure in the ESR protection.
BACKGROUND OF THE INVENTION
In an Ethernet network, the way to improve reliability is mainly by deploying some redundant links. Therefore, backup links can be used when the main link is failed. The ZTE Ethernet Switch Ring (ZESR) proposes a ring network protection method based on this application. Each ring has a link, which is called a ring protection link, and when the links protected by the rings are all in good condition, at least one of the two ports of the ring protection link is blocked so as to prevent protected data from passing through the link. For the protection of the multiple points failure on the loop (i.e., another single point failure occurs on the loop during the recovery of a single point failure), the rapid response capability of the loop is also essential to the ring network protection.
At present, in the ring network protection method, each node on the loop is given different roles respectively: a master node and transit nodes, and there is only one master node in a ring, the rest are all transit nodes. When all the links are in a good condition, the master node will block slave ports to prevent the protected data from forming a ring. When a failure occurs on the loop, the master node will open the blocked slave ports to back up the link. The states defined for the master node are: init, pre-up, up, and down, and the states defined for the slave node are: init, up and down, wherein init is the initial state which happens after the domain configuration; the master node and transit nodes are all in up state when there is no failure on the loop and are all in down state when there is a failure; and the pre-up state is the transitional state of the loop from down to up and is the special state of the master node.
FIG. 1 is a diagram of ESR protection according to the conventional art. As shown in FIG. 1 , nodes S 1 , S 2 , S 3 and S 4 support the Ethernet network switching function and they establish an ESR protection domain, wherein node S 1 is the master node, and nodes S 2 , S 3 and S 4 are transit nodes. The ESR protection domain includes a closed ring composed of nodes S 1 , S 2 , S 3 and S 4 . When the links protected by the ring are all in good condition, the master node S 1 blocks the slave port and each node shows the loop state of up.
FIG. 2 is a diagram showing the situation of the loop after the ESR protection has a link failure according to the conventional art. As shown in FIG. 2 , when a loop is failed, for example the link between the nodes S 3 and S 4 in FIG. 1 is failed, the nodes S 3 and S 4 will block the ports of the failed link and simultaneously send out a loop failure protocol message. After receiving the loop failure message, the master node will switch the link, i.e., opening the slave ports, and sends a protocol message to notify each transit node of the state change of the loop. And the transit node will set the loop state to down and will refresh a Media Access Control (MAC) address table after receiving the notification from the master node. At the moment, each node shows the loop state of down. If the loop is recovered, in order to prevent a loop, the failed node will stop sending the link failure protocol message to wait for the notification from the master node rather than opening the recovered port at once. The master node will consider that the loop failure has been recovered when not receiving the loop failure message within a certain time, and at the moment, the master node will switch back the flow, i.e., making the protected traffic flow transmitted from the link where the master port is located, and blocks the slave ports. In order to prevent the master port from port oscillating and ensure the normal work of the master port, the protocol sets the pre-up state for the master node. The master node will enter the pre-up state when not receiving the loop failure protocol message within a certain time. FIG. 3 is a diagram showing the situation of the loop when the ESR protection failure is just recovered according to the conventional art. As shown in FIG. 3 , a pre-up timer is started in the pre-up state, and after the timer is timed out, the master port is opened, the slave ports are blocked, the loop is recovered to the up state, and the master node notifies each transit node of the state change. Each transit node will switch the loop state from down to up after receiving the notification from the master node, and the failed nodes S 3 and S 4 further need to open the failed ports to ensure the normal flow.
If the loop is failed again in the pre-up state, in this case the transit node that detects the failure will send the loop failure protocol message to the master node. When the master node receives the loop failure protocol message, it will only process according to the loop failure and will send the protocol message to notify each node to enter the down state. In this case, the most efficient method for ensuring the smooth flow of the loop is to open the recovered failed ports at once. However, the master node cannot notify the recovered failed ports to open due to the received loop failure protocol message.
FIG. 4 is a diagram showing a second failure in the ESR according to the conventional art. As shown in FIG. 4 , when failure occurs again between nodes S 2 and S 3 , the ports of the nodes S 3 and S 4 cannot be opened at once. Even if the port of the node S 3 can be opened, the port of the node S 4 cannot be opened, and the MAC address cannot be refreshed. Therefore, the flow is still unsmooth, and thereby the ring network protection capability and user experience are affected.
SUMMARY OF THE INVENTION
For the reasons above, the main objective of the present invention is to provide an ESR protection method and transit node, which can improve the ring network protection capability as well as the user experience.
To achieve the objective, the technical solution of the present invention is implemented as follows.
An ESR protection method, for introducing a pre-up state for transit nodes, comprising:
after a loop failure is recovered, the transit node on the loop entering the pre-up state if not receiving a loop failure protocol message within a set time; and
when the transit node is in the pre-up state and the loop is failed again, i.e., the transit node receives the loop failure protocol message in the pre-up state, the transit node opening a master and a slave ports and refreshes a MAC address.
When the loop failure occurs, the method specifically comprises:
the failed transit node that detects the loop failure periodically sending the loop failure protocol message to other nodes on the loop;
a master node switching the loop state to down state and sending a loop failure update protocol message to each transit node after receiving the loop failure protocol message from the failed node; and
the transit node updating the loop state to down state and refreshing the MAC address after receiving the loop failure update protocol message.
After the loop failure is recovered, the method specifically comprises:
the failed transit node stopping sending the loop failure protocol message and setting the recovered port to a preforward state; and
the failed transit node entering the pre-up state after stopping sending the loop failure protocol message for the set time, and other transit nodes on the loop also entering the pre-up state when not receiving the loop failure protocol message within the set time.
When the transit node is in the pre-up state and the loop is failed again, the method specifically comprises:
the failed transit node that detects the loop failure this time blocking the failed port, and periodically sending the loop failure protocol message to other nodes on the loop; and other transmit nodes receiving the loop failure protocol message in the pre-up state, opening the master and slave ports at once, and refreshing the MAC address.
The method further comprises: the master node entering the pre-up state when not receiving the loop failure protocol message within the set time.
The method further comprises: the master node receiving the loop failure protocol message in the pre-up state and opening the master and the slave ports at once.
An ESR transit node comprises: a failure detection unit, a loop failure protocol message receiving unit, a state maintenance unit and an execution unit, wherein
the failure detection unit is adapted for detecting whether a loop failure is recovered and notifying the state maintenance unit when the loop failure is recovered;
the loop failure protocol message receiving unit is adapted for receiving a loop failure protocol message and notifying the state maintenance unit after receiving the loop failure protocol message;
the state maintenance unit is adapted for switching the loop state to a pre-up state when not receiving the loop failure protocol message within a set time, and notifying the execution unit when the loop state is in the pre-up state and the notification from the loop failure protocol message receiving unit is received; and
the execution unit is adapted for opening a master port and a slave port and refreshing a MAC address after receiving the notification from the state maintenance unit.
The ESR transit node further comprises a loop failure protocol message sending unit, and a loop failure update protocol message receiving unit, and
the failure detection unit is further adapted for detecting whether the loop failure occurs and notifying the loop failure protocol message sending unit when the loop failure occurs;
the loop failure protocol message sending unit is adapted for periodically sending the loop failure protocol message to other nodes on the loop after receiving the notification from the failure detection unit;
the loop failure update protocol message receiving unit is adapted for receiving the failure update protocol messages from other loop nodes and notifying the state maintenance unit; and
the state maintenance unit is further adapted for updating the loop state to a down state according to the failure update protocol message and notifying the execution unit to refresh the MAC address.
The failure detection unit is further adapted for notifying the loop failure protocol message sending unit when detecting that the loop failure is recovered;
the loop failure protocol message sending unit is further adapted for stopping sending the loop failure protocol message and notifying the execution unit after receiving the notification from the failure detection unit; and
the execution unit is further adapted for setting the recovered port to a preforward state after receiving the notification from the loop failure protocol message sending unit.
In the ESR protection method and transit node, the pre-up state is introduced for the transit node which will enter the pre-up state when not receiving the loop failure protocol message within the set time; and all the failure-free ports of the transit node on the loop are opened when the transit node receives the loop failure protocol message in the pre-up state. Since the pre-up state is introduced for the transit node and the transit node controls whether to open the recovered failed port by itself, the unsmooth flow caused by the master node which cannot notify the recovered failed port to open is avoided, and the ring network protection capability and user experience can be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of ESR protection according to the conventional art;
FIG. 2 is a diagram showing the situation of a loop after the ESR protection has a link failure according to the conventional art;
FIG. 3 is diagram showing the situation of a loop when the ESR protection failure is just recovered according to the conventional art;
FIG. 4 is a diagram showing a second failure in the ESR according to the conventional art;
FIG. 5 is a diagram showing the flow of an ESR protection method of the present invention;
FIG. 6 is a diagram showing the flow of an ESR protection method of the first embodiment of the present invention; and
FIG. 7 is a diagram showing an ESR of the second embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The basic idea of the present invention is that: the pre-up state is introduced for the transit nodes which will enter the pre-up state when not receiving the loop failure protocol message within the set time. When a transit node receives the loop failure protocol message in the pre-up state, all the failure-free ports of the transit node on the loop are opened.
The implementation of the technical solution is further described below in detail with reference to the drawings.
FIG. 5 is a diagram showing the flow of an ESR protection method of the present invention. As shown in FIG. 5 , the ESR protection method generally includes the following steps.
Step 501 : When a loop failure occurs, each node on the loop updates the loop state to down respectively.
Specifically, when a transit node on the loop detects the loop failure, the failed transit node will periodically send the loop failure protocol message to other nodes on the loop; the master node switches the loop state to down and sends a loop failure update protocol message to each transit node after receiving the loop failure protocol message from the failed node; and the transit node updates the loop state to down and refreshes the MAC address after receiving the loop failure update protocol message.
Step 502 : After the loop failure is recovered, the transit node on the loop will enter the pre-up state when not receiving the loop failure protocol message within the set time.
Specifically, after the loop failure is recovered, the failed transit node stops sending the loop failure protocol message and sets the recovered port to a preforward state; and the failed transit node enters the pre-up state after stopping sending the loop failure protocol message for a set time, and other transit nodes on the loop also enter the pre-up state when not receiving the loop failure protocol message within the set time.
In addition, the master node also enters the pre-up state when not receiving the loop failure protocol message within the set time.
Step 503 : When the transmit node is in the pre-up state and another loop failure occurs, the transit node opens the master and slave ports and refreshes the MAC address.
Specifically, when another transit node on the loop detects the loop failure, the failed transit node that detects the loop failure this time blocks the failed port, and periodically sends the loop failure protocol message to other nodes on the loop. Other transit nodes receive the loop failure protocol message in the pre-up state, determine that another failure occurs on the loop, open the master and slave ports at once, and refresh the MAC address. The transit node recovered from failure sets the port, which has been recovered to be in the preforward state, to the open state.
In addition, the master node will also open the master and slave ports at once when receiving the loop failure protocol message in the pre-up state.
The present invention further discloses an ESR transit node, comprising: a failure detection unit, a loop failure protocol message receiving unit, a state maintenance unit and an execution unit, wherein,
the failure detection unit is adapted for detecting whether the loop failure is recovered and notifying the state maintenance unit when the loop failure is recovered;
the loop failure protocol message receiving unit is adapted for receiving the loop failure protocol message and notifying the state maintenance unit after receiving the loop failure protocol message;
the state maintenance unit is adapted for switching the loop state to the pre-up state when not receiving the loop failure protocol message within the set time, and notifying the execution unit when the loop is in the pre-up state and the notification from the loop failure protocol message receiving unit is received; and
the execution unit is adapted for opening the master and slave ports and refreshing the MAC address after receiving the notification from the state maintenance unit.
The ESR transit node further includes a loop failure protocol message sending unit, and a loop failure update protocol message receiving unit.
The failure detection unit is further adapted for detecting whether the loop failure occurs and notifying the loop failure protocol message sending unit when the loop failure occurs.
The loop failure protocol message sending unit is adapted for periodically sending the loop failure protocol message to other nodes on the loop after receiving the notification from the failure detection unit.
The failure update protocol message receiving unit is adapted for receiving the failure update protocol messages from other loop nodes and notifying the state maintenance unit.
The state maintenance unit is further adapted for updating the loop state to the down state according to the failure update protocol message and notifying the execution unit to refresh the MAC address.
The failure detection unit is further adapted for notifying the loop failure protocol message sending unit when detecting that the loop failure is recovered.
The loop failure protocol message sending unit is further adapted for stopping sending the loop failure protocol message and notifying the execution unit after receiving the notification from the failure detection unit.
The execution unit is further adapted for setting the recovered port to the preforward state after receiving the notification from the loop failure protocol message sending unit.
First Embodiment
In this embodiment, the loop includes a master node, a transit node 1 and a transit node 2 . FIG. 6 is a diagram showing the flow of an ESR protection method of the first embodiment of the present invention. As shown in FIG. 6 , the ESR protection method comprises the following steps.
Step 601 : When a failure occurs in the link of the transit node 1 , the transit node 1 regularly and continuously sends out the loop failure protocol message.
Step 602 : The master node switches the loop and sets the loop state to the down state, and sends the loop failure update protocol message to the transit node 1 and transit node 2 after receiving the loop failure protocol message from the transit node 1 .
Step 603 : The transit node 1 and transit node 2 update the loop state to the down state and refresh the MAC address after receiving the loop failure update protocol message from the master node.
Step 604 : After the failure is recovered, the transit node 1 stops sending the loop failure protocol message at once and sets the recovered port to the preforward state.
Step 605 : The transit node 1 enters the pre-up state after stopping sending the loop failure protocol message for a period of time (such as 8 s).
Step 606 : The master node and transit node 2 enter the pre-up state when not receiving the loop failure protocol message for a period of time (such as 8 s).
Generally, the master node and transit nodes will enter the pre-up state when not receiving the loop failure protocol message for the same period of time.
Step 607 : The transit node 2 blocks the failed port and regularly and continuously sends out the loop failure protocol message when detecting the loop failure.
Step 608 : The failure node 1 sets the port, which has been recovered to be in the preforward state, to the forward state at once and refreshes the MAC address when receiving the loop failure protocol message and determining that another failure occurs on the loop.
Step 609 : The master node receives the loop failure protocol message, sets the master and slave ports to the forward state, and sends the loop update protocol message to the transit node 1 and transit node 2 to notify them of the loop state of down and notify each node to refresh the MAC address.
Step 610 : The transit nodes 1 and 2 receive the loop update protocol message from the master node, and then update the loop state to the down state and refresh the MAC address, and the loop is recovered to the single point failure process flow.
It can be seen that the loop protection problem of multiple points failure can be effectively solved by setting the pre-up state for the transit node, and processing the port in the preforward state when the transit node receives the loop failure protocol message in the pre-up state.
Second Embodiment
FIG. 7 is a diagram of an ESR of the second embodiment of the present invention. As shown in FIG. 7 , nodes S 1 , S 2 , S 3 and S 4 compose the ESR, wherein S 1 is the master node and other nodes are the transit nodes. A failure first occurs in the link between the nodes S 3 and S 4 . When the link between the nodes S 3 and S 4 is recovered from the failure, the nodes S 3 and S 4 will stop sending the loop failure protocol message and set the port on the loop to the preforward state to wait for the loop recovery update protocol message from the master node. In addition, the master node S 1 and each transit node will enter the pre-up state when not receiving the loop failure protocol message for a period of time and enter the up state after the pre-up state is timed out. If another failure occurs on the loop when each node is in the pre-up state, for example a failure occurs in the link between the nodes S 2 and S 3 , the nodes S 2 and S 3 will send out the loop failure protocol message. When the node S 4 receives the loop failure protocol message and is in the pre-up state at the moment, and the port is in the preforward state, the port on the loop is opened, with the process flow being the same as that of the node S 3 .
What described above are only preferred embodiments of the present invention, and the protection scope of the present invention is not limited herein.
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An Ethernet Switch Ring (ESR) protection method for introducing the pre-up state for the transit node, includes, after a loop failure is recovered, the transit node on the loop entering the pre-up state if not receiving the loop failure protocol message within a set time. And when the transit node is in the pre-up state and the loop fails again, i.e., the transit node receives the loop failure protocol message in the pre-up state, the transit node opens the master and slave ports and refreshes the MAC address. Effectively, the transit node is an ESR transit node.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/593,908, filed Aug. 24, 2012, which is a continuation of U.S. patent application Ser. No. 12/243,622, filed Oct. 1, 2008, which issued as U.S. Pat. No. 8,265,560 on Sep. 11, 2012, which is a continuation of U.S. patent application Ser. No. 11/099,325, filed Apr. 5, 2005, which issued as U.S. Pat. No. 7,450,905, on Nov. 11, 2008, which is a continuation of U.S. patent application Ser. No. 10/427,174, filed May 1, 2003, which issued as U.S. Pat. No. 6,882,849, on Apr. 19, 2005, which is a continuation of U.S. patent application Ser. No. 10/003,487, filed Nov. 1, 2001, which issued as U.S. Pat. No. 6,591,109 on Jul. 8. 2003, which claims the benefit of U.S. Provisional Application No. 60/313,336 filed Aug. 17, 2001, which are incorporated by reference as if fully set forth herein.
FIELD OF THE INVENTION
[0002] The invention generally relates to wireless time division duplex (TDD) communication systems using code division multiple access (CDMA). In particular, the invention relates to reducing cross cell user equipment interference in such systems.
BACKGROUND
[0003] FIG. 1 is an illustration of a wireless TDD/CDMA communication system 10 . The communication system 10 has base stations 12 1 to 12 n ( 12 ) which communicate with user equipments (UEs) 14 1 to 14 n ( 14 ). Each base station 12 has an associated operational area or cell. The base station communicates with UEs 14 in its cell.
[0004] In CDMA communication systems, multiple communications are sent over the same frequency spectrum. These communications are distinguished by their channelization codes. To more efficiently use the frequency spectrum, TDD/CDMA communication systems use repeating frames divided into timeslots, such as fifteen timeslots, for communication. In TDD, each cell's timeslots are used solely for either the uplink or downlink at a time. A communication sent in such a system has one or multiple associated code(s) or timeslot(s) assigned to it. The use of one code in one timeslot with spreading factor of sixteen is referred to as a resource unit.
[0005] Cross cell interference is a problem in such systems as illustrated in FIG. 2 . If two different cell's UEs 14 are close to each other, their uplink transmissions interfere with the other UE's downlink transmissions in the same timeslot. As shown in FIG. 2 , UE 14 1 uplink transmission U 1 interferes with UE 14 2 downlink transmission D 2 . Likewise, UE 14 2 uplink transmission U 2 interferes with UE 14 1 downlink transmission D 1 . Although the effective isotropic radiant power (EIRP) of UEs 14 is much less that base stations 12 , the close proximity of the UEs 14 results in the unacceptable interference. This problem is exacerbated when adding new users or user services. Although a cell's base station and UE 14 may make timeslot interference measurements, such as interference signal code power (ISCP), to assure its new transmissions will not see unacceptable interference, other cells' users may end up experiencing unacceptable interference due to the new transmission. As a result, existing calls may be dropped or unacceptable quality of service (QOS) may occur.
[0006] Accordingly, it is desirable to reduce cross cell interference.
SUMMARY
[0007] A method for reducing cross cell interference in a wireless time division duplex communication system using code division multiple access, the system having at least one user equipment (UE) and a base station (BS) is disclosed. The method begins by measuring an interference level of each timeslot at the BS. A timeslot is eliminated for additional uplink communication if the measured interference level exceeds a first threshold. An interference level of each timeslot is measured at the UE, and the timeslot is eliminated for downlink communication for the UE if the measured interference level exceeds a second threshold. UEs in nearby cells that are large interferers are identified and their downlink timeslot usage is gathered. A timeslot is eliminated for uplink communication for a large interferer UE that uses the timeslot for downlink communication.
[0008] A system for reducing cross cell interference in a wireless time division duplex communication system using code division multiple access includes a user equipment (UE), a base station (BS), and a Node B. The UE includes an interference measurement device for measuring interference in a timeslot, a transmitter, and a receiver. The BS includes an interference measurement device for measuring interference in a timeslot, a transmitter, and a receiver. The Node B includes a resource allocation device configured to receive interference measurement values from the UE and the BS; eliminate timeslots for communication where the measured interference exceeds a first threshold; identify UEs in nearby cells that are large interferers; gather downlink timeslot usage for large interferer UEs; and eliminate a timeslot for uplink communication for a large interferer UE that uses the timeslot for downlink communication.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an illustration of a wireless TDD/CDMA communication system.
[0010] FIG. 2 is an illustration of cross interference between UEs.
[0011] FIG. 3 is a flow chart for UE cross cell interference reduction.
[0012] FIG. 4 is a flow chart for determining potentially interfered UEs.
[0013] FIG. 5 is an illustration of neighboring cell UE usage.
[0014] FIG. 6 is an illustration of large interfering UE timeslot usage.
[0015] FIG. 7 is an illustration of available UE timeslots.
[0016] FIG. 8 is a simplified UE cross cell interference reduction system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Although the UE cross cell interference reduction is explained in the context of unsectorized cells, the approach is extendable to any UE operating area division, such as sectors of a cell. In such an extension, each operating area, such as a sector, is treated as a separate cell in the analysis.
[0018] FIG. 3 is a flow chart for UE cross cell interference reduction. For each cell, the cell's base station 12 measures the interference level in each timeslot, such as by using ISCP, step 22 . The measured interference in each timeslot is compared to a threshold. If the measured interference in a timeslot exceeds the threshold, that timeslot is eliminated as a timeslot for any additional uplink communications in that cell, step 23 . The threshold level is typically set by the system operator.
[0019] Each UE 14 measures the interference level in each timeslot, such as by ISCP, step 24 . To determine available downlink timeslots for a particular UE 14 , the measured interference in each timeslot is compared to a threshold. The threshold level is typically set by the system operator. If the measured interference exceeds the threshold, that timeslot is eliminated for the downlink for that particular UE 14 , step 25 .
[0020] Another concern is whether a particular UE's new uplink transmissions will interfere with another cell's UE downlink transmission. In TDD, UEs 14 in the same cell do not transmit on uplink and downlink in the same timeslot. Since the transmissions are new, other cells' UEs 14 cannot measure the resulting interference levels until the new transmissions begin. These new transmissions may result in a drop of a user or unacceptable QOS for existing users.
[0021] Determining other nearby cells' UEs 14 which may interfere with a particular UE 14 is per the flow chart of FIG. 4 . Each neighboring cell's UE uplink timeslot usage is gathered, step 29 . This usage is typically stored at the radio network controller (RNC) 42 and/or at the Node-B 46 (see FIG. 8 ). Only the UE usage of nearby cells or, alternately, only adjacent cells are used. Further cells' UEs 14 are too far away to suffer interference from the particular UE 14 . An example of nearby UE uplink usage is shown in FIG. 5 . Each UE 14 is represented by a different letter, “B” to “L”. The particular UE 14 is an unshown letter “A”.
[0022] Using the particular UE's timeslot interference measurements, the timeslots are categorized into either a large or small interference category, step 30 . The small or large interference determination is performed such as by a threshold test. The threshold is typically set by the system operator. All nearby cell UEs 14 transmitting uplink communications in timeslots having a small interference are considered too far away to suffer interference from the particular UE's uplink communications, step 31 . All the other UEs are considered to be potentially interfered with by this UE's uplink communications, step 32 .
[0023] To illustrate using the example of FIG. 5 , UE A has nearby UEs B-L. Uplink timeslots are indicated with a “U”. Out of the eight uplink timeslots (slots S 1 , S 3 , S 5 , S 7 , S 9 , S 11 , S 13 , S 15 ), three slots have large interferences (slots S 1 , S 3 and S 7 ) and five have small interferences (slots S 5 , S 9 , S 11 , S 13 and S 15 ). The UEs 14 transmitting in small interference uplink slots are UE C, D, F, G, H, I, J, K and L and in large interference uplink slots are UE B, D, F and H. Although UE D and F have an uplink transmission in a large interference cell, they also have an uplink transmission in a small interference cell. As a result, UE D and F are not considered the interfering UEs 14 in the large interference timeslots. In this example, UE B and H are determined to be the interfering UEs.
[0024] In this simplified example, there was no ambiguous information. However, ambiguous information may exist. For instance, if UE H also had an uplink transmission in a small interference cell, such as slot S 9 , the information is ambiguous. UE H would be considered both a large interferer in slot S 7 (being the only uplink user) and a small interferer in slot S 9 . In a conservative implementation, UE H could be deemed a large interferer. In a more aggressive implementation, UE H could be deemed a small interferer. There may be an unaccounted for interferer or interference source in that timeslot (slot S 7 ).
[0025] Another situation where ambiguous information may occur is where multiple potential large interferers transmit uplink communications in the same timeslots. To illustrate, UE H may also transmit in the uplink in slots Si and S 3 . As a result, UE B may or may not be a large interferer. UE H may be the only large interferer. In this case, UE B is still deemed a large interferer to be conservative.
[0026] After the large interferer UEs 14 are determined, step 26 ( FIG. 3 ), those UEs' downlink timeslot usage is gathered, such as in FIG. 6 , step 27 . For all the timeslots that the large interferers use for the downlink, that timeslot is eliminated for the uplink for that UE, as shown by an “X”, step 28 . As a result, a table such as in FIG. 7 is produced. The table indicates which timeslots are available to the particular UE 14 . The available timeslots are blank and the non-available have an “X”. Timeslots are assigned to the particular UE by selecting from the non-eliminated timeslots.
[0027] FIG. 8 illustrates a simplified system implementation for cross cell UE interference reduction. The RNC 42 has a resource allocation device 44 . The resource allocation device 44 allocates the resources, such as code and timeslot assignments, for the cells. The resource allocation device 44 has an associated memory 45 for storing information, such as UE code and timeslot assignments, interference measurements and UE timeslot availability lists. Depending on the type of system, the computational component of cross cell UE interference reduction may be performed by the RNC resource allocation device 44 , the Node-B resource allocation device 48 or shared between the two. Typically, performing the computation at the Node-B 46 allows for faster updates.
[0028] The Node-B 46 communicates with the radio network controller 42 . The Node-B 46 has a resource allocation device 48 and an associated memory 49 . The resource allocation device 48 allocates resources to that Node-B′s users. The resource allocation device memory 49 stores information, such as the Node-B′s UE timeslot and code assignments, interference measurements and UE timeslot availability lists.
[0029] The Node-B 46 typically communicates with a group of base stations 12 . The base station 12 has a channel code and timeslot controller 54 . The channel code and timeslot controller 54 controls the timeslots and channel codes assigned to user communications as directed by the Node-B 46 and RNC 42 . A modulation and spreading device 56 processes data to be transmitted to the users. The data is processed to be time multiplexed with a channel code as directed by the channel and timeslot controller 54 . A transmitter 52 formats the processed data for transfer over the radio interface 78 . The resulting signal passes through an isolator or switch 58 and is radiated by antenna or antenna array 60 .
[0030] Signals are received by the base station 12 using the antenna or antenna array 60 . The received signals pass through the isolator or switch 58 to a receiver 50 . The receiver 50 processes the received signals with channel codes in the timeslots directed by the channel code and the timeslot controller 54 to recover the received user data. The base station 12 also has an interference measurement device 74 . The interference measurement device 74 measures the timeslot interference levels.
[0031] The UE 14 receives signals over the radio interface 78 using its antenna or antenna 1 array 62 . The received signals pass though an isolator or switch 64 to a receiver 68 to recover the received data for the user as directed by the channel code and timeslot controller 70 . The channel code and timeslot controller 70 sends the channel code and timeslot information to the receiver 68 and UE modulation and spreading device 72 . The controller 70 also retrieves the code and timeslot assignments signaled by the base station 12 .
[0032] A UE interference measurement device 76 measures the interference levels in the timeslots. The modulation and spreading device 72 processes user data with the channel codes and timeslots as directed by the UE controller 70 . The processed data is formatted for transmission over the air interface 78 by the transmitter 66 . The resulting signal passes through the isolator or switch 64 and is radiated by the antenna or antenna array 62 .
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A method for reducing cross cell interference in a wireless time division duplex communication system using code division multiple access, the system having at least one user equipment (UE) and a base station (BS) is disclosed. The method begins by measuring an interference level of each timeslot at the BS. A timeslot is eliminated for additional uplink communication if the measured interference level exceeds a first threshold. UEs in nearby cells that are large interferers are identified and their downlink timeslot usage is gathered. A timeslot is eliminated for uplink communication for a large interferer UE that uses the timeslot for downlink communication.
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RELATED APPLICATION
This is a continuation-in-part of co-pending application Ser. No. 09/574,549 filed May 18, 2000 now U.S. Pat. No. 6,360,613.
FIELD OF THE INVENTION
This invention relates generally to the field of sport balls, such as tennis balls. More particularly, the invention comprises the combination of a container for a plurality of sport balls with a device for testing the playing condition of the balls.
BACKGROUND
Tennis balls and certain other types of sport balls, such as racquetballs and handballs, are manufactured with a predetermined internal pressure, which imparts resiliency. The pressure is retained within a sphere of elastomeric material; however, the material is not perfectly impermeable. The internal pressure diminishes over time and with extended play. As the pressure diminishes, so does the resiliency of the ball, which has a deleterious effect on the playing characteristics of the ball.
Official organizations for tennis and other sports have established specifications for the balls used to play the respective sports. For example, the International Tennis Federation (ITF) Rules of Tennis specify that the ball shall have a bound of more than 53 inches and less than 58 inches when dropped 100 inches upon a concrete base. The Rules also specify that the forward and return deformation of the ball when placed under a load of 18 pounds shall be between 0.220 inch and 0.290 inch. Both of these specifications relate to the resiliency of the ball and hence to its playing characteristics. Recreational players are generally not concerned with whether or not a particular ball meets the precise specifications of an official organization. Such players are more concerned with the general playability of a ball and will often test a ball by squeezing it by hand or bouncing it on pavement. These informal tests are highly subjective. A number of devices have been proposed for objectively testing sport balls, particularly tennis balls. Such devices are shown, for example, in U.S. Pat. Nos. 5,222,391; 5,245,862; 5,291,774; 5,511,410; 5,567,870; 5,639,969; and 5,760,312.
Some of the prior art testing devices shown in the above-mentioned patents are intended for laboratory use, while others are intended to be used by individual players. However, all of the known prior art devices are relatively complex and, therefore, relatively expensive. Many of the devices have electronic components and all have one or more moving parts. There remains a perceived need for an inexpensive ball tester that can be provided to consumers at the time that the balls are purchased, analogous to the way that many dry cell batteries are sold with integral devices for testing the condition of the battery. Preferably, such a device would be simple to use and would be incorporated into the package in which balls are sold and stored so that the player would not be burdened with the inconvenience and weight of an additional item to carry.
SUMMARY OF THE INVENTION
The present invention provides a device for testing the playing condition of sport balls. The invention is preferably configured as a testing device in combination with a container for storing the sport balls; however, the invention may also be configured as a stand-alone testing device. In one embodiment particularly suited for testing tennis balls, the invention comprises a generally cylindrical canister substantially similar to conventional tennis ball canisters. A ball condition test disk is inserted into the canister and supported by means on the inside wall of the canister. The disk has a base portion, which is supported within the canister, and an indicator arm. A ball is placed into the canister where it rests on the indicator arm with a portion of the ball protruding out of the open end of the canister. When the protruding portion of the ball is pressed against a flat surface, the indicator arm is deflected, thereby giving an indication of the playing condition of the ball.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a first type of combination container and tester in accordance with the present invention.
FIG. 2 is a side view of the apparatus of FIG. 1 in a ball-testing configuration.
FIG. 3 is an end view of the testing device showing the ball condition indicator.
FIG. 4 is a perspective view of a second type of combination container and tester in accordance with the present invention.
FIG. 5 is a detailed view of the ball condition tester seen in FIG. 4 .
FIG. 6 is a top plan view of the ball condition tester.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, for purposes of explanation and not limitation, specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of wellknown methods and devices are omitted so as to not obscure the description of the present invention with unnecessary detail.
FIG. 1 illustrates a combination ball container and tester 10 in accordance with the present invention. Container/tester 10 comprises a cylindrical tube 12 closed at end 14 and a cap 16 . In the case of a device for tennis balls, cylindrical tube 12 is preferably dimensioned to house three or four balls 20 as is customary. Cylindrical tube 12 is preferably made of a clear plastic material, such as PETE, of sufficient strength to maintain internal pressurization sufficient for extended storage of balls 20 prior to use. A pressure seal (not shown) is provided at end 15 of tube 12 under cap 16 . The pressure seal is removed and discarded by the consumer when balls 20 are first used.
Cap 16 preferably includes a plurality of L-shaped slots 30 which cooperate with protrusions 32 on cylindrical tube 12 to provide a bayonet-type fitting to retain cap 16 in place. Slots 30 may have a spiral configuration to provide a mechanical advantage when securing cap 16 in place. Alternatively, tube 12 and cap 16 may have cooperating screw threads instead of a bayonet-type fitting. Cap 16 allows container/tester 10 to be used for conveniently storing and transporting balls 20 even after the pressure seal has been removed from tube 12 . Cap 16 is preferably made of a clear plastic material, but is preferably somewhat more rigid than tube 12 . Thus, cap 16 may be made of styrene, polycarbonate or similar material.
Referring now to FIG. 2, a ball 20 is shown being tested for playing condition. The ball is placed inside cap 16 and the cap is secured over closed end 14 of tube 12 with slots 30 engaging protrusions 34 . Protrusions 34 are spaced from end wall 14 so that ball 20 is slightly compressed when cap 16 is secured in place. As explained above, ITF specifications call for a forward deformation of more than 0.220 inch and less than 0.290 inch under a load of 18 pounds. Thus, if the dimensions are selected so that cap 16 compresses ball 20 by an amount in the specified range, a ball in new condition will exert a force of approximately 18 pounds against cap 16 . In order to ascertain the playing condition of the ball, it is simply necessary to obtain an approximate measure of the force exerted against cap 16 . Any suitable force indicator may be used, such as, for example, a spring-operated indicator or an electronic display coupled to a pressure transducer.
In one preferred embodiment, an indicator 18 is attached to the inside of cap 16 . Indicator 18 comprises an opaque fluid enclosed within a pouch of flexible plastic. An indicator of this type is disclosed in U.S. Pat. No. 3,987,699, the disclosure of which is incorporated herein by reference. When the fluid within indicator 18 is displaced as a result of pressure exerted against indicator 18 by compressed ball 20 , a visual indication of the displacement is provided. For example, the fluid may be a dark color, which in the absence of pressure completely obscures an underlying color on one wall of the pouch. When the thickness of the fluid is sufficiently reduced, the underlying color shows through. The degree to which the underlying color appears is directly related to the pressure exerted against indicator 18 and thereby provides a visual indication of the playing condition of ball 20 .
FIG. 3 is an end view of cap 16 , through which indicator 18 may be viewed. A ball in good playing condition will exert sufficient force against indicator 18 to displace the fluid therein within a central region 40 . Region 40 will thus have a different hue from surrounding region 42 . A ball in poorer playing condition will exert less force against indicator 18 and the color differentiation between regions 40 and 42 will be diminished. In addition, the diameter of central region 40 will appear reduced. A ball in very poor condition will exert insufficient force against indicator 18 to displace the fluid and the entire face of indicator 18 will appear as a solid hue.
FIG. 4 illustrates an alternative embodiment of the invention 100 . A can or canister 102 for storing a plurality, typically three, tennis balls is substantially similar to conventional tennis ball canisters. Canister 102 is preferably made of a clear plastic material, such as PETE. Canister 102 differs from a conventional tennis ball canister in that it is provided with means 104 for supporting a ball-testing disk 106 . As illustrated, supporting means 104 may comprise a circumferential rib on the interior surface of canister 102 . Alternative support means may also be employed, for example, disk 106 may be supported by a plurality of dimples or similar protrusions on the inner surface of canister 102 . Whichever means of support are employed, it is important that they protrude into the interior volume of canister 102 only enough to adequately support disk 106 , but not so much as to interfere with the movement of balls 20 throughout the volume.
Referring to FIG. 5, ball-testing disk 106 has a generally conical shape defined by skirt portion 108 . The outer diameter of disk 106 is such that it may be easily inserted into canister 102 , but will be firmly supported by support means 104 . Disk 106 includes an indicator arm 110 with an indicator tip 112 . The indicator arm 110 has as inverted “V” shape with a relatively sharp point 111 . This provides for a small area of contact between the indicator arm and the ball being tested, thereby maximizing the deflection of the indicator arm.
Disk 106 is preferably made of a relatively rigid plastic material, such as Delrin or the like. The disk is preferably made by an injection molding process and may be engraved with a product logo, etc. Due to the generally conical shape of the disk, a plurality of the disks will naturally tend to nest and can be easily stacked in a shipping container or a dispenser for placing the disks into tennis ball canisters.
FIG. 6 is a top plan view of ball-testing disk 106 . While the disk has a generally circular outer perimeter corresponding to the circular cross-section of canister 102 , it can be seen that the sides 114 , 115 of disk 106 are somewhat flattened. This facilitates the insertion of disk 106 through the opening of canister 102 . The outer perimeter of disk 106 bulges outwardly slightly at 116 , 117 and 118 to ensure that the disk will be securely supported by support means 104 . These bulges also hold disk 106 in place when canister 102 is inverted. It should be noted that indicator tip 112 is set back slightly from the outer perimeter of the disk to ensure that it will not strike the support means 104 when indicator arm 110 is deflected during a test of ball condition.
Referring again to FIG. 4, the playing condition of a ball 20 is tested by first placing disk 106 on support means 104 and then inserting ball 20 into canister 102 to rest upon indicator arm 110 . A portion of ball 20 protrudes from the opening of canister 102 . The canister is grasped and the protruding portion of ball 20 is placed against a flat surface, such as a wall or tabletop. Pressure is applied on the canister until the rim of the opening contacts the flat surface. The pressure causes the indicator arm 110 to be deflected. The amount of deflection is a function of the rigidity of ball 20 . This, in turn, is a function of the internal pressure in ball 20 . A fresh ball, having an internal pressure established at the time of manufacture, will provide the greatest deflection of indicator arm 110 . Over the life span of the ball, the pressure decreases and the amount of deflection is correspondingly less. At some point, the pressure decreases to an extent that the ball is no longer considered playable. The playing condition of ball 20 is thus ascertained by the deflection of indicator arm 110 as seen by the position of indicator tip 112 viewed through the transparent wall of canister 102 . The wall of canister 102 may be provided with a scale or other indicia by which the deflection of indicator arm 110 may be measured. The scale may provide a quantitative measure of ball condition or may simply provide a pass/fail indication. In one embodiment, canister 102 may be provided with a frosted ring or band surrounding support means 104 . The frosted band may extend down the side of canister 102 far enough to obscure indicator tip 112 in all positions except when deflected by a ball in playable condition. Thus, when a ball is tested, the appearance of indicator tip 112 below the frosted band provides an indication that the ball is in playable condition.
An individual ball 20 may be easily tested for playing condition as described above. The invention also facilitates rapid testing of a plurality of balls, such as may be required, for example, by a pro shop. This is easily accomplished by placing the balls to be tested on a flat surface, such as a tabletop. Canister 102 , with ball-testing disk 106 installed, is then simply pressed down on each of the balls in succession. The playing condition of the ball is observed with indicator tip 112 and the ball may then be kept or discarded in accordance with its indicated playing condition. Pressure on the canister may be released to roll the ball around on the supporting surface to bring the point 111 of disk 106 into contact with the ball at multiple locations on the surface of the ball. Thus, a ball may be tested at the multiple locations to determine an “average” playing condition. This also allows the ball to be tested at an optimum location, such as on a seam. Optionally, the sport balls may be provided with a marking, either at the time of manufacture or subsequently, to indicate a test location so as to enhance repeatability of the test.
It will be recognized that the above-described invention may be embodied in other specific forms without departing from the spirit or essential characteristics of the disclosure. Thus, it is understood that the invention is not to be limited by the foregoing illustrative details, but rather is to be defined by the appended claims.
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A container for storing sport balls incorporates a device for testing the playing condition of the balls. The test device is in the form of a disk with a base portion supported within the container and an indicator arm. A ball to be tested is placed into the container where it rests on the indicator arm with a portion of the ball protruding out of the open end of the container. The exposed portion of the ball is pressed against a flat surface. This deflects the indicator arm and provides a visual indication of the playing condition of the ball.
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BACKGROUND OF THE INVENTION
Maintaining the well being of the GI tract of a mammal is a very desirable goal. Particularly relevant are inflammatory conditions of the GI tract. The Desulfovibrio spp. bacteria (including but not limited to desulfuricans, intestinalis, vulgaris etc.) are sulfate reducing bacteria that produce hydrogen sulfide which when released by the bacteria, can cause inflammation cells of the GI tract. Helicobacter bacteria (including but not limited to heilmannii, felix, pylori, bizzozeronii, salomonis ) can cause ulcerations and inflammation of the cells of the stomach and upper intestines. Some signs of inflammation of the GI tract include acute or chronic diarrhea, soft stools, blood in stool, vomiting, poor nutrient digestion and absorption, weight loss and poor appetite. Diseases such as gastritis, enteritis, inflammatory bowel disease, ulcers, some types of cancer and others are known to have GI inflammation as a main component. Pathogenic bacteria such as Desulfovibrio spp., which reduce sulfate to sulfide, can also cause an increase in gas or stool odor due to increased levels of sulfide or other odiferous compounds in the stool.
We have now found that cats with inflammatory bowel disease (IBD) have a higher number of Desulfovibrio and/or Helicobacter spp. than normal, healthy cats. We have also found that Helicobacter was detectable in all cats with inflammatory bowel disease (IBD) whereas only 5/12 normal cats treated had detectable levels of helicobacter. We have also found that 45% of tested IBD cats had levels of bifidobacteria, a beneficial bacterial group, below standard detection levels, while 9% of normal, healthy cats had bifcdofacteria below standard detection levels.
SUMMARY OF THE INVENTION
In accordance with the invention, there is an orally edible food composition for use by a companion animal comprising an edible food composition in combination with a component which reduces the levels of Desulfovibrio and/or Helicobacter spp. in the companion animal.
A further aspect of the invention is a method for reducing the level of Desulfovibrio and/or Helicobacter spp. in a companion pet which comprises orally administering the food of the invention.
DETAILED DESCRIPTION OF THE INVENTION
As stated previously, it has now been discovered that Desulfovibrio spp. are higher in cats with a GI tract inflammation disorder, IBD, than normal cats not having this disorder. Therefore, it would be beneficial to any companion pet having a higher level of Desulfovibrio and/or Helicobacter spp. with or without overt clinical signs of a disease or disorder generally accompanied by GI tract inflammation to have their levels reduced. Benefits can also be derived from preventing Desulfovibrio and/or Helicobacter spp. from rising, that is a preventive effect.
The bacteria can be reduced by active agents. These include antibacterial materials such as antibiotics, chemotherapeutics and the like. Surprisingly, fibers can also reduce levels of Desulfovibrio and/or Helicobacter spp. as well. Examples of such fibers include an oligosaccharide, a galactan, a beta glucan and mixtures thereof. Examples of oliosaccharides include xylooligosaccharide, galactooligosaccharide, fructooligosacharide and the like. Examples of a beta glucan include yeast cell extract, sprouted barley, oat fiber, curdlan (polysaccharide from microbial fermentation), and the like. Examples of galactans include arabinogalactan, and the like. Preferably a polyphenol(s) can also be present with the active agent, particularly where the active agent is a fiber, and more particularly where the fiber is a galactan such as arabinogalactan. The polyphenol is generally of a structure having at least two phenols and more preferably is a flavonoid such as a taxifolin. Minimum quantities of the polyphenol in the composition are a minimum of about 0.01, 0.05 or 0.1 wt % as measured on a companion pet's daily diet. The maximum generally does not exceed about 2, 1, or 0.75 wt % as measured on a companion pet's daily diet, all weights dry matter basis.
An anti Desulfovibrio and/or Helicobacter spp. effective amount of component can be employed. An antibacterial agent such as an antibiotic or chemotherapeutic agent can be provided orally to the pet at a minimum of about 2 & 5 mg/kg of body weight. Maximums are generally no more than about 25, 50 mg/kg of body weight. With respect to a fiber, the minimum is about 0.1, 0.5, or 1.0 wt % and the maximum generally should not exceed about 5, 10, or 20 wt % as measured on a companion pet's daily diet, dry matter basis.
Desulfovibrio and/or Helicobacter spp. reduction can be effective in helping to manage diseases and conditions in a companion pet wherein GI tract inflammation is a main component. Examples of companions pets are dogs, cats, horses, and the like.
EXAMPLE
Showing Presence of Increased Level of Pathogenic Bacteria in IBD Cats
1. Protocol for Screening of Fecal Samples from Cats:
Fecal samples were collected from normal healthy cats and those cats diagnosed with IBD. The normal cats were maintained on Science Diet® Feline maintenance® dry while the cats with IBD were maintained on a therapeutic gastrointestinal diet. The fecal samples were frozen at −70° C. prior to analysis. For analysis, samples were mixed with phosphate buffer saline to a ratio of 1:10 (w/w), vortexed with glass beads and centrifuged to remove particulate matter. An aliquot of 375 μl sample was added to a tube containing 1.125 ml of 4% paraformaldehyde and left at 4° C. for 4–5 hours. The samples were centrifuged and washed twice in PBS, then mixed with 150 μl of filtered ethanol and stored at −20° C. prior to fluorescent in situ hybridization analysis (FISH for microbial enumeration). Genus specific 16S rRNA-targeted probes were synthesized and monolabelled at the 5′ end with fluorescent dye to detect the bacteria of interest in the fermentation media. Total nucleic acid was stained to obtain the total cell counts. The data are expressed as log 10 cells/g feces. FISH allows bacerial quantification of stored samples and includes both culturable and non-culturable diversity.
Results
TABLE 1
Log 10 of colony forming units of pathogenic bacteria in normal and
IBD cats
Normal
IBD
Desulfovibrio
cfu/g
7.0 ± 2.5
7.7 ± 0.6
feces
Helicobacter
cfu/g
2.9 ± 3.6
7.3 ± 0.6
feces
These results show that cats with GI tract inflammation, specifically IBD, had an increased quantity of pathogenic bacteria present in the GI tract.
EXAMPLE 2
Invivo Effect of AG on Desulfovibrio in IBD and Normal Cats
2. Protocol for Feeding Study
Eleven (11) cats with IBD and 10 normal healthy cats were fed foods containing 1.0% beetpulp with 0.6% arabinogalactan extract from the Western larch tree. The extract was approximately 90 wt % arabino galactan and about 4 wt % polyphenols, the predominant polyphenol being taxifolin, the remainder being moisture, all on a dry matter basis for two weeks. Following this, the cats were switched to food containing 1.5% beetpulp alone. Fecal samples were collected on days 0, day 14 and day 28. The samples were prepared as follows for FISH analysis: To freeze each fecal sample, 5 g of feces was suspended in anaerobic phosphate buffered saline (PBS) at pH7.3 in a sterile bag or plastic container to give a final concentration of 10% (45 ml for 5 g). The slurry was homogenized/mixed in the bag to avoid contamination. A different container was used for each sample. 5 ml of the slurry was mixed with an equal amount of glycerol to give a 50:50 mix which was frozen for analysis by FISH.
Results:
Thirteen (13) complete sets of fecal samples were obtained. When the cats were on food containing 0.6% AG extract, 4/13 cats had decreased Desulfovibiro spp. of 0.3 log units and above. 8/13 cats had small decreases or no change in the levels of Desulfovibrio spp. while only 1/13 cats had an increase in Desulfovibrio spp. When the cats were switched to food without AG, 10/13 cats had increased levels of Desulfovibrio spp. of 0.3 log units and above, 2/13 cats had no change and only 1/13 cats had decreased levels of Desulfovibrio spp.
The results show that AG extract was able to prevent an increase in Desulfovibrio spp. in most of the cats and tended to decrease in some of the cats. This was at the level that was fed compared to beetpulp, which tended to cause an increase in Desulfovibrio spp. in most of the cats.
EXAMPLE 3
In Vitro Experiment Showing that Various Fibers Decreased Levels of Desulfovibrio spp.
Fermentation vessels containing anaerobic phosphate buffered medium were prepared and 1 ml canine fecal inoculum (10% w/v fecal sample to buffer) added. The composition of the media was as described in Sunvold G D, Hussein H S, Fahey G C, Merchen N R, and Reinhart G A (1995), In vitro fermentation of selected fiber sources by dogs fecal inoculum and in vivo digestion and metabolism of fiber supplemental diets. J. Animal Sci. 73:1099–1109 (1995). Fermentations were carried out at 39° C. Experiments were conducted in a blind-coded manner with different fibers. After 8 hours incubation, 1 ml culture fluid was removed. An aliquot of this was prepared for FISH. After 8 hours, 1 ml of culture fluid was removed and mixed with 4% paraformaldehyde in PBS and fixed for FISH. Genus specific 16SrRNA-targeted probes were synthesized and monolabelled at the 5″ end with fluorescent dye to detect bacteria of interest in the fermentation media. Total nucleic acid was stained to obtain total microbial counts. The results showed that several different types of fibers were able to decrease the growth of Desulfovibrio spp. by 0.5 to 1.0 log units during the 8 hour fermentation (see Table 2).
TABLE 2
Numbers of Desulfovibrio spp. after 8 hour incubation
(log cfu/ml of fecal inoculum).
Log 10 CFU AT 0
LOG 10 CFU AT 8
HOUR
HOUR
Arabinogalactan
7.5 ± 0.3
6.4 ± 1.0
Xylooligosaccharide
7.2 ± 0.4
6.8 ± 0.9
Galacto-oligosaccharide
7.0 ± 1.0
6.8 ± 0.9
Fructooligosaccharide
6.9 ± 1.0
6.3 ± 0.8
Inulin
7.3 ± 0.2
6.4 ± 1.0
Sprouted barley
6.8 ± 0.9
5.8 ± 0.0
SUMMARY
Therefore, we have shown both in vitro and in vivo that AG decreased the level of Desulfovibrio spp.
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A method for reducing the quantity of Desulfovibrio and/or Helicobacter spp. in the GI tract of a companion pet which comprises orally administering to the said pet a Desulfovibrio and/or Helicobacter spp. reducing quantity of a fiber or other component.
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This application is a continuation of application Ser. No. 094,733 filed Aug. 18, 1987 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to skid-steering vehicles such as tractors and military tanks where the vehicle is driven by two ground engaging members which may be two tracks or two sets of wheels, placed on each side of the vehicle, and steered by an imposed difference in speeds of the tracks or sets of wheels.
The present invention provides a transmission consisting of prime movers, hydraulic pumps, hydraulic motors, associated circuitry and a gear box that provides new capabilities in such skid-steering vehicles both in improved high speed performance and in improved vehicle lay-out and control characteristics while still meeting necessary space and weight criteria.
Many low speed tractors and the like have separate hydraulic motors driving each track through gearing to provide both steering and traction. However, they are inherently limited in speed, for any reasonable input power, because steering requires that the tracks or sets of wheels be skidded at any speed, and the power needed to skid the tracks or sets of wheels is excessive at high vehicle speeds.
High speed skid-steer vehicles, such as those used for military applications, overcome this problem by using differential epicyclic gearing `superposed` on the drive train to each track or set of wheels with one element of each such differential being independently driven by, commonly, a hydraulic motor to provide steering. Usually the input drive is connected to the annulus gear of both differential epicyclic gear sets, while the output to the tracks or sets of wheels is connected to the planet frame, the steering input being connected to the sun gear.
During turning at speed, the required torque difference is generated to skid the tracks or sets of wheels, with the turning power, often many times the drive power, being almost entirely transmitted directly from the inside track or set of wheels to the outside track or set of wheels through the superposed gears, the drive transmission continuing only to transmit drive power from the prime mover.
Typically, such a transmission would consist of a mechanical, hydrokinetic-mechanical or hydrostatic-mechanical transmission connecting the prime mover to both annuli for traction purposes. The prime mover also drives a hydraulic pump which in turn drives a hydraulic motor driving the two sun gears, through gearing in opposite directions. If the motor is held stationary, the track or wheel set speeds will be equal and the vehicle will tend to travel in a straight line. If the motor is rotated, a speed difference will be superimposed on the tracks or sets of wheels causing the vehicle to turn.
Another variety of turn control described in the patent literature, but to the inventor's knowledge not used in practice, attaches a hydraulic pump/motor to one element of each of the superposed epicyclic gears, without an engine driven pump, thus providing a torque and speed ratio between these elements. Such an arrangement would not provide the same ease of control as the more common system described in the previous paragraph.
These basic drive and steering systems, with many detailed variations are described in many patents, the most relevant to the present invention are:
__________________________________________________________________________U.S Pat. No. 1,984,830 Higley U.S Pat. No. 2,336,911 ZimmermannU.S Pat. No. 2,377,354 Merritt U.S Pat. No. 2,518,578 TomlinsonU.S Pat. No. 2,730,182 Sloane U.S Pat. No. 2,874,591 ThomaU.S Pat. No. 3,081,647 Blenke U.S Pat. No. 3,177,964 AndersonU.S Pat. No. 3,199,286 Anderson U.S Pat. No. 3,349,860 RossU.S Pat. No. 3,461,744 Booth U.S Pat. No. 3,590,658 TuckU.S Pat. No. 3,815,698 Bradley U.S Pat. No. 4,174,762 HopkinsU.S Pat. No. 4,393,952 Schreiner GB 941,735GB 945,425 GB 2,084,702__________________________________________________________________________
SUMMARY AND GENERAL DESCRIPTION OF THE INVENTION
This invention can be applied to provide a high speed drive and steer system with all the power being transmitted hydraulically. All-hydraulic power is known for low speed drives without a superposing gear system, and split hydrostatic-mechanical drives are known for high speed drives, with full hydraulic steering. However, until now, full hydraulic drives were always too heavy and bulky to be competitive with mechanical, hydrokinetic-mechanical or hydrostatic-mechanical drives.
For example, taking a transmission suitable for a 18,000 kg high speed military vehicle, the complete hydraulic system weight (not including the superimposing gearing) using a conventional drive system with drive pump and motor and separate steer pump and motor is estimated as being 740 kg. On the other hand, a transmission according to the invention would have a hydraulic system estimated weight of only 440 kg; providing a 40% weight saving with a corresponding reduction in size.
A full hydraulic drive as provided by the invention allows great flexibility as to the vehicle arrangement as the prime mover can be positioned anywhere in the vehicle and simply connected to the final drive with conduits. It will be shown that the invention allows the vehicle to be driven by a number of prime movers, which can be of different types, situated wherever convenient in, or indeed external to, the vehicle.
The prime movers are typically diesel engines, but can be gasoline engines, gas or steam turbines, electric motors or any other known kind of similar device. Inherent in the use of a full hydraulic drive is the smooth stepless change of drive ratio to suit speed and traction requirements, as compared with the step changes that occur with any geared transmission.
The invention uses a superposing gearbox that allows for two identical inputs, as against a single power input with a separate steering input. The characterizing property of such gearing is that it provides a drive ratio such that the sum of the two outputs is proportional to the sum of the inputs, and a steering ratio such that the difference of the outputs is a proportion of the difference of the inputs. The two ratios can be separately adjusted by selection of the internal gearing ratios.
Thus, it both inputs have the same speed, both outputs will have the same speed. If the inputs are at different speeds, the outputs will also be at different speeds, but conforming to the equations set out below.
DEFINITIONS
DRATIO=(LIN+RIN)/(LON+RON)
SRATIO=(LIN-RIN)/(LON-RON)
THEN
LIN=((LON+RON) *DRATIO+(LON-RON) *SRATIO)/2
RIN=((RON+LON) *DRATIO+(RON-LON) *SRATIO)/2
LOT=((LIT+RIT) *DRATIO+(LIT-RIT) *SRATIO)/2
ROT=((RIT+LIT) *DRATIO+(RIT-LIT) *SRATIO)/2
WHERE
DRATIO=DRIVE RATIO
SRATIO=STEER RATIO
LIN, RIN=LEFT, RIGHT INPUT SPEEDS
LON, RON=LEFT, RIGHT OUTPUT SPEEDS
LOT, ROT=LEFT, RIGHT OUTPUT TORQUES
LIT,LOT=LEFT, RIGHT INPUT TORQUES
(TORQUE CALCULATIONS ASSUME 100% EFFICIENCY)
Such a gearbox can be made by combining, in various ways, two or more differential gear sets. The term `differential gear` is taken to include all forms of gear assemblies that provide a differential action between three elements, such that the speed of any one element is dependent on the speed of the other two. One example is the differential commonly used in the axles of automobiles. In this case the differential casing, on which the crown wheel is mounted, is one element with the two bevel gears connected to the axles being the other two elements. A second example is an epicyclic gear set where the sun gear, the annulus gear and the planet frame represent the three differential elements. There are other forms of differential gearing known to those skilled in the art.
The simplest of these gear boxes, and claimed to be novel by the inventor, uses only two differential gear sets, as shown in one preferred embodiment, using differentials of the epicyclic type, as a diagram on FIG. 1, which is described below. Other embodiments either interconnect other elements of the epicyclics, with internal ratios adjusted to suit, or use other forms of differential gearing.
The invention thus consists in a transmission for a skid-steering vehicle having two ground engaging members, the gearbox consisting of a first input receiving member and a second similar input receiving member internal gearing connecting said input receiving members respectively to a first output member and a second output member through which said ground engaging members are driven, the internal gearing being arranged and constructed so that the sum of rotational speeds of said output member is proportional to the sum of the rotational speeds of said input members and the differece between the rotational speeds of said output members is proportional to the difference in rotational speeds of said input members characterized in that the internal gearing consists of two only differential gearing sets each comprising three elements with interconnections between two of the elements of one said differential set with two of the elements of said second differential set.
The invention further consists in a transmission for a skid steering vehicle having two ground engaging members including a gearbox having two output members through which said ground engaging members are driven and two input members, the gearbox being constructed and arranged so that the sum of the rotational speeds of the output members is proportional to the sum of the rotational speeds of the input members and the difference between the rotational speeds of the output members is proportional to the difference between the rotational speeds of the input members characterized in that the input members are each driven by a hydraulic motor.
DETAILED DESCRIPTION OF THE INVENTION
In order that the invention may be better understood and put into practice a preferred form thereof is hereinafter described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 illustrates diagrammatically a gearbox for use in a transmission according to the invention;
FIG. 2 shows diagrammatically a transmission according to the invention;
FIG. 3 is a diagrammatic plan view of a vehicle incorporating a transmission according to the invention and
FIG. 4 shows diagrammatically a transmission according to this invention which employs variable displacement motors.
Referring to FIG. 1, the input receiving members or gears 1a,1b act as the sun gears of the differentials and drive the planet gears 5a,5b. These planet gears are mounted in planet frames 4a,4b and also mesh with the annulus gears 6a,6b. The planet frames 4a, 4b also carry gears 3a,3b which drive the output receiving member or shafts 2a,2b. The annulus gear 6a is torsionally connected to the planet frame 4b by connecting member 7. Similarly the annulus 6b is torsionally connected to planet frame 4a by connecting member 8, thus the two elements of one differential are connected to two elements of the other.
If the sun gears on the input shafts have N1 teeth, the epicyclic annulus gears N2 teeth, the gears 3a,3b N3 teeth, and the gears on the output shaft have N4 teeth, then the characteristic ratios of the gearbox can be calculated as follows:
DRIVE RATIO=N4/N3
STEER RATIO=N3 (2(N2/N1)+1)/N4
FIG. 2 shows a diagram of a preferred embodiment of the transmission according to the invention. This diagram only shows the main features of the transmission and many details, as used by a designer skilled in the art, are omitted for the sake of clarity.
A prime mover 11 drives a main transmission hydraulic pump 12 and an auxiliary pump 13. The auxiliary pump draws fluid from reservoir 14 and delivers fluid through filter 15 to fan motor 16 and then through cooler 17. The fluid then enters the low pressure side of the main power loop, pressurizing the low pressure side of the loop to a pressure set by relief valve 18, which discharges back to the reservoir 14.
The main pump pumps draws fluid from the low pressure side of the loop and pumps it as high pressure fluid through the reversing valves 21a, 21b to the drive motors 19a, 19b. The fluid then returns, again through the reversing valves, to the inlet of the pump.
The pressure in the main loop is limited by the relief valves 22, 23. Relief valve 23 also acts to limit the pressure on the fan motor 16 because of the conduit 24. When relief valve 22 is bypassing flow, some or all of its discharge may pass down conduit 24 to the fan motor and cause it to rotate at greater speed.
The two motors 19a,19b drive the gearbox 20 with output shafts 20a,20b. This gearbox may be of the type shown in FIG. 1.
The motors are variable displacement, controlled preferably by a microprocessor based hydro-electronic control system, not shown, although other control means, such as hydro-mechanical, may be used. The control system senses the demand drive and steering commands and adjusts the displacement of the motors together to provide the necessary output drive torque characteristic, and differentially to provide the necessary steering characteristic.
Because varying the motor displacements varies the output torque of the motors, and does not directly vary their speed, a closed loop control system is required to adjust automatically the displacements, and thus the torques, to provide the demand difference in speed required for turning. For this reason, the control complexity is greater than would be provided if each motor were to be of fixed displacement and each driven by a separate pump. However, with the availability of microprocessors, control complexity is of less importance than in previous times, and a number of advantages accrue from the use of a single pump.
Firstly, the number of components is obviously reduced.
Secondly, because, during turning, all power may have to go to one motor, each pump would have to be substantially the same size as the single pump, with increases in size and weight if two pumps are used.
Thirdly, only two main conduits are required if a single pump is used. This not only reduces the piping complexity, but is a considerable advantage if more than one prime mover is used.
In any event, the use of variable displacement motors 119a, 119b, as can be seen in FIG. 4, allows a much wider speed range in the hydraulic transmission as variable motors typically have an increased speed capability of up to 50% at reduced displacement, as compared with a fixed displacement motor.
Conventional wisdom would teach the use of over-centre motors so that the torque on one side can be reversed for tight turns by swinging that motor over-centre into reverse.
(The term `over-centre` describes the capability of some designs of hydraulic pumps and motors to have their displacement varied from a maximum value through zero to a negative maximum value, such negative value usually having the same magnitude as the positive maximum value. In a swash-plate design this is achieved by swinging the swash plate from its maximum forward angle, through to zero and then further `over-centre` to its maximum reverse angle. The effect in a pump is to reverse the direction of flow through the pump, while in a motor the direction of output rotation is reversed. Other designs of pumps and motors do not have this capability and are designated as one-side-of-centre units.)
The following is a table of the manufacturers and the locations thereof of typical units for the above-described `over-centre` and `one-side-of-centre` pumps and motors:
______________________________________Manufacturer Location Model Number______________________________________1. Sundstand Iowa, U.S.A. Series PV252. Abex Denison Ohio, U.S.A. Series 83. Volvo Troll Hattan, Sweden V11-110 or V30D4. Ifield Engineering Sydney, Australia V150 Pty. Ltd.______________________________________
However, in a preferred form of the invention separate reversing valves 21a, 21b on each motor are used for the following reasons.
Firstly, this allows the use of motors that only swing one side of centre. Such motors are inherently more compact and are usually more efficient as the bent axis type of motor can be more readily used. In addition, it is known that such motors can be configured so that the clearance volume is held substantially constant over the displacement range by pivotting the axis off-centre (see Ifield U.S. Pat. No. 4,129,063).
Secondly, the reversing valves can be operated much more quickly than a motor can be swung over-centre which is important when a sudden turn is required. The transition from drive to over-run while turning also requires a sudden change in torque direction. Additionally, the ability to suddenly apply hydraulic braking is an advantage.
Thirdly, conventional wisdom would teach the use of an over-centre pump for reverse drive. However, the reversing valves allow a pump of one-side-of-centre design to be used as reverse can be achieved by operating both valves simultaneously. As already described for the motors, such a pump can be much more compact and can be more efficient than an over-centre pump.
Fourthly, if braking and reverse is to be provided by operating the reversing valves, only one of the main conduits 25 need ever be at high pressure. The other conduit 26 can be at low pressure under all circumstances. This allows for one conduit of lighter construction and considerably simplifies the overall hydraulic circuitry as the boost inlet and discharge valves normally needed for over-centre operation are not required.
Braking is then done against the braking relief valve 22, which is shown as electrically controlled. Operation of the brake pedal will, perhaps through the microprocessor control system, cause an increasing signal with increasing pedal depression. Such control could also be provided mechanically or hydraulically.
It should be understood that, because the pump is not capable of over-centre operation and because only one conduit is ever pressurized, the braking energy cannot be absorbed by over-running the engine. All the hydraulic braking energy passes into the working fluid across the relief valve 22. This would cause overheating of the fluid so it is necessary to increase the fan speed and the flow through the cooler.
This could be done by increasing the engine speed with the microprocessor controller, but can also be achieved automatically with the circuitry shown on FIG. 2. As long as fluid is passing through relief valve 22, it is available to increase the speed of the fan motor 16 and then passes through the cooler 17, up to a pressure limited by relief valve 23.
The embodiment of the invention shown on FIG. 2 thus provides for full hydraulic drive using compact and efficient pumps and motors, with minimum circuitry and pipework, and provides for rapid steering and braking response.
FIG. 3 shows a diagrammatic plan view of a typical military armoured personnel carrier, with the roof removed, with the transmission according to the invention using two diesel engines as prime movers. It is seen that the prime movers 31a, 31b fit into the rear corners of the vehicle, above the tracks 32a, 32b, in a space that otherwise has limited utility.
Hydraulic pumps 33a, 33b are mounted on each engine and connected through conduits (not shown) to the two hydraulic motors 34a, 34b. According to the invention both pumps are connected to both motors in parallel.
The two hydraulic motors are mounted on the gearbox 35, mounted at the front of the vehicle, which drives the track sprockets 36a, 36b through final reduction gearing 37a, 37b.
A conventional arrangement with one engine and mechanical power transmission requires that the engine and complete transmission be at the front of the vehicle and takes up considerable valuable floor space. This space is shown as outline 38. The weight distribution of the vehicle is also adversely effected with a degradation in vehicle performance, particularly when braking or when on water.
The dual engine scheme, according to the invention, also allows operation, at half power, on one engine only, still with full tractive force capability. This means that both engines have to fail before the vehicle is immobilized. The vehicle is quieter with only one engine operating which can be an advantage under ambuscade conditions. The two smaller engines can fall more readily into the mass production range of engines, with a result that the two engines can be cheaper than one large one. Also, in times of conflict, it would be possible to use any number of high production gasoline engines as is necessary to provide the required vehicle performance.
While the invention has been particularly shown and described in reference to preferred embodiments thereof, it will be understood by those skilled in the art that changes in form and details may be made therein without departing from the spirit and scope of the invention.
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A transmission for a skid-steering vehicle having two tracks or two sets of wheels in which power is transferred from one or more prime movers to the tracks or wheels through a gearbox is proportional to the sum of the input speeds and the difference between the output speeds is proportional to the difference between the input speeds, the internal gearing of the gearbox consisting of two only differential gearing sets each comprising three elements within connections between two of the elements of one of the differential set with two of the elements of the other differential set. A fully hydraulic drive is preferably provided between the prime mover and hydraulic motors driving the gearbox.
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TECHNICAL FIELD
[0001] The present invention is in the field of dishwashing, in particular it relates to dishwashing methods including methods for washing dishware/tableware in an automatic dishwashing machine using dishwashing products in multi-compartment pouch form. The methods of the invention provide excellent cleaning results.
BACKGROUND OF THE INVENTION
[0002] Unitised doses of dishwashing detergents are found to be more attractive and convenient to some consumers because they avoid the need of the consumer to measure the product thereby giving rise to a more precise dosing and avoiding wasteful overdosing or underdosing. For this reason automatic dishwashing detergent products in tablet form have become very popular. Detergent products in pouch form are also known in the art.
[0003] It is well known to use bleach in dishwashing detergent formulations in order to remove stains, especially tea, coffee, fruit juice and carotenoid stains. Chlorine and peroxygen bleaches are effective for stain removal. While chlorine bleach is a very effective cleaning agent, it is not compatible with a variety of detergent ingredients and may require additional processing in order to be incorporated into a final product. Peroxide bleaches on the other hand are more compatible with conventional detergent ingredients. However, one of the problems found when formulating peroxygen containing dishwashing detergent compositions is the fact that the bleach is liable to decompose in contact with moisture, thereby reducing the amount of active bleach available for the dishwashing process. Once the decomposition process is initiated, moreover, decomposition is auto catalysed by the presence of free radicals generated by the decomposition process. The products of bleach decomposition can also oxidise detergency enzymes, thereby reducing the amount of enzyme available for the dishwashing process.
[0004] In the case of flexible unitised doses such as pouches, capsules or sachets which are moisture permeable, bleach decomposition gives rise to an additional problem due to the generation of gaseous oxygen. Usually the pouch material is not permeable to oxygen and this can lead to bloating or even destruction of the pouch and to a detrimental effect on appearance and on dispenser fit.
[0005] Some detergent ingredients used in dishwashing detergent compositions are liquids. These liquid ingredients can be difficult or costly to include in a solid detergent composition. Also, certain ingredients are preferably transported and supplied to detergent manufacturers in a liquid form and require additional, and sometimes costly, process steps to enable them to be included in a solid detergent composition. An example of these detergent ingredients are surfactants, especially nonionic surfactants which are typically liquid at room temperature or are typically transported and supplied to detergent manufacturers in liquid form. Another example are organic solvents.
[0006] Current methods of incorporating liquid ingredients into solid detergent compositions include absorbing the liquid ingredient onto a solid carrier, for example by mixing, agglomeration or spray-on techniques. Typically, solid detergent compositions comprise only low amounts of these liquid detergent ingredients due to the difficulty and expense of incorporating these liquid ingredients into a solid detergent. The problems are particularly acute in the case of solid compositions which are subject to a densification step and especially to the levels of densification applied in machine dishwashing tablet manufacture. Furthermore, the incorporation of liquid ingredients into solid detergent compositions can impact on the dissolution characteristics of the composition (for example as the result of forming surfactant gel phases) and can also lead to problems of flowability. It would be advantageous to have a detergent composition which allows the different ingredients to be in their natural state i.e., liquid or solid. This would facilitate the manufacturing process and furthermore allow the delivery of liquid ingredients prior or post to the delivery of solid ingredients. For example differential dissolution of active ingredients would be beneficial in the case of enzyme/bleach compositions to avoid oxidation of enzymes by the bleach in the dishwashing liquor. It would also be advantageous to separate bleach from perfume.
[0007] An objective of the present invention is to provide dishwashing methods and products delivering improved cleaning performance and product stability. Another object is to provide dishwashing methods and products which have simplified processing, which allow for the problems of product incompatibility and which are capable of providing differential dissolution of active components.
SUMMARY OF THE INVENTION
[0008] According to a first aspect of the present invention, there is provided a method of washing dishware/tableware in an automatic dishwashing machine, the method comprising simultaneously or sequentially delivering quantities of a particulate or densified particulate automatic dishwashing product and of an anhydrous liquid, gel or paste form dishwashing detergent auxiliary contained in separate compartments of a multi-compartment pouch into the same or different cycles of the dishwashing machine.
[0009] Suitable multi-compartment pouches (which term includes capsules, sachets and other compartmentalized unit dose containers) for use herein include water-soluble, water-dispersible and water-permeable pouches. Preferred for use herein are water soluble pouches, based on partially hydrolysed polyvinylacetate/polyvinyl alcohol as pouch material. Although, soluble in water, these pouches have the disadvantage that they are permeable to moisture.
[0010] The term anhydrous as used herein is intended to include compositions containing less than about 10% of water by weight of the composition, preferably less than about 5% of water and more preferably less than about 1%. The water can be present in the form of hydrated compounds, i.e. bound water or in the form of moisture. It is preferred that the composition contains less than about 1%, preferably less than about 0.1% free moisture. Free moisture can be measured by extracting 2 g of the product into 50 ml of dry methanol at room temperature for 20 minutes and then analysis a 1 ml aliquot of the methanol by Karl Fischer titration. The term water-soluble as used to describe the pouch means that the pouch or a compartment thereof dissolves or disperses in water to release some or all of the contents thereof at some temperature or range of temperatures in the normal operating range of a dishwashing machine (ambient to 70° C.). Under other temperatures or conditions of use, however, the pouch or compartment thereof may be insoluble in water, remaining intact for extended periods greater than that of the normal operating regime of the dishwashing machine.
[0011] In a preferred embodiment the particulate dishwashing product is densified. Densification can be achieved by compaction, compression, tamping, tapping, stamping, vibrating, subjecting to inertial forces, etc, densification being preferably such as to provide a bulk density increase of at least about 10%, preferably at least about 20%, more preferably at least about 30%. The final bulk density is preferably at least about 0.6 g/cc, more preferably at least about 0.8 g/cc, especially at least about 1 g/cc, and more especially at least about 1.3 g/cc.
[0012] In a preferred embodiment, the densified particulate dishwashing product is in the form of a tablet. Multi-compartment pouches comprising a tablet and an anhydrous liquid, gel or paste present the known advantages of tablets, such as high product density, minimum storage volume requirements and efficient packing, but they also allow for the simultaneous or sequential release of a liquid, gel or paste in quantities which it would be impossible to achieve through normal tabletting techniques. A further advantage of said pouches is that the user does not touch or come into direct contact with the tablet and the remainder of the automatic dishwashing composition.
[0013] From the manufacturing viewpoint, multi-compartment pouches comprising a particulate automatic dishwashing product in the form of a tablet are very convenient because the filling of pouches with particulate product can be complex and prone to inaccuracies. It is often slow and likely to produce dust, such that it can be very difficult to avoid dust deposition on the pouch seal area. This can be detrimental to achieving a strong seal.
[0014] The tablet can be formed using any suitable method, but preferably by compression, for example in a tablet press. Preferably, the tablet is a compressed shaped body prepared by mixing together the components of the automatic dishwashing detergent followed by applying a compression pressure of at least about 40 kg/cm 2 , preferably at least about 250 kg/cm 2 , more preferably at least about 350 kg/cm 2 (3.43 kN/cm 2 ), even more preferably from about 400 to about 2000, and especially from about 600 to about 1200 kg/cm 2 (compression pressure herein is the applied force divided by the cross-sectional area of the tablet in a plane transverse to the applied force—in effect, the transverse cross-sectional area of the die of the rotary press). Such tablets being preferred herein from the viewpoint of providing optimum tablet integrity and strength (measured for example by the Child Bite Strength [CBS] test) and product dissolution characteristics. The tablets preferably have a CBS of at least about 6 kg, preferably greater than about 8 kg, more preferably greater than about 10 kg, especially greater than about 12 kg, and more especially greater than about 14 kg, CBS being measured per the US Consumer Product Safety Commission Test Specification.
[0015] The tablet can take a variety of geometric shapes such as spheres, cubes, etc but preferably has a generally axially-symmetric form with a generally round, square or rectangular cross-section.
[0016] The tablet can be prepared such that it comprises at least one mould in its surface. The mould or moulds can also vary in size and shape and in their location, orientation and topology relative to the tablet. For example, the mould or moulds can be generally circular, square or oval in cross-section; they can form an internally-closed cavity, depresion or recess in the surface of the tablet, or they can extend between unconnected regions of the tablet surface (for example axially-opposed facing surfaces) to form one or more topological ‘holes’ in the tablet; and they can be axially or otherwise symmetrically-disposed relative to the tablet or they can be asymmetrically disposed. Preferably, the mould is preformed, for example being created using a specially designed tablet press wherein the surface of the punch that contacts the detergent composition is shaped such that when it contacts and presses the detergent composition it presses a mould, or multiple moulds into the detergent tablet. Preferably, the mould will have an inwardly concave or generally concave surface to provide improved housing and physical storage of the liquid, gel or paste containing compartment. Alternatively, the mould can be created by compressing a preformed body of detergent composition disposed annularly around a central dye, thereby forming a shaped body having a mould in the form of a cavity extending axially between opposing surfaces of the body. Tablets with moulds are very useful from the viewpoint of accommodating the compartment comprising the anhydrous liquid, gel or paste dishwashing detergent auxiliary of the present invention.
[0017] According to a preferred embodiment of the present invention, the particulate dishwashing product comprises one or more moisture-sensitive detergent actives and the detergent auxiliary comprises a humectant in levels sufficient to act as a moisture sink for stabilising the moisture-sensitive detergent active. A detergent active is considered to be moisture-sensitive when it can interact with moisture to decrease its detergency activity as for example detergency bleach. Particulate bleaches suitable for use herein include inorganic peroxides inclusive of perborates and percarbonates, organic peracids inclusive of preformed monoperoxy carboxylic acids, such as phthaloyl amido peroxy hexanoic acid and di-acyl peroxides. Preferred peroxides for use herein are percarbonate and perborate bleach.
[0018] Humectant is a substance which can pick up or emit moisture to the surroundings depending on the surrounding relative humidity. When formulated as part of the detergent auxiliary, the humectants used herein are capable of acting as moisture sink for the powder layer. This stabilises the moisture-sensitive detergent active. The humectants should have a humidity equilibrium point such as to enable them to act as moisture sink but preferably they should take up less than about 10%, more preferably less than about 5% even more preferably less than about 1% of water at a relative humidity of 50% or less, preferably at relative humidity of 75% or less, and more preferably at relative humidity of 90% or less under ambient conditions of temperature and pressure (20° C. and 1 atmosphere). Humectants suitable for use herein include non-aqueous hydrophilic organic solvents inclusive of glycols and polyhydric alcohols, for example sorbitol, glycerol, dipropylene glycol and mixtures thereof, and also various hygroscopic solids inclusive of inorganic or organic salts such as silicates, phosphates and citrates, as well as sugars, etc. Preferred for use herein are humectants and humectant mixtures comprising glycols, more preferably polyethylene glycols and especially mixtures of polyethylene glycols of different molecular weight. For example, mixtures of polyethylene glycol having a molecular weight of about 200 to about 1,200, more preferably from about 200 to about 800 and polyethylene glycol having a molecular weight of about 2,000 to about 6,000 more preferably from about 2,600 to about 4,000. In the mixtures of polyethylene glycol used herein the low molecular weight and the high molecular weight polyethylene glycol are usually in a weight ratio of at least 10:1 and preferably at least 100: 1.
[0019] In a preferred embodiment, the anhydrous detergent auxiliary composition comprises a detergency enzyme. The enzyme is preferably in liquid form and is delivered to the wash liquor substantially prior to the particulate products, thereby minimizing or avoiding interaction with actives, such as bleach, which can have a deleterious effect on enzyme stability and performance in the wash solution.
[0020] In preferred embodiments the dishwashing composition comprises an organic solvent system. The organic solvent system can simply act as a liquid carrier, but in preferred compositions, the solvent can aid removal of cooked-, baked- or burnt-on soil and thus has detergent functionality in its own right. The organic solvent system (comprising a single solvent compound or a mixture of solvent compounds) preferably has a volatile organic content above 1 mm Hg and more preferably above 0.1 mm Hg of less than about 50%, preferably less than about 20% and more preferably less than about 10% by weight of the solvent system. Herein volatile organic content of the solvent system is defined as the content of organic components in the solvent system having a vapor pressure higher than the prescribed limit at 25° C. and atmospheric pressure. The organic solvent system for use herein is preferably selected from organoamine solvents, inclusive of alkanolamines, alkylamines, alkyleneamines and mixtures thereof; alcoholic solvents inclusive of aromatic, aliphatic (preferably C 4 -C 10 ) and cycloaliphatic alcohols and mixtures thereof; glycols and glycol derivatives inclusive of C 2 -C 3 (poly)alkylene glycols, glycol ethers, glycol esters and mixtures thereof; and mixtures selected from organoamine solvents, alcoholic solvents, glycols and glycol derivatives. In one preferred embodiment the organic solvent comprises organoamine (especially alkanolamine) solvent and glycol ether solvent, preferably in a weight ratio of from about 3:1 to about 1:3, and wherein the glycol ether solvent is selected from ethylene glycol monobutyl ether, diethylene glycol monobutyl ether, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether, propylene glycol monobutyl ether, and mixtures thereof. Preferably, the glycol ether is a mixture of diethylene glycol monobutyl ether and propylene glycol butyl ether, especially in a weight ratio of from about 1:2 to about 2:1.
[0021] According to another embodiment of the invention the dishwashing auxiliary composition can take the form of a paste having a density greater than about 1100 Kg/m 3 , preferably greater than about 1300 Kg/m 3 .
[0022] Multi-compartment pouches suitable for use herein can include compartments with different solubility profiles controlled by for example pH, temperature or any other means. High temperature water-soluble pouches allow handling of the pouches at ambient temperature with wet hands.
[0023] The multi-compartment pouches herein comprise at least one compartment containing a powder or densified powder composition and at least one containing an anhydrous liquid, gel or paste. This powder composition comprises traditional solid materials used in dishwashing detergent, such as builders, alkalinity sources, together with moisture-sensitive detergent active such as bleaches, etc. The liquid, gel or paste compositions comprise traditional liquid materials used in dishwashing detergents, such as non-ionic surfactants or the organic solvents described hereinabove together with a humectant. Preferably the compartment comprising the detergent auxiliary is placed above or adjacent the compartment comprising the moisture-sensitive detergent active in order to help protect the moisture-sensitive detergent active and to reduce the surface area of the pouch containing compartment which is exposed to moisture.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The present invention envisages the use of dishwashing detergent and auxiliary compositions in a multi-compartment pouch, whereby a moisture-sensitive detergent active and a humectant are contained in separate compartments. The humectant is capable of acting as a moisture sink and acts to stabilize the moisture-sensitive detergent active.
[0025] Unitised dose forms specially useful for use herein are pouches. The pouch herein is typically a closed structure which comprises two or more compartments, made of materials described herein. Subject to the constraints of dispenser fit, the pouch can be of any form, shape and material which is suitable to hold the composition, e.g. without allowing the release of the composition from the pouch prior to contact of the pouch to water. The exact execution will depend on, for example, the type and amount of the composition in the pouch, the number of compartments in the pouch, the characteristics required from the pouch to hold, protect and deliver or release the composition and/or components thereof.
[0026] The composition, or components thereof, are contained in the internal volume space of the pouch, and are typically separated from the outside environment by a barrier of water-soluble material. Typically, different components of the composition contained in different compartments of the pouch are separated from one another by a barrier of water-soluble material.
[0027] In the case of multi-compartment pouches, the compartments may be of a different colour from each other, for example a first compartment may be green or blue, and a second compartment may be white or yellow. One compartment of the pouch may be opaque or semi-opaque, and a second compartment of the pouch may be translucent, transparent, or semi-transparent. The compartments of the pouch may be the same size, having the same internal volume, or may be different sizes having different internal volumes.
[0028] For reasons of deformability and dispenser fit under compression forces, pouches or pouch compartments containing a component which is liquid will usually contain an air bubble having a volume of up to about 50%, preferably up to about 40%, more preferably up to about 30%, more preferably up to about 20%, more preferably up to about 10% of the volume space of said compartment.
[0029] The pouch is preferably made of a pouch material which is soluble or dispersible in water, and preferably has a water-solubility of at least 50%, preferably at least 75% or even at least 95%, as measured by the method set out hereafter using a glass-filter with a maximum pore size of 20 microns.
[0030] 50 grams±0.1 gram of pouch material is added in a pre-weighed 400 ml beaker and 245 ml±1 ml of distilled water at the appropriate temperature is added. This is stirred vigorously on a heatable plate with a magnetic stirrer set at 600 rpm, for 30 minutes. Then, the mixture is filtered through a folded qualitative sintered-glass filter with a pore size as defined above (max. 20 micron). The water is dried off from the collected filtrate by any conventional method, and the weight of the remaining material is determined (which is the dissolved or dispersed fraction). Then, the % solubility or dispersability at the specified temperature can be calculated.
[0031] Preferred pouch materials are polymeric materials, preferably polymers which are formed into a film or sheet. The pouch material can, for example, be obtained by casting, blow-moulding, extrusion or blow extrusion of the polymeric material, as known in the art.
[0032] Preferred polymers, copolymers or derivatives thereof suitable for use as pouch material are selected from polyvinyl alcohols, partially hydrolysed polyvinylacetates, polyvinyl pyrrolidone, polyalkylene oxides, acrylamide, acrylic acid, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polycarboxylic acids and salts, polyaminoacids or peptides, polyamides, polyacrylamide, copolymers of maleic/acrylic acids, polysaccharides including starch and gelatine, natural gums such as xanthum and carragum. More preferred polymers are selected from polyacrylates and water-soluble acrylate copolymers, methylcellulose, carboxymethylcellulose sodium, dextrin, ethylcellulose, hydroxyethyl cellulose, hydroxypropyl methylcellulose, hydroxybutyl methylcellulose, maltodextrin, polymethacrylates, and most preferably selected from polyvinyl alcohols, polyvinyl alcohol copolymers, partially hydrolysed polyvinylacetates and hydroxypropyl methyl cellulose (HPMC), hydroxybutyl methylcellulose (HBMC), and combinations thereof. Preferably, the level of polymer in the pouch material, for example a PVA polymer, is at least 60%.
[0033] The polymer can have any weight average molecular weight, preferably from about 1000 to 1,000,000, more preferably from about 10,000 to 300,000 yet more preferably from about 20,000 to 150,000.
[0034] Mixtures of polymers can also be used as the pouch material. This can be beneficial to control the mechanical and/or dissolution properties of the compartments or pouch, depending on the application thereof and the required needs. Suitable mixtures include for example mixtures wherein one polymer has a higher water-solubility than another polymer, and/or one polymer has a higher mechanical strength than another polymer. Also suitable are mixtures of polymers having different weight average molecular weights, for example a mixture of PVA or a copolymer thereof of a weight average molecular weight of about 10,000-40,000, preferably around 20,000, and of PVA or copolymer thereof, with a weight average molecular weight of about 100,000 to 300,000, preferably around 150,000.
[0035] Also suitable herein are polymer blend compositions, for example comprising hydrolytically degradable and water-soluble polymer blends such as polylactide and polyvinyl alcohol, obtained by mixing polylactide and polyvinyl alcohol, typically comprising about 1-35% by weight polylactide and about 65% to 99% by weight polyvinyl alcohol.
[0036] Preferred for use herein are polymers inclusive of polyvinylacetate which are from about 60% to about 98% hydrolysed, preferably about 80% to about 90% hydrolysed, to improve the dissolution characteristics of the material.
[0037] Most preferred pouch materials are PVA films known under the trade reference Monosol M8630, as sold by Chris-Craft Industrial Products of Gary, Ind., US, and PVA films of corresponding solubility and deformability characteristics. Other films suitable for use herein include films known under the trade reference PT film or the K-series of films supplied by Aicello, or VF-HP film supplied by Kuraray.
[0038] The pouch material herein can also comprise one or more additive ingredients. For example, it can be beneficial to add plasticisers, for example glycerol, ethylene glycol, diethyleneglycol, propylene glycol, sorbitol and mixtures thereof. Other additives include functional detergent additives to be delivered to the wash water, for example organic polymeric dispersants, etc.
[0039] The pouch can be prepared according to methods known in the art. The pouch is typically prepared by first cutting an appropriately sized piece of pouch material, preferably the pouch material. The pouch material is then folded to form the necessary number and size of compartments and the edges are sealed using any suitable technology, for example heat sealing, wet sealing or pressure sealing. Preferably, a sealing source is brought into contact with the pouch material, heat or pressure is applied and the pouch material is sealed.
[0040] The pouch material is typically introduced to a mould and a vacuum applied so that the pouch material is flush with the inner surface of the mould, thus forming a vacuum formed indent or niche in said pouch material. This is referred to as vacuum-forming.
[0041] Another suitable method is thermo-forming. Thermo-forming typically involves the step of forming an open pouch in a mould under application of heat, which allows the pouch material to take on the shape of the mould.
[0042] Typically more than one piece of pouch material is used for making multi-compartment pouches. For example, a first piece of pouch material can be vacuum pulled into the mould so that said pouch material is flush with the inner walls of the mould. A second piece of pouch material can then be positioned such that it at least partially overlaps, and preferably completely overlaps, with the first piece of pouch material. The first piece of pouch material and second piece of pouch material are sealed together. The first piece of pouch material and second piece of pouch material can be made of the same type of material or can be different types of material.
[0043] In a preferred process, a piece of pouch material is folded at least twice, or at least three pieces of pouch material are used, or at least two pieces of pouch material are used wherein at least one piece of pouch material is folded at least once. The third piece of pouch material, or a folded piece of pouch material, creates a barrier layer that, when the sachet is sealed, divides the internal volume of said sachet into at least two or more compartments.
[0044] The pouch can also be prepared by fitting a first piece of the pouch material into a mould, for example the first piece of film may be vacuum pulled into the mould so that said film is flush with the inner walls of the mould. A composition, or component thereof, is typically poured into the mould. A pre-sealed compartment made of pouch material, is then typically placed over the mould containing the composition, or component thereof. The pre-sealed compartment preferably contains a composition, or component thereof. The pre-sealed compartment and said first piece of pouch material may be sealed together to form the pouch.
[0045] The detergent auxiliary herein can comprise traditional detergency components and can also comprise organic solvents having a cleaning function and organic solvents having a carrier or diluent function or some other specialised function. The compositions will generally be built and comprise one or more detergent active components which may be selected from colorants, bleaching agents, surfactants, alkalinity sources, enzymes, thickeners (in the case of liquid, paste, cream or gel compositions), anti-corrosion agents (e.g. sodium silicate) and disrupting and binding agents (in the case of powder, granules or tablets). Highly preferred detergent auxiliary components include a builder compound, an alkalinity source, a surfactant, an enzyme and a bleaching agent.
[0046] Unless otherwise specified, the components described hereinbelow can be incorporated either in the automatic dishwashing product or detergent auxiliary.
[0047] The organic solvents should be selected so as to be compatible with the tableware/cookware as well as with the different parts of an automatic dishwashing machine. Furthermore, the solvent system should be effective and safe to use having a volatile organic content above 1 mm Hg (and preferably above 0.1 mm Hg) of less than about 50%, preferably less than about 30%, more preferably less than about 10% by weight of the solvent system. Also they should have very mild pleasant odours. The individual organic solvents used herein generally have a boiling point above about 150° C., flash point above about 100° C. and vapor pressure below about 1 mm Hg, preferably below 0.1 mm Hg at 25° C. and atmospheric pressure.
[0048] Solvents that can be used herein include: i) alcohols, such as benzyl alcohol, 1,4-cyclohexanedimethanol, 2-ethyl-1-hexanol, furfuryl alcohol, 1,2-hexanediol and other similar materials; ii) amines, such as alkanolamines (e.g. primary alkanolamines: monoethanolamine, monoisopropanolamine, diethylethanolamine, ethyl diethanolamine; secondary alkanolamines: diethanolamine, diisopropanolamine, 2-(methylamino)ethanol; ternary alkanolamines: triethanolamine, triisopropanolamine); alkylamines (e.g. primary alkylamines: monomethylamine, monoethylamine, monopropylamine, monobutylamine, monopentylamine, cyclohexylamine), secondary alkylamines: (dimethylamine), alkylene amines (primary alkylene amines: ethylenediamine, propylenediamine) and other similar materials; iii) esters, such as ethyl lactate, methyl ester, ethyl acetoacetate, ethylene glycol monobutyl ether acetate, diethylene glycol monoethyl ether acetate, diethylene glycol monobutyl ether acetate and other similar materials; iv) glycol ethers, such as ethylene glycol monobutyl ether, diethylene glycol monobutyl ether, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether, propylene glycol butyl ether and other similar materials; v) glycols, such as propylene glycol, diethylene glycol, hexylene glycol (2-methyl-2,4 pentanediol), triethylene glycol, composition and dipropylene glycol and other similar materials; and mixtures thereof.
[0049] Surfactant
[0050] In the methods of the present invention, the detergent surfactant is preferably low foaming by itself or in combination with other components (i.e. suds suppressers). Surfactants suitable herein include anionic surfactants such as alkyl sulfates, alkyl ether sulfates, alkyl benzene sulfonates, alkyl glyceryl sulfonates, alkyl and alkenyl sulphonates, alkyl ethoxy carboxylates, N-acyl sarcosinates, N-acyl taurates and alkyl succinates and sulfosuccinates, wherein the alkyl, alkenyl or acyl moiety is C 5 -C 20 , preferably C 10 -C 18 linear or branched; cationic surfactants such as chlorine esters (U.S. Pat. No. 4,228,042, U.S. Pat. No. 4,239,660 and U.S. Pat. No. 4,260,529) and mono C 6 -C 16 N-alkyl or alkenyl ammonium surfactants wherein the remaining N positions are substituted by methyl, hydroxyethyl or hydroxypropyl groups; low and high cloud point nonionic surfactants and mixtures thereof including nonionic alkoxylated surfactants (especially ethoxylates derived from C 6 -C 18 primary alcohols), ethoxylated-propoxylated alcohols (e.g., Olin Corporation's Poly-Tergent® SLF18), epoxy-capped poly(oxyalkylated) alcohols (e.g., Olin Corporation's Poly-Tergent® SLF18B—see WO-A-94/22800), ether-capped poly(oxyalkylated) alcohol surfactants, and block polyoxyethylene-polyoxypropylene polymeric compounds such as PLURONIC®, REVERSED PLURONIC®, and TETRONIC® by the BASF-Wyandotte Corp., Wyandotte, Mich.; amphoteric surfactants such as the C 12 -C 20 alkyl amine oxides (preferred amine oxides for use herein include lauryldimethyl amine oxide and hexadecyl dimethyl amine oxide), and alkyl amphocarboxylic surfactants such as Miranol™ C2M; and zwitterionic surfactants such as the betaines and sultaines; and mixtures thereof. Surfactants suitable herein are disclosed, for example, in U.S. Pat. No. 3,929,678, U.S. Pat. No. 4,259,217, EP-A-0414 549, WO-A-93/08876 and WO-A-93/08874. Surfactants are typically present at a level of from about 0.2% to about 30% by weight, more preferably from about 0.5% to about 10% by weight, most preferably from about 1% to about 5% by weight of composition. Preferred surfactant for use herein are low foaming and include low cloud point nonionic surfactants and mixtures of higher foaming surfactants with low cloud point nonionic surfactants which act as suds suppresser therefor.
[0051] Builder
[0052] Builders suitable for use in detergent and cleaning compositions herein include water-soluble builders such as citrates, carbonates and polyphosphates e.g. sodium tripolyphosphate and sodium tripolyphosphate hexahydrate, potassium tripolyphosphate and mixed sodium and potassium tripolyphosphate salts; and partially water-soluble or insoluble builders such as crystalline layered silicates (EP-A-0164514 and EP-A-0293640) and aluminosilicates inclusive of Zeolites A, B, P, X, HS and MAP. The builder is typically present at a level of from about 1% to about 80% by weight, preferably from about 10% to about 70% by weight, most preferably from about 20% to about 60% by weight of composition.
[0053] Amorphous sodium silicates having an SiO 2 :Na 2 O ratio of from 1.8 to 3.0, preferably from 1.8 to 2.4, most preferably 2.0 can also be used herein although highly preferred from the viewpoint of long term storage stability are compositions containing less than about 22%, preferably less than about 15% total (amorphous and crystalline) silicate.
[0054] Enzyme
[0055] Enzymes suitable herein include bacterial and fungal cellulases such as Carezyme and Celluzyme (Novo Nordisk A/S); peroxidases; lipases such as Amano-P (Amano Pharmaceutical Co.), M1 Lipase® and Lipomax® (Gist-Brocades) and Lipolase® and Lipolase Ultra® (Novo); cutinases; proteases such as Esperase®, Alcalase®, Durazym® and Savinase® (Novo) and Maxatase®, Maxacal®, Properase® and Maxapem® (Gist-Brocades); and α and β amylases such as Purafect Ox Am® (Genencor) and Termamyl®, Ban®, Fungamyl®, Duramyl®, and Natalase® (Novo); and mixtures thereof. Enzymes are preferably added herein as prills, granulates, or cogranulates at levels typically in the range from about 0.0001% to about 2% pure enzyme by weight of composition.
[0056] Bleaching agent
[0057] Bleaching agents suitable herein include chlorine and oxygen bleaches, especially inorganic perhydrate salts such as sodium perborate mono-and tetrahydrates and sodium percarbonate optionally coated to provide controlled rate of release (see, for example, GB-A-1466799 on sulfate/carbonate coatings), preformed organic peroxyacids and mixtures thereof with organic peroxyacid bleach precursors and/or transition metal-containing bleach catalysts (especially manganese or cobalt). Inorganic perhydrate salts are typically incorporated at levels in the range from about 1% to about 40% by weight, preferably from about 2% to about 30% by weight and more preferably from abut 5% to about 25% by weight of composition. Peroxyacid bleach precursors preferred for use herein include precursors of perbenzoic acid and substituted perbenzoic acid; cationic peroxyacid precursors; peracetic acid precursors such as TAED, sodium acetoxybenzene sulfonate and pentaacetylglucose; pernonanoic acid precursors such as sodium 3,5,5-trimethylhexanoyloxybenzene sulfonate (iso-NOBS) and sodium nonanoyloxybenzene sulfonate (NOBS); amide substituted alkyl peroxyacid precursors (EP-A-0170386); and benzoxazin peroxyacid precursors (EP-A-0332294 and EP-A-0482807). Bleach precursors are typically incorporated at levels in the range from about 0.5% to about 25%, preferably from about 1% to about 10% by weight of composition while the preformed organic peroxyacids themselves are typically incorporated at levels in the range from 0.5% to 25% by weight, more preferably from 1% to 10% by weight of composition. Bleach catalysts preferred for use herein include the manganese triazacyclononane and related complexes (U.S. Pat. No. 4,246,612, U.S. Pat. No. 5,227,084); Co, Cu, Mn and Fe bispyridylamine and related complexes (U.S. Pat. No. 5,114,611); and pentamine acetate cobalt(III) and related complexes(U.S. Pat. No. 4,810,410).
[0058] Low cloud point non-ionic surfactants and suds suppressers
[0059] The suds suppressers suitable for use herein include nonionic surfactants having a low cloud point. “Cloud point”, as used herein, is a well known property of nonionic surfactants which is the result of the surfactant becoming less soluble with increasing temperature, the temperature at which the appearance of a second phase is observable is referred to as the “cloud point” (See Kirk Othmer, pp. 360-362). As used herein, a “low cloud point” nonionic surfactant is defined as a nonionic surfactant system ingredient having a cloud point of less than 30° C., preferably less than about 20° C., and even more preferably less than about 10° C., and most preferably less than about 7.5° C. Typical low cloud point nonionic surfactants include nonionic alkoxylated surfactants, especially ethoxylates derived from primary alcohol, and polyoxypropylene/polyoxyethylene/polyoxypropylene (PO/EO/PO) reverse block polymers. Also, such low cloud point nonionic surfactants include, for example, ethoxylated-propoxylated alcohol (e.g., Olin Corporation's Poly-Tergent® SLF18) and epoxy-capped poly(oxyalkylated) alcohols (e.g., Olin Corporation's Poly-Tergent® SLF18B series of nonionics, as described, for example, in U.S. Pat. No. 5,576,281).
[0060] Preferred low cloud point surfactants are the ether-capped poly(oxyalkylated) suds suppresser having the formula:
[0061] wherein R 1 is a linear, alkyl hydrocarbon having an average of from about 7 to about 12 carbon atoms, R 2 is a linear, alkyl hydrocarbon of about 1 to about 4 carbon atoms, R 3 is a linear, alkyl hydrocarbon of about 1 to about 4 carbon atoms, x is an integer of about 1 to about 6, y is an integer of about 4 to about 15, and z is an integer of about 4 to about 25.
[0062] Other low cloud point nonionic surfactants are the ether-capped poly(oxyalkylated) having the formula:
R I O(R II O) n CH(CH 3 )OR III
[0063] wherein, R I is selected from the group consisting of linear or branched, saturated or unsaturated, substituted or unsubstituted, aliphatic or aromatic hydrocarbon radicals having from about 7 to about 12 carbon atoms; R II may be the same or different, and is independently selected from the group consisting of branched or linear C 2 to C 7 alkylene in any given molecule; n is a number from 1 to about 30; and R III is selected from the group consisting of:
[0064] (i) a 4 to 8 membered substituted, or unsubstituted heterocyclic ring containing from 1 to 3 hetero atoms; and
[0065] (ii) linear or branched, saturated or unsaturated, substituted or unsubstituted, cyclic or acyclic, aliphatic or aromatic hydrocarbon radicals having from about 1 to about 30 carbon atoms;
[0066] (b) provided that when R 2 is (ii) then either: (A) at least one of R 1 is other than C 2 to C 3 alkylene; or (B) R 2 has from 6 to 30 carbon atoms, and with the further proviso that when R 2 has from 8 to 18 carbon atoms, R is other than C 1 to C 5 alkyl.
[0067] Other suitable components herein include organic polymers having dispersant, anti-redeposition, soil release or other detergency properties invention in levels of from about 0.1% to about 30%, preferably from about 0.5% to about 15%, most preferably from about 1% to about 10% by weight of composition. Preferred anti-redeposition polymers herein include acrylic acid containing polymers such as Sokalan PA30, PA20, PA15, PA10 and Sokalan CP10 (BASF GmbH), Acusol 45N, 480N, 460N (Rohm and Haas), acrylic acid/maleic acid copolymers such as Sokalan CP5 and acrylic/methacrylic copolymers. Preferred soil release polymers herein include alkyl and hydroxyalkyl celluloses (U.S. Pat. No. 4,000,093), polyoxyethylenes, polyoxypropylenes and copolymers thereof, and nonionic and anionic polymers based on terephthalate esters of ethylene glycol, propylene glycol and mixtures thereof.
[0068] Heavy metal sequestrants and crystal growth inhibitors are suitable for use herein in levels generally from about 0.005% to about 20%, preferably from about 0.1% to about 10%, more preferably from about 0.25% to about 7.5% and most preferably from about 0.5% to about 5% by weight of composition, for example diethylenetriamine penta (methylene phosphonate), ethylenediamine tetra(methylene phosphonate) hexamethylenediamine tetra(methylene phosphonate), ethylene diphosphonate, hydroxy-ethylene-1,1-diphosphonate, nitrilotriacetate, ethylenediaminotetracetate, ethylenediamine-N,N′-disuccinate in their salt and free acid forms.
[0069] The compositions herein can contain a corrosion inhibitor such as organic silver coating agents in levels of from about 0.05% to about 10%, preferably from about 0.1% to about 5% by weight of composition (especially paraffins such as Winog 70 sold by Wintershall, Salzbergen, Germany), nitrogen-containing corrosion inhibitor compounds (for example benzotriazole and benzimadazole—see GB-A-1137741) and Mn(II) compounds, particularly Mn(II) salts of organic ligands in levels of from about 0.005% to about 5%, preferably from about 0.01% to about 1%, more preferably from about 0.02% to about 0.4% by weight of the composition.
[0070] Other suitable components herein include colorants, water-soluble bismuth compounds such as bismuth acetate and bismuth citrate at levels of from about 0.01% to about 5%, enzyme stabilizers such as calcium ion, boric acid, propylene glycol and chlorine bleach scavengers at levels of from about 0.01% to about 6%, lime soap dispersants (see WO-A-93/08877), suds suppressors (see WO-93/08876 and EP-A-0705324), polymeric dye transfer inhibiting agents, optical brighteners, perfumes, fillers and clay.
[0071] Liquid detergent compositions can contain low quantities of low molecular weight primary or secondary alcohols such as methanol, ethanol, propanol and isopropanol can be used in the liquid detergent of the present invention. Other suitable carrier solvents used in low quantities includes glycerol, propylene glycol, ethylene glycol, 1,2-propanediol, sorbitol and mixtures thereof.
EXAMPLES
[0072] [0072] Abbreviations used in Examples In the examples, the abbreviated component identifications have the following meanings: Carbonate Anhydrous sodium carbonate STPP Sodium tripolyphosphate anhydrous (anhydrous) STPP Sodium tripolyphosphate hydrated to approximately 8% (hydrated) Silicate Amorphous Sodium Silicate (SiO 2 :Na 2 O = from 2:1 to 4:1) HEDP Ethane 1-hydroxy-1,1-diphosphonic acid Perborate Sodium perborate monohydrate Percarbonate Sodium percarbonate of the nominal formula 2Na 2 CO 3 .3H 2 O 2 Termamyl α-amylase available from Novo Nordisk A/S Savinase protease available from Novo Nordisk A/S FN3 protease available from Genencor SLF18 low foaming surfactant available from Olin Corporation ACNI alkyl capped non-ionic surfactant of formula C 9/11 H 19/23 EO 8 -cyclohexyl acetal C 14 AO tetradecyl dimethyl amine oxide C 16 AO hexadecyl dimethyl amine oxide Duramyl α-amylase available from Novo Nordisk A/S DPG dipropylene glycol
[0073] In the following examples all levels are quoted as parts by weight.
Examples 1 to 4
[0074] The compositions of examples 1 to 4 are made in the form of a two compartment PVA pouch. The dual compartment pouch is made from a Monosol M8630 film as supplied by Chris-Craft Industrial Products. The pouches made by presealing the liquid composition using the technique described hereinabove. The particulate composition and the anhydrous composition are placed in two different horizontal layered compartments, the anhydrous composition being placed above the particulate composition. The exemplified pouches show a good stability of the particulate automatic dishwashing product.
Example 1 2 3 4 Particulate composition C 14 AO 5.55 5.55 C 16 AO 5.55 5.55 ACNI 5.55 5.55 SLF18 5.55 5.55 STPP (anhydrous) 21.0 21.0 21.0 21.0 STPP (hydrated) 31.5 31.5 31.5 31.5 HEDP 1.0 1.0 1.0 1.0 Savinase 0.7 0.7 0.7 0.7 Termamyl 0.7 0.7 0.7 0.7 Perborate 13.55 13.55 Percarbonate 13.55 13.55 Carbonate 15.0 10.0 15.0 15.0 Silicate 5.0 10.0 5.0 5.0 Perfume 0.5 0.5 0.5 0.5 Anhydrous composition DPG 99.5 95.0 95.0 99.5 FN3 Liquid 2.60 2.4 Duramyl Liquid 2.0 2.4 Dye 0.5 0.4 0.2 0.5
Examples 5 to 8
[0075] The particulate compositions of examples 1 to 4 are formed into tablets. The tablets are prepared as follows. The detergent composition is prepared by admixing the granular and liquid components and is then passed into the die of a conventional rotary press. The press includes a punch suitably shaped for forming a mould in the upper surface of the tablet. The cross-section of the die is approximately 30×38 mm. The composition is then subjected to a compression force of 940 kg/cm 2 , the punch is elevated, and a tablet comprising the mould is ejected from the tablet press.
[0076] Separately, PVA pouches are formed and filled with the anhydrous auxiliary compositions of examples 1 to 4.
[0077] The multi-compartment pouches are made by placing PVA film into a tray having a series of tablet-shaped depresions. The tray is filled with tablets, the tablets being positioned into the tray such that the tablet moulds are facing upwards. A layer of pouches comprising the anhydrous composition is placed with the pouches over and adjacent the moulds of the tablets and is used to close, by solvent sealing, the layer of open pouches comprising the tablets.
[0078] Monosol M8630 film as supplied by Chris-Craft Industrial Products was used to make the pouches.
[0079] The exemplified pouches show a good stability of the particulate automatic dishwashing product.
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A method of washing dishware/tableware in an automatic dishwashing machine, the method comprising simultaneously or sequentially delivering quantities of a particulate or densified particulate automatic dishwashing product and of an anhydrous liquid, gel or paste form dishwashing detergent auxiliary contained in separate compartments of a multi-compartment pouch into the same or different cycles of the dishwashing machine. The method provides improved cleaning performance and product stability.
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BACKGROUND
[0001] This relates generally to graphics processing. Graphics processing is the processing of electronic data for its display on a display screen, such as a computer monitor or television.
[0002] The Gilbert-Johnson-Keerthi (GJK) algorithm was invented by Elmer G. Gilbert, Daniel W. Johnson, and S. Sathiya Keerthi in 1988. See Gilbert, E. G. et al. “A Fast Procedure for Computing the Distance Between Complex Objects in Three Dimensional Space,” IEEE Journal of Robotics and Automation, Vol. 4, Issue 2, April 1988, pages 199-203.
[0003] The GJK algorithm determines the minimum distance between two convex sets. A convex set is basically a depiction of an object. The GJK algorithm uses a Minkowski sum of the two convex shapes. The smooth algorithm modifications obtain the closest pair of points for two convex sets A and B.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a schematic depiction for one embodiment of the present invention;
[0005] FIG. 2 is a depiction of a data format for use in accordance with one embodiment;
[0006] FIG. 3 is a depiction of two objects and the application of the GJK algorithm to those objects;
[0007] FIG. 4 is a flow chart for one embodiment of the present invention; and
[0008] FIG. 5 is a system depiction for one embodiment.
DETAILED DESCRIPTION
[0009] Referring to FIG. 1 , a graphics processor core 30 may include a U-pipe 32 and V-pipe 38 . The U-pipe 32 is coupled to a vector processing unit (VPU) 34 and an arithmetic logic unit (ALU) 36 . The vector processing unit 34 is coupled to general purpose registers (GPRs) 42 (e.g. sixteen general purpose registers times four threads) and vector registers (VXXs) 40 (e.g. thirty two vector registers times four threads). The hardware registers need not be large enough to capture the total data structure in some embodiments.
[0010] The V-pipe 38 is coupled to an arithmetic logic unit 36 and the 32 vector registers 40 of sixteen general purpose registers 42 . The input to the U-pipe 32 and the V-pipe 38 comes from a data cache 47 and an instruction cache 45 that feeds an instruction fetching, and picking unit 44 .
[0011] A data cache 47 receives the output from various processing units 34 and 36 and provides data over a two-way way bus to a level 2 or L2 cache 48 . The L2 cache 48 is coupled by a ring bus 46 to main memory. A clocking (CLX) unit 49 provides clocking signals to the bus between the data cache and the L2 cache and the bus between the L2 cache and the ring bus.
[0012] The processor core 30 , shown in FIG. 1 , is a single instruction multiple data (SIMD) processor. It uses SIMD load/store instructions. Since the operation is based on a SIMD width of 512 bits or sixteen elements, it operates most efficiently if the data is vectored or a aligned so that the starting address of a data structure starts in an address that is a multiple of the SIMD width. Thus, in the example described above, with thirty two vector registers, the SIMD width is sixteen elements or 512 bits. Then it is desirable that the addresses of data structures start at multiples of four, sixteen and, most preferably, sixty four.
[0013] Advantageously, the SIMD processor core 30 works with vectored or aligned data. The processor exploits data level parallelism by efficiently utilizing the SIMD hardware to improve performance in some embodiments. Thus, “aligned, vectored” data refers to data structures that are efficient for a parallel SIMD architecture because their starting addresses are multiples of the executing SIMD processor's width. The registers are 512 bit wide SIMD registers in one embodiment.
[0014] Referring to FIG. 2 , a data structure for use in one embodiment, where the SIMD width is 16 elements, is depicted. Of course, other widths may be utilized, but similar principles may be used to align the data to the SIMD width. The data storage structure, shown in FIG. 2 , contains the initial separating axes for supporting a mapping function, position and rotation of a local coordinate system, number of points in a convex set, and the position of each point. However, the present invention is not limited to convex shapes represented as a convex hull of vertices sets.
[0015] The data structure, shown in FIG. 2 , attempts to arrange the necessary information in an aligned, vectored fashion. N, in the first row, refers to the number of vertices in the objects A and B in each column and X, Y, and Z are tuples for the vertex coordinates in three-dimensional space that represent the objects A and B. The X 1 -X 16 , Y 1 -Y 16 , and Z 1 -Z 16 variables in rows 2 , 3 , and 4 represent the separating axes, which constitute direction vectors to the local coordinate system. Rows five and up relate to vertices of the sixteen objects. Each vertex is represented using its X, Y, and Z coordinate values. The number of X, Y and Z tuples is the same as the number of vertices in the object. With an SIMD width of sixteen, the data structures are sixteen elements wide in this embodiment.
[0016] Referring to FIG. 3 , two objects, labeled A and B, are depicted. These objects enclose a convex set (not shown) that may be a more complex structure to define than the objects that are effectively bounding boxes around convex sets. The minimum distance between the object A and the object B is indicated in the figure.
[0017] “Convex” refers to the actual shape of the item within the bounds depicted by the objects A and B in FIG. 3 . The set of points for each vertex, consisting of X, Y, and Z coordinates, enclose the convex object.
[0018] In accordance with some embodiments, the GJK algorithm is adapted to operate on aligned, vectored data suitable for multiple core, parallel processors, such as the one depicted in FIG. 1 . In this regard, the data is vectored or aligned with respect to the SIMD width of such a processor.
[0019] The sequence for applying the GJK algorithm, according to one embodiment, is shown in FIG. 4 . The sequence 139 may be implemented in software, hardware, or firmware. In a software implemented embodiment, it may be implemented by instructions stored in a computer readable medium, such as a magnetic, optical, or semiconductor storage device. The instructions may be executed by a suitable processor, controller, or computer, including a graphics processor core of a type shown in FIG. 1 , or a general purpose processor that includes the ability to operate on multiple threads in parallel using single instruction multiple data architecture.
[0020] Thus, as shown at block 10 , initially, the aligned, vectored data is prepared. Next, the data is processed using an iterative vectored GJK algorithm to compute the minimum distance between the two objects A and B. The vectored support mapping is implemented in the context of fully vectored GJK implementation. The instructions enable branch avoiding with the help of masked operations. Any “if-else” statement can be expressed as linear code using masked operations in one embodiment.
[0021] The vectored GJK algorithm contains only two loops in one embodiment. The first loop, indicated in block 12 supports the mapping function. This loop processes all points in a given set. The second loop, indicated in block 14 , repeats the algorithm until the optimum point (i.e. shortest distance between objects) in the algorithm is identified.
[0022] The pseudo code for the algorithm uses the Minkowski sum for A and B sets for the objects A and B. Thus, the sum of the two objects results in their combination. Namely, A+B={a+b: a in A, b in B}. The Minkowski difference for A and B sets is a new set: A−B={a−b: a in A, b in B}=A+(−B). CH(S) denotes a convex hull of S vertices.
[0023] The input to the algorithm is a convex hull of the Minkowski difference of the sets A and B, which is M. First, an arbitrary simplex Q is chosen from M. Then a point P is computed, closest to the origin in the convex hull of Q vertices. If P is the origin, then exit. In such case, a zero is returned.
[0024] Otherwise, Q is reduced to the smallest subset Q′ of Q, such that P is in the convex hull of Q′ vertices. Then V is equal to the support map computation (Sc) of the furthest vertex along a given direction for −P, which is the supporting point in the direction −P. If V is no more extreme in direction −P, then P itself can exit and return ∥P∥. Next, add V to Q and then go back to computing the point P closest to the origin in the convex hull of Q vertices.
[0025] In some embodiments, the vectored approach enables processing pairs of sets employing SIMD units and simultaneously using multi-threaded processor capabilities. A significant performance increase may be achieved in multi-core processors in some embodiments. The greatest performance boost may be achieved by processing sets with the same number of points. In this case, the memory utilization is most effective. For games, this is a most likely estimation because even complex bodies have no more than a few dozen vertices.
[0026] The computer system 130 , shown in FIG. 5 , may include a hard drive 134 and a removable medium 136 , coupled by a bus 104 to a chipset core logic 110 . A keyboard and mouse 120 , or other conventional components, may be coupled to the chipset core logic via bus 108 . The core logic may couple to the graphics processor 112 , via a bus 105 , and the main or host processor 100 in one embodiment. The graphics processor 112 may also be coupled by a bus 106 to a frame buffer 114 . The frame buffer 114 may be coupled by a bus 107 to a display screen 118 . In one embodiment, a graphics processor 112 may be a multi-threaded, multi-core parallel processor using SIMD architecture.
[0027] In the case of a software implementation, the pertinent code may be stored in any suitable semiconductor, magnetic, or optical memory, including the main memory 132 or any available memory within the graphics processor. Thus, in one embodiment, the code to perform the sequence 139 of FIG. 4 may be stored in a machine or computer readable medium, such as the memory 132 or the graphics processor 112 , and may be executed by the processor 100 or the graphics processor 112 in one embodiment. In one embodiment, the core 30 is part of the graphics processor 112 .
[0028] The techniques described herein apply to any convex object, including two, three, and higher dimensional surfaces. While a linear time algorithm is used to calculate the support map in the embodiment described above, other algorithms may also be used.
[0029] The graphics processing techniques described herein may be implemented in various hardware architectures. For example, graphics functionality may be integrated within a chipset. Alternatively, a discrete graphics processor may be used. As still another embodiment, the graphics functions may be implemented by a general purpose processor, including a multicore processor.
[0030] References throughout this specification to “one embodiment” or “an embodiment” mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one implementation encompassed within the present invention. Thus, appearances of the phrase “one embodiment” or “in an embodiment” are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be instituted in other suitable forms other than the particular embodiment illustrated and all such forms may be encompassed within the claims of the present application.
[0031] While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.
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Parallel and vectored data structures may be used in a single instruction multiple data processor that applies the Gilbert-Johnson-Keerthi algorithm. As a result, the performance of multi-core processors doing graphics processing may be increased in some cases.
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BACKGROUND OF THE INVENTION
Fiberglass is a thin glass fiber, which can be strong, light-weight, and a good insulator. These properties make fiberglass useful for a variety of applications. For example, fiberglass may be used as an insulator (e.g., an electrical insulator, a thermal insulator, or a sound insulator). Fiberglass may also be used in rigid objects, such as automobile panels, metal poles, or sports equipment (e.g., such that the rigid object consists primarily of fiberglass or such that fiberglass reinforces other materials).
Fiberglass can be made by introducing molten glass into a bushing. The bushing includes side walls and a bottom plate to contain the molten glass. The bottom plate (comprising or attached to a tip plate) includes a number of small holes. Thus, a stream of the molten glass flows from each of these holes and underlying tips. These streams may be converted into fibers.
Bushings are subject to harsh conditions. For example, the force caused by the molten material above the bottom plate may cause the bottom plate to sag over time, especially as manufacturers use increasingly larger bushings in order to produce fiberglass at a faster rate. Additionally, bushings are subject to extremely high temperatures, as the glass introduced into the bushings must stay in a molten state. Not only must the bushing withstand the high temperatures, but it must also withstand the heat expansions and subsequent contractions that accompany these temperatures. Thus, it is desirable to use a bushing system that can withstand the harsh conditions of fiber manufacturing.
BRIEF SUMMARY OF THE INVENTION
In one embodiment, the invention provides a bushing system that comprises a bushing having a bottom plate with a plurality of holes from which filaments are drawn. At least one elongated support extends through the bushing generally along a longitudinal axis to hold and stabilize the bushing. To handle the harsh conditions under which the bushing is subjected, the support comprises an alumina-based ceramic that generally resists sagging or excessive expansion and contraction during heating and cooling. In turn, deformation of the bottom plate is significantly reduced, thereby helping to prevent the geometry of the holes from changing. This in turn helps to prevent the breakage of the filaments when drawn through the holes.
In one aspect, a plurality of elongated supports are employed and are spaced apart from each other and aligned with the longitudinal axis. Each of the supports may comprise yttria doped alumina. Further, a frame may be used to receive the elongated supports. This frame may comprise a pair of horizontal rails upon which the support is configured to rest.
In another aspect, the alumina-based ceramic comprises a yttria doped alumina. In one arrangement, the alumina-based ceramic comprises alumina in major part, yttria in minor part and magnesia in minor amount. Further, the minor amount of yttria may be in the range from about 0.1 weight percent to about 5 weight percent.
To produce the alumina-based ceramic, alumina in major part may be combined with yttria oxide in minor amount and magnesium carbonate in minor amount to form an admixture. The admixture may be extruded and sintered at a temperature in the range from about 1550 degrees C. to about 1700 degrees C. Another technique for forming can include isostatic pressing. In some cases, the minor amount of yttria is in the range from about 0.1 weight percent to about 5 weight percent. The minor amount of magnesium carbonate (MgCO3) may be in the range from about 0.01 weight percent to about 1.5 weight percent, and in some cases from about 0.01 weight percent to about 0.2 weight percent. Further, the admixture may be milled and then spray dried prior to extrusion or pressing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1B show an example of a bushing system 100 .
FIG. 2 shows a cut-away depiction of part of a bushing system, illustrating examples of support-receiving elements.
FIGS. 3A-3C , 4 , and 5 A- 5 B show front views of a bushing system.
FIG. 6 shows a process for manufacturing fibers.
DETAILED DESCRIPTION OF THE INVENTION
As described above, over time, the bottom plate of a bushing may sag due to the load above it. This can cause the holes in the bottom plate to deform, thereby affecting the stream of molten glass that is forced through the hole. In turn, this can interfere with the other glass fibers, essentially ruining the production run. Once deformed, the bushing may need to be re-worked which usually entails melting down the bushing and recasting it. This can be both time consuming and expensive. Moreover, some of the expensive metals used to make the bushing will be lost.
To address this problem, the bottom plate may be supported by elongated supports running in a direction parallel to the plane of the bottom plate. The ends of the supports may rest on a frame surrounding the bushing, such that the supports are supported by the frame. One critical aspect of the invention is to construct these supports such that they only minimally expand/contract and/or sag when subject to extremely harsh production conditions. One exemplary way to accomplish this is by constructing the supports of a material comprising alumina-based ceramic, and in particular a yttria doped alumina.
One particular advantage of using such materials is that the supports may be made smaller, thus requiring less metal on the bushing to hold the supports. Or, the bushing could be may larger while maintaining the size of the cross sectional dimension of the supports, thus increasing production volumes. These efforts may significantly reduce the cost of the bushing. Further, the bushing will have a longer life, further reducing production costs.
Exemplary Bushing System
FIGS. 1A and 1B show an example of a bushing system 100 . Bushing system 100 may include a bushing 120 , which may comprise a material that is substantially erosion-resistant. Bushing 120 may comprise platinum, rhodium, or an alloy thereof.
Bushing 120 may comprise a screen (not shown), a number of side walls 122 and a bottom plate 124 . The screen may prevent contaminants in a molten material from entering the bushing 120 . Bottom plate 124 extends along a longitudinal direction 126 a and a horizontal direction 126 b, as shown in FIG. 1B . Bottom plate 124 includes a plurality of small orifices or holes 128 (as shown in FIG. 2 ). In some cases, bottom plate 124 may be similar to the plates described in U.S. Patent Application No. 2010/0064734, incorporated herein by reference. As one example, bottom plate 124 may include at least, equal to, and/or up to about 25, 50, 100, 250, 500, 1,000, 2,500, 5,000 or 10,000 holes.
The diameters of the holes may be at least, equal to, and/or up to about 0.1, 0.25, 0.5, 1, 2.5, 5, 10, 25, 50, 100, 250, 500 or 1,000 m. The holes may be located in rows or staggered double rows. A tip or hollow nozzle may be located beneath each hole and may be connected to, welded to or integral with the hole. As mentioned above, it is critical that these holes not be deformed as this could case the glass stream to break and ruin a production run.
Bushing 120 may comprise a screen (not shown), a number of side walls 122 and a bottom plate 124 . The screen may prevent contaminants in a molten material from entering the bushing 120 . Bottom plate 124 extends along a longitudinal direction 126 a and a horizontal direction 126 b, as shown in FIG. 1B . Bottom plate 124 includes a plurality of small orifices or holes 128 (as shown in FIG. 2 ). For example, bottom plate 124 may include at least, equal to, and/or up to about 25, 50, 100, 250, 500, 1,000, 2,500, 5,000 or 10,000 holes. The diameters of the holes may be at least, equal to, and/or up to about 0.1, 0.25, 0.5, 1, 2.5, 5, 10, 25, 50, 100, 250, 500 or 1,000 m. The holes may be located in rows or staggered double rows. A tip or hollow nozzle may be located beneath each hole and may be connected to, welded to or integral with the hole.
Bushing 120 may include one or more support-receiving elements 130 . Side walls 122 may include an aperture 132 , which can receive a support 140 . In some instances, aperture 132 is only slightly larger than the support 140 . Side wall 122 may include an aperture perimeter that defines the shape of aperture 132 . In some instances, the aperture perimeter consists of a material different from the rest of side wall 122 . The aperture perimeter may be welded to side wall 122 .
Support-receiving elements 130 may be constructed in a variety of ways. Three non-limiting examples are illustrated in FIG. 2 and are referenced by reference numerals 130 a, 130 b and 130 c and are described in more detailed hereinafter. It will be appreciated that bushing 120 may include all of the same type of support-receiving elements (e.g., all made of support-receiving elements 130 a ), or could include combinations of different types of support-receiving elements. Further, the support-receiving elements 130 are coupled in part to bottom plate 124 using one or more connectors 134 . As also shown in FIG. 2 , a variety of connectors may be used, either the same kind or different kinds. These are referenced using reference numerals 134 a , 134 b, and 134 c and are described in more detail below.
The support-receiving elements may comprise a sleeve, tubular element, hook or the like as described in more detail below. For example, support-receiving element 130 comprises a square or rectangular tube or sleeve that extends between the two side walls 122 . Between the side walls, each tubular element 130 is substantially hollow, such that, for example, a support 140 may extend completely through tubular element 130 . In some embodiments, the cross-section of tubular element 130 parallels the cross-section of the support 140 . Connecting support-receiving element 130 to bottom plate 124 are connectors 134 . If a force is applied to bottom plate 124 (e.g., by a molten material on top of the plate) that would promote sagging of the plate, the supports 140 assist to prevent such sagging. More specifically, the top of tubular support-receiving element 130 applies a downward force since it is connected to the bottom plate 124 . Support 140 counters this downward force and thus assists in preventing bottom plate 124 from sagging. As such, connecting bottom plate 124 to the support-receiving element may thus reduce or eliminate sagging.
Support-receiving element 130 of FIG. 1A is similar to support-receiving element 130 a of FIG. 2 . However, it will be appreciated that instead of using a continuous tube as the support-receiving element, other configurations may be used as illustrated in FIG. 2 . For example, a single surface may be used to form support-receiving element 130 b that sits atop support 140 . Bushing 100 may include one or more connectors 134 b, which may connect bottom plate 124 with support-receiving element 130 b.
As another example, bushing 100 may include a support-receiving element 130 c in the form of a hook 134 c that also serves to couple the support-receiving element 130 c to bottom plate 124 . In this way, the support-receiving element and the connector comprise the same component. However, as shown in FIG. 1A a connector 134 similar to connector 134 c may also be used in combination with a support-receiving element 130 that is similar to support-receiving element 130 a. In FIG. 1A , connector 134 in the form of a hook may extend from bottom plate 124 up and around tubular element 130 . Thus, if bottom plate 124 were to begin to sag, and support 140 pressed against the top of tubular element 130 , the hook connection may inhibit bottom plate 124 from sagging.
In some embodiments, support-receiving element 130 , the perimeter of aperture 132 , and/or connector 134 are made of substantially the same material as that of bottom plate 124 of bushing 120 . For example, this may allow support-receiving element 130 a to expand in longitudinal direction 126 a by an amount similar to the expansion of bottom plate 124 . In some instances, support-receiving element 130 , the perimeter of aperture 132 and/or connector 134 are made of a material that is different from the material of bottom plate 124 . For example, support-receiving element 130 and/or connector 134 may comprise a material that is more heat-resistant and/or exhibits less heat expansion than the material of bottom plate 124 . In some embodiments, support-receiving element 130 , the perimeter of aperture 132 , and/or connector 134 comprises a precious metal, such as platinum.
Support 140 may traverse through apertures 132 and/or support-receiving elements 134 along the longitudinal direction 126 a. The supports may comprise an elongate member. For example, the length of an elongated support 140 may be at least about 5, 10, 50, 100, 500, or 1000 times greater than a width or height of elongated support 140 . Support 140 may have a width or diameter, width, or height that is at least, equal to, or up to about 0.1 mm, 0.5 mm, 1 mm, 5 mm, 10 mm, 50 mm, 100 mm, or 500 mm. Support 140 may have a cross-section that is, for example, round or comprises a substantially straight line. In some instances, the cross-section is substantially a circle, a square, an oval or a rectangle. In some instances, the bottom of the cross-section is substantially flat.
Support 140 may have a width, height, or diameter that is, for example, at least, equal to, or up to about 0.1 mm, 0.5 mm, 1 mm, 5 mm, 10 mm, or 50 mm. Support 140 may have a length that is, for example, at least, equal to, or up to about 10 mm, 50 mm, 100 mm, 500 mm, or 1,000 mm. For example, in one instance, support 140 has a width of approximately 8 mm, a height of approximately 16 mm, and a length of 270 mm. Support 140 may be longer than the length bottom plate 124 in the longitudinal direction 126 a . This may, for example, allow the ends of the support 140 to be supported by a frame 160 . Support 140 may be, for example, at least, equal to, or up to about 0.1 mm, 0.5 mm, 1 mm, 5 mm, 10 mm, 50 mm, 100 mm, or 500 mm longer than the length of bottom plate 124 in the longitudinal direction 126 a. Supports may be separated from each other by a length that is, for example, at least, equal to, or up to about 1 mm, 2.5 mm, 5 mm, 10 mm, or 25 mm, 50 mm.
Support 140 may comprise a ceramic material. Support 140 may include alumina, silicon nitride, zirconia, nickel, iron, titanium, tungsten, molybdenum, niobrium or an alloy thereof. The material of support 140 may be such that support 140 has a lower thermal expansion coefficient and/or a greater hot creep strength than does bottom plate 124 .
In one particular embodiment, support 140 may comprise a yttria-doped alumina. The yttria doping may allow support 140 to exhibit less creep deformation at high temperatures than an otherwise comparable non-doped support. Thus, using an yttria-doped alumina support may decrease sag of bottom plate 124 . Additionally, yttria doping may allow a smaller support 140 to be used to support bottom plate 124 and/or may reduce the amount of materials (e.g., precious metals) to be included in bushing system 100 . Alternatively or in addition, yttria doping may allow support 140 to support a larger bottom plate 124 and bushing (thereby increasing a throughput rate of the system), may increase the effective life of support 140 , and/or may increase the efficacy of support 140 in inhibiting sag of bottom plate 124 . One exemplary yttria-doped ceramic comprises a yttria doped alumina. In one arrangement, the alumina-based ceramic comprises alumina in major part, yttria in minor part and magnesia in minor amount. In one particular embodiment, the minor amount of yttria may be in the range from about 0.1 weight percent to about 5 weight percent.
Manufacture of supports 140 may begin, for example, by providing alumina particles or a mixture of powders which react to form alumina. Combined with the alumina is yttria oxide and magnesium carbonate to form an admixture. The amount of yttria may be in the range from about 0.1 weight percent to about 5 weight percent. The amount of magnesium carbonate may be in the range from about 0.01 weight percent to about 1.5 weight percent.
The admixture is placed into an aqueous solution, such as water, and the admixture is milled to reduce the particle size. Following milling, the admixture is spray dried. The processed admixture may be extruded or pressed to shape the supports in the desired shape. The green body is then sintered at a temperature in the range from about 1550 degrees C. to about 1700 degrees C. During sintering, magnesia is produced from the magnesium carbonate. The end product is cooled and may optionally be ground to smooth and/or straighten the support.
In some embodiments, support 140 may be substantially solid. In some embodiments, support 140 is substantially hollow. In some embodiments, support 140 comprises a hollow and a solid part.
As shown in FIGS. 1A and 1B , frame 160 may support bushing 120 . In one embodiment, frame 160 supports an exterior portion of the bushing. For example, the frame may support an outer portion of the bushing surrounding the portion of the bushing comprising holes 128 . In some instances, bushing 120 may comprise one or more flanges 138 . Flanges 138 may extend over a portion of frame 160 . In some instances, flanges 138 extend along longitudinal direction 126 a.
Frame 160 may support elongated supports 140 . For example, as shown in FIGS. 1A and 1B , supports 140 may extend beyond bushing 120 in the longitudinal direction. Part or all of the portion of the supports extending beyond bushing 120 may be supported by frame 160 . In some instances, frame 160 supports bushing 120 by supporting supports 140 . In some instances, frame 160 directly supports bushing 120 .
Frame 160 may include one, two or more horizontal rails 162 , which extend along horizontal direction 126 b. Horizontal rails 162 may provide an upward force on supports 140 . In some embodiments, one or more lateral portions of supports 140 rest on horizontal rails 162 . The lateral portions may, for example, include an end portion of support 140 and/or a portion of the support that is not directly above bottom plate 124 . In some embodiments, support 140 does not directly rest on horizontal rails 162 , but one or more lateral portions of supports 140 are positioned over horizontal rails 162 and are indirectly supported by the rails. For example, one or more movement-promoting elements 148 , 150 , 152 , 190 , 192 , 194 may separate the rails from the lateral portions, shown in FIGS. 3A-3C , 4 , and 5 A- 5 B.
Frame 160 may comprise a metal. For example, frame 160 may comprise iron or steel. Frame 160 may comprise a material or may itself have a lower thermal expansion coefficient and/or a greater hot creep strength than does bottom plate 124 or than does support 140 . In some instances, different parts of frame 160 are made from different materials.
Bushing 160 may be heated in order to ensure that material contained within the bushing is kept within a desired temperature. For example, bushing 160 may be heated to over 2000° F. to ensure that molten glass within the bushing stays in the molten state. These high temperatures may cause parts of bushing 160 and supports 140 to expand. If supports 140 are not free to move with respect to frame 160 , damage may be caused to one or more of support 140 , bushing 120 (e.g., at aperture perimeters on side wall 122 or support-receiving element 130 ), and frame 160 . For example, at high temperatures, the welding connecting aperture perimeters to side wall 122 may fail and support-receiving element 130 may tear, which may result in molten material (e.g., molten glass) leaking from bushing 120 . Thus, in some embodiments, bushing systems are provided that reduce friction, permit relative movement, and/or promote relative movement between supports 140 and frame 160 (e.g., horizontal rails 162 ) at high temperatures (e.g., 2200°-2400° F.).
Bushing system 100 further includes a cooling water inlet 180 that leads to a cooling loop that lays on top of the bushing flange to seal to the bushing block to keep molten glass from escaping. Adjacent cooling water inlet 180 is a cooling water outlet 181 . Also, cooling water tubes 183 permit cooling water to be used to cool the bushing. Tubes 183 extend traverse across the bushing to permit cool water to be input from one side and the water to be removed from the other side. Tubes 186 provide air that is used during hanging to induce outside downward air flow along the array of bushing tips to further provide cooling during fiberization of the primary glass strands.
Support-Receiving Elements
As described above, a bushing may include one or more support-receiving elements. FIG. 2 shows a cut-away depiction of a part of other bushing-system embodiments, which, for example, illustrate several other examples of support-receiving elements 230 a - 230 c. In each of the three depicted example, side walls 222 include an aperture 232 , which can receive a support. In some instances, the aperture (e.g., aperture 232 a ) is only slightly larger than the support 240 . In some instances, the aperture (e.g., aperture 232 c ) extends to the top or to the bottom of the wall. While FIG. 2 shows two apertures corresponding to each support, a side wall 222 may include larger apertures 232 that can receive multiple supports.
As described in connection with FIG. 1A , support-receiving element 230 may be comprise a sleeve or a tubular element. FIG. 2 shows an example where a tubular support-receiving element 230 a is used in a bushing. In this instance, tubular element 230 a includes a substantially solid, continuous surface extending between two side walls 222 . Additionally each tubular element 230 a may be substantially hollow, such that, for example, a support 240 may extend completely through tubular element 230 a. In this instance, the cross-section of tubular element 230 a parallels the cross-section of the support 240 . As described in further detail below, tubular element 230 a is connected to bottom plate 224 (which comprises holes 228 ). Thus, if a force is applied to bottom plate 224 (e.g., by a molten material on top of the plate) that would promote sagging of the plate, the supports 240 (being supported by horizontal rails 262 ) may press on the top of tubular support-receiving element 230 a. Connecting bottom plate 224 to the support-receiving element may thus reduce or eliminate sagging.
Support-receiving element 230 b comprises a top surface. Support 240 can then be positioned beneath the top surface. Support 240 may apply an upwards force on the top surface of support-receiving element 230 b when a downwards force is applied to bottom plate 224 of a bushing. Thus, connecting bottom plate 224 to support-receiving element 230 b may reduce or eliminate sagging that may otherwise occur.
Support-receiving element 230 c comprises an element extending from bottom plate 224 over support 240 . In some instances, element 230 c comprises a hook-shape; in some instances, element 230 c comprises a U-shape. Support 240 may apply an upwards force on the top portion of support-receiving element 230 c when a downwards force is applied to bottom plate 224 of a bushing. Thus, connecting bottom plate 224 to support-receiving element 230 c may reduce or eliminate sagging that may otherwise occur.
As describe above, the bushing may include one or more connectors 234 , which may connect bottom plate 224 with support-receiving element 230 . Connectors 234 may include for example, a rod (e.g., 234 a ), a plate, a bar (e.g., 234 b ), a U-shaped component (e.g., 234 c ) or a hook. Connector 234 may be independent of support-receiving element 230 (e.g., connectors 234 a and 234 b are distinct from support-receiving elements 230 a and 230 b ) or connector 234 may comprise support-receiving element 230 (e.g., connector 234 c comprises support-receiving element 230 c ).
In some embodiments, bottom plate 224 is rigidly connected to support 240 . For example, hooks of connector 234 c may be firmly attached to support 240 , or a shape or material of the hook may discourage movement of support 240 relative to component 234 c. In some embodiments, connectors 234 and/or support-receiving element 230 c are configured to allow support 240 to move relative to bottom plate 224 . For example, support 240 may be able to slide and/or expand longitudinally (and independently of bottom plate 224 ) within support-receiving element 230 a. As another example, hooks of connector 234 c may permit movement of support 240 relative to component 234 c.
FIG. 2 shows a plurality of connectors 234 connecting bottom plate 224 to a single support 240 . In some instances, support 240 is connected to bottom plate 224 by a single connector. For example, connectors 234 may include a vertically oriented plate that extends across a substantial portion or across the entire bottom plate 224 in the longitudinal direction 226 a. As another example, a single component (e.g., a post) may be positioned substantially in the center of bottom plate 224 along the longitudinal direction 226 a.
FIG. 2 shows a variety of support-receiving elements 230 and a variety of connectors 234 . A bushing system may include a plurality of support-receiving elements 230 (e.g., to receive multiple supports 240 ) and a plurality of connectors 234 . In some instances, the connectors are all of the same type and/or the support-receiving elements are all of the same type. In other instances, a system may include multiple types of connectors and/or multiple types of support-receiving elements (e.g., as shown in FIG. 2 ). While FIG. 2 shows pairs between specific types of connectors 234 and support-receiving elements 230 , the pairs may be rearranged and/or other types of connectors 234 and support-receiving elements 230 not specifically described herein may be used.
Fiber Manufacturing Process
FIG. 6 shows a process 600 for manufacturing fibers. At 605 , a bushing system is provided. The bushing system may include any parts and may have any properties described herein. For example, the bushing system may include a bushing, supports to support a bottom plate of the bushing, a frame to support the supports, a friction-reducing means to reduce the effective friction between the supports and the frame, and a space—void of refractory insulating castable—surrounding a portion of the supports outside the bushing.
At 610 , a molten material is received into a bushing of a bushing system. In some instances, a forehearth receives the molten material (e.g., a molten glass) from a refining zone of a melting furnace. While the material is in the forehearth, the temperature of the molten material may decrease and/or the molten material may be mixed. A plurality of refractory lined legs may extend from the forehearth to one or more bushings. The molten material may pass through a screen of the bushing, which may prevent contaminants in the molten material (e.g., fragments from the refractory lined legs) from entering the bushing.
At 615 , heat is applied to the bushing. In some instances, bushing is electrically heated, e.g., by applying current to electrical terminals connected to the bushing. The bushing may be heated to a temperature that is within a center or upper portion of a fiberizing range for the material. If the temperature is too high, the material flowing out of holes of the bushing may form into discrete droplets and may not be able to be pulled into fibers. If the temperature is too low, the fiber may subsequently break due to excessive shear stresses during attenuation of the fiber. Thus, the bushing may be maintained at a temperature not associated with either of these disadvantages. The bushing may need to be maintained at a temperature higher than the ideal fiberizing temperature, as cooling may occur within tips under a bottom plate of the bushing. In some instances, the bushing is maintained at a temperature that is at least, equal to, or up to about 1,800° F., 2,000° F., 2,200° F., 2,400° F., 2,600° F., or 2,800° F. The temperature may be one which allows the molten material to exit tips underlying a bottom plate in the upper portion of the fiberizing range, such that the molten material exiting the tips forms into cones at the end of tip.
At 620 , molten streams (produced through holes of the bushing) are received. In some instances, the molten material itself creates a sufficient head pressure to cause the material to exit through holes on a bottom plate, thereby forming molten streams. The streams may be received closely below each tip end under the bottom plate. In some instances, the molten streams comprise a molten cone formed under tips underlying the bottom plate. For example, they may be received within a fraction of an inch below the tip end. A high-speed winder may catch the streams and may subsequently attenuate them.
At 625 , the streams are attenuated. During attenuation, the diameter of the streams may be decreased by a factor of, for example, at least, equal to, or up to about 2, 5, 10, 20, 50 or 100, to result in diameters of, for example, at least, equal to, or up to about 1, 5, 10, 13, 16, 19, 25, 50 or 100 microns. The winder may apply tension and pull the streams at hundreds to thousands of feet per minute to reduce the diameter. The molten material may be cooled during the attenuation. At 630 , the attenuated streams are solidified by continuing to cool the material.
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A bushing system includes a bushing having a bottom plate with a plurality of holes from which filaments are drawn. At least one elongated support extends through the bushing generally along a longitudinal axis to hold and stabilize the bushing. To handle the harsh conditions under which the bushing is subjected, the support comprises an alumina-based ceramic that generally resists sagging or excessive expansion and contraction during heating and cooling.
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This invention relates to an apparatus for manufacturing slats for a shutter on the surface of which ribs or other embossing patterns or shapes are applied by using an embossing roll for forming the patterns on the surface of the slat to be used for a shutter.
It is well known that metal band sheet may be formed into the configuration of a slat of a shutter by cold roll forming, as in U.S. Pat. No. 3,264,724 issued on Aug. 9, 1966.
In such a cold roll forming apparatus, a number of forming roll members each composed of an upper roll and a lower roll are disposed along a path line of the material and the material fed through these roll members are gradually formed into the configuration of a slat for a shutter.
It has been desired to provide patterns on the surface of such a slat, in order to improve the appearance and the strength of the slat. And for this purpose, metal band sheet already embossed by steel band manufacturers may be used and the material may then be formed into a slat configuration in a cold roll forming apparatus. However, not only has it been difficult to obtain metal bands having the desirable patterns, but there is the problem that the patterns such as ribs still remain in the interlocking part of the slats, which prevents smooth movement between linked slats when winding the shutter. When the slats are wound around a shutter winding drum, slats are piled around and the surfaces of the slats rub against each other, which results in wearing of the coating on the surface of the slats. Therefore, it has been difficult to form embossing patterns on the surface of a slat.
Therefore, it is an object of this invention to provide an apparatus for manufacturing a slat for a shutter having embossing patterns as ribs on a desired part of the surface of the slat.
SUMMARY OF THE INVENTION
In order to implement the above and other objects of this invention, the present invention uses the conventional roll forming apparatus and an embossing roll is additionally inserted in the apparatus so as to form desired patterns on the surface of a slat at the desired forming stage of the material. Therefore, the forming of the patterns on the slat surface may be made with the forming process of the slat configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features, objects and advantages of the present invention will become apparent by the following description with reference to the attached drawings in which:
FIG. 1 is an explanatory view of a slat whose central surface is almost flat;
FIG. 2 is another explanatory view of a slat whose central surface further has longitudinal ribs;
FIG. 3 is a view of a slat of an embodiment of this invention having additional patterns between the side ribs shown in FIG. 2;
FIG. 4 is a view showing an example of patterns formed in the central flat surface of the slat according to the apparatus of this invention;
FIG. 5 is a view showing another example of patterns formed in the slat by the apparatus of this invention;
FIG. 6 is a side view of an embodiment of a roll forming apparatus according to this invention;
FIG. 7 is a plan view of the apparatus of FIG. 6;
FIG. 8 is a perspective view, in a partly exploded form, of a main roll member including a pattern embossing portion the member being inserted in the apparatus; and
FIG. 9 is a perspective view, partly exploded, of an auxiliary roller member inserted in the apparatus, the member including a pattern embossing portion.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1-3, there are shown slats 1a, 1b and 1c, whose both edges are bent so as to enable interlocking with other slats in a completed shutter. The central surface of the slat in FIG. 1 is almost flat. In FIG. 2, continuous and longitudinal ribs 3 are formed in parallel with each other. These longitudinal ribs 3 will strengthen the slat.
In FIG. 3, further embossing patterns 4 are provided between both ribs 3. It will be realized therefore that the ribs 3 form a concave surface therebetween and this concave surface at the central portion of the slat prevents any damage to the patterns when a shutter is wound around the shutter winding drum. The patterns embossed in the central portion of the slats may be ribs or any other patterns. In FIG. 4, the patterns provided are ribs 4 protruded downwardly in the figure, and in FIG. 5, there are shown texturized patterns 4.
The present invention can form any slat configuration such as FIGS. 1, 2 and 3 through the conventional roll forming apparatus by preparing various rolls. For example, an embossing roll member for forming the patterns shown in FIGS. 3-5 or that for the ribs 3 may be included in the apparatus or both of them may be included and used together. In the apparatus according to this invention, the necessary embossing rolls may be mounted already in the apparatus, so that when the rolls for ribs 3 and patterns 4 are mounted, the slat formed by the apparatus may at first take the configuration of FIG. 1 at the first stage, and then take the configuration of FIG. 2 at the next stage by the embossing roll for the ribs 3. Then the slat may finally be formed with the patterns 4 by the roll for such patterns as shown in FIG. 3.
In the roll forming apparatus shown in FIGS. 6 and 7, the numeral 5 is a drive housing and the numeral 6 denotes an outboard housing, between which a main roll member 12 (FIG. 8) for forming a slat (not shown) is mounted. The numeral 7 in the figures is an inlet guide stand for metal band material, and 8 is a side roll stand. The numeral 9 is a stand for an auxiliary roll member. The numeral 10 is a motor and the main roll members are driven by this motor 10 through a transmission 11. The drive housings 5 receive power from a common driving shaft through gears provided in the respective housings 5.
A band material of a determined width is fed through the apparatus to form a slat in a continuous manner. The formed slat is cut into a desired length with a cutter, not shown. The cut slats are then connected respectively at the interlocking parts thereof with other slats so as to provide a shutter curtain.
Both the main roll member and the auxiliary roll member may comprise an upper roller and a lower roller, and they may be in an integral or separate member. The separate type of the main roll member 12 is shown in FIG. 8 and the integral auxiliary roll member 16 is shown in FIG. 9. The separate elements of the roll are formed into a roll by clamping, etc. This separate type has a lower production cost than the former integral type, because the patterns may only be embossed in a single roll element of the roll. For example, a roll element for forming the almost flat intermediate portion 2 (see FIG. 1) may only be replaced with other element for forming desired patterns.
The upper and lower roll shafts are connected to the driving source and the upper rolls may be respectively moved upward when not to be used. Therefore, plural embossing rolls may be included in the apparatus and the upper roll not to be used may only be lifted and removed from the path line. The metal band only slips on the lower rolls and no patterns are formed on their surface.
If there is any concave or convex pattern in the rolls, a difference arises in the circumferential velocity of the rolls, and a good surface finish on the slat may not be obtained. Therefore the forming rolls for the desired patterns are capable of relative rotation. In other words, in the case of the main roll member the gear connected with the driving source can be removed and may be rotated only by frictional power.
The roll forming apparatus generally includes only the main roll members, or alternatively, a single roll member or a plurality of auxiliary roll members are inserted between the main roll members or next to the final main roll member.
Conventionally, the auxiliary roll member in the roll forming apparatus is inserted thereinto for correcting the warping of the material under forming or preventing any displacement of the center position of the material. For example, a roll forming apparatus for forming a special sectional pattern cannot be used for forming another shape because additional stages must be prepared. Therefore, desired auxiliary roll members of generally shorter diameter are added between the main roll members in order to add stages to obtain a better result. The auxiliary roll members are not driven and also both the upper and lower rolls thereof may be made removable from the path line of the material upwardly and downwardly, respectively.
According to a further embodiment of this invention, the auxiliary roll member for forming the desired patterns may be inserted between the main roll members (as shown in FIG. 9), instead of such forming main roll member. The upper and lower rolls of this auxiliary roll member can be removed from the path line upwardly and downwardly respectively, as already explained. When this auxiliary roll member is not used, therefore, the slat material can be fed without contacting the auxiliary roll member.
Either the upper roll or the lower roll of the pair consisting of the main roller member and auxiliary roll member may be etched or engraved for forming the ribs or other patterns, and the other roll may be made of hard urethane or hard rubber. In such a case, the slat material is fed between the rolls and patterns can be formed on the surface thereof. If forming is not required on the slat, the upper roll may only be shifted.
With reference to FIG. 8, a main roll member 12 is supported on two roll shafts 13a and 13b provided between the drive housing 5 and the outboard housing 6. As is clear from FIG. 8, the main roll member 12 is composed of a pair consisting of a lower roll 12a and an upper roll 12b, each of which is composed of separate roll elements. In the main roll member 12, necessary forming is effected to form the desired patterns in the slats. If it is desired that such patterns not be formed in a slat, the rolls may be removed from the line by adjusting screws 18 and 19. In FIG. 8, the numerals 14 and 15 identify adjusting screws to adjust the distance between the upper and lower rolls.
In FIG. 9, an auxiliary roll member 16 is rotatably mounted on two roll shafts 17a and 17b which are supported between auxiliary roll stands 9 and 9. The auxiliary roll member 16 is not driven. In other words, it rotates at a circumferential velocity naturally determined by the flow of the material due to the frictional power between the material and rolls. In the embodiment disclosed, the lower roll 16a and the upper roll 16b are formed in an integral form respectively. But these rolls 16a and 16b may be formed as divided roll elements, as the main roll member of FIG. 8. The numeral 18 is an adjusting screw for adjusting the upward or downward movement of a lower roll shaft 17a, and the numeral 19 is an adjusting screw for an upper roll shaft 17b. With these adjusting screws 18, 19 it is possible to remove the upper and lower rolls 16a and 16b from the path line or to adjust the space between the upper and lower rolls.
As is mentioned above, according to the present invention the conventional roll forming apparatus can be used and an embossing roll may only be treated to have desired patterns to provide a slat of good design. This special roll may be inserted in place of the main roll member or the auxiliary roll member in the roll forming apparatus at any stage of the process, most desirably at the later stage of the process. The desired pattern is formed simultaneously with the forming of the ordinary slat. Particularly, the slat with both ribs 3 and patterns 4 may be produced simply by the apparatus. Thus the present invention provides stronger and well designed shutter slats at a low cost.
Since the slat made according to this invention is superior in strength, the width of the slat can be made larger than the conventional slat, which results in an improvement of the manufacturing efficiency. Also, material may be saved and the efficiency of the manufacturing operation may be improved. Its effect is most important in the manufacture of a shutter.
According to the present invention, a slat with the longitudinal ribs on both sides as in FIG. 2 may be manufactured easily. This provides not only the improvement in design and strength, but also the following feature: That is, at the time of winding the shutter around the upper winding drum, the slats rotate with respect to each other at the interlocking parts and the slats contact each other. By the existence of ribs, contact pressure between the surfaces of the slat is lowered so as to prevent any damage or removal of the coating.
The material used in the manufacture of slats is band steel, and this material may be easily obtained at a relatively low cost.
The foregoing detailed description has been given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as modifications will be obvious to those skilled in the art.
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A cold roll forming apparatus for forming a slat for a shutter having forming rolls successively disposed along a path line of the material and a pattern embossing roll disposed along the path line is shown. Metal band sheet fed through the apparatus is formed into a predetermined slat configuration and simultaneously repeated patterns are embossed on the flat surface of the slat.
BACKGROUND OF THE INVENTION
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BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT
The present invention relates to a synthesis method of alkoxysilanes. In particular, the present invention relates to direct depolymerization of biogenic and other high surface area silica sources using both simple and hindered diols to produce alkoxysilanes in one or two steps that can be separated and purified directly from the reaction mixture by distillation, extraction or filtration followed by solution modification and distillation or extraction.
Although coal and crude oil make up less than 0.01% of the Earth's crust, their utility to society is enormous given that they serve as the basis for much of the world's fuel, for most organic materials ranging from plastic bags to fibers for textiles, to food packaging to major components in flat panel displays, etc. In contrast, silicon (as silica, SiO 2 ) lies just below carbon in the periodic chart, offers many chemical bonding similarities; makes up more than 40% of the Earth's minerals, and yet has much less impact on our society despite being important for applications ranging from solar cells to silicone rubbers to potential drug analogs (1).
In part this problem arises because unlike carbon, silicon-silicon and silicon-carbon double bonds are very hard to synthesize unless sterically stabilized and hence are not easily polymerized using the same chemistries as used for carbon. In part this problem also arises because the silicon-oxygen bond (534 KJ/mol) is one of the strongest bonds found in nature. Thus, most Si containing compounds and materials are produced from metallurgical grade silicon or Si met , which is made by carbothermal reduction of silica with carbon in a high temperature, capital equipment and energy intensive process; see reactions (1)-(3). The much higher purities required for photovoltaic (Si pv ) and electronic (Si eg ) grade silicon require additional processing steps typically those of the Siemens process, reactions (5) and (6), which generate byproduct HCl, which is normally recycled.
Nonetheless, because all chlorosilanes and HCl gas are corrosive, toxic and polluting, such production processes including those used to produce fumed silica (reaction 7) require expensive and extensive safeguards adding to the overall cost of the final products. Because Si met is a kinetic product, where SiC is the thermodynamic product; its synthesis requires electric arc furnace processing at ≈1900° C. adding to the overall cost even for Si(OEt) 4 or Si(OMe) 4 .
Likewise, precipitated silicas are most commonly made via high temperature reaction of sand with sodium carbonate followed by dissolution and precipitation with H 2 SO 4 :
As can be seen, each mole of Na 2 SiO 3 produced releases one mole of CO 2 and requires one mole of H 2 SO 4 producing one mole of precipitated silica and one mole of Na 2 SO 4 , which must be disposed. Thus the production of precipitated (ppt) silicas such as used as filler in polymers (tires for example), as the abrasive in toothpaste, or in vacuum insulation panels also requires high temperatures and generates unwanted byproducts, especially CO 2 and Na 2 SO 4 (1,4).
Reactions (1)-(7) begin with SiO 2 , reduce it to the metal (e.g. Si met ) and then re-oxidize it back; often to some form of SiO 2 including fumed silica. This approach is illogical and because all these processes are equipment and energy intensive, it is unreasonably costly.
Thus, beginning in the early 30's, repeated attempts were made to develop low temperature, low cost methods of depolymerizing silica thereby generating alternate routes to silicon containing compounds as well as precipitated silica and more recently fumed silica. The success of such a process, as suggested by reaction (10) can be considered a “Grand Challenge” for silicon chemists. The idea of being able to distill the resulting product should allow the direct production of very high purity silicon containing materials including precipitated (ppt) SiO 2 directly from any silica source at low temperatures greatly reducing energy costs and the need for high capital equipment investments. There would also be a great advantage in producing fumed silica.
For example, high purity ppt or fumed silica is used in applications ranging from edible products (e.g. toothpaste) to polishing aids for planarizing silicon wafers to the production of high purity silica for optical applications (lenses, gratings, optical fibers, photonic band gap materials) to the production of crucibles for growing electronics grade silicon boules (1,4).
Thus researchers beginning in 1931 with Rosenheim et al (5), followed by Weiss et al (1961), (6) Frye (1964), (7) Boer et al (1968), (8,9) Barnum (1970), (9, 10) and Corriu (1986) (11) explored SiO 2 depolymerization. This work covers a wide range of SiO 2 feedstocks from amorphous silica to quartz powder, but all of these studies focused on some form of reaction (11) generating hexacoordinated triscatecholato Si I (5-11).
The key to the success of this reaction is the fact that silicon, unlike carbon, is able to form five and six bonds and thus the original Si—O bond strength of tetrahedral silicon is diminished. Unfortunately, I cannot be distilled and is so stable that it is water-soluble and would have to be reacted with H 2 O 4 to produce ppt. SiO 2 . From a practical perspective, this process while offering a low temperature route to ppt SiO 2 would require three moles of catechol per mole of ppt SiO 2 or ≈330 g of catechol to produce 60 g of ppt SiO 2 and coincidentally 280 g of Na 2 SO 4 . This is quite unattractive; although no CO 2 would be produced.
A search for something simpler than catechol led us to try ethylene glycol (ca 1988) to promote silica depolymerization according to reactions (12) and (13), (12, 13). The depolymerization mechanism again builds on expansion of the coordination sphere around silicon.
Still more recently, we were able to demonstrate that reaction (12) can be promoted catalytically using alkali base, reaction (14), (14,15). Our proof-of-principle studies were done with fumed silica (350 m 2 /g), which defeats the overall objective of the “Grand Challenge;” however, these studies were important as they determined that: (1) reaction (14) is first order in base concentration and surface area; (2) the activation energy for the reaction is 60 kJ/mol; and (3) the reaction is faster with amorphous rather than crystalline silica (14). Unfortunately, the tetraglycoxysilane or GS cannot be distilled, it forms polymers [i.e. Si(eg) 2 ] on heating and is thus difficult to purify and therefore is again not a solution to the grand challenge although it is closer to what is desired.
As a consequence, we sought amorphous biogenic silica sources with high surface areas identifying rice hull ash (RHA) and diatomaceous earth (DE) as reasonable replacements for fumed silica. RHA is produced in 250 k ton/yr quantities in the U.S. alone, is mostly amorphous and offers specific surface areas (SSAs) typically of ≈20-80 m 2 /g. The samples used in our study are 70-90 wt % silica with 5-20 wt % carbon and 5 wt % minerals that are removed easily by washing with dilute HCl (16). We also were able to obtain a sample of rice hulls that had been ashed at ≧600° C. (A-RH) to produce a material that was >95 wt % silica and with SSAs≈230 m 2 /g. DE is available from multiple sources with SSAs ranging from 1-70 m 2 /g and is mostly amorphous.
Many plants ranging from diatoms to grasses to trees take soluble silica from water sources and transport it within their systems and deposit it in various forms and places ranging from the shells of diatoms, to the cells of hard woods, to rice hulls and stalks. In the majority of instances the transport systems involved in the biosilificiation process are not designed to also transport heavy metals. Consequently biogenically deposited silica is relatively free of heavy metal impurities making it a prospective source for high purity silicon containing materials ranging from alkoxysilanes to silica to silicon nitride to silicon carbide to silicon metal. Biogenically produced silica can be defined as being a sustainable resource as for example in the case of any currently farmed silica accumulating plant. Their availability in industrially meaningful quantities as byproducts of existing human efforts to produce food and fiber makes this resource commercially important.
For example, rice hulls are produced in 100 million ton quantities annually world-wide as a generally undesirable byproduct of rice milling (17,18). They can contain 12-20 wt % silica in an amorphous, high surface area form. There are now multiple studies in the patent and open literature on the recovery of silicon containing materials from rich hulls. Thus, rice hulls and rice hull ash have been used as a starting point to make solar grade silicon, silicon carbide, silicon nitride and also to recover relatively pure silica through dissolution with a base such as alkali or alkaline earth carbonates or hydroxides, tetramethylammonium or choline hydroxide as noted in the following references and references used in these papers which are incorporated herein as prior art (1-18).
In a recent patent (U.S. Pat. No. 8,916,122), we described a method of producing alkoxysilanes and precipitated silicas from biogenic silicas and GS in particular. In a first step, biogenically concentrated silica is mixed with a liquid polyol and then is heated to distill out residual water. In a second step, a base is added and the reaction is heated to distill out the water that forms as shown in reactions (14) and (15).
In this patent it was suggested but never reduced to practice that it should be possible to produce distillable alkoxysilanes in the form of spirosiloxanes (19); however, this patent never discusses the production of simple alkoxysilanes such as TEOS.
SUMMARY OF THE INVENTION
Thus, in the current patent, we have explored and reduced to practice both synthesis methods. The diversion from the original patent is as follows:
At this juncture, processing can take one of two routes. In the simpler version, a spirosiloxane product, as suggested in reaction (15), can be distilled directly from the reaction mixture if it has a boiling point below of near that of the liquid polyol. Alternately, for boiling points higher than the polyol, filtration removes the carbon enriched RHA or other undissolved biogenic silica to recover the solution of alkoxysilane, pentacoordinated silicate and polyol. Thereafter the formed alkoxysilane is purified by filtering if it forms a solid on cooling, distilling the polyol from the alkoxysilane, or by extraction from the original reaction solution using a solvent for the alkoxysilane that is a non-solvent for the polyol.
Still another method of separation not recognized previously is the use of a membrane that selectively passes the non-polar alkoxysilane but rejects the polar polyol and other reactants. Alternately, the residual base present in polyol/alkoxysilane solution is neutralized to eliminate the residual alkali metal base and the various purification processes as just noted can be conducted. The resulting solutions or spirosiloxanes can thereafter be treated to produce simple alkoxysilanes as detailed below.
Another important function of such a process would be to coincidentally, inexpensively and accurately reduce the total silica content in rice hull ash with the intent to precisely raise the relative carbon content as practiced in U.S. Pat. No. 8,475,758.
In this invention we demonstrate that it is possible to dissolve the silica in RHA or other biogenic sources of silica using a catalytic amount of base and a high boiling solvent that contains at least two hydroxyl groups capable of chelating the silicon atom as it is catalytically extracted from any silica surface to form a stable spirosiloxane or a polymeric analog as suggested in reactions (14)-(16).
U.S. Pat. No. 8,916,122 suggests that it is possible to make spirosiloxanes from biogenic silicas but no examples were presented. In this patent, we provide examples of the synthesis of spirosiloxanes directly from biogenic silica but more importantly, we also provide examples of the direct and indirect synthesis of simple alkoxysilanes from the same sources and also demonstrate the production of fumed silica directly from both types of materials. Our processes are advantageous because they:
(1) greatly reduce the base needed to dissolve any biogenic silica but especially RHA; (2) allow direct distillation of a spirosiloxane from the reaction solution without need for further filtration and recovery/purification thereafter; (3) permit the transformation of glycoxysilanes, e.g. Si[(CH 2 CH 2 O) m (CH 2 ) n OH] 4 or Si[CH 2 (CH 2 )nOH] 4 (m, n=1-10) or its polymeric form for example Si(eg) 2 directly into easily separated alkoxysilanes such as Si(OEt) 4 , TEOS. (4) The direct use of either the spirosiloxane or TEOS for the production of colloidal, precipitated or fumed silica without first making SiCl 4 .
All of these advantages provide lower cost materials, avoid high temperatures and excessive release of CO 2 and the need for costly capital equipment and high energy expenditures. Furthermore, the production of electricity coincident with the production of RHA makes these processes energy positive and since the energy comes from rice plants that take CO 2 out of the air to make carbon containing materials, the whole process is close to carbon neutral.
The examples of U.S. Pat. No. 8,916,122 provide the basic methods we use in the current discovery; however, some of the methods require modifications that are not obvious to one of average skill. The examples of Table 1 are conducted using standard conditions as listed. These conditions are meant to be exemplary rather than optimal. Some of the examples listed below involve larger scale efforts to demonstrate scalability and to explore partial optimization, which proves to be possible.
Table 1 also presents the characterization data for the starting materials that include both biogenic and mineral sources of silica, the reaction products and coincidentally compares the extent of dissolution using standard conditions listed. With the exception of vermiculite, all of the sources are amorphous silica. In general, the amount of SiO 2 that dissolves for all sources relates to specific surface areas, SSAs and reaction temperatures. Vermiculite's low silicon content and crystallinity are likely at least partially responsible for its poor dissolution rates.
TABLE 1
Percent SiO 2 depolymerized; 0.3 mol SiO 2 , 0.03 mol NaOH, 300 ml distilled, 4-8 h.
Diol (bp° C.)
2-methyl-2,4-
2,2,4-trimethyl-
SSAs
EGH 2
HO(CH 2 ) 4 OH
pentanediol
1,3-pentanediol
SiO 2
m 2 /g
(197°)
(235°)
(197°)
(232°)
Celite
1
12%
13%
4%
1.5%
Vermiculite 4
2.5
3
3
—
RHA
26
20
23
24
12
DE
23
16
18
4
3
Fumed SiO 2
350
98 +
98 +
98 +
98 +
A-RH
230
60
—
Mass
Spiro
Spiro
Spiro
Spiro
Spec. †
149, 80%
205, 15%
260, I = 15%
316, I = 7%
intensity 23
intensity
—CH 3 245 100%
273 (—Me 2 CH)
I = 30%
1- H (δ)
Si(glycoxy) 4 23
C H 2 O 3.41, C H 2
C H OH 4.20,
C H OH 3.7, C H 2 OH,
C H 2 O 3.74
1.45
C H 2 1.47, 1.64
3.32, C H 1.87
C H 2 OH 3.94
Si(OROH) 4
C H 3 1.30, 1.24, 1.18
C H 3 0.73, 0.75, 0.95,
C H 2 O 3.70
II
III
C H 2 1.65
C H 2 O 4.30,
C H O 3.4, CH 2 O,
C H 2 1.48, 1.66
3.20, C H 1.59
C H 3 1.28, 1.22, 1.18,
C H 3 0.87, 0.88, 0.97,
13- C (δ)
Si(glycoxy) 4 23
C H 2 O 62.55
C (Me) 2 OH 71.56,
C H 2 OH, 83.11
C H 2 O 3.74
C H 2 29.84
C (H,Me)OH 65.64,
C HOH 73.3, C
C H 2 OH 3.94
Si(OROH) 4
C H 2 49.47
39.04,
C H 2 O 64.80
(C H 3 ) 2 31.82, 27,71,
C H 29.08 C H 3
C H 2 31.99
C H 3 24.31
23.27, 19.66, 16.60,
II
III
C (Me) 2 OH 74.63, 74.38
C HO 82.52, C H 2 O
C (H,Me)OH
69.17, C 40.80?
67.82, 67.60
C H 30.57 C H 3
C H 2 48.40, 48.32
23.11, 18.72, 15.16
(C H 3 ) 2 32.20, 27.98
C H 3 24.17
29 Si (δ)
−82
−82
−82
−81.85
† MALDI, EI, FABS 29 Si NMRs show GS is analogous to LEOS and Si(OBu—OH) 4 peak, spirosiloxane shifted.
1 H, 13 C NMRs suggest chirality in spirosiloxanes, likely a racemic mixture.
Thus for all sources, SiO 2 depolymerization in 1,4-butanediol is greater than in EGH 2 (b.p. 200° C.) as the former boils some 40° C. higher than the latter. The depolymerization rates for 2-methyl-2,4-pentanediol (b.p. 200° C.) are similar but not quite as high as EGH 2 . Dissolution of celite and diatomaceous earth are not always effective as mass spectral analyses suggest that the diol “cracks” producing propanol as the major product rather than the spirosiloxane II. Both DE and Celite likely have highly acidic sites that account for the observed cracking products. The ashed rice hulls give the second highest dissolution under standard conditions, as might be expected with SSAs of ≈230 m 2 /g.
Vermiculite is a common aluminosilicate mineral with no free SiO 2 available for dissolution, yet some dissolution obtains. We have not characterized the product(s); although some alumina dissolution may occur concurrently given Al-EG complexes have been reported previously (20).
The distillation of 2-methyl-2,4-pentanediol and II occur at nearly the same temperature making isolation and purification somewhat problematic. However, we were pleasantly surprised to find that both II and 2-methyl-2,4-pentanediol are hexane soluble with the diol also being water soluble. Hence simply washing hexane solutions of the recovered, distilled mixture or the reaction filtrate removes the diol and leaves pure II, which is easily recovered and can be redistilled at ≈200° C. to give much higher purities. Simple rotary evaporation leads to II as a liquid that slowly crystallizes on cooling (21,22).
Compound III and the parent diol are also hexane soluble but the diol is not water soluble; however, III can be isolated simply by washing with MeOH. Both spirosiloxanes can be distilled to higher purity. Both II and III are the first examples of a distillable form of silica made at low temperatures directly from biogenic silica.
What is not obvious in the Table 1 studies is that if one were to use 2-methyl-2,4-pentanediol as the diol under the stated reaction conditions but with a standard rice hull ash, the rate of dissolution would be closer to 45% (Example 1). This same rice hull ash treated under similar conditions but in EGH 2 undergoes silica dissolution in much shorter times but to the same conversions as demonstrated in Example 2. In this instance, the synthesis of spirosiloxane II for example is best done by adding 2-methyl-2,4-pentanediol to the already dissolved GS of Example 2.
Perhaps most important is that it is possible to isolate by filtration and concentrate GS per Reaction (14) and thereafter add methanol, ethanol or other simple alcohol to create an equilibrium as shown in reaction (16). Note that a different diol can be used in reactions like (16) as illustrated in the Table 1 examples. Thereafter, equilibration provides a significant amount of Si(OR) 4 that can be recovered in several ways.
The simplest method is simply to distill the product. The next simplest is to extract the Si(OR) 4 into hexanes or other hydrocarbon solvent and simply remove the solvent by evaporation. This can offer moderate to excellent yields as demonstrated in the examples. If the hydrocarbon phase and the alcohol phase are not miscible then the extraction of the Si(OR) 4 into the hydrocarbon phase can drive the reaction (16) equilibrium and more Si(OR) 4 can form and again be drawn into the hydrocarbon phase.
As an alternative, passing the solution through or immersing in the solution, a semipermeable membrane that is permeable only to Si(OR) 4 and not to the Si polymer of (16) or the ROH used in the equilibration process, then Si(OR) 4 can be drawn off as it forms and this will again drive equilibration. The latter two approaches have the advantage of minimizing the amount of ROH used in the exchange process. Note that the rate of equilibration will be improved if the process is acid or base catalyzed. The base that is already present in the original reaction solution will serve as a catalyst for equilibration as seen in Example 14. Alternately the addition of a non-aqueous acid or acid anhydride will catalyze the equilibration without also generating precipitated silica. The acid could be an organic acid or anhydride or HCl or CO 2 gas or other acid known to a general practitioner of the art of alkoxy exchange, e.g. in transesterification.
The recovered Si(OR) 4 can be further purified to a high degree by distillation. The resulting Si(OR) 4 or the originally recovered spirosiloxane can thereafter be combusted using a variety of methods as described in Example 15 but also by simple combustion in H 2 /O 2 flames in the form as an aerosol. The advantage to the current approach is that the combustion process does not involve the use of toxic, polluting and corrosive SiCl 4 and therefore does not need the capital and equipment intensive methods inherent in the use of SiCl 4 . Indeed, the 100 m long tube normally used with SiCl 4 can be replaced with a combustion tube of just a few meters long, e.g. 1-10 meters (23).
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BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing TGA-DTA of silica depleted RHA after the work-up of spirosiloxane;
FIG. 2 is a graph showing GPC of tetraethoxysilane, Gelest; tetramethoxysilane, Sigma-Aldrich; TEOS from Si(2-methyl-2,4-pentanediolato) 2 (SP); TMOS Si(2-methyl-2,4-pentanediolato) 2 (SP); TEOS from glycoxysilane (GS); and TEOS from Si(1,4-butanediolato) 2 (BSP);
FIG. 3 is a photograph showing that colloidal silica at pH 1 is transparent with no light scattering;
FIG. 4 is a photograph showing that gelled silica at pH 7 after neutralization with Na 2 CO 3 and for standing 30 min shows extensive scattering but likely due to bubbles;
FIG. 5 is a photograph showing that addition of 10 mL of ethanol to silica at pH 7, shows scattering from disruption of diol chelation;
FIGS. 6( a ), 6( b ), and 6( c ) are photographs showing TEM images of fumed SiO 2 , wherein FIG. 6( a ) is LF-FSP of compound I, FIG. 6( b ) is LF-FSP of TEOS, FIG. 6( c ) is commercial; and
FIGS. 7( a ) and 7( b ) are graphs showing FTIR of fumed SiO 2 , wherein FIG. 7( a ) is LF-FSP, FIG. 7( b ) is commercial.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Hereunder, preferred embodiments of the present invention will be explained with reference to the accompanying drawings.
Example 1. 2-methyl-2,4-pentanediol Dissolution Reaction Just Run, ˜45% Conversion
RHA (1000 g, 85 wt. % silica content, 14.16 moles of silica) was dissolved in 10 L of 2-methyl, 2,4-pentanediol (hexylene glycol, HG) and placed in a 22 L flask, equipped with a heating mantle and a mechanical stirrer. Then, catalyst (10 mol. % NaOH) dissolved in 900 mL of ethanol was added to the reaction flask. The reaction mixture was slowly heated and refluxed for 2 days. Then the distillation started—first the ethanol/water was distilled out, and then the temperature was increased to start the SP/HG distillation. SP was distilled out and fresh HG added. The distillation was carried about 40 h and ˜9 L of distilled SP was collected, and then worked up (addition of hexane and three water washing steps). After addition of hexane, the solution formed two immiscible layers (diol and hexane) that were separated prior the washing steps. Then the hexane layer (containing the spirosiloxane product) was washed with water three times, dried over sodium sulfate and collected. In the final step the hexane was removed on a rotary evaporator to yield the product (1624 g of spirosiloxane). This means that we were able to extract ˜45% silica from the starting RHA. The theoretical yield for 45% silica dissolution is 1657 g (98% yield).
Example 2. Ethylene Glycol Dissolution Reaction Just Run With HG Added 40% Conversion
RHA (630 g, 7.87 moles of silica) was placed in a 12 L flask, equipped with a heating mantle and a mechanical stirrer. Catalyst (10 mol. % NaOH) was added with 7 l of EGH 2 and distillation started. Silica dissolution rates are seen in Table 1.
TABLE 1
Percent silica dissolved (by LOI) from processed RHA with 10 mol.
% NaOH.
Time, h
Silica Dissolution
6
28.2%
12
31.7%
18
35.4%
24*
37.1%
*At 37% dissolution, the reaction was converted to synthesize spirosiloxane (SP).
Then, 3.5 L of 2-methyl, 2,4-pentanediol (hexylene glycol, HG) was added and spirosiloxane distillation commenced. SP was distilled out (˜3 L) and collected, and then worked up (addition of hexane and three water washing steps). After addition of hexane, the solution formed two immiscible layers (diol and hexane) that were separated prior the washing steps. Then the hexane layer (containing the spirosiloxane product) was washed with water three times, dried over sodium sulfate and collected. In the final step the hexane was removed on a rotary evaporator to yield the product (spirosiloxane) giving ˜507 g spirosiloxane (˜80% yield).
The remaining RHA was washed with ethanol and filtered off and analyzed by TGA-DTA, FIG. 1 . TGA-DTA of RHA showed 43 wt. % silica content. This means that we were able to extract almost half of the silica from the starting RHA (74.9 wt. % silica content).
Example 3. Conversion of I to TEOS
To a flame dried 500 mL round bottom flask equipped with magnetic stirrer under N 2 were added ˜25 mL of activated 4 Å molecular sieves, 10 g (0.038 mol) of Si(2-methyl-2,4-pentanediolato) 2 (I), and 400 mL of dry 200 proof ethanol. The reaction mixture was allowed to stir for 1 h before addition of 2.5 mL (0.015 mol) of TFA. The reaction was left to stir at room temperature for 24 h. It was then filtered to remove molecular sieves and precipitated solids formed during the reaction process (ROP/silica byproducts). Then 400 mL of hexanes was added to the filtered solution and washed with water (3×150 mL) to remove TFA and diol. The pH of the resulting hexanes solution was then checked for neutrality. The hexanes solution was then dried over Na 2 SO 4 and filtered. Then the solvent was removed in-vacuo, resulting in a colorless oil of Si(OEt) 4 as determined by GPC, yield 5.2 g, 65%.
Example 4. Conversion of I to TEOS
To a flame dried 250 mL round bottom flask equipped with magnetic stirrer under N 2 were added ˜10 mL of activated 4 Å molecular sieves, 5 g (0.019 mol) of Si(2-methyl-2,4-pentanediolato) 2 (I), and 200 mL of dry 200 proof ethanol. The reaction mixture was allowed to stir for 1 h before addition of 0.625 mL (0.008 mol) of TFA. The reaction was left to stir at room temperature for 24 h. It was then filtered to remove molecular sieves and precipitated solids formed during the reaction process (ROP/silica byproducts). Then 800 mL of hexanes was added to the filtered solution and washed with water (3×300 mL) to remove TFA and diol. The pH of the resulting hexanes solution was then checked for neutrality. The hexanes solution was then dried over Na 2 SO 4 and filtered. Then the solvent was removed in-vacuo, resulting in a colorless oil of Si(OEt) 4 as determined by GPC, yield 2.3 g, 63%.
Example 5. Conversion of I to TEOS
To a flame dried 250 mL round bottom flask equipped with magnetic stirrer under N 2 were added ˜10 mL of activated 4 Å molecular sieves, 5 g (0.019 mol) of Si(2-methyl-2,4-pentanediolato) 2 (I), and 200 mL of dry 200 proof ethanol. The reaction mixture was allowed to stir for 1 h before addition of 0.45 mL (0.006 mol) of TFA. The reaction was left to stir at room temperature for 24 h. It was then filtered to remove molecular sieves and precipitated solids formed during the reaction process (ROP/silica byproducts). Then 400 mL of hexanes was added to the filtered solution and washed with water (3×150 mL) to remove TFA and diol. The pH of the resulting hexanes solution was then checked for neutrality. The hexanes solution was then dried over Na 2 SO 4 and filtered. Then the solvent was removed in-vacuo, resulting in a colorless oil of Si(OEt) 4 as determined by GPC, yield 2.2 g, 61%.
Example 6. GS Conversion to TEOS
To a flame dried 500 mL round bottom flask equipped with magnetic stirrer under N 2 were added ˜25 mL of activated 4 Å molecular sieves, 10 g (0.036 mol) of glycolato silicate (GS), and 400 mL of dry 200 proof ethanol. The reaction mixture was allowed to stir for 1 h before addition of 2.5 mL (0.015 mol) of TFA. The reaction was left to stir at room temperature for 24 h. It was then filtered to remove molecular sieves and precipitated solids formed during the reaction process (ROP/silica byproducts). Then 800 mL of hexanes was added to the filtered solution and washed with water (3×300 mL) to remove TFA and diol. The pH of the resulting hexanes solution was then checked for neutrality. The hexanes solution was then dried over Na 2 SO 4 and filtered. Then the solvent was removed in-vacuo, resulting in a colorless oil of tetraethoxysilane. Crude yield 2.5 g, 40%.
Example 7. GS Conversion to TEOS
To a flame dried 250 mL round bottom flask equipped with magnetic stirrer under N 2 were added ˜10 mL of activated 4 Å molecular sieves, 5 g (0.018 mol) of glycolato silicate (GS), and 200 mL of dry 200 proof ethanol. The reaction mixture was allowed to stir for 1 h before addition of 0.625 mL (0.008 mol) of TFA. The reaction was left to stir at room temperature for 24 h. It was then filtered to remove molecular sieves and precipitated solids formed during the reaction process (ROP/silica byproducts). Then 400 mL of hexanes was added to the filtered solution and washed with water (3×150 mL) to remove TFA and diol. The pH of the resulting hexanes solution was then checked for neutrality. The hexanes solution was then dried over Na 2 SO 4 and filtered. Then the solvent was removed in-vacuo, resulting in a colorless oil of tetraethoxysilane. Crude yield 1.46 g, 40%.
Example 8. GS Conversion to TEOS
To a flame dried 250 mL round bottom flask equipped with magnetic stirrer under N 2 were added ˜10 mL of activated 4 Å molecular sieves, 5 g (0.018 mol) of glycolato silicate (GS), and 200 mL of dry 200 proof ethanol. The reaction mixture was allowed to stir for 1 h before addition of 0.45 mL (0.006 mol) of TFA. The reaction was left to stir at room temperature for 24 h. It was then filtered to remove molecular sieves and precipitated solids formed during the reaction process (ROP/silica byproducts). Then 400 mL of hexanes was added to the filtered solution and washed with water (3×150 mL) to remove TFA and diol. The pH of the resulting hexanes solution was then checked for neutrality. The hexanes solution was then dried over Na 2 SO 4 and filtered. Then the solvent was removed in-vacuo, resulting in a colorless oil of tetraethoxysilane. Crude yield 2.1 g, 56%.
Example 9. GS Conversion to TEOS
To a flame dried 250 mL round bottom flask equipped with magnetic stirrer under N 2 were added ˜10 mL of activated 4 Å molecular sieves, 5 g (0.018 mol) of glycolato silicate (GS), and 75 mL of dry 200 proof ethanol. The reaction mixture was allowed to stir for 1 h before addition of 0.625 mL (0.008 mol) of TFA. The reaction was left to stir at room temperature for 24 h. It was then filtered to remove molecular sieves and precipitated solids formed during the reaction process (ROP/silica byproducts). Then 400 mL of hexanes was added to the filtered solution and washed with water (3×150 mL) to remove TFA and diol. The pH of the resulting hexanes solution was then checked for neutrality. The hexanes solution was then dried over Na 2 SO 4 and filtered. Then the solvent was removed in-vacuo, resulting in a colorless oil of tetraethoxysilane. Crude yield 1.4 g, 40%.
Example 10. GS Conversion to TEOS
To a flame dried 250 mL round bottom flask equipped with magnetic stirrer under N 2 were added ˜10 mL of activated 4 Å molecular sieves, 5 g (0.018 mol) of glycolato silicate (GS), and 75 mL of dry 200 proof ethanol. The reaction mixture was allowed to stir for 1 h before addition of 0.625 mL (0.008 mol) of TFA. The reaction was left to stir at room temperature for 24 h. It was then filtered to remove molecular sieves and precipitated solids formed during the reaction process (ROP/silica byproducts). Then 400 mL of hexanes was added to the filtered solution and washed with water (3×150 mL) to remove TFA and diol. The pH of the resulting hexanes solution was then checked for neutrality. The hexanes solution was then dried over Na 2 SO 4 and filtered. Then the solvent was removed in-vacuo, resulting in a colorless oil of tetraethoxysilane. Crude yield 2.1 g, 55%.
Example 11. (Butanediolato) 4 Si Conversion to TEOS
To a flame dried 500 mL round bottom flask equipped with magnetic stirrer under N 2 were added ˜25 mL of activated 4 Å molecular sieves, 10 g (0.026 mol) of Si(1,4-butanediolato) 4 (BSP), and 400 mL of dry 200 proof ethanol. The reaction mixture was allowed to stir for 1 h before addition of 2.5 mL (0.015 mol) of TFA. The reaction was left to stir at room temperature for 24 h. It was then filtered to remove molecular sieves and precipitated solids formed during the reaction process (ROP/silica byproducts). Then 800 mL of hexanes was added to the filtered solution and washed with water (3×300 mL) to remove TFA and diol. The pH of the resulting hexanes solution was then checked for neutrality. The hexanes solution was then dried over Na 2 SO 4 and filtered. Then the solvent was removed in-vacuo, resulting in a colorless oil of tetraethoxysilane. Crude yield 710 mg, 14%.
Example 12. I Conversion to TMOS (Biphase System)
To a flame dried 500 mL round bottom flask equipped with magnetic stirrer under N 2 were added ˜25 mL of activated 4 Å molecular sieves, 10 g (0.038 mol) of Si(2-methyl-2,4-pentanediolato) 2 (SP), and 200 mL of dry methanol and 200 mL of dry hexanes (an immiscible mixture). The reaction mixture was allowed to stir for 1 h before addition of 2.5 mL (0.015 mol) of TFA. The reaction was left to stir at room temperature for 24 h. The mixture was then poured into a separatory funnel and the two layers were separated. The hexane layer was then filtered and washed with water (3×300 mL) to remove TFA and residual diol. The pH of the resulting hexanes solution was then checked for neutrality. The hexanes solution was then dried over Na 2 SO 4 and filtered. Then the solvent was removed in-vacuo, resulting in a colorless oil of tetramethoxysilane. Crude yield 3 g, 40%.
Example 13. Conversion of GS to TMOS+Oligomers
To a dry 1000 mL round bottom flask equipped with magnetic stirrer were added 50 g (0.03 mol) of glycolato silicate (16.3 wt. %), and 300 mL of anhydrous methanol. Then 300 mL of hexane were added to the reaction mixture. The reaction was left to stir at room temperature for 24 h. Then the hexane and methanol layers were separated in a sep-funnel and the hexane layer was washed with distilled water (3×300 mL) to remove the diol. The hexane solution was then dried over Na 2 SO 4 and filtered. Then the solvent was removed in-vacuo, resulting in a colorless oil of tetramethoxysilane.
Example 14. Conversion of Si(2-methyl-2,4-pentanediolato) 2 to Colloidal or Precipitated Silica
To a 250 mL round bottom flask equipped with magnetic stirrer were added 10 g (0.038 mol) of Si(2-methyl-2,4-pentanediolato) 2 , 50 mL of 200 proof ethanol, 4 mL of H 2 O and 2 mL of 12N HCl such that the pH is <3. The reaction was left to stir at room temperature for 24 h, resulting in a transparent colloidal dispersion of silica particles as indicated by the lack of laser light scattering in FIG. 3 . The colloidal silica appears to be stabilized by the presence of the 2-methyl-2,4-pentanediol. Addition of Na 2 CO 3 to neutralize the solution results in slow gelation, FIG. 4 . Alternately, the additional ethanol or hexanes causes silica to precipitate rather than gel as the 2-methyl-2,4-pentanediol appears to be solvated and removed from the silica surface.
Example 15. Fumed Silica
Spirosiloxane I was synthesized using the method described above. Distilled I was used for all the following experiments. TEOS was prepared as in Example 3. Methanol, ethanol, and propanol were purchased from Decon Labs (King of Prussia, Pa.). TEOS was purchased from Sigma-Aldrich (Milwaukee, Wis.).
LF-FSP.
Methanol, ethanol or propanol solutions of I and TEOS were obtained by dissolving sufficient I and TEOS to make a 1, 3 or 5 wt % silica ceramic yield solution. The general methods for conducting LF-FSP have been described in references x, y, z.
The properties of the as-produced fumed silica are identical to those of SiCl 4 derived silica and typical particle sizes are as shown in Table 2. Comparative transmission electron micrographs of the silicas are shown in FIG. 5 . Comparative FTIRs for fumed silica produced from I and SiCl 4 are shown in FIGS. 6( a ), 6( b ), and 6( c ) .
TABLE 2
SSA of LF-FSP produced silica.
Precursor
Solvent/Fuel
Precursor concentration (wt %)
SSA (m 2 /g)
SS
MeOH
1
230
3
190
EtOH
1
220
3
190
5
140
PrOH
1
210
TEOS
EtOH
1
230
EtOH
3
180
EtOH
5
150
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The direct depolymerization of biogenic and other high surface area silica sources uses both simple and hindered diols to produce alkoxysilanes in one or two steps that can be separated and purified directly from the reaction mixture by distillation, extraction or filtration followed by solution modification and distillation or extraction. The alkoxysilanes can take the form of spirosiloxanes or simple alkoxysilanes or oligomers thereof. Thereafter they can be treated with acid to produce colloidal or precipitated silica or aerosolized and combusted to provide fumed silica without the intervention of SiCl 4 .
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FIELD OF THE INVENTION
[0001] The invention relates to the field of internet, and in particular, to a system and method for identifying the floor of a main body of a webpage.
BACKGROUND OF THE INVENTION
[0002] With the development and popularization of mobile terminals, people more and more use a mobile terminal to browse a webpage. However, since most websites on the internet do not make a special treatment on the webpage presentation of a mobile terminal, deformations of the presentation of most webpages occur on the mobile terminal, which leads to an extremely poor reading experience for a user.
[0003] The current methods for improving a user's reading experience are to extract and rearrange main bodies of a webpage, and then re-present them to the user. For a news and information webpage with massive content, the effect is good, but user comments will be discarded; for a forum in which a main body is divided into multiple “floors”, etc., the effect is worse: only the main body of a certain floor can be identified, or the main body cannot be identified. Spam word information in a source webpage is not removed, and the content of the webpage does not have a fixed effect, and the effects of the generated webpage and the source webpage will appear.
SUMMARY OF THE INVENTION
[0004] In view of the above problems, the invention is proposed to provide a system and method for identifying the floor of a main body of a webpage which overcome the above problems or at least in part solve or mitigate the above problems.
[0005] According to an aspect of the invention, there is provided a system for identifying a main body of a webpage, which comprises: a webpage parse & layout module configured to parse source codes of the webpage, perform a layout calculation on the parsed result, and generate a DOM tree of the webpage; a node identification module configured to traverse starting from the root node of the DOM tree, and identify a main body node and/or a spam word node in the DOM tree; and a floor division module configured to divide the identified main body node according to floors of the webpage.
[0006] According to another aspect of the invention, there is provided a method for identifying a main body of a webpage, which comprises: parsing source codes of the webpage, performing a layout calculation on the parsed result, and generating a DOM tree of the webpage; traversing starting from the root node of the DOM tree, and identifying a main body node and/or a spam word node in the DOM tree; and dividing the identified main body node according to floors of the webpage.
[0007] According to yet another aspect of the invention, there is provided a computer program comprising a computer readable code which causes a server to perform the method for identifying a main body of a webpage according to any of claims 15 - 28 , when said computer readable code is running on the server.
[0008] According to still another aspect of the invention, there is provided a computer readable medium storing the computer program as claimed in claim 29 therein.
[0009] The beneficial effects of the invention lie in that:
[0010] After the invention identifies and extracts the content of a traditional internet webpage, it may effectively extract a BBS main body, a news main body and comments, and restore a presentation feature of “divided floors” of the content of a main body in the original webpage, of which the presentation effect maintains the original “multi-floor” feature, so as to provide a user with an excellent reading experience.
[0011] The above description is merely an overview of the technical solutions of the invention. In the following particular embodiments of the invention will be illustrated in order that the technical means of the invention can be more clearly understood and thus may be embodied according to the content of the specification, and that the foregoing and other objects, features and advantages of the invention can be more apparent.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Various other advantages and benefits will become apparent to those of ordinary skills in the art by reading the following detailed description of the preferred embodiments. The drawings are only for the purpose of showing the preferred embodiments, and are not considered to be limiting to the invention. And throughout the drawings, like reference signs are used to denote like components. In the drawings:
[0013] FIG. 1 shows schematically a structure diagram of a system according to an embodiment of the invention;
[0014] FIG. 2 shows schematically a flow chart of a method according to an embodiment of the invention;
[0015] FIG. 3 shows schematically a DOM tree generated according to an embodiment of the invention;
[0016] FIG. 4 shows schematically a diagram of a mobile terminal webpage generated according to the DOM tree of FIG. 3 ;
[0017] FIG. 5 shows schematically a block diagram of a server for performing a method according to the invention; and
[0018] FIG. 6 shows schematically a storage unit for retaining or carrying a program code implementing a method according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] In the following the invention will be further described in connection with the drawings and the particular embodiments.
[0020] A structure diagram of a system according to an embodiment of the invention is as shown in FIG. 1 .
[0021] The webpage parse & layout module 100 parses and performs a layout calculation on source codes of a webpage. When parsing HTML source codes and laying out, an HTML parse engine is adopted, and a commonly used open source HTML parse engine is e.g., webkit. The parse & layout is based on a label in the source codes of the webpage, which may be based on, but not limited to, the div label, to generate a DOM tree of the webpage, and calculate the position and the height shown by individual nodes when the webpage is presented. One generated DOM tree is as shown in FIG. 3 .
[0022] Since on a mobile terminal, the dynamic effect of an internet webpage is difficult to be displayed, the dynamic effect needs to be given up in the process of generating the DOM tree, and only a link to pictures and the text format of a main body are kept.
[0023] The node identification module 200 traverses the whole DOM tree starting from the body node, and identifies the main body content and the spam word content by the algorithm which can classify data rules, such as a typical decision tree algorithm.
[0024] The node identification module 200 comprises a statistics module, a comparison module and a main body identification module. First, the statistics module calculates the node distribution value, the text density and the spam word density of the page of each webpage; then, the comparison module compares the node distribution value, the text density and the spam word density with a corresponding preset threshold; and finally, the main body identification module identifies the content in the DOM tree, of which the node distribution value, the text density and the spam word density fall within the threshold, as a main body. Therein, the node distribution represents the composition of child nodes of a node, for example, the number of individual labels, such as div, img, table, etc., the proportion of the labels in the child nodes; the text density represents an average text length obtained by dividing the text length in a node by the number of its child nodes; and the spam word (non-body vocabulary) density represents a value of the division of the length of all the ad words in a node by the length of all the texts in the node. The spam word is identified based on a dictionary, and maintained manually, for example, a word and a phrase such as print preview, support, hot comments, no hot comments yet, etc., which are irrelevant to a main body in the webpage.
[0025] From the above three features, a threshold is obtained according to the decision tree algorithm, and nodes within the range of the threshold are all identified as a main body, and others are identified as spam words.
[0026] The floor division module comprises a position division module and a feature word division module.
[0027] The position division module performs a floor division and identification according to the path and positional relationship of a main body node on the DOM tree, and the rules which are based on when dividing are as follows.
[0028] 1. if two main body nodes are adjacent to each other on the DOM tree, then the two nodes belong to one and the same floor.
[0029] As shown in FIG. 3 , br represents a line break, and the br label is an empty label. The main body node 1 and the main body node 2 have a common father node div 1 , and the main body node 1 and the main body node 2 are adjacent to each other, and therefore the main body node 1 and the main body node 2 may be identified as nodes in one and the same floor.
[0030] 2. if one main body node and other main body nodes which have already been determined as belonging to one and the same floor have a common father node, then these main body nodes belong to one and the same floor.
[0031] For example, the main body node 3 in FIG. 3 and the main body node 2 , the main body node 1 have a common father node div 1 , and the main body node 2 and the main body node 1 have been determined as belonging to one and the same floor, therefore, the main body node 3 also belongs to the same floor.
[0032] 3. if a common father node of two main body nodes is body, then the two main body nodes are divided into different floors.
[0033] For example, for the main body node 1 and the main body node 4 , their paths in the DOM tree are respectively:
[0034] main body 1 →div 1 →body
[0035] main body 4 →div 3 →body
[0036] The common father node of their paths is body, and thereby they should be identified as being at different floors.
[0037] 4. if the relationship between main body nodes is not comprised in the above situations, then they are divided into different floors.
[0038] The feature word division module performs a division primarily according to a feature word in a node, for example, a BBS main body or a news & information review, i.e.
[0039] the content published by the author, is presented simultaneously together with relevant information of the author, and they appear alternately, usually as follows:
[0040] author information→main body→author information→main body→author information→main body . . .
[0041] A further “floor” division is performed on a main body by identifying a key word (e.g., publish time, register time, etc.) in a non-body node indicating the information of an author.
[0042] The mobile terminal page generation module comprises a layout generation module configured to re-lay out the content of a main body node according to its divided floors, and generating a mobile terminal page. In the above process, according to the DOM tree as shown in FIG. 3 , the floor distribution result of the main body nodes is as shown in FIG. 4 , namely,
[0043] floor 1 : main body 1 , main body 2 , main body 3 ;
[0044] floor 2 : main body 4 ;
[0045] floor 3 : main body 5 , main body 6 .
[0046] A flow chart of the method provided by the invention is as shown in FIG. 2 .
[0047] S 102 : performing a parse & layout calculation on source codes of a webpage. When parsing HTML source codes and laying out, an HTML parse engine is adopted, and a commonly used open source HTML parse engine is e.g., webkit. The parse & layout is based on a label in the source codes of the webpage, primarily the div label, to generate a DOM tree of the webpage, and calculate the position and the height shown by individual nodes when the webpage is presented. One generated DOM tree is as shown in FIG. 3 .
[0048] Since on a mobile terminal, the dynamic effect of an internet webpage is difficult to be displayed, the dynamic effect needs to be given up in the process of generating the DOM tree, and only a link to pictures and the text format of a main body are kept.
[0049] S 104 : traversing the whole DOM tree starting from the body node, and identifying the main body content and the spam word content, by the algorithm which can classify data rules, such as a typical decision tree algorithm.
[0050] First, the node distribution value, the text density and the spam word density of the page of each webpage are calculated; then, the node distribution value, the text density and the spam word density are compared with a preset threshold respectively; and finally, the content in the DOM tree, for which the threshold is not exceeded, is identified as a main body.
[0051] Therein, the node distribution represents the composition of child nodes of a node, for example, the number of an individual label, such as div, img, table, etc., the proportion of the labels in the child nodes; the text density represents an average text length obtained by dividing the text length in a node by the number of its child nodes; and the spam word (non-body vocabulary) density represents a value of the division of the length of all the ad words in a node by the length of all the texts in the node. The spam word is identified based on a dictionary, and maintained manually, for example, a word and a phrase such as print preview, support, hot comments, no hot comments yet, etc., which are irrelevant to a main body in the webpage.
[0052] From the above three features, a threshold is obtained according to the decision tree algorithm, and nodes within the range of the threshold are all identified as a main body, and others are identified as spam words.
[0053] S 106 : dividing the identified main body node according to floors of the webpage, and the used method comprises division by position and division by feature word. Division by position is to perform a floor division and identification according to the path and positional relationship of a main body node on the DOM tree, and the rules which are based on when dividing are as follows.
[0054] 1. if two main body nodes are adjacent to each other on the DOM tree, then the two nodes belong to one and the same floor.
[0055] As shown in FIG. 3 , br represents a line break, and the br label is an empty label. The main body node 1 and the main body node 2 have a common father node div 1 , and the main body node 1 and the main body node 2 are adjacent to each other, and therefore the main body node 1 and the main body node 2 may be identified as nodes in one and the same floor.
[0056] 2. if one main body node and other main body nodes which have already been determined as belonging to one and the same floor have a common father node, then these main body nodes belong to one and the same floor.
[0057] For example, the main body node 3 in FIG. 3 and the main body node 2 , the main body node 1 have a common father node div 1 , and the main body node 2 and the main body node 1 have been determined as belonging to one and the same floor, therefore, the main body node 3 also belongs to the same floor.
[0058] 3. if a common father node of two main body nodes is body, then the two main body nodes are divided into different floors.
[0059] For example, for the main body node 1 and the main body node 4 , their paths in the DOM tree are respectively:
[0060] main body 1 →div 1 →body
[0061] main body 4 →div 3 →body
[0062] The common father node of their paths is body, and thereby they should be identified as being at different floors.
[0063] 4. if the relationship between main body nodes is not comprised in the above situations, then they are divided into different floors.
[0064] Division by feature word is to perform a division according to a feature word in a main body. For example, a BBS main body, a news & information review, i.e. the content published by the author, is presented simultaneously together with relevant information of the author, and they appear alternately, usually as follows:
[0065] author information→main body→author information→main body→author information→main body . . .
[0066] A further “floor” division is performed on a main body by identifying a key word (e.g., publish time, register time, etc.) in a non-body node indicating the information of an author.
[0067] A mobile terminal page is generated, wherein the content of a main body node is re-laid out according to its divided floors, and then a mobile terminal page is generated. In the above process, according to the DOM tree as shown in FIG. 3 , the floor distribution result of the main body nodes is as shown in FIG. 4 , namely,
[0068] floor 1 : main body 1 , main body 2 , main body 3 ;
[0069] floor 2 : main body 4 ;
[0070] floor 3 : main body 5 , main body 6 .
[0071] It should be noted that, in the individual components of the controller of the invention, the components therein are divided logically according to the functionality to be realized by them, however, the invention is not limited thereto, and the individual components may be re-divided or combined as needed, for example, some components may be combined into a single component, or some components may be further decomposed into more sub-components.
[0072] Embodiments of the individual components of the invention may be implemented in hardware, or in a software module running on one or more processors, or in a combination thereof. It will be appreciated by those skilled in the art that, in practice, some or all of the functions of some or all of the components in the system for identifying a main body of a webpage according to individual embodiments of the invention may be realized using a microprocessor or a digital signal processor (DSP). The invention may also be implemented as an apparatus or device program (e.g., a computer program and a computer program product) for carrying out a part or all of the method as described herein. Such a program implementing the invention may be stored on a computer readable medium, or may be in the form of one or more signals. Such a signal may be obtained by downloading it from an Internet website, or provided on a carrier signal, or provided in any other form.
[0073] For example, FIG. 5 shows a server which may carry out the method for identifying a main body of a webpage according to the invention, e.g., an application server. The server traditionally comprises a processor 510 and a computer program product or a computer readable medium in the form of a memory 520 . The memory 520 may be an electronic memory such as a flash memory, an EEPROM (electrically erasable programmable read-only memory), an EPROM, a hard disk or a ROM. The memory 520 has a memory space 530 for a program code 531 for carrying out any method steps in the methods as described above. For example, the memory space 530 for a program code may comprise individual program codes 531 for carrying out individual steps in the above methods, respectively. The program codes may be read out from or written to one or more computer program products. These computer program products comprise such a program code carrier as a hard disk, a compact disk (CD), a memory card or a floppy disk. Such a computer program product is generally a portable or stationary storage unit as described with reference to FIG. 6 . The storage unit may have a memory segment, a memory space, etc. arranged similarly to the memory 520 in the server of FIG. 5 . The program code may for example be compressed in an appropriate form. In general, the storage unit comprises a computer readable code 531 ′, i.e., a code which may be read by e.g., a processor such as 510 , and when run by a server, the codes cause the server to carry out individual steps in the methods described above.
[0074] “An embodiment”, “the embodiment” or “one or more embodiments” mentioned herein implies that a particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the invention. In addition, it is to be noted that, examples of a phrase “in an embodiment” herein do not necessarily all refer to one and the same embodiment.
[0075] In the specification provided herein, a plenty of particular details are described. However, it can be appreciated that an embodiment of the invention may be practiced without these particular details. In some embodiments, well known methods, structures and technologies are not illustrated in detail so as not to obscure the understanding of the specification.
[0076] It is to be noted that the above embodiments illustrate rather than limit the invention, and those skilled in the art may design alternative embodiments without departing the scope of the appended claims. In the claims, any reference sign placed between the parentheses shall not be construed as limiting to a claim. The word “comprise” does not exclude the presence of an element or a step not 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 a hardware comprising several distinct elements and by means of a suitably programmed computer. In a unit claim enumerating several devices, several of the devices may be embodied by one and the same hardware item. Use of the words first, second, and third, etc. does not mean any ordering. Such words may be construed as naming.
[0077] Furthermore, it is also to be noted that the language used in the description is selected mainly for the purpose of readability and teaching, but not selected for explaining or defining the subject matter of the invention. Therefore, for those of ordinary skills in the art, many modifications and variations are apparent without departing the scope and spirit of the appended claims. For the scope of the invention, the disclosure of the invention is illustrative, but not limiting, and the scope of the invention is defined by the appended claims.
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The invention discloses a system for identifying a main body of a webpage, which comprises: a webpage parse & layout module configured to parse source codes of the webpage, perform a layout calculation on the parsed result, and generate a DOM tree of the webpage; a node identification module configured to traverse starting from the root node of the DOM tree, and identify a main body node and a spam word node in the DOM tree; a floor division module configured to divide the identified main body node according to floors of the webpage; and a mobile terminal page generation module configured to generate a mobile terminal page. After the invention identifies and extracts the content of a traditional internet webpage, it may effectively extract a BBS main body, a news main body and a comment, and restore a presentation feature of “divided floors” of the content of a main body in the original webpage, of which the presentation effect maintains the original “multi-floor” feature, so as to provide a user with an excellent reading experience.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of and priority under 35 U.S.C. 119(e) of U.S. Provisional Patent Application No. 60/731,769 entitled DOLL AND FACE-LICKING PUPPY COMBINATION filed Oct. 31, 2005 in the name of Kelly Matheny and James Molina, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates generally to toy dolls and toy puppies and particularly to interactive features operative therebetween.
BACKGROUND OF THE INVENTION
Dolls and toy plush figures such as puppies or the like are well known in the art and have been provided in a virtually endless variety. In attempting to provide evermore interesting and amusing doll and toy figure products, practitioners in the art have endeavored to provide various features and operative mechanisms therein. Thus, dolls have for example been provided having moving mouths, moving eyes, sound production and other features. Similarly, plush figures such as dogs or the like have been provided with operative mechanisms for moving their tongues, moving their eyes or making sound. In addition, practitioners in the toy arts have endeavored to provide interactive capability or cooperative action between dolls and toy figures.
For example, U.S. Pat. No. 5,181,877 issued to Perkitny sets forth an APPARATUS FOR SIMULATING A LICKING MOTION having a tongue disposed within an animal-shaped housing. The tongue is pivotally connected at one end to a main gear wheel and extends partially through an aperture in the housing. A motor and gear mechanism engage and rotate the main gear in response to a control assembly. As the main gear rotates, the tongue moves within the aperture at varying angles to simulate licking motion.
U.S. Pat. No. 6,695,673 issued to Stadbauer sets forth a MECHANICAL ANIMAL REPRODUCTION configured to resemble a dog having a head. A tongue extends through an opening in the dog head which is coupled to a drive apparatus for moving the tongue toward or away from the head to simulate “lapping” motion.
In a related art area in which magnetic elements are used in cooperation with toy figures and toy animal figures, U.S. Pat. No. 3,867,786 issued to Greenblatt sets forth a MAGNETICALLY CONTROLLED ANIMATED TOY in which an animal body such as a toy dog incorporates a magnetic control to enhance the toy. As a result, the dog is able to participate in toy activities rather than remaining passive.
U.S. Pat. No. 3,401,485 issued to Goodrum, Jr. sets forth a MAGNETICALLY ACTIVE TOY DOG having a pair of articulated forelegs hinged to the dog body and a separate piece simulating a bone having a magnet therein. A second magnet in the dog's nose interacts with the magnet in the bone causing the dog to sit up and beg in response to the action to the bone as the bone is moved relative to the dog.
U.S. Pat. No. 6,386,937 issued to Cappello, et al. sets forth a MAGNETICALLY COUPLED TOY APPARATUS having two toy components such as a doll and a nursing bottle. The nursing bottle contains a motor-driven rotating magnet in the nipple portion thereof. A second permanent magnet is mounted in a flexible region around the mouth of the doll. When the nipple containing the rotating magnet is place in proximity with the mouth of the doll, relative motion between the magnets imparts movement to the mouth and lip regions of the doll.
U.S. Pat. No. 3,411,237 issued to Crosman and U.S. Pat. No. 3,531,893 issued to Samo set forth early examples of magnetically interacting doll features.
U.S. Pat. No. 6,887,121 issued to Whitehead; U.S. Pat. No. 6,824,441 issued to Wiggs, et al.; U.S. Pat. No. 6,056,619 also issued to Wiggs, et al. and U.S. Pat. No. 6,062,938 issued to Meng-suen set forth toy apparatus in which a toy article is moved across a surface under the influence of a moving magnet beneath the surface and a cooperating magnetic element within the toy article.
Published U.S. patent application Ser. No. 2002/0115376 filed in the name of Brian Whitehead sets forth a TOY WITH MOVEMENT MEANS in which a doll is movable upon a play base and is articulated and moved both in response to cooperating magnets within the doll and proximate the base.
U.S. Pat. No. 5,304,087 issued to Terzian, et al.; U.S. Pat. No. 6,585,556 issued Smimov; U.S. Pat. No. 6,159,017 issued to Coomansingh; U.S. Pat. No. 6,053,797 issued to Tsang, et al.; U.S. Pat. No 6,007,404 issued to Trevino; U.S. Pat. No. 5,651,716 issued to Mowrer, et al.; U.S. Pat. No. 5,876,263 issued to DeCesare, et al.; U.S. Pat. No. 5,190,492 issued to Berenguer; U.S. Pat. No. 5,074,820 issued to Nakayama; and U.S. Pat. No. 5,376,038 issued to Arad, et al. set forth toy apparatus generally related to the subject matter of the present invention.
While the foregoing described toy devices have to some extent improved the toy art and in some instances enjoyed commercial success, there remains nonetheless a continuing need in the art for evermore improved, amusing and entertaining toy device combinations.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide an improved toy product. It is a more particular object of the present invention to provide an improved toy product which replicates interaction between a child-like doll and an animal-like toy figure. It is a still more particular object of the present invention to provide an improved toy combination which provides a human-like doll and a puppy-like toy figure in which the puppy-like toy figure appears to lick the face of the doll. In accordance with the present invention, there is provided a face-licking puppy in combination with a doll having a head and a body. The head is formed of a hollow plastic material and defines typical facial features of a human doll. The toy further includes a plush figure which resembles a typical puppy or small dog. Thus, the plush dog figure includes a body and a head formed of a plush material. The head defines typical puppy features such as eyes, nose, mouth and ears. Additionally, an elongated flexible tongue extends from the puppies mouth and supports a magnetically responsive element at the end portion thereof. A mechanism supported within the doll's head moves a pair of magnets behind the interior of the cheek portions of the dolls face. As the magnets move in response to the movement mechanism, the puppy is brought into proximity with one side of the doll such that the magnetically responsive element within the dogs tongue is attracted to the moving magnet in the proximate cheek of the doll. The movement of the magnet and the attraction between the magnetic element in the dogs tongue and the magnet cause the dogs tongue to move up and down upon the outer surface of the doll cheek simulating a licking action by the dog.
In another aspect, the present invention provides a combination doll and animal figure comprising: a doll having a head defining an interior, a face and cheek areas; a first magnetic element within the head; moving means supported within the head moving and supporting the first magnetic element proximate one of the cheek areas; an animal figure having an elongated flexible tongue; and a second magnetic element supported within the flexible tongue, the first and second magnetic elements being magnetically attractive to each other, the flexible tongue being held against the one cheek area and moved thereon by magnetic attraction between the first and second magnetic elements as the first magnetic element moves.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel, are set forth with particularity in the appended claims. The invention, together with further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several figures of which like reference numerals identify like elements and in which:
FIG. 1 sets forth a front perspective view of a doll and face-licking puppy combination constructed in accordance with the present invention;
FIG. 2 sets forth an operative drawing of the magnet moving mechanism operative within the doll's head;
FIG. 3 sets forth a front view of the cam operative within the movement mechanism of FIG. 2 ;
FIG. 4 sets forth a front view of the gear rack operative within the mechanism shown in FIG. 2 ; and
FIG. 5 sets forth a partial section view of the tongue end of the face-licking puppy used in the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
By way of overview, the present invention doll and face-licking puppy combination provides a doll which is fabricated in accordance with general fabrication techniques and thus includes a body supporting a head. The head is formed of a rodocast hollow plastic structure and defines conventional facial features typical of dolls. A magnet drive mechanism is battery-powered and is supported within the interior of the doll's head. The magnetic drive mechanism supports a pair of moving magnets within each of the cheek portions of the doll's head proximate the interior cheek surfaces thereof. The combination also includes a plush dog figure preferably formed to resemble a puppy or small dog. The puppy includes a head and typical dog features including a mouth from which a flexible ribbon-like tongue extends. The tongue supports a magnetic element, either a magnet or a ferro magnetic metal material or other magnetically interactive material, at its end portion. When the puppy is brought into proximity with the doll's head and the magnet drive mechanism is activated, the moving magnets within the doll's cheek attract and move the end portion of the doll's tongue causing the doll tongue to appear to lick the cheek of the doll.
More specifically, FIG. 1 sets forth a doll constructed in accordance with the present invention and generally referenced by numeral 10 together with a plush puppy figure generally referenced by numeral 30 . Doll 10 includes a head 11 which is preferably fabricated in a rotocast process or other process which forms a generally hollow plastic head. Head 11 defines typical doll facial features. In accordance with the present invention, a magnet drive mechanism 20 shown in greater detail in FIGS. 2 , 3 and 4 is supported within head 11 by conventional fabrication means (not shown). Doll head 11 defines a left cheek portion 12 and a right cheek portion 13 . In further accordance with the present invention, magnet drive mechanism 20 supports a pair of moving magnets 21 and 22 within the interior surfaces of cheeks 13 and 12 respectively.
Puppy 30 is formed in accordance with conventional fabrication techniques to provide a soft plush figure having a mouth 31 . In accordance with the present invention, puppy 30 also includes an elongated generally ribbon-like flexible tongue. In further accordance with the present invention and as is shown in FIG. 5 , tongue 32 supports a magnetically responsive element 33 at the end portion thereof. It will be apparent to those skilled in the art that any combination of magnetically attractive materials may be used for magnets 21 and 22 and element 33 of tongue 32 . Thus, for example in the preferred fabrication of the present invention, magnets 21 and 22 are permanent magnets while magnetic element 33 within tongue 32 may be either a cooperating magnet or a piece of ferro magnetic metal such as steel or the like. Alternatively, however, it will be apparent to those skilled in the art that virtually any cooperating combination of magnets and/or metal elements may be used for elements 21 , 22 and 33 without departing from the spirit and scope of the present invention. The important aspect with respect to the present invention is the cooperating attraction between magnetic elements one or more of which are moving within doll head 11 and one of which is supported within tongue 32 .
In operation, the activation of magnet drive 20 in the manner described below causes magnets 21 and 22 to move within cheeks 13 and 12 . Correspondingly, as puppy 30 is moved to the position shown in FIG. 1 , magnet 22 attracts magnetic element 33 drawing the end portion of tongue 32 against cheek 12 . As magnet 22 moves within cheek 12 , magnetic element 33 is moved upon the outer surface of cheek 12 causing puppy 30 to appear to lick cheek 12 .
While not shown in FIG. 1 , it will be apparent to those skilled in the art that the positioning of puppy 30 proximate the right side of head 11 of doll 10 such that magnetic element 33 is brought against right cheek 13 produces a similar interaction between element 33 and magnet 21 and thereby causes puppy 30 to appear to lick right cheek 13 . The resulting play effect is extremely realistic and very accurately simulates the licking action typical of a puppy playing with a child.
FIG. 2 sets forth an operational diagram of the mechanism operative within magnet drive 20 . While not shown in FIG. 2 , it will be apparent to those skilled in the art that the diagram shown in FIG. 2 is in essence “schematic” in that the conventional support apparatus within head 11 which facilitates the support and movement of the operative elements of the mechanism have been omitted for clarity. More specifically, magnet drive 20 includes a motor 40 which will be understood to be coupled to a source of battery power “not shown” and which includes an output gear 41 rotated by the action of motor 40 . A plurality of speed reduction gears 42 , 43 , 44 , 45 , 46 and 47 are coupled in series combination to provide torque gain and speed reduction for the output rotational power of motor 40 . Gear 47 is joined to a rotating cam 48 by a shaft 51 (better seen in FIG. 3 ). Thus, cam 48 rotates by direct coupling to gear 47 . Cam 48 further includes an offset or eccentric post 50 .
Mechanism 20 further includes a slideably supported dual gear rack 52 . Gear rack 52 is better seen in FIG. 4 and thus includes a plurality of gear teeth 53 on one side thereof and a second plurality of gear teeth 54 on the remaining side thereof. As is also better seen in FIG. 4 , gear rack 52 defines a transverse slot 55 . Post 50 of cam 48 is received within slot 55 . A gear 56 supported by a bearing 57 engages gear teeth 54 . A shaft 58 is supported by baring 57 and is joined to a magnet holder 60 . One or more magnets 22 are supported within magnet holder 60 . As described above in FIG. 1 , moveable magnet 22 is supported proximate to the interior surface of left cheek 12 of doll 10 .
Magnet 21 (seen in FIG. 1 ) is supported on the opposite side of gear rack 52 and thus is not visible due to the side view of FIG. 2 . It will be understood however that magnet 21 is supported by an identical combination of a gear engaging teeth 53 of gear rack 52 as well as a supporting bearing and shaft together with a magnet holder all of which are substantially identical to gear 56 , bearing 57 , shaft 58 and magnet holder 60 .
In operation, energizing motor 40 rotates output gear 41 which is rotationally coupled by gears 42 through 45 to gear 46 . Gear 47 is joined to gear 46 and integrally formed therewith. The rotation of gear 47 is coupled by shaft 51 to cam 48 . As cam 48 rotates, post 50 is moved within slot 55 (seen in FIG. 4 ) causing an isolating movement of gear rack 52 in the vertical direction indicated by arrows 65 . The vertical oscillation of gear rack 55 in turn causes an oscillatory rotational movement of gear 56 . The motion of gear 56 is coupled to magnet 22 by shaft 58 and holder 60 . Once again, while not shown in FIG. 2 , it will be understood that the operative mechanism supporting magnet 21 which is identical to gear 56 , bearing 57 , shaft 58 and holder 60 produces a simultaneous oscillatory rotational movement of magnet 21 . This rotational movement in turn produces the above-described oscillatory movements of magnets 21 and 22 within doll head 11 (seen in FIG. 1 ).
FIG. 3 sets forth a front view of cam 48 . As described above, cam 48 supports an offset or eccentric post 50 and is coupled to gear 47 (seen in FIG. 2 ) by a shaft 51 .
FIG. 4 sets forth a front view of dual gear rack 52 . Gear rack 52 defines a plurality of gear teeth 53 in a linear gear rack on one side and a mirror image set of gear teeth 54 on the opposite side. Gear rack 52 further defines a transversely extending slot 55 . It will be recalled that slot 55 receives post 50 of cam 48 (seen in FIG. 3 ).
FIG. 5 sets forth a partial section view of flexible tongue 32 . As mentioned above, flexible tongue 32 supports a magnetic element 33 . Flexible tongue 32 is preferably formed of a fabric material or the like and preferably completely encloses magnetic element 33 . Magnetic element 33 may be either a ferro magnetic element such as a small disk or the like or, alternatively, element 33 may be fabricated of a permanently magnetic material. Tongue 32 must be sufficiently flexible to facilitate the movement set forth and described above in FIG. 1 to mimic the face-licking action of puppy 30 .
What has been shown is a novel doll and face-licking puppy figure in combination. The combination shown provides a realistic face-licking operation between the puppy figure and the doll due to the interaction of magnetic elements within the doll and the puppies tongue. The resulting animation is extremely realistic and is accomplished in an extremely efficient and cost effective manner.
While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
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A combination doll and toy puppy include interacting magnetic elements therein which mimic a face-licking action by the puppy. The doll includes a partially hollow head within which one or more magnets are movably supported behind the cheek portions of the doll's face. A battery-powered electric motor driven gear drive mechanism is operative within the doll's head to move the one or more magnets behind the doll's cheeks. The puppy includes a flexible extending tongue having a magnetic element supported in the end portion thereof. When the puppy is brought sufficiently close to the doll's face, the magnet in the puppy's tongue is attracted to the moving magnet within the doll's cheek area to mimic the face-licking action.
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RELATED APPLICATION
This application is a continuation of application Ser. No. 08/478,407, filed Jun. 7, 1995, now abandoned which is a continuation-in-part application of application Ser. No. 08/118,186, filed Sep. 9, 1993, now abandoned.
FIELD OF THE INVENTION
The present invention relates to recycling wastepaper, and more particularly to recycling processes for recovering papermaking fibers and for making absorbent granular materials from wastepaper.
BACKGROUND OF THE INVENTION
It has been common practice for many years to make paper, especially tissue, from recycled paper. Paper recycling has in recent years become an important and attractive alternative to disposal of wastepaper by deposition in landfills or by incineration. When the wastepaper source includes a significant amount of coated paper, as much as 30-45% of the original wastepaper will be reject material which is unusable for papermaking. This reject material has typically been discarded in landfills. Increasing costs and decreasing availability of landfill space makes it desirable to find beneficial uses for this reject material.
In the process of recycling waste paper, such as newspapers, magazines, office paper waste, the paper fibers are separated from the other solid components by using large quantities of water. The printing materials, such as laser print, photocopier print and ink, are removed before the paper fibers are conducted to the papermaking machine. Usually, these rejected solid materials are discharged with the water into large settling basins. The solid materials that settle out in the basins are then dumped in a landfill, or otherwise discarded. The material that settles out in the basins is known as paper mill sludge.
The increasing cost of wastepaper makes it desirable to capture as much of the papermaking fibers as practicable. In view of the large quantities of water required for papermaking, it is important to use a process that conserves water. There have been various proposals for systems for utilizing rejected solid materials such as paper mill sludge to produce absorbent granules and other products. Kaolin clay is one of the rejected solid materials that has been recognized as having good absorbent capabilities.
Conventional absorbent granules are produced from naturally occurring clay and are commonly used as agricultural chemical carriers. However, some of the agricultural chemicals (e.g., Diazinon) react with clay carriers. Accordingly, it would be advantageous to develop an agricultural chemical carrier that contains clay, but does not react with agricultural chemicals. Also, naturally occurring clays tend to create dust during handling. This is potentially hazardous to workers.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an efficient and economical wastepaper recycling process for recovering fibers for use in papermaking and producing useful granular products from the reject stream. It is another object of this invention to produce a granular product that has high absorbency, is free flowing, substantially dust free and has high resistance to attrition. A further object is to produce a material of broad utility as a water and oil absorbent.
The process of this invention utilizes wastepaper, preferably office waste that is printed with laser print, photocopier print, or other inks, as well as stationery and magazines that have a coated surface. The wastepaper is pulped with water, caustic and surfactants to produce a slurry containing cellulose fibers, cellulose fines and fillers. The slurry passes through wire washers which separate papermaking fibers from the fines and fillers. Papermaking fibers are a mixture of long and short fibers, although it is recognized that some of the short fibers will pass through the screens. For the purposes of this description, long fibers are greater than about 1 mm in length and short fibers are between about 1 mm and about 0.1 mm in length. The papermaking fiber stream, also referred to as the "accepts stream", is directed through a cleaning and deinking step and then to a conventional papermaking machine for processing into paper. Separately, various streams from the papermaking machine and other sources are passed through a fiber recovery system where a series of wire washers separate papermaking fibers from these streams, sending the papermaking fibers back to the cleaning and deinking stages. The rejects from this fiber recovery system contain essentially the same solid materials as the first reject stream mentioned above. These reject streams are combined and sent to a flotation clarifier where a flocculating polymer is added and air is injected to cause the suspended solids (fines and fillers) to be concentrated as a flotate. Clarified water is removed from the clarifier for reuse in the process.
In order to sterilize the absorbent material, the flotate stream is pasteurized at a minimum temperature of 160 degrees F., and then a second flocculating polymer is added to the flotate stream. This flotate stream then passes through a belt press or similar dewatering device where the water content is further reduced. The filter cake from the belt press is in the form of a gray, wet cake. The wet cake then passes to a size reducer where the material is broken up. The wet granules are then sent through a conveyor dryer to produce dry granules of irregular shape and having good absorbent characteristics.
The granules produced by this process have a high liquid holding capacity. The term granules is intended to include small particles and chunks that may be as large as 0.5 inches across. Their composition, by weight, is approximately 35-50% inorganic fillers (kaolin clay, calcium carbonate, titanium dioxide) and 50-65% organic (cellulose fines, starches, tannins, lignin, etc.). Less than 10% of the cellulosic material in the granules is in the form of fibers greater than 1 mm in length. The granules are free flowing and resistant to attrition. The bulk density of the granules is between about 28-38 lbs./cu.ft. These granules are useful as oil and water absorbents as well as carriers for agricultural chemicals.
DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention is illustrated in the accompanying drawings, in which:
FIG. 1 is a schematic view of the process and apparatus for recovering the papermaking fibers and manufacturing the granules according to the present invention; and
FIG. 2 is a graph of the particle size distribution of the material before and after the pin mixer.
DETAILED DESCRIPTION
The process of this invention utilizes wastepaper that is collected from offices or other sources that contain primarily recyclable paper grades, including magazines (with clay and calcium carbonate based coatings) and printed paper such as paper used for laser printing, photocopying and other paper.
Referring to FIG. 1, wastepaper is supplied to a hydropulper 2 along with water, caustic agents, such as sodium hydroxide, and dispersants to separate the fiber from the other components of the wastepaper. Plastics, debris and other foreign objects are removed by conventional means. The pulp slurry from the hydropulper, which contains more than 95% water, passes through a pipe 4 to a washer 6 where several conventional washing steps are performed. In the washer 6, the slurry flows over wire screens where fibers useful for papermaking pass across the screens and the reject stream passes through the screens and is conducted out of the washer through a pipe 16. The screens have slotted openings of about 100 to 300 microns in width. Preferably, the screens are semi-cylindrical and the slurry is sprayed tangentially onto the screens. Fibers suitable for papermaking pass across the surface of the screens, while small particles, such as kaolin clay, cellulose fines and other suspended solids pass through the screens. Some of the fibers may also pass endwise through the screens. The papermaking fibers from the surface of the screen are included in the accepts stream that is pumped through the pipe 8 and are subject to further cleaning, deinking and processing, indicated at 10, before being supplied through a pipe 12 to a papermaking machine 14.
The reject stream from the washer 6 is in the form of a slurry containing less than 1.5% solids. Typically, 50% by weight of the solids are fillers such as kaolin clay, calcium carbonate and titanium dioxide. The remaining 50% is mostly sugars, tannins, lignins, and cellulose fiber or fines, which is referred to generally herein as cellulosic material. To the extent there are cellulose fibers in the reject stream, most of these fibers are less than 1 mm in length. This slurry, which contains at least 98.5% water, is conducted through the pipe 16 to a dissolved air flotation clarifier 18. Suitable clarifiers are commercially available (e.g., Supracell from Krofta, or Deltafloat from Meri). A flocculating polymer, such as Drewfloc 441 from Drew Chemical Co., or Calgon TRP 945, is added to the reject stream in the pipe 16 before the slurry enters the clarifier. Air is injected into the feed stream of the clarifier 18. The slurry fills the clarifier 18, and the flocculated suspended solids float on the air bubbles to the surface of the clarifier. At this point, the mat of solids, which has a consistency of 3-9%, is skimmed or raked off the surface and removed from the clarifier through the pipe 20. The clarified water from the clarifier 18 is conducted back into the hydropulper 2 through the pipe 22 to be reused and a portion of the clarified water is recycled via pipe 33 to other places in the mill.
In accordance with this invention, nearly all unscreened mill process effluents that contain papermaking fibers are treated in a fiber recovery unit 26. Here the stream passes through screens that separate the papermaking fibers from fillers such as kaolin clay, cellulose material, sugars, lignins, tannins, etc., in a manner similar to the washer 6. This effluent includes some reject water streams, dumping or spills from pulp and paper chests, plant wash-ups, etc., indicated as stream 24 in FIG. 1. Previously, this effluent would have been discharged to a sewer. Papermaking fibers are returned through pipe 28 from the fiber recovery unit 26 to the washer 6. Pipe 30 conducts the reject stream from the fiber recovery unit 26 to the clarifier 18.
The white water stream 25 from the papermaking machine is supplied to another flotation clarifier 27 where the flocculated suspended solids are removed in the same manner as in the clarifier 18. Process white water stream 23 is returned to the washer 6.
The flotate from the clarifiers 18 and 27 is supplied to a heater 36 through pipes 20 and 34 respectively. The heater 36 may be of any suitable type, such as a steam injection unit, or a heat exchanger. The flow rate of the stream and the heat applied should be sufficient to raise the temperature of the stream for sufficient time to achieve pasteurization of the stream. Preferably, the stream should be heated to a temperature of at least 160° F.
The stream passes out of the heat exchanger 36 through a pipe 38, and a second polymer (such as Drewfloc 453 from Drew Chemical Co.) is added to the slurry to cause the solids to dewater as the slurry enters a belt press 40. The belt press can be any one of the commercially available units (e.g., Kompress Belt Filter Press, Model GRS-S-2.0 from Komline Sanderson). At the outlet of the belt press, the filter cake contains 35-40% solids. Process white water from the belt press is returned to the hydropulper 2 through the pipe 42.
If a filter cake having a higher solids content is desired, a screw press may be used after the belt press, or instead of the belt press. Alternatively, a belt press with compressive rolls can be employed. The filter cake would pass through the nip between the rolls for additional dewatering. These arrangements can be used to produce a filter cake having a solids content of up to 45%.
If small particles are desired as the final product, the filter cake from the belt press 40 is conveyed by a screw conveyor 44 to a pin mixer 46 (such as the Turbulator from Ferro-Tech). The pin mixer has a cylindrical shell and a rotatable shaft mounted on the central axis of the shell. The shell is stationary and is supported on a frame so that the central axis of the shell is horizontal. The shaft has radial pins that are spaced about 1/8" from the interior wall of the shell. Pieces of the filter cake from the conveyor 44 are deposited in the shell at one end of the shell. The rate of filling of the shell should be adjusted so that the cake material occupies only about 2% of the volume of the shell. By maintaining a low density in the pin mixer 46, the filter cake is broken up by the rotating pins so that individual granules are separated as the material progresses from the inlet of the pin mixer to the outlet. It has been found that the pin mixer 46 produced optimum size particles for use as an agricultural carrier by running in the middle of its speed range, which is at 1500-4500 feet per minute tip speed of pins. Higher speeds give larger particles. Lower speeds yield a larger variability in sizes, with no net increase in smaller sized granules. It has been discovered that, when operating the mixer with a partially filled chamber in the middle of its speed range, the pin mixer 46 reduces the size of the particles as compared to the size of the particles that are discharged from the screw conveyor 44.
The effect of the pin mixer 46 on the particle size is shown in FIG. 2, which compares the percent of particles retained on screens of progressively smaller openings (higher mesh numbers). As shown in FIG. 2, a substantially greater percentage of the particles that are discharged from the pin mixer 46 have a smaller size than the particles entering the pin mixer 46. Another way of stating this is that FIG. 2 shows that only 8% of the particles discharged from the pin mixer 46 have a size large enough to be retained on a #8 mesh screen or larger (e.g., #4), while 25% of the particles supplied to the pin mixer have a size large enough to be retained on a #8 mesh screen or larger. Additives may be added at this point (e.g., to increase density or absorbency) but it is important not to increase the water content of the press cake since this would cause the particles to agglomerate, yielding a larger than desirable particle size and a less absorbent product. Operating the pin mixer in this fashion allows for uniform densification of the granules. It has been found that backmixing dried granules with the wet feed prior to the pin mixer also leads to a smaller, denser granule. Preferably, up to 50% by weight of the dried granules can be added. No additional binders are necessary since the matrix produced by the kaolin clay, along with the lignin, tannin, starch and short fibrils in the feedstock, serve as the binder for the granules. The resulting open pore structure yields an absorbent irregular particle.
From the pin mixer 46, the granulated but still moist material moves, preferably under the force of gravity, onto a swing conveyor 48, to the belt of a conveyor dryer 50, such as a Proctor & Schwartz two-zone conveyor dryer. The belt is porous and a fan blows hot air through the belt to dry the granules. The velocity of the air flow is sufficiently low to avoid movement of the granules on the belt. At the outlet, the granules have a minimum solids content of 90% by weight, and preferably greater than 95%.
Vibrating screens 52, such as manufactured by Sweco, are used to classify the material by size according to product specifications.
Alternatively, instead of supplying filter cake to the pin mixer 46, the filter cake from the belt press 40 may be conveyed by a conveyor 54 to a dryer 56, such as a Komline Sanderson paddle-type dryer, as shown schematically in FIG. 1. In the dryer 56, the filter cake particles are further dried and may be ground into fine dry particles. The dried particles may have any desired solids content depending on the time and extent of drying. Preferably, the particles have a solids content of 90 to 100% by weight. Even more preferably, the particles have a solids content of 96 to 99% by weight. Also, the particles desirably have a bulk density of from 45 lbs/ft 3 to 50 lbs/ft 3 and a size ranging from 4 to 300 mesh.
The particles from dryer 56 may be used directly as a product, or optionally mixed with wet filter cake particles at the dry/wet particle mixing stage 60. The dry particles from dryer 56 are conveyed through 62. The wet particles are conveyed through 58. Alternatively, the dried particles from dryer 56 may be returned to the main conveyor 44 and mixed with the filter cake particles to produce a final product. Preferably, the dry/wet particle mixing whether in a separate mixing stage 60 or in the main conveyor 44 provides a product having a solids content of from 40 to 60% by weight, preferably 45 to 50% by weight. Alternatively, the wet particles from the belt press 40 may be used directly with little or no mixing of dry particles. The particles used as a final product either with or without addition of dry particles from the dryer 56 have a bulk density of from 50 lbs/ft 3 to 60 lbs/ft 3 and a size ranging from 4 to 100 mesh. The mixing ratio of dry particles from dryer 56 to wet particles from belt press 40 ranges from 0 to 50% by weight, preferably 5 to 30% by weight.
The purpose of the heater 36 is to prevent the growth of bacteria in the material produced by this process. If the filter cake or the granules from the pin mixer 46 are conducted through a dryer, as described above, the heater 36 may be omitted since any bacteria will be killed in the dryer. However, if coarse wet particles are produced, it is necessary to kill the bacteria. An alternative to the heater 36 would be the use of a stationary horizontal cylinder with a rotating auger that would advance the particles through the cylinder. Steam injected into the cylinder would heat the material sufficiently to cause the bacteria to be killed.
The granules produced by this process contain approximately 50% by weight of organic materials, such as cellulosic fines, starches, tannins and lignins. The granules contain less than 10% fiber by weight over 1 mm in length. The inorganic fillers comprise about 50% by weight of the granules and are made up primarily of kaolin clay, calcium carbonate and titanium dioxide. The granules have an irregular, generally spherical shape. The granules from the conveyor dryer 50 vary in size. Typically, about 50% will be retained on an 8×16 mesh screen, i.e., 50% would pass through an U.S. Sieve No. 8 mesh screen but would be retained on a 16 mesh screen. Typically, the remaining portion would be about 40% in the 16×30 mesh size range, and about 10% in the 20×60 mesh size range. The granules have a bulk density of about 30-40 lb./cu. ft. Bulk density can be increased by adding prior to the pin mixer a densifier such as Barium Sulfate.
The granular material according to the present invention is able to withstand agitation such as might occur during shipment, handling, and storage. Resistance to attrition of the granules is between 90 and 95%. This percentage is based on the following test procedure. A weight of 75 grams of sample is shaken on a limiting screen for ten minutes and 50 grams of the material retained is then shaken in a pan for ten minutes with ten steel balls (5/8" in diameter). The entire sample is then shaken on the limiting screen for ten minutes. The percentage of the original 50 grams retained on the limiting screen is the resistance to attrition cited above. Granular material according to the present invention has been found to generally have a pH between 8.5-9.4.
Granular material according to the present invention is adapted to absorb various liquids to desired degrees as a function of percentage of weight of the granules. When the granular material according to the present invention is intended for use as an agricultural carrier, it has a liquid holding capacity (LHC) toward odorless kerosene of between 25-29%. The material for use as a floor absorbent, when tested with material retained on an 8×35 mesh, is able to absorb about 70-80% of its weight of water, and about 50-60% of its weight of oil.
Since particles or granules used as an agricultural carrier are preferably small, the use of the pin mixer is an effective way to obtain smaller particles in an efficient manner. It has also been found that the particles produced using the pin mixer have less tendency to produce dust during the treatment and storage of the dry particles than naturally occurring clay. This is particularly important when the particles are used as an agricultural carrier because of the presence of herbicides or pesticides that may adversely affect workers if substantial amounts of dust are present. These granules are also useful as oil and grease absorbents and as pet litter.
While this invention has been illustrated and described in accordance with preferred embodiments, it is recognized that variations and changes may be made therein without departing from the invention as set forth in the claims.
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A process is disclosed which utilizes the "non-papermaking" portion of waste paper to produce a highly absorbent, essentially fiber-free granule which can be used, for example, as an agricultural chemical carrier. The process maximizes the amount of long (papermaking) fiber sent to the paper machine.
The waste paper is broken up in a hydropulper, and the pulp stock is screened so that papermaking fibers are retained and sent forward to the papermaking process, and the solid material in the reject stream, such as kaolin clay and inorganic materials pass through a flotation clarifier to separate the solids. The slurry is then dewatered by means of a belt press to form a filter cake. The filter cake then enters a pin mixer where it is broken up into individual granules. The granules are then dried to a solids content of greater than 95%.
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This application is a continuation of PCT/FI98/00051, filed Jan. 21, 1998.
BACKGROUND OF THE INVENTION
The invention relates to a method of and an apparatus for treating wood chips and in particular for improving the wood chips properties particularly in pulping processes of the pulp and paper industry. In said method the chips are divided into various fractions on the basis of a fragment size before any other treatment phases of the chips.
In pulping processes wood chips treating methods, in which over-thick (e.g. above 8 mm) chip fragments are separated from the wood chips by a screen and directed to be treated by a chip compressor, have been used for years. Known chip compressor structures are described, for example, in U.S. pat. Nos. 4,953,795 and 5,385,309, Finnish patent application (No.) 911 972 and Finnish utility model (No.) 2412. The chip compressor basically comprises two adjacent conveniently profiled rolls arranged to rotate in relation to parallel rotation axes. The chips to be treated are fed between the rolls.
Advantages gained by treating over-thick chips with compressors are thoroughly described, for example, in U.S. pat. No. 4,953,795. In brief, using compressor treatment the cooking properties of over-thick chips are improved to the level of accept-size chips.
BRIEF DESCRIPTION OF THE INVENTION
An object of the invention is to further develop the method in question and the apparatus implementing the method so that the cooking properties of the treated chips can further be improved. This object is achieved with the method and apparatus characterized by what is disclosed in the independent claims. The preferred embodiments of the invention are the subject of the dependent claims.
The basic idea of the invention is that accept-size chips, too, are treated by a compressor similar to the one previously employed only for treating over-thick chips. According to studies the cooking properties of accept chips, too, can further be significantly improved by compressor treatment.
An efficient but gentle compressor treatment of chip fragments of various sizes requires a nip, or the distance between press rolls, of various sizes and in some cases also a different profiling of roll surfaces, rotation speed and compressive force of the rolls. On this account a chip stream is divided into several fractions by a screen on the basis of the fragment size, whereupon each of the different fractions are directed to a specific chip compressor, whose nip, profiling, speed and compressive force are selected to suit this particular chip fraction.
Employing the method and apparatus according to the invention a more even cooking is achieved in the cooking process of the pulp, a higher total yield and a lower rejection level when cooking to the same kappa level compared with untreated chips or with chips from which only the over-thick fraction is treated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following the invention will be described in greater detail by means of the preferred embodiments with reference to the accompanying drawings, in which
FIG. 1 is a diagram showing a preferred embodiment of a method and an apparatus according to the invention;
FIG. 2 is a diagram showing another preferred embodiment of a method and an apparatus according to the invention;
FIG. 3 is a diagram showing a further preferred embodiment of a method and an apparatus according to the invention;
FIG. 4 shows a preferred roll arrangement of a chip compressor; and
FIG. 5 shows a profile of the rolls shown in FIG. 4 in perspective and in enlarged scale.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 chips C are at first fed to a disk screen 1 , whose disk spacings and rotation speeds of disk axes are selected in such a manner that by using the screen 1 the following chip fractions are separated: a fraction C 1 whose thickness is below 5 mm; a fraction C 2 whose thickness is between 5-8 mm; a fraction C 3 whose thickness is above 8 mm but whose length is below 45 mm; and a fraction C 4 whose length is above 45 mm. The fraction C 1 is then directed to a sawdust screen 2 by which for example a below 3 mm fraction C 1 a can further be separated from it for combustion (by a conveyor 3 ), a 3-5 mm fraction C 1 b for sawdust cooking (by a conveyor 4 ) and the remaining part C 1 c is directed to chip cooking (by a conveyor 5 ). The fraction C 2 is directed to a chip compressor 6 comprising two adjacent rolls 6 a and 6 b arranged to rotate around parallel rotation axes and whose nip, profilings, rotation speeds and compressive force are so selected that an optimal treatment result is achieved given the fragment size of the fraction. Similarly the fraction C 3 is directed to a corresponding chip compressor 6 whose said parameters are in turn selected to suite this fragment size. The fraction C 4 is directed to a sliver chipper 7 , whereupon it is returned to the beginning of the disk screen 1 as a, in fragment size, reduced fraction C 4 a.
In the implementation according to FIG. 2 the chips C′ from which sawdust and splints are separated, is at first fed into the first disk screen 1 a ′ of the screening arrangement 1 ′ dividing the chips into fractions which are below and above 4 mm in fragment size. The below 4 mm fraction C 1 a ′ is fed into the conveyor 5 leading directly to the chip cooking. The above 4 mm fraction C 1 b ′ is in turn fed into a second disk screen 1 b ′, which is located lower than the first disk screen 1 a ′, and divides said fraction into fractions below and above 6 mm. The below 6 mm fraction C 2 a ′ is then fed into the chip compressor 6 , whose nip, profilings, speeds and compressive force are selected to suit the 4-6 mm chip fragments. The above 6 mm fraction C 2 b ′ is further fed into the next disk screen 1 c ′ which is located lower than the second disk screen 1 b ′ and divides said fraction into fractions below and above 8 mm. The below 8 mm fraction C 3 ′ is fed into the chip compressor 6 whose said parameters are selected to suit the 6-8 mm chip fragments. The above 8 mm fraction C 4 ′ is in turn fed into a third chip compressor 6 , whose said parameters are selected to suit this fragment size. The chip streams treated by all three chip compressors are preferably gathered to the same conveyor 5 leading to the cooking into which the below 4 mm fraction C 1 a ′ is fed.
In the third preferred implementation according to FIG. 3 the chips C″ are at first fed into a flat screen 1 ″ preferably having three levels. The chip fraction C 3 ″ (oversize fraction) that has remained above the highest screen disk 1 a ″ is fed into a chip compressor, whose nip, profilings, speeds and compressive force are selected to suit this fraction. The chips C 2 ″ (accept fraction) that has remained above the middle screen level 1 b″ is fed into a second chip compressor 6 whose said parameters are in turn selected to suit this fraction.
The sawdust fraction C 1 ″ that has fallen into the lowest screen level 1 c ″ is in turn gathered directly as fuel to the conveyor 3 .
The above described screens 1 , 1 ′, 1 ″, the sawdust screen 2 and the sliver chipper 7 are commonly of the prior art and will therefore not be further than above described here.
Also the chip compressor 6 as such is of the prior art, but its preferred embodiment particularly applicable to the implementation of this invention is described in greater detail in FIGS. 4 and 5. The chip compressor 6 described in these Figures comprises two adjacent rolls 6 a and 6 b arranged to rotate around parallel rotation axes A and B. On the surface of both rolls 6 a and 6 b there is a profiling P comprising radial grooves Pr that form wave profiles on the surface of the rolls 6 a and 6 b and substantially axial grooves Pa that form notch rows to the wave profiles, whereby the profile peaks Pp of one roll 6 a are located at the profile grooves Pr of the other roll. The distance between the two profile peaks Pp and the depth of the wave profile grooves Pr on each roll 6 a and 6 b and the adjustable distance between the rolls are selected to suit the respective chips C, C′, C″ passing through the rolls. Reference marks S describe the segments, by which the wave profiles are formed, attached to the jacket of the roll 6 a , 6 b . There is a more detailed description of this structure in said Finnish utility model (No.) 2412.
The invention has above been described only with reference to a few exemplary implementations. One skilled in the art can, however, implement the details of the invention in several alternative ways within the scope of the attached claims.
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An apparatus for improving the pulping characteristics of wood chips. Several chip compressors are used to treat the wood chips in the desired manner.
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FIELD OF THE INVENTION
[0001] This invention relates to methods and means for the harvesting of oil slicks.
[0002] In British Patent Specification No. 2 310 381 there is described an oil slick harvesting vessel which has a mid-mounted endless belt conveyor for conveying spilled oil from one side of the vessel to the other and deployable hinged end panels which can be connected to the end panels of other like vessels to encompass an area into which the spilled oil can be directed in operation of the endless belt conveyors of the interconnected harvesting vessels.
[0003] It is an object of the present invention to provide an improved method and means for harvesting oil slicks.
SUMMARY OF THE INVENTION
[0004] According to a first aspect of the present invention there is provided a method of harvesting an oil slick, which method includes:—
a) providing an oil slick harvesting vessel which has an endless belt conveyor for conveying spilled oil from one side of the vessel to the other and deployable hinged panels which extend along both ends and said other side of the vessel, b) deploying the hinged panels so that they encompass an area on said other side of the vessel and within which the spilled oil can be collected, and c) operating the endless belt conveyor to transfer the spilled oil into the encompassed area.
[0008] The endless belt conveyor is preferably so arranged that the end thereof at said one side of the vessel is at a lower level than the other end thereof so that, during operation of the endless belt conveyor, spilled oil contacted by the endless belt conveyor will be lifted and transferred into the encompassed area.
[0009] Pump means may also be provided for drawing water towards said endless belt conveyor and into the vessel from said one side thereof and discharging it downwardly from the vessel.
[0010] The pump means (if provided) and the endless conveyor will thus be operated in such manner that the flow of water into or towards the vessel produces a flow of the spilled oil into contact with the endless belt conveyor for transfer thereof into the encompassed area.
[0011] According to a second aspect of the present invention there is provided an oil slick harvesting vessel which has an endless belt conveyor for conveying spilled oil from one side of the vessel to the other, and deployable hinged panels which extend along both ends and said other side of the vessel and which are deployable so that they encompass an area on said other side of the vessel and within which the spilled oil can be collected.
[0012] The hinged panels are preferably provided with sealing means in the form of gaskets to stop any egress of oil from the encompassed or circumscribed area.
[0013] The hinged panels preferably comprise two hinged panels at each end of the vessel, each of which has a length substantially equal to the width of the vessel. The hinged panels preferably also comprise three hinged panels at said other side of the vessel, each of which has a length substantially equal to the length of the vessel.
[0014] Pump means may be provided for drawing water towards and into the vessel from said one side thereof and discharging it downwardly from the vessel, the arrangement being such that, on operating the pump means and the endless conveyor, a flow of water is produced into the vessel so as to produce a flow of the spilled oil into contact with the endless belt conveyor for transfer thereof into the encompassed area.
[0015] The discharge outlets of the pump means are preferably located below the vessel and arranged for rotation to provide steerable thrust.
[0016] The endless belt conveyor preferably includes a number of parallel flat belts which extend side by side within the vessel and, unlike the conveyor of the harvesting vessel described in British Patent Specification No. 2 310 381, do not include scoops. The arrangement is thus such that the oil is transferred from one side of the vessel to the other, i.e. to the encompassed area, due to the natural viscosity of the oil. The picked up oil is preferably scraped off the endless belts by means of blades or bars, each of which extends for the full width of the associated belt and is located at or adjacent the uppermost end of the belt. An access platform is preferably provided above the vessel.
[0017] The harvesting vessel preferably has a length of the order of 10 metres and a width of the order of 5 metres, with two hingedly connected panels at each end of the vessel and pivotally connected to the ends of said other side of the vessel. The free ends of the hingedly connected panels at the ends of the vessel are then pivotally connected to the three hingedly connected panels which each extend for substantially the length of the other side of the vessel.
[0018] The panels will preferably have a height (or depth) of the order of 9 metres with the arrangement such that the water line will be about 3 metres below the tops of the panels, giving a depth of about 6 metres below the water line.
[0019] The vessel will preferably have a Global Positioning System (GPS) for communication and control purposes and, in an emergency, several vessels will normally be transported to an oil slick by means of helicopters, by ship or by road and placed at strategic points, working independently of each other while maintaining communication with one another.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a diagrammatic perspective view of an oil slick harvesting vessel with its panels fully deployed,
[0021] FIG. 2 is a diagrammatic plan view of the oil slick harvesting vessel of FIG. 1 with its panels fully folded, and
[0022] FIGS. 3 and 4 are diagrammatic plan views of the oil slick harvesting vessel if FIG. 1 with its panels partially deployed.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] The vessel 10 shown in the drawings is of rectangular form in plan view and has a length of the order of 10 metres and a width of the order of 5 metres, with two hingedly connected panels 11 A and 11 B or 12 A and 12 B at each end of the vessel 10 . The panels 11 A and 12 A are pivotally connected to the ends of one of the sides of the vessel 10 and the panels 11 B and 12 B are pivotally connected to the ends of the panels 11 A and 12 A. Each of the panels 11 A, 11 B, 12 A and 12 B has a length which is substantially equal to the width of the vessel 10 so that, when the panels 11 A, 11 B, 12 A and 12 B are in their compact storage or travelling positions, they are located against the ends of the vessel 10 and extend substantially parallel to the adjacent end of the vessel 10 .
[0024] The free ends of panels 11 B and 12 B are then pivotally connected to three hingedly connected panels 13 A, 13 B and 13 C which each extend for substantially the length of a side of the vessel 10 . Panel 13 A is pivotally connected to panel 11 B, panel 13 B is pivotally connected to panel 13 A and panel 13 C is pivotally connected at its one vertical edge to panel 13 B and at its other vertical edge to panel 12 B. When the panels 13 A, 13 B, and 13 C are in their compact storage or travelling positions, they are located against the side of the vessel 10 and extend substantially parallel to the adjacent side of the vessel 10 .
[0025] When the vessel 10 reaches a location at which there is an oil slick which requires collection, the panels 11 A, 11 B, 12 A, 12 B, 13 A, 13 B and 13 C are moved under the action of hydraulic piston and cylinder mechanisms (not shown) from the positions shown in FIG. 2 into the positions shown in FIG. 3 , and then into the positions shown in FIG. 4 , and finally into the positions shown in FIG. 1 , such movements of the panels being carried out progressively under the control of the piston and cylinder mechanisms such that, when the panels are in the positions shown in FIG. 1 , a substantial area is encompassed or circumscribed by the panels and by the side of the vessel 10 to which panels 11 A and 12 A are pivotally connected. The panels will typically be provided with sealing means in the form of gaskets fitted to the hinged or pivotal connections between adjacent panels and between panels 11 A and 12 A and the side of the vessel 10 .
[0026] A series of endless belt conveyors 14 are mounted on the vessel 10 , with the belts of the conveyors 14 extending parallel to one another from side to side of the vessel 10 . The belts of the conveyors 14 are inclined to the horizontal with the lower ends of the conveyor runs on the side of the vessel 10 remote from the area encompassed by the panels. During operation of the conveyors 14 , the oil which comes into contact with the belts of the conveyors 14 is transferred from the side of the vessel 10 remote from the encompassed area to the other side of the vessel 10 due to the natural viscosity of oil. The picked up oil is scraped off the endless belts by means of a series of blades or bars, each of which extends for the full width of the associated belt and is located at or adjacent the uppermost end of the associated belt.
[0027] The belts of the conveyors 14 are designed so that the seaward side of each belt adjusts so that the bottom of the belt has maximum contact with the oil as, if the conveyor belts are immersed too deeply into the water, they tend to convey only a small amount of water mixed with oil. Even though a certain amount of water is picked up by the conveyor belts, when the mixture of oil and water is deposited into the encompassed area, it will tend to travel downwardly through the oil, mixing with the water below.
[0028] Pumps (not shown) can be provided for drawing water towards and into the vessel 10 from the side thereof remote from the deployed panels and discharging it downwardly from the vessels, the arrangement being such that, on operating the pumps and the endless conveyors 14 , a flow of water is produced into the vessel 10 so as to produce a flow of the spilled oil into contact with the endless belt conveyors 14 for transfer thereof into the encompassed area. The oil slick is encouraged by the pumps to remain in contact with the conveyor belts.
[0029] The discharge outlets of the pumps will be located below the vessel 10 and arranged for rotation to provide steerable thrust to facilitate suitable positioning of the vessel 10 .
[0030] The harvesting vessel 10 typically has a length of the order of 10 metres and a width of the order of 5 metres, while the panels 11 A, 11 B, 12 A, 12 B, 13 A, 13 B and 13 C will typically have a height (or depth) of the order of 9 metres with the arrangement such that the water line will be about 3 metres below the tops of the panels, giving a depth of about 6 metres below the water line. To enable the vessel to sit two thirds below the water line and, at the same time, to be as light as possible for transport purposes, the majority of the required ballast will be provided by allowing water to flood tanks within the vessel. The hingedly connected panels will have buoyancy for the top third, while the outer skin of each panel facing away from the encompassed or confined area will be perforated with holes allowing water to fill the void and act as ballast.
[0031] If harvesting a volatile mixture, such that there is a high risk of explosion either through the production of an inflammable vapour by evaporation or as a result of the mixture itself being of a highly inflammable nature, a foam barrier containing a fire preventative agent is preferably sprayed onto the surface within the encompassed area. The foam barrier will have a composition such that it floats on the surface of the harvested oil. The oil and water mix will have a density greater than that of the foam barrier so that the oil and mixture conveyed into the encompassed area will travel downwardly through the fire barrier. The mixture will then separate allowing the oil to build up below the fire barrier while the water will sink to below the layer of oil.
[0032] Harvesting of the oil slick will be continued such that the oil within the encompassed area will build up to a level approaching the full depth of the vessel 10 , at which time a conventional tanker can be used to surface pump the collected and separated oil from within the encompassed area. With a vessel having end and side panels of the size described above, the encompassed area will be of sufficient size to enable 1 million litres of oil to be harvested. Most of the harvested oil will have been unaffected by the recovery process and can, therefore, be recycled.
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A method of harvesting an oil slick includes: a) providing an oil slick harvesting vessel ( 10 ) which has an endless belt conveyor ( 14 ) for conveying spilled oil from one side of the vessel ( 10 ) to the other and deployable hinged panels ( 11, 12 and 13 ) which extend along both ends and said other side of the vessel ( 10 ); b) deploying the hinged panels ( 11, 12 and 13 ) so that they encompass an area on said other side of the vessel ( 10 ) and within which the spilled oil can be collected, and c) operating the endless belt conveyor ( 14 ) to transfer the spilled oil into the encompassed area.
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[0001] This application claims the benefit of prior provisional patent application Serial No. 60/384,311 filed May 30, 2002.
TECHNICAL FIELD
[0002] This invention relates generally to a method and apparatus for providing distributed ignition of a combustion engine and, more particularly, to a method and apparatus for controlling the timing and amount of a pilot fuel injected into a combustion engine for distributed ignition.
BACKGROUND
[0003] Low cetane, i.e., high octane, fuels, such as natural gas, have several advantages over other hydrocarbon fuels that are combusted in internal combustion engines. For example, natural gas is less expensive relative to other hydrocarbon fuels. Moreover, natural gas burns cleaner during operation of the internal combustion engine relative to other hydrocarbon fuels. By burning cleaner, a reduced amount of combustion byproducts such as carbon monoxide, oxides of nitrogen, and hydrocarbons are released into the environment during engine operation. In addition, because lubricants of the internal combustion engine become contaminated with combustion byproducts over time, the production of a reduced amount of combustion byproducts results in less contamination, thereby increasing the useful life of the lubricants.
[0004] One type of internal combustion engine is a diesel engine. Diesel engines combust fuel by compressing a mixture of air and fuel to a point where the fuel is ignited by heat which results from such compression. When natural gas is used as a fuel in a diesel engine, the natural gas does not readily ignite as it is compressed. In order to overcome this problem, an ignition source is provided to ignite the natural gas. The ignition source may be provided by a spark plug similar to those used in spark ignition engines. However, in certain types of diesel engines, e.g., dual fuel engines, the ignition source is provided by injecting a small amount of pilot fuel, such as diesel fuel, into a mixture of air and natural gas (or other gaseous fuel). As the mixture of air, natural gas and pilot fuel is compressed, the pilot fuel ignites, which in turn provides a diesel type ignition of the natural gas.
[0005] A disadvantage associated with using pilot fuel as an ignition source is the resulting generation of an increased amount of oxides of nitrogen (NO x ). In particular, the ratio of air to the combination of natural gas and pilot fuel in the combustion chamber varies with the proximity to the injected streams of pilot fuel. Rich mixtures are created near the location of injection of pilot fuel, while lean mixtures are created further away from the location of the injection. Combustion of the rich mixtures tend to produce more NO x than does the combustion of the lean mixtures.
[0006] One way to reduce the amount of NO x produced during the combustion process is to create a lean homogeneous mixture of air, natural gas and pilot fuel throughout the combustion chamber prior to ignition of the pilot fuel. Because the homogeneous mixture is lean throughout the entire combustion chamber, only lean mixtures are combusted. Combustion of only lean mixtures produces a lesser quantity of NO x than does combustion of a combination of rich mixtures and lean mixtures.
[0007] In commonly-owned U.S. Pat. No. 6,095,102, Willi et al. (Willi) discloses a method for injecting a quantity of pilot fuel into a combustion chamber having a supply of gas/air mixture. The pilot fuel is injected during the compression stroke in the range from about 21 degrees to 28 degrees before top dead center (BTDC) and is used to provide distributed ignition of the gas/air mixture. Willi discloses that injection of the pilot fuel in advance of what has been typically done in the industry, e.g., from 5 to 20 degrees BTDC, provides for a homogeneous mixture of the pilot fuel with the main portion of the gas and air. Furthermore, Willi discloses that the exact desired timing of the injection is determined by sensing the amount of NO x in the exhaust stream during each subsequent exhaust stroke and varying the timing until an optimal level of NO x is attained.
[0008] It has been found that, since Willi's initial disclosed method, variations in engines and engine operating conditions result in situations in which the optimal desired timing of the pilot fuel injection resides outside of the 21 to 28 degree BTDC range during the compression stroke. Furthermore, sensing the level of NO x and responsively varying the pilot injection timing does not always yield the best results. For example, optimal results may be achieved by varying the timing of the pilot fuel injection as well as the amount of pilot fuel injected. This can only be accomplished by determining parameters other than merely sensing NO x , and responsively controlling both the timing and the amount of the pilot fuel injection.
[0009] The present invention is directed to overcoming one or more of the problems as set forth above.
SUMMARY OF THE INVENTION
[0010] In one aspect of the present invention a method for injecting pilot fuel in a combustion engine is disclosed. The method includes the steps of determining a load of the engine, determining a desired injection timing of the pilot fuel and a desired quantity of pilot fuel to be injected as a function of a desired homogeneous distribution of the pilot fuel based on the engine load, and adjusting the injection timing and quantity of the pilot fuel to the desired values.
[0011] In another aspect of the present invention a method for providing distributed ignition of a combustion engine is disclosed. The method includes the steps of introducing a quantity of fuel/air mixture into a combustion chamber of the engine, determining an operating load of the engine, determining a desired injection timing of a pilot fuel and a desired quantity of the pilot fuel to be injected as a function of a desired homogeneous distribution of the pilot fuel with the fuel/air mixture based on the engine load, and injecting the pilot fuel at the desired time.
[0012] In yet another aspect of the present invention an apparatus for providing distributed ignition of a combustion engine is disclosed. The apparatus includes a cylinder assembly which includes (1) an engine block having a piston cylinder defined therein, (2) an engine head secured to the engine block, and (3) a piston which translates within the piston cylinder, wherein the engine block, the engine head, and the piston cooperate to define a combustion chamber. The apparatus further includes an intake port positioned in fluid communication with the combustion chamber during intake of a primary fuel and air mixture, a fuel injector positioned in the engine head and operable to inject pilot fuel into the combustion chamber during a compression stroke of the engine, an engine load determining device, and a controller which receives information from the engine load determining device and responsively determines a desired injection timing of the pilot fuel and a desired quantity of pilot fuel to be injected based on a desired homogeneous distribution of the pilot fuel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a partial cross sectional, partial schematic view of a combustion engine which incorporates the features of the present invention;
[0014] [0014]FIG. 2 is a block diagram illustrating a preferred embodiment of the present invention; and
[0015] [0015]FIG. 3 is a partial cross sectional, partial schematic view of a combustion engine which incorporates features of a preferred embodiment of the present invention.
DETAILED DESCRIPTION
[0016] Referring to FIG. 1, there is shown an engine assembly 10 . The engine assembly 10 includes a plenum member 12 , and an air source 14 . The plenum member 12 has an inlet opening 16 , and an exit opening 15 defined therein. The air source 14 supplies air to the inlet opening 16 . Air from the air source 14 advances into a plenum chamber 24 defined in the plenum member 12 via the inlet opening 16 .
[0017] The engine assembly 10 further includes a cylinder assembly 26 . The cylinder assembly 26 includes a block 28 having a piston cylinder 30 defined therein. An engine head 32 is secured to the block 28 . The engine head 32 has an intake port 34 , an exhaust port 36 , and a fuel injector opening 60 defined therein. An intake conduit 38 places the intake port 34 in fluid communication with the exit opening 15 of the plenum member 12 . An exhaust passage 52 places the exhaust port 36 in fluid communication with an exhaust manifold 54 .
[0018] The engine assembly 10 further includes a piston 40 which translates in the piston cylinder 30 in the general direction of arrows 42 and 44 . As the piston 40 moves downwardly in the general direction of arrow 44 to the position shown in FIG. 1, a connecting rod 43 urges a crankshaft 50 to rotate in the general direction of arrow 51 . Subsequently, as the crankshaft 50 continues to rotate in the general direction of arrow 51 , the crankshaft 50 urges the connecting rod 43 and the piston 40 in the general direction of arrow 42 to return the piston 40 to the uppermost position (not shown).
[0019] The piston 40 , the piston cylinder 30 , and the engine head 32 cooperate so as to define a combustion chamber 46 . In particular, when the piston 40 is advanced in the general direction of arrow 42 , the volume of the combustion chamber 46 is decreased. On the other hand, when the piston 40 is advanced in the general direction of arrow 44 , the volume of the combustion chamber 46 is increased as shown in FIG. 1.
[0020] The engine assembly 10 further includes a primary fuel source 18 in fluid communication with the intake conduit 38 . A primary fuel supply valve 41 controls the amount of primary fuel, such as natural gas, advanced to the intake conduit 38 . In particular, the primary fuel supply valve 41 moves between an open position, which advances primary fuel to the intake conduit 38 , and a closed position, which prevents advancement of primary fuel to the intake conduit 38 . It should be appreciated that the amount of primary fuel advanced by the primary fuel valve 41 controls the ratio of air to primary fuel, or air/fuel ratio, advanced to the combustion chamber 46 . Specifically, if it is desired to advance a leaner mixture to the combustion chamber 46 , a primary fuel control signal received via a signal line 96 causes the primary fuel supply valve 41 to operate so as to advance less primary fuel to the intake conduit 38 . On the other hand, if it is desired to advance a richer mixture of air and primary fuel to the combustion chamber 46 , a primary fuel control signal received via the signal line 96 causes the primary fuel supply valve 41 to operate so as to advance more primary fuel to the intake conduit 38 .
[0021] It is noted that other methods of introducing the primary fuel and air mixture to the combustion chamber 46 may be used without deviating from the spirit and scope of the present invention. For example, the primary fuel may be mixed with air at any point from the air source 14 through the intake conduit 38 , including upstream of a turbocharger (not shown). Alternatively, the primary fuel may be injected directly into the combustion chamber 46 , and subsequently mixed with the intake of air.
[0022] The primary fuel is typically a fuel having a high octane number, i.e., low cetane number. Preferably, the primary fuel is natural gas. However, the primary fuel may be of some other type, such as gasoline, methanol, ethanol, and the like, and may be either gaseous or liquid.
[0023] An intake valve 48 selectively places the plenum chamber 24 in fluid communication with the combustion chamber 46 . The intake valve 48 is actuated in a known manner by a camshaft (not shown), a pushrod (not shown), and a rocker arm (not shown) driven by rotation of the crankshaft 50 . When the intake valve 48 is placed in the open position (shown in FIG. 1), air and primary fuel are advanced from the intake conduit 38 to the combustion chamber 46 via the intake port 34 . When the intake valve 48 is placed in the closed position (not shown), primary fuel and air are prevented from advancing from the intake conduit 38 to the combustion chamber 46 since the intake valve 48 blocks fluid flow through the intake port 34 .
[0024] An exhaust valve 56 selectively places the exhaust manifold 54 in fluid communication with the combustion chamber 46 . The exhaust valve 56 is actuated in a known manner by a camshaft (not shown), a pushrod (not shown), and a rocker arm (not shown) each of which are driven by the rotation of the crankshaft 50 . When the exhaust valve 56 is placed in the open position (not shown), exhaust gases are advanced from the combustion chamber 46 to the exhaust manifold 54 via a fluid path that includes the exhaust port 36 and the exhaust passage 52 . From the exhaust manifold 54 , exhaust gases are advanced to an exhaust conduit 55 . When the exhaust valve 56 is placed in the closed position (shown in FIG. 1), exhaust gases are prevented from advancing from the combustion chamber 46 to the exhaust manifold 54 since the exhaust valve 56 blocks fluid flow through the exhaust port 36 .
[0025] Combustion of the mixture of primary fuel and air in the combustion chamber 46 produces a number of exhaust gases. After the mixture of primary fuel and air is combusted in the combustion chamber 46 , exhaust gases are advanced through the exhaust conduit 55 . Included among the exhaust gases are quantities of oxides of nitrogen (NO x ).
[0026] The engine assembly 10 further includes a fuel reservoir 70 . A fuel pump 72 draws low pressure fuel from the fuel reservoir 70 and advances high pressure fuel to a fuel injector 62 via a fuel line 74 . The fuel injector 62 is positioned in the injector opening 60 and is operable to inject a quantity of fuel into the combustion chamber 46 through the injector opening 60 . In particular, the fuel injector 62 injects fuel into the combustion chamber 46 upon receipt of an injector control signal on a signal line 100 . Furthermore, the fuel can be any one of the following group of fuels: diesel fuel, crude oil, lubricating oil, or an emulsion of water and diesel fuel. More generally, the fuel may be any type of fuel which has a higher cetane number than the primary fuel, thus having the property of combusting more readily than the primary fuel.
[0027] The engine assembly 10 further includes a controller 90 . The controller 90 is preferably a microprocessor-based engine control unit. As FIG. 2 illustrates, the controller 90 preferably includes a set of maps 202 . Each map 202 is a three-dimensional map of fuel injection timing, fuel injection quantity, and NO x for a determined engine operating load. A change in engine load would result in a new map 202 being referenced. Furthermore, the changes in loads, and hence maps, are based on a determined constant engine speed. A change in engine speed would require reference to additional maps.
[0028] The engine speed is determined by an engine speed determining device 206 , such as a speed sensor or some such device well known in the art. The engine load is determined by an engine load determining device 204 . Examples of engine load determining devices include, but are not limited to, cylinder pressure transducers to measure work per cycle, estimation based on measurement of intake pressure and oxygen in the exhaust, and estimation based on measured fuel mass flow rate.
[0029] Referring to FIG. 3, a preferred embodiment of the present invention is shown. The embodiment of FIG. 3 differs from the embodiment of FIG. 1 in that the pilot fuel is introduced into the combustion chamber 46 by way of the intake port 34 , rather than by means of direct injection. For example, a port injector 302 may inject pilot fuel into the intake conduit 38 , as shown. Alternatively, other devices may be used to deliver the pilot fuel into the intake port 34 , such as an acoustic atomizer, an air assisted injector, and the like. Alternatives to the preferred embodiment include introducing the pilot fuel at some other location upstream of the intake conduit 38 , for example upstream of the supply of primary fuel and air.
[0030] When the pilot fuel is introduced through the intake port 34 , the desired timing of pilot fuel injection is no longer an issue. However, the desired amount of pilot fuel to use is still of concern, and is still determined based on engine load, such as determined by use of the maps 202 . The maps 202 , however, would not include fuel injection timing as a parameter.
INDUSTRIAL APPLICABILITY
[0031] In operation, the typical engine assembly 10 operates in a four stroke cycle which includes an intake stroke, a compression stroke, a power stroke, and an exhaust stroke. Although the below discussion pertains specifically to a four stroke engine, the principles of the present invention may apply as well to other types of engines, such as a two stroke engine.
[0032] The first stroke is the intake stroke, during which the exhaust valve 56 is positioned in the closed position and the intake valve 48 is positioned in the open position as shown in FIG. 1. During the intake stroke, the piston 40 is advanced downwardly in the general direction of arrow 44 thereby creating a low pressure in the combustion chamber 46 . This low pressure draws primary fuel and air from the intake conduit 38 downwardly into the combustion chamber 46 so as to form a homogeneous mixture of air and primary fuel in the combustion chamber 46 .
[0033] Advancing to the compression stroke, the intake valve 48 and the exhaust valve 56 are both positioned in their respective closed positions. As the piston 40 moves upwardly in the general direction of arrow 42 , it compresses primary fuel and air in the combustion chamber 46 . At a time during the compression stroke, the fuel injector 62 injects pilot fuel into the combustion chamber 46 so as to ignite the mixture of primary fuel and air. The pilot fuel is injected in advance of 20 degrees before top dead center (BTDC) to allow sufficient time for the pilot fuel to form a homogeneous mixture with the fuel/air mixture already present in the combustion chamber 46 .
[0034] The controller 90 receives information from the engine load determining device 204 and the engine speed determining device 206 and responsively accesses a relevant map 202 . The map 202 provides an indication of a desired injection timing of the pilot fuel and a desired quantity of pilot fuel to be injected based on a desired homogeneous distribution of the pilot fuel and a desired reduced amount of NO x being exhausted. The controller 90 then delivers command signals via signal lines 208 and 210 , which in turn control, respectively, the pilot fuel injection timing and the pilot fuel injection quantity.
[0035] Alternatively, the controller 90 may determine the desired pilot fuel injection timing and quantity by methods other than reference to maps. For example, the controller 90 may receive information from a cylinder pressure transducer (not shown) or information relevant to engine speed fluctuations and responsively determine a desired injection quantity based on combustion variability. Furthermore, the controller 90 may receive information relevant to cylinder pressure rise rate, e.g., from measurement of cylinder pressure or the use of a “knock” sensor (not shown), and responsively determine a desired injection timing. The above two alternatives may be used in cooperation with each other to determine both the desired injection timing and the desired injection quantity.
[0036] It is noted that the pilot fuel is injected in advance of 20 degrees BTDC. The exact timing, as determined above, is indicative of a reduced amount of NO x emissions. For example, it is found that NO x increases as timing is advanced to a point. However, as timing is further advanced, NO x begins to decrease until the level of NO x reaches a transition point, i.e., the amount of decrease of NO x does not change significantly for additional advances in timing. It is desired to control the timing, and also the quantity, of the pilot fuel to attain NO x emissions at about the transition point. It is found that, with various engines and under various operating conditions, the optimal timing varies anywhere from 20 degrees BTDC to the initiation of the compression stroke, i.e., about 180 degrees BTDC.
[0037] In the preferred embodiment of FIG. 3, the pilot injection quantity is desired and the timing of the pilot fuel is not an issue. For example, it may be determined by the above maps or alternative means that the desired injection quantity may be somewhere in the range of 0.5% to 1% of the total fuel introduced into the combustion chamber 46 . It is noted, however, that these quantities are exemplary only and may differ in value.
[0038] Other aspects can be obtained from a study of the drawings, the disclosure, and the appended claims.
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A method and apparatus for injecting pilot fuel in a combustion engine. The method and apparatus includes determining a load of the engine, determining a desired injection timing of the pilot fuel and a desired quantity of pilot fuel to be injected as a function of a desired homogeneous distribution of the pilot fuel based on the engine load, and adjusting the injection timing and quantity of the pilot fuel to the desired values.
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to the stabilization of watercraft, such as kayaks and canoes, and especially to the stabilization of a kayak or canoe to allow an individual to stand or move therein without the kayak or canoe rocking or rolling over. More particularly, the invention relates to a pontoon assembly which is in a raised rest position for paddling but which can be rapidly extended alongside the kayak or canoe to provide stabilization.
[0002] Floats and pontoons for stabilizing watercraft which are positioned alongside of the watercraft are old and well known in the art. Devices are presently available to address stabilization through the addition of floatation devices. In more recent times these devices have been provided with clamping supports and allow floatation to be clamped to a canoe and are generally held on a fixed extended position from the side of the watercraft. These devices are used to prevent sudden overbalance movement by an occupant in the canoe which can quickly tip or capsize the canoe. Most prior art pontoon assemblies are somewhat cumbersome. Many are attachable but at the same time are large and very unwieldy and are difficult to add or remove from the water.
[0003] It is desirable not to have the pontoons extended when one is paddling a kayak or a canoe and then to rapidly extend the floatation device as needed to stabilize the canoe when the canoe is not in motion and when the occupant desires to stand, such as while fishing or to move around in the kayak. It is an object of the present invention that a floatation assembly can be rapidly and removably attached and removed to and from a kayak or canoe and which can be extended to use as a flotation device either on one or both sides of the kayak. The floatation on both sides can be raised for paddling a kayak with greater ease.
[0004] In the past, there have been a large number of outboard floatation devices especially for adding to a canoe and these include the Birkett U.S. Pat. No. 4,641,594 for a canoe conversion kit for use alone as an iceboat or for easy mounting on a canoe to convert the canoe to a sailboat. In the Nielsen U.S. Pat. No. 5,174,233, a self-adjusting boat outrigger is provided. The Morriseau U.S. Pat. No. 6,860,216 is a canoe pontoon assembly which has side runners which are attached adjacent to the canoe to prevent the canoe from tipping over. Pontoons are adjustable for height and width and deploys a ballast to stabilize a canoe. The Hall U.S. Pat. No. 6,000,355 is a stabilized watercraft having an elongated V-type hull and stabilizers mounted in outrigger fashion. Each stabilizer has an elongated floatation member that can be extended and retracted with a pantographic-type extension mechanism. The Grzybowski U.S. Pat. No. 6,305,306 is a watercraft stabilization system for a canoe which has a pair of floatation devices. The Barker, Jr. U.S. Pat. No. 5,988,090 is a stabilization pontoon system for a small watercraft which has a pair of adjustable outriggers connected by a linkage system to an actuator so that each pontoon can be lowered into the water to stabilize the watercraft.
[0005] The present invention, on the other hand, is directed primarily to watercraft, such as a kayak or canoe, and to an outrigger floatation system which is in a raised or storage position while paddling the kayak or canoe and which can be rapidly extended to add stabilization to the watercraft so that the occupant can stand for fishing or doing other functions without the watercraft tipping over and capsizing. A pontoon can be extended from one or both sides, as desired.
SUMMARY OF THE INVENTION
[0006] The present invention relates generally to a stabilization system for watercraft, such as kayaks and canoes, and to a pontoon assembly for stabilizing a watercraft. A base member is removably attachable to a watercraft for holding the pontoon assembly. An elongated pontoon support arm has two end portions and has a pontoon attached to one end portion. A supporting bracket for the pontoon supporting arm is movably attached to the base member and slidably supports the pontoon supporting arm therein between the two end portions thereof so that the pontoon supporting arm can tilt on and slide in the arm supporting bracket. A linkage is movably attached to the base and to the other end of the pontoon supporting arm and has a pair of link members movably attached to each other. The linkage is adapted to raise the other end of the pontoon supporting arm to lower and extend the pontoon into an operative position. The pontoon supporting arm tilts on and slides in a pontoon supporting arm supporting bracket to lower one end of the pontoon supporting arm when the linkage is raised and to raise and withdraw the pontoon into a rest position when the linkage is lowered. A locking mechanism is used to lock the linkage in a raised position with the pontoon in an operative position. Pontoons can be mounted on both sides of the base member to allow individual pontoons to be extended from one or both sides of a canoe or kayak. Each elongated pontoon supporting arm has a handle mounted to the other end portion thereof. The pontoon supporting arm and the pontoon can be held in an operative position with a locking mechanism which may be an eccentrically mounted block rotatably attached to the pontoon supporting arm for rotation to different block positions between the pontoon supporting arm and the linkage. The linkage has two links movably attached to each other to allow the linkage to fold when lowering the pontoon supporting arms into a rest position. When the linkage is extended and unfolded, one link moves a portion thereof over the second link to thereby stop or lock the two links together in an extended position with the pontoon supporting arm at the other end in a raised position and the pontoon in a lowered and extended position. A handle on one of the linkage link members allows one of the hinged links to be lifted for folding the linkage to the lower pontoon support arm other end to raise and withdraw the pontoon to a rest position. The pontoon assembly would normally have one base member with two pontoon assemblies attached thereto. The supporting arm bracket has a passageway therethrough for the pontoon supporting arm to slide therein and the passageway has a self-lubricating polymer surface or the entire supporting bracket which may be made of a self-lubricating polymer. The pontoon assembly is attached to a kayak with a strap wrapping around the kayak, which strap is attached to a reel shaft rotatably attached to the base. The reel shaft has a ratchet and pawl mechanism operatively attached thereto for tightening and locking the strap around the watercraft to hold the base and pontoon assembly to the watercraft.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Other objects, features, and advantages of the present invention will be apparent from the written description and the drawings in which:
[0008] FIG. 1 is a perspective view of a kayak having the watercraft stabilization system attached thereto with the pontoons in a raised and rest position;
[0009] FIG. 2 is a perspective view of the kayak of FIG. 1 having the pontoons in an extended and operative position;
[0010] FIG. 3 is a perspective view of the kayak of FIGS. 1 and 2 having one pontoon extended in an operative position and a second one in a raised rest position;
[0011] FIG. 4 is a perspective view of a portion of the pontoon assembly;
[0012] FIG. 5 is a perspective view of the pontoon connected in one position to the pontoon supporting arm; and
[0013] FIG. 6 is a perspective view of the pontoon of the present invention connected in a second position to the pontoon supporting arm.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] Referring to the drawings, a watercraft stabilization system 10 is illustrated, as shown in FIGS. 1-6 , mounted to a kayak 11 . The system 10 can also be mounted to a canoe, as desired, or any other watercraft. The watercraft stabilization system 10 has base member 12 which is mounted to the watercraft 11 , as shown in FIGS. 1-3 . The base 12 is removably attached to the kayak in FIGS. 1 through 3 using a strap 15 which wraps around the kayak and base member 12 and is tightened and locked around the kayak with a ratchet and pawl mechanism 14 having a handle 15 which rotates the shaft having a strap 13 attached thereto for tightening onto the kayak. The base 12 has a pair of pontoon supporting arms supporting brackets 16 each movably attached to one end of the base 12 and each having a passageway therethrough. A pontoon supporting arm 17 supports a pontoon 18 on one end thereof and is slidably mounted in the supportive bracket 16 . The supportive bracket 16 has a passageway therethrough and is movably mounted on a pin 20 to the base 12 so that the support arm 17 can tilt on and slide in the bracket 16 . Each support arm 17 has a handle 21 on one end for lifting and moving the position of the pontoon support arm 17 and pontoon 18 .
[0015] A linkage 22 has a pair of links 23 and 24 movably attached together with a pin 25 . The link 23 is attached to one end portion of the pontoon supporting arm 17 using a pin 26 while the link 24 is pinned to the base 12 with a pin 27 . This arrangement allows the linkage 22 to be folded into a rest position thereby sliding and raising the pontoon 18 into the rest position, as shown in FIG. 1 . The linkage 22 can be unfolded to a raised position, as shown in FIG. 2 , to tilt and slide the pontoon support arm 17 into an extended or operative position positioning the pontoon 18 in a position to stabilize the watercraft 11 . The linkage 22 is locked in the raised or operative position by the link 24 end portion extending well beyond the pin 25 so that in the extended position, the link 24 extending portion 28 acts as a stop or lock when it folds against the top of the link 23 . To release the lock from the extended position, a small handle 30 is provided which allows the link 24 to be lifted sufficiently that a pontoon support arm 17 can be slid and tilted with a handle 21 to thereby fold the linkage 22 into a folded or rest position.
[0016] The pontoon 18 can be positioned in different positions by a locking block 31 pinned with a pin 32 to one end of the pontoon supporting arm 17 . The pin 32 is pinned to the block 31 in an off center position that allows the block 31 to eccentrically to position different faces against the surface of the link 23 . The block 31 can have numbers 33 or other indica to indicate different positions for supporting the pontoon support arm 17 relative to the link 23 thereby positioning the pontoon in a different raised or lowered position. In addition, each pontoon 18 is attached to the pontoon supporting arm 17 with a strap 34 which is attached to a support arm 35 . Arm 35 is movably pinned with pin 36 to allow the pontoon 18 to extend, as shown in FIG. 5 , when the pontoon is in the water. The pontoon, as shown in FIG. 6 , is allowed to drop when in a raised position. This keeps the pontoon 18 closer to the kayak when the pontoon is not in use.
[0017] In operation, a pair of pontoon assemblies are attached to a watercraft 11 , such as a kayak or canoe, as shown in FIGS. 1 , 2 and 3 . Each assembly is attached to the base member 12 , which base member is two members attached together as a unit and attached to the watercraft 11 . Each pontoon assembly operates separately and can extend a pontoon 18 to either side of the watercraft 11 . The pontoon 18 extends from the rest position in FIG. 1 with each pontoon withdrawn from the water and supported on the sides of the watercraft 11 . Each pontoon 18 can then be extended by grabbing either of the handles 21 on the pontoon support arm 17 and raising it to shift one pontoon at a time into an operative position, as shown in FIGS. 2 and 3 . When raising the handle 21 to raise the pontoon supporting arm 17 , the supporting arm raises the linkage 22 to rotate the link members 23 and 24 until the locking portion 28 of link 24 stops onto link member 23 . Link member 23 comes to a rest on the locking block 31 which has been rotated and positioned to position the pontoon supporting arm 17 and the pontoon 18 in the desired position in the water beside the watercraft 11 . This results by the pontoon supporting arm 17 tilting with the arm supporting bracket 16 tilting on the pin 20 on the base member 12 and simultaneously sliding in the arm supporting bracket to both extend and lower the pontoon beside the canoe or kayak. When the arm 17 is raised, the pontoon 18 drops by arm 35 rotating on pin 36 , as shown in FIG. 6 . When the arm 17 lowers the pontoon 18 in the water, the pontoon is forced into the position shown in FIG. 5 where it is held in position by the end of the arm 35 pressing against arm 17 .
[0018] The operation is more clearly illustrated in FIG. 4 . When it is desired to raise the pontoons 18 , the handle 21 on either pontoon supporting arm 17 is grasped and lifted while the handle 30 can also be slightly lifted to ease the lifting of the handle 21 . Lifting the handle 21 pulls and tilts pontoon supporting arm 17 in the bracket 16 while folding the linkage 23 and 24 on the pin 25 to bring it to a rest position, as shown in FIG. 1 .
[0019] A watercraft stabilization system has been illustrated which can be easily attached to a watercraft, such as a canoe or a kayak. It should also be clear that while a stabilization system has been illustrated attached to a kayak, it can as easily be attached to a canoe or other watercraft. In attaching to a kayak, the strap 13 is wrapped around the kayak to hold the base member 12 and braces 38 resting on the side of the kayak. The strap is attached to one end of one base member 12 and rides in the second base member 12 and is attached to a reel or shaft which is rotated by a handle 15 and locked in place with a ratchet and paw mechanism 14 .
[0020] It should be clear at this point that a watercraft stabilization system has been provided which advantageously is rapidly deployed for stabilizing the watercraft and is rapidly lifted and tilted to a rest position for paddling or moving the watercraft. However, the present invention should not be considered limited to the forms shown which are to be considered illustrative rather than restrictive.
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This invention relates generally to the stabilization of watercraft, such as kayaks and canoes, and especially to the stabilization of a kayak to allow an individual to stand or move in a kayak without the kayak rocking or rolling over. The pontoon assembly is mounted to a kayak which allows for extending a stabilizing pontoon individually on each side of the watercraft and locking the pontoon at an operative position. Each pontoon can be rapidly raised to a rest position for paddling the kayak or canoe.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/528,950, filed on Oct. 30, 2014, entitled “ADVERTISEMENT SCHEME FOR USE WITH INTERACTIVE CONTENT”, which is a continuation of U.S. patent application Ser. No. 13/189,219, filed on Jul. 22, 2011, now U.S. Pat. No. 8,879,891, entitled “ADVERTISEMENT SCHEME FOR USE WITH INTERACTIVE CONTENT”, which is a continuation of U.S. patent application Ser. No. 11/558,348, filed on Nov. 9, 2006, now U.S. Pat. No. 8,000,581, entitled “ADVERTISEMENT SCHEME FOR USE WITH INTERACTIVE CONTENT”, the entire disclosures of which are all hereby fully incorporated by reference herein in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to advertising, and more specifically to advertising in interactive content, such as video games and the like.
[0004] 2. Discussion of the Related Art
[0005] One traditional form of advertising is the television commercial. Such television commercials typically consist of brief advertising spots that range in length from a few seconds to several minutes. The commercials appear between shows and interrupt the shows at regular intervals. The goal of advertisers is to keep the viewer's attention focused on the commercial.
[0006] Advertising has also been used in video games. Such advertising often takes the form of advertisements that are inserted and placed on billboards, signs, etc., that are displayed in the scenes of the game.
[0007] It is with respect to these and other background information factors that the present invention has evolved.
SUMMARY OF THE INVENTION
[0008] One embodiment provides a method for use in advertising, comprising: initiating playing of interactive content; suspending playing of the interactive content; displaying an advertisement; and resuming playing of the interactive content.
[0009] Another embodiment provides a computer program product comprising a medium for embodying a computer program for input to a computer and a computer program embodied in the medium for causing the computer to perform steps of: initiating playing of interactive content; suspending playing of interactive content; displaying an advertisement; and resuming playing of the interactive content.
[0010] Another embodiment a system for use in advertising comprising: a display; a processing system configured to initiate playing of interactive content, suspend playing of the interactive content, display an advertisement on the display, and resume playing of the interactive content.
[0011] A better understanding of the features and advantages of various embodiments of the present invention will be obtained by reference to the following detailed description and accompanying drawings which set forth an illustrative embodiment in which principles of embodiments of the invention are utilized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The above and other aspects, features and advantages of embodiments of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
[0013] FIG. 1 is a flow diagram illustrating a method for use in advertising in accordance with an embodiment of the present invention;
[0014] FIGS. 2A, 2B, 2C and 2D are screen shots illustrating example indications that the playing of the interactive content will be suspended that may be used in accordance with embodiments of the present invention;
[0015] FIG. 3 is a screen shot illustrating an example advertisement that may be played in accordance with embodiments of the present invention;
[0016] FIGS. 4A and 4B are screen shots illustrating example indications that the playing of the interactive content will be resumed that may be used in accordance with embodiments of the present invention;
[0017] FIG. 5 is a block diagram illustrating a network that may be used to run, implement and/or execute the methods shown and described herein in accordance with embodiments of the present invention; and
[0018] FIG. 6 is a block diagram illustrating a computer system that may be used to run, implement and/or execute the methods shown and described herein in accordance with embodiments of the present invention.
DETAILED DESCRIPTION
[0019] Embodiments of the present invention provide an advertisement scheme for use with interactive content, such as for example video games, entertainment software, or any other type of interactive content. In some embodiments, during game play, the game slows down, then stops, and a commercial is played. The user may be given an indication or other warning that a commercial is coming. By way of example, the indication may comprise a slowing down of the game play. This way, when the game slows down, the user knows to get ready for a commercial, the game then stops, and the commercial is played. After the commercial, the game resumes (i.e. starts again). In some embodiments the game may resume by slowly starting again, which allows the user to remember where he or she was in the game.
[0020] Referring to FIG. 1 , there is illustrated a method 100 that operates in accordance with an embodiment of the present invention. The method 100 , which may be used in advertising, may be used in any interactive entertainment system or any content where the user interacts with the content.
[0021] The method 100 begins in step 102 where the playing of interactive content is initiated. In some embodiments, an optional step 104 may be used to provide the user with an indication that the playing of the interactive content will be suspended. In some embodiments, the indication may comprise a slowing down of the playing of the interactive content. For example, in some embodiments, the interactive content may be played in slow motion before being suspended. In other implementations, the slowing down of the content may be gradual so that the speed at which the interactive media is played is decreased until the playing of the interactive media is suspended.
[0022] Various transmission mechanisms may optionally be used to couple player minds out of (and back into) the game environment. For example, in some embodiments, the indication provided in optional step 104 may comprise displaying a warning message, a notice, bell, audio signal, visual signal, audio-visual signal, or some other indication that alerts a user of an upcoming break, such as a commercial break, in the playing of the media content. FIGS. 2A, 2B, 2C and 2D illustrate example suspension indications that may be used in accordance with embodiments of the present invention. Namely, In FIG. 2A the game playing on client display device 210 may be gradually slowed down. In FIG. 2B a warning message 212 that the game play is about to stop may be displayed on the client display device 210 . In FIG. 2C a visual warning signal such as a blinking light 214 may be used to indicate that game play is about to stop. In FIG. 2D an audio signal played through speakers 216 connected to the client device may be used to indicate suspension of playing of media.
[0023] In step 106 ( FIG. 1 ) the playing of the interactive content is suspended. According to some embodiments, the playing of content may be suspended at predefined times. In other embodiments, suspension of playing of interactive content may occur randomly. During step 106 when the playing of the interactive content is suspended, in some embodiments, a stop point may be recorded referring to the point at which the playing of the media content was suspended. This stop point may be the time within the media content where the playing of the content is suspended, or other such identifiers that may be used to identify the point within the media content at which the playing is suspended.
[0024] In step 108 an advertisement is displayed. By way of example, the advertisement may be similar to a traditional TV commercial, or may comprise some other type of advertisement. For example, FIG. 3 illustrates an example advertisement 308 played on client display device 310 . In this example the advertisement 308 is for “Best Brand Soda” having the slogan “You've Got to Try It!”. In some embodiments, the advertisement may be preselected, randomly chosen, selected based on demographics, selected based on a user profile or other criteria, or selected by some other process. In embodiments where interactive content is played on several client devices (discussed below), commercial advertisements may be played on one or more or all client devices. In some embodiments, the advertisement may be played on the whole screen. Thus, when the playing of interactive content is suspended, a commercial or other advertisement is played.
[0025] In some embodiments, a portion of the content may be replayed before resuming the playing of the interactive content. For example, as shown in optional step 110 ( FIG. 1 ), at least a portion of the interactive content is rewound prior to the resuming playing of the interactive content. That is, a portion of the game may be rewound to replay the last few seconds or minutes slowly to allow the user to begin playing again. In some embodiments, the recorded stop point is used, so that a portion of the content before the content is played back in either normal speed or slow motion up to the stop point and normal playing of content is resumed after the stop point.
[0026] In some embodiments, an indication may be provided alerting the user that playback of the content is about to resume before resuming playing of the content. The indication may be a notice, an audio indication such as a bell, an audio visual signal, or other such indications. In some embodiments, objects, targets, scenes, players, scores, or other such information may be highlighted or animated to bring focus into key elements of the interactive content at the time of resuming playing of content. FIGS. 4A and 4B illustrate example resuming indications that may be used in accordance with embodiments of the present invention. Namely, In FIG. 4A a warning message 412 that the game play is about to resume may be displayed on the client display device 410 . In FIG. 4B the rank 414 , score 416 and/or object 418 , such as an automobile, may be highlighted or animated to bring focus into those elements of the interactive content at the time of resuming playing of content.
[0027] Next, in step 112 ( FIG. 1 ) the playing of the interactive content is resumed. In some embodiments a signal scheme may trigger and coordinate the resuming of playing of content to establish a safe and fair transition. Various transition mechanisms may be used to transition from a suspended state to resuming playing of the content. In some embodiments, the speed of the content may be increased until the speed returns to its normal speed. In some embodiments, the speeding up may be gradual to insure an effective transition.
[0028] Embodiments of the present invention may be used in stand alone games or in network gaming environments. Referring to FIG. 5 , there is illustrated a system 500 that may be used in implementing a network gaming environment in accordance with an embodiment of the present invention. In the system 500 , a plurality of players are able to interact with each other, such as for example in a network game. This may be accomplished by each player operating a client device 502 that has access to a network 504 , such as for example the Internet.
[0029] In some implementations, the gaming network may be synchronized using a signaling scheme where a signal is sent to all players on the network to suspend and play a game. Additionally, signals may be sent to facilitate slowing down or speeding up the playing of the content at the same time to provide a fair and simultaneous game play environment. Other synchronization schemes utilizing recording stop points and time stamps may be used in some embodiments. In network gaming one or more players may all see the same or different commercials when game play stops. In embodiments where different commercials are played synchronization schemes may be used to ensure that regardless of the commercial that is playing on each client device the game stops and resumes at the same time. Such synchronization schemes may also be used to ensure that the game stops and resumes in a similar manner at all client devices to ensure a fair playing environment.
[0030] In some embodiments, where a game is played over a network, suspension of the content, and optionally an indication, may be initiated when the server transmits a message to all game clients coordinating the state change. For example, in a network gaming framework, a signal may be transmitted to some or all players to indicate a break and to coordinate the break in all player units. In some embodiments, the signal scheme may trigger and coordinate game functions across the game environment to establish a safe and fair transition from active game play to a pause state. In some implementations, the points at which the suspending of the playing of the media takes place is pre-recorded and suspending of the content is initiated when the players encounter a stop point within the content. In some implementations, where media content is being played simultaneously on several client playback devices, a signal scheme, or other schemes, may be used to coordinate the suspension of the content on all devices. In other embodiments, the playing of the content may be suspended at random points. In some implementations a signal scheme may be used to send a signal causing all client devices to suspend playing of the content on all client apparatuses.
[0031] In embodiments where the content is displayed to multiple clients, the same advertisement may be played on all client devices, while in other embodiments different advertisements may be played on some or all of the client devices. The advertisements that are played on client devices may be randomly assigned to different devices, or in some implementations, the advertisements specific to some or all of the client devices, based on a user profile or other criteria, may be sent to those devices.
[0032] The methods and techniques described herein may be utilized, implemented and/or run on many different types of computers, graphics workstations, televisions, entertainment systems, video game systems, DVD players, DVRs, media players, home servers, video game consoles, and the like. Referring to FIG. 4 , there is illustrated a system 400 that may be used for such implementations. However, the use of the system 400 is certainly not required.
[0033] By way of example, the system 600 may include, but is not required to include, a central processing unit (CPU) 602 , a graphics processing unit (GPU) 604 , digital differential analysis (DDA) hardware 606 , a random access memory (RAM) 608 , and a mass storage unit 610 , such as a disk drive. The system 600 may be coupled to, or integrated with, a display 612 , such as for example any type of display, including any of the types of displays mentioned herein.
[0034] The CPU 602 and/or GPU 604 may be used to execute or assist in executing the steps of the methods and techniques described herein, and various program content and images may be rendered on the display 612 . Removable storage media 614 may optionally be used with the mass storage unit 610 , which may be used for storing code that implements the methods and techniques described herein. However, any of the storage devices, such as the RAM 608 or mass storage unit 610 , may be used for storing such code. Either all or a portion of the system 600 may be embodied in any type of device, such as for example a television, computer, video game console or system, or any other type of device, including any type of device mentioned herein.
[0035] While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.
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A method for use in advertising includes initiating playing of interactive content, suspending playing of the interactive content, displaying an advertisement, and resuming playing of the interactive content. A computer program product includes a medium embodying a computer program for causing a computer to perform these operations, and a system for use in advertising includes a display and a processing system configured to perform these operations.
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BACKGROUND OF THE INVENTION
Liquid crystals represent a novel state of matter intermediate between the crystalline and isotropic liquid states of matter. This unique behavior may lead to a variety of useful applications including the use of such materials in electrooptical devices, in thermography, etc.
Liquid crystalline (LC) polymers combine the desirable properties of macromolecules with the anisotropic properties of liquid crystals. An important application of LC polymers includes the formation of high tensile strength fibers. Another end use is the blending of such LC polyesters with existing polymers for the production of molecular composites.
Certain monomers containing the biphenyl mesogen, as depicted in FIG. 1, which can be used to form liquid crystalline polyesters are known. Specifically, the monomer where r=2 is identified by CAS Registry No. 20994-26-7 whereas r=6 is identified by CAS Registry No. 97087-90-6. A computer search revealed the following references which appear to show the synthesis and use of one or both of these monomers as follows:
1. Sato, M. et al., "Synthesis and Liquid-Crystalline Properties of Thermotropic Homo- and Copolycarbonates", J. Polym. Sci., Part A: Polym. Chem., 26(11) 3077-3088 (1988) appears to name both monomers. The homo- and copolycarbonates described have flexible spacers between mesogens and between the carbonate linkages.
2. The monomer where r=6 is mentioned in "Combined Liquid-Crystalline Polymers with Chiral Phases 2. Lateral Substituents", by H. Kapitza et al., Makromol. Chem. 189(8) 1793-1807 (1988). The polyester-polyether polymers described therein have mesogenic groups in the main chain as well as in the side groups.
3. The monomer where r=2 is mentioned in U.S. Pat. No. 4,791,187.
4. Both monomers (r=2 and r=6) are mentioned in "Liquid Crystalline Behavior of Central Core-Type Model Compounds for Thermotropic Polycarbonates", by M. Sato et al., Makromol. Chem., Rapid Comm., 8(8), 383-386 (1987). The thermotropic polycarbonates were prepared by reaction of omega, omega'-(4,4'-biphenylenedioxy)dialkanols with n-alkyl or phenylchlorocarbonate.
5. M. Sato et al. in "New Liquid-Crystalline Polycarbonates from Diols Containing a Biphenyl Ring Sequence As Central Core", Makromol. Chem., Rapid Commun., 7(4), 231-234 (1986) mentions liquid crystal polycarbonates prepared by melt condensation of 6,6'-(4,4'-biphenylenedioxydihexanol (the monomer when r=6) and alkylene di-phenyl dicarbonates in the presence of zinc acetate.
6. B. Reck et al., in "Combined Liquid Crystalline Polymers: Mesogens in the Main Chain and as Side Groups", Makromol. Chem., Rapid Commun., 6(4), 291-299 (1985) shows the preparation and polymerization of the monomers where r=2 and 6 with phenylazophenoxy or biphenyloxy group containing diethyl malonate derivatives.
7. M. Kawaguchi et al. in "Synthesis and Physical Properties of Polyfunctional Methacrylates. Part 4. Synthesis and Physical Properties of Aromatic Dimethacrylate Copolymers", Dent Mater. J., 3(2), 272-279 (1984) describes copolymers of methyl methacrylate and dimethacrylates of various dihydroxy compounds, including 4,4'-(2-hydroxyethoxy) biphenyl as possible dental resonance materials. The monomer where r=2 was prepared and esterified with methacryloyl chloride.
8. Japanese Kokai No. 58/217553 (abstracted in Chem. Abstr. 101:39330m) describes thermoplastic resin compositions including those containing the methylenedianiline terminated monomer where r=2.
9. U.S. Pat. No. 3,562,335 describes 4,4'-dialkoxybiphenyls and in its disclosure shows preparation of the monomer where r=2.
More recently, U.S. Pat. No. 4,833,229 relating to a thermotropic copolyester having a nematic structure of the liquid crystalline phase issued. It was derived from a saturated aliphatic dicarboxylic acid, a 4,4'-dihydroxybiphenyl, and a p-hydroxybenzoic acid.
DESCRIPTION OF THE INVENTION
One embodiment is the novel monomer bis(2-hydroxybutoxy) biphenyl which is shown in FIG. 1 as 2a (where r=4). This monomer can be synthesized as shown in Example 2 by the reaction of 4,4'-biphenol with 4-bromobutyl acetate.
The liquid crystalline nature of these types of monomers have been previously reported, e.g., the monomer with r=6 has been characterized as displaying various smetic transitions. As will be described in greater detail below, the effect of such a smetic mesogen can be incorporated into a polymer with various ratios of terephthalic and isophthalic units to investigate the effects of non-mesogenic kinks on stabilizing the liquid crystalline state of such polymers.
A second preferred embodiment of the present invention involves the novel polyester compositions of the general type shown in FIG. 2. However, the particular embodiments shown in the formula can more generally be depicted as ##STR1## where Ar is 1,4-phenylene, ArAr is a 4,4'-biphenylene mesogenic group, and r ranges from about 2 to about 8. In the formula that is given, Ar can be substituted or unsubstituted phenyl group and ArAr indicates a biphenyl mesogenic group that can also be substituted or unsubstituted. As used herein, the term "biphenyl" is to be construed as covering two phenyl rings linked together, for example, as biphenyl rings or fused together as naphthyl rings. Exemplary substituents on either Ar or ArAr include lower alkyl, aryl, halogen, and the like.
These polymers display a nematic texture when viewed under an optical polarizing microscope and can be, for example, synthesized by reaction of the known and novel bis(hydroxy-alkoxy) biphenyls, including those shown in FIG. 1, with terephthaloyl chloride. Generally speaking, the r group in the depicted biphenyl reagent of FIG. 1 can range from about 2 to about 8. The synthesis of these novel preferred polyester compositions is illustrated in Examples 4-6 which follow and are advantageously carried out in a hydrocarbon solvent (e.g., a halogenated solvent such as tetrachlorethane) in the presence of an amine which serves as an acid acceptor (e.g., pyridine).
The instant invention is further understood by the Examples which follow.
EXAMPLE 1
This Example illustrates the preparation of bis(2-hydroxy-ethoxy)biphenyl which is Compound 1a in FIG. 1.
4,4'-Biphenol (18.6 grams, 0.1 mole) was stirred into a solution of sodium hydroxide (16.0 grams) in 200 mil of ethanol. The resulting slurry was heated to reflux, at which point 2-bromoethanol (55.0 grams, 0.044 mole) was added dropwise over a thirty minute period. The mixture was refluxed for twenty-four hours, was cooled, and was poured into a large volume of water. The resulting slurry was warmed for thirty minutes, was cooled and was filtered. The precipitate was then washed with water, then with acetone, and was recrystallized twice from dioxane to give the pure compound in 60% yield. It had a melting point of 210° C.
EXAMPLE 2
This Example illustrates preparation of bis(2-hydroxy-butoxy)biphenyl, which is compound 2a in FIG. 1.
Into a solution of 4,4'-biphenol (19.0 grams, 0.10 mole) in 100 ml of methanol was placed one equivalent of sodium methoxide, prepared from sodium and methanol immediately prior to use. The mixture was stirred a short while, and the methanol was replaced with 300 ml of dimethylformamide (DMF). To this solution was then added 4-bromobutyl acetate (60.0 grams, 0.30 mole), and the reaction mixture was heated at 60° C. for forty-eight hours, at which point the mixture was cooled and the precipitate was collected by vacuum filtration. The crude solid (25.5 grams) was then added to a solution of potassium hydroxide (20.0 grams) in ethanol-water (2:1). The reaction mixture was then heated to reflux for forty-eight hours. The mixture was then cooled and was neutralized with a dilute HCl solution. The mixture was cooled further, and the precipitate was collected and recrystallized from acetone-DMF, giving the pure product (30% overall yield) having a melting point of 193° C.
EXAMPLE 3
This Example illustrates preparation of bis(6-hydroxy-hexoxy)biphenyl, which is compound 3a in FIG. 1.
Compound 3a was prepared and purified in a manner similar to compound 1a, as described in Example 1. Thus, 4,4'-biphenol (30.0 grams, 0.16 mole) was mixed with 25 grams of NaOH in ethanol, was then reacted with 6-chlorohexanol (100 grams, 0.73 mole), to give the pure compound in 70% yield having a melting point of 175°-176° C.
EXAMPLE 4
This Example illustrates preparation of polymer 1b as shown in FIG. 2.
An amount equalling 3.843 grams of diol 1a, which was synthesized in Example 1, was dissolved in 90 ml of 1,1,2,2-tetrachloroethane and 8 ml of pyridine. The reaction mixture was warmed under an argon atmosphere and a substantially equal equivalent amount of terephthaloyl chloride (2.844 grams) was introduced to the reaction flask. The resulting mixture was stirred and heated at 100° C. for twenty-four hours. The polymer was then precipitated in a large volume of methanol, collected, and extracted with methanol, was then dried in a vacuum oven, giving the pure homo polymer in 86% yield.
Analytical calculations for (1b, C 24 H 20 O 6 ): C, 71.28; H, 5.00. Found: C, 71.40; H, 5.27.
EXAMPLE 5
This Example illustrates preparation of polymer 2b as shown in FIG. 2.
An amount equalling 8.868 grams of diol 2a, which was made in Example 2, was dissolved in 110 ml of 1,1,2,2-tetrachloroethane and 33 ml of pyridine. The reaction mixture was warmed under an argon atmosphere and a substantially equal equivalent amount of terephthaloyl chloride (5.499 grams) was introduced to the reaction flask. The resulting mixture was stirred and heated at 70° C. for twenty-four hours. The polymer was then precipitated in a large volume of methanol, collected, and extracted with methanol, was then dried in a vacuum oven, giving the pure homo polymer in 90% yield.
Analytical calculations for (2b, C 28 H 28 O 6 ): C, 73.02; H, 6.13. Found: C, 72.93; H. 6.03.
EXAMPLE 6
This Example illustrates preparation of polymer 3b as shown in FIG. 2.
An amount equalling 3.407 grams of diol 3a, made in Example 3, was dissolved in 80 ml of 1,2-dichlorethane and 3 ml of pyridine. The reaction mixture was warmed under an argon atmosphere and a substantially equal equivalent amount of terephthaloyl chloride (1.796 grams) was introduced to the reaction flask. The resulting mixture was stirred and heated at reflux temperature for twenty-four hours. The polymer was then precipitated in a large volume of methanol, collected, and extracted with methanol, then dried in a vacuum oven, giving the pure homo polymer in 75% yield.
Analytical calculations for (3b, C 32 H 36 O 6 ): C, 74.39; H, 7.02. Found: C, 74.25; H, 6.96.
EXAMPLE 7
This Example illustrates the preparation of a polyester from the condensation of diol 3a, as shown in FIG. 1, with adipoyl chloride.
An amount equalling 4.850 gm of diol 3a, made in Example 3, was dissolved in 75 ml of 1,2-dichloroethane and 5 ml of pyridine. The reaction mixture was warmed under an argon atmosphere and a substantially equivalent amount of terephthaloyl chloride (2.297 gm) was introduced to the reaction flask. The resulting mixture was stirred and was heated to reflux temperature for eighteen hours. The polymer was then precipitated in a large volume of methanol, was collected, and was extracted with methanol. It was then dried in a vacuum oven, giving a substantially pure homopolymer in 87% yield.
The analytical calculation for (C 30 H 40 O 6 ): C, 72.55; H, 8.12. Found: C, 72.85; H, 8.04.
EXAMPLE 8
This Example illustrates preparation of the type of polymers described above where monomer 3a is condensed with various ratios of terephthaloyl chloride and isophthaloyl chloride. This synthesis is for a polymer having a ratio of terephthalic to isophthalic units of 2:1.
An amount of monomer 3a (1.0066 gm), terephthaloyl chloride (0.3530 gm), and isophthaloyl chloride (0.17467 gm) were placed in an argan-purged Schlenk tube. The tube was then charged with 10 ml of 1-chloronaphthalene. A condenser was attached to the tube and a slight purge of argon was applied throughout the reaction. The mixture was heated to 170° C. where a yellow solution persisted for one hour. The clear solution was then slowly heated to 210° C. over a three hour period and was then held at this temperature until the evolution of HCl ceased (about two days). The solution was then diluted with 20 ml of 1,2-dichloroethane and was then precipitated in methanol. The solid polymer was collected, was extracted with methanol, and was allowed to dry in a vacuum oven at 110° C. for three days giving the polymer in 95% yield.
Analytical calculation for (C 32 H 36 O 6 ): C, 74.39; H, 7.02. Found: C, 74.18; H, 6.95.
RESULTS
The inherent viscosity measurements of the synthesized polymers, (30° C. in 1,1,2,2-tetrachloroethane), gave values typically ranging from 0.50 to 1.18 dL/G. The values were: 1b 0.70; 2b 0.78; and 3b 1.17. The inherent viscosity for a product having the general structure
--[O(CH.sub.2).sub.6 OArArO(CH.sub.2).sub.6 OC(O)(CH.sub.2).sub.4 C(O)--]
with Ar being phenyl, was 0.73 dL/G. Polymers (1b, 2b, 3b) displayed a dense schlieren texture under an optical polarizing microscope, which is best observed from cooling from the isotropic phase. Thermal transition data, as measured by DSC and confirmed by optical microscopy, are as follows: for 1b, fusion begins at 214° C., clearing temperature=224° C.; for 2b, fusion begins at 160° C., clearing temperature=182° C.; for 3b, fusion begins at 120° C., clearing temperature=161° C. The proton NMR spectra of the polymers are consistent with the structures.
In other results, the 50/50 random copolymer, derived from monomers 1a and 3a, was prepared in similar fashion to the homopolymers, and found to be pure by elemental analysis. Surprisingly the copolymer does not show any birefringent textures. The results are somewhat unexpected.
The aliphatic analog, depicted by the general structural formula shown above, derived from monomer 3a was prepared in the usual manner and was found to be pure by elemental analysis. A single endothermic peak was observed by DSC at 132° C. This polymer appeared to be much more crystalline in nature as compared to the other polymers shown herein. It could not be easily characterized as liquid crystalline.
Inherent viscosity measurements, as previously described, were taken on polymers 4a-4d as also described above. The values were: 4a, 1.62; 4b, 1.50; 4c, 1.53; and 4d, 1.58. The polymers displayed similar textures, as also described before, although the development of textures was hindered by the higher viscosity of these materials. Thermal transition data, as measured by DSC and confirmed by optical miscroscopy, revealed isotropization transition for 4a at 149° C.; for 4b at 146° C.; for 4c at 118° C.; and for 4d at 121° C. and sharp monotropic transition for 4a at 121° C.; for 4b at 108° C.; for 4c at 108° C.; and for 4d at 112° C. The proton NMR spectra of the polymers was consistent with the structures and compositions. The x-ray diffraction studies on drawn fibers indicated enhanced development of the liquid crystalline state and suppression of the crystalline state with increasing content of isophthalic units.
The foregoing illustrate certain preferred embodiments of the invention and, for that reason, should not be construed in a limiting sense. The scope of protection sought is set forth in the claims which follow.
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Novel liquid crystal polyesters can be formed by reaction of bis(hydroxyalkoxy)biphenyls (including the novel bis(2-hydroxybutoxy)biphenyl) with terephthaloyl chloride.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of application Ser. No. 11/039,135 filed Jan. 19, 2005, now issued as U.S. Pat. No. 7,416,202 which is a continuation of application Ser. No. 10/603,848 filed Jun. 25, 2003, now issued as U.S. Pat. No. 6,874,801 which is a continuation of application Ser. No. 10/041,273 filed Nov. 7, 2001 now issued as U.S. Pat. No. 6,588,783.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
BACKGROUND OF THE INVENTION
[0003] This invention relates generally to the field of vehicle accessories, and more particularly to automotive side bars for assisting entry into high road clearance vehicles.
[0004] The present invention relates in general to vehicle side bars for sport utility vehicles, pick-up trucks, jeeps and similar vehicles.
[0005] A vehicle side bar is an accessory which has gained considerable popularity in recent years. In essence, it is a wide tubular bar which is attached to the side of a vehicle just below the passenger cab. It usually covers the length of the cab and projects laterally to the outside of the cab side or door surface. It is usually bolted or welded to the main longitudinal frame beam of the vehicle chassis.
[0006] The side bar is both an appearance accessory and provides some protection for door and side of the vehicle cab to deflect debris.
[0007] Many vehicles of earlier date had running boards along the side of the vehicle to provide a stable platform to stand on and assist in entry and exit from the vehicle. More recently, side bars have been manufactured and sold, primarily by small and large automotive accessory companies. Side bars, while primarily a styling accessory, have been modified to provide a step built into the side bar to assist in entry of and exit from the vehicle. The side bar system of the present invention, in contrast with side bars with a step built into the bar, provides a step assembly independent of the side bar providing a stable step closer to the ground.
[0008] Running boards were at one time a standard feature on most passenger vehicles, including light duty trucks such as pickup trucks. The running board provided an intermediate step that was an aid in entering the passenger compartment of the vehicle.
[0009] As vehicle designs changed, the bodies of the vehicles were lowered and the running disappeared from the design of the vehicle. The body of the vehicles, in addition to being lowered was widened to provide more space in the passenger compartment. This design concept of eliminating running boards carried over to other vehicles that were not lowered in design, such as four wheel drive pickups and sport utility vehicles.
[0010] Four wheel drive vehicles are intentionally designed with a relatively high road clearance, that is the frame and body is supported at a relatively high distance from the ground. This is a desired characteristic, since the user of the vehicles wants the maximum clearance for traversing adverse road conditions such as deep snow, muddy and rutted roads and the like. Additionally four wheel drive vehicles are often driven off improved roadways where all types of conditions are likely to be encountered.
[0011] One of the problems with a high clearance vehicle is the height of the entry into the passenger compartment. The floor of the passenger cab is of necessity high above the ground and for many individuals, the required “step” is too high to permit easy entry.
[0012] Side bars such as those similar to and described in U.S. Pat. No. 4,935,638 provide a step on the side bar itself. This step is many times still too high off the ground to permit easy entry into the vehicle. Aesthetically, a step built into the side bar also visually disrupts the clean line and streamlined appearance of the bar.
BRIEF SUMMARY OF THE INVENTION
[0013] The primary object of the invention is assists entry into vehicle passenger compartment. Another object of the invention is to provide an intermediate step between the ground and the floor of the passenger compartment.
[0014] Another object of the invention is to provide a stylish appearance accessory to vehicle.
[0015] A further object of the invention is to provide a functional side step and/or a protective device for the door and side of the vehicle cab.
[0016] Other objects and advantages of the present invention will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.
[0017] In accordance with a preferred embodiment of the invention, there is disclosed an apparatus for assisting entry into high road clearance vehicles having a generally cylindrical side bar adapted for attachment to a vehicle chassis, one or more smaller U-shaped cylindrical bars attached to and suspended from said bar comprised of two end portions and a center bar, and a generally flat surface on the top of each of said center bar of said U-shaped bars.
[0018] In accordance with another preferred embodiment of the invention, there is disclosed an apparatus for assisting entry into high road clearance vehicles having a generally cylindrical side bar adapted for attachment to a vehicle chassis, one or more U-shaped cylindrical bars attached to and suspended from said bar comprised of two end portions and a center bar; and a non-skid surface on the top of each of said center bars of said U-shaped bars.
[0019] The tubular side bar is mounted onto the vehicle chassis by means of mounting brackets which attach to the chassis and the side bar by a variety of conventional means including but not limited to welds, brazing or attachment with nuts and bolts.
[0020] The smaller U-shaped tubular bars are attached to the side bar by welds, brazing or other means. Similarly, a step is constructed by attaching a flat bar to the top of the U-shaped tubing. This configuration is the step assembly. An additional lower step can be constructed by using another small U-shaped tubular bar and attaching it to the first step assembly. In this manner additional steps can be produced for higher clearance vehicles.
[0021] The side bar and attached step assembly mounted by brackets to the vehicle chassis form a streamlined accessory just below the bottom of the vehicle passenger cab and extending from just aft of the forward wheel fender to just forward of the rear wheel fender. The step assembly (or assemblies) is (are) suspended from the side bar and positioned just below each door or passenger exit to assist entry and exit from the vehicle.
[0022] The composition of the tubular bars and flat bar can be metal or any of a number of high strength composite materials. The finish of the bars can be but is not limited to chrome, polished metal or high or low gloss paint to complement the appearance of the vehicle.
[0023] The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
BRIEF DESCRIPTION OF THE SEVERAL DRAWINGS
[0024] FIGS. 1A and 1B are top and side plan views of the invention.
[0025] FIG. 2 is a longitudinal cross sectional view of the invention taken along line A-A of FIG. 1 .
[0026] FIGS. 3A through E are top and side plan views of the side bar, step assembly components and mounting brackets.
[0027] FIG. 4 is a side perspective view of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Detailed descriptions of the preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Various aspects of the invention may be inverted, or changed in reference to specific part shape and detail, part location, or part composition. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
[0029] Turning now to the drawings, FIG. 1A illustrates side bar 20 attached to the underside of vehicle 22 , partially shown in phantom. Vehicle 22 may be one of any number of sport utility vehicles, pick up trucks or other vehicles. Side bar 20 is typically welded or brazed to mounting brackets 26 which are then attached to vehicle underside chassis 24 of vehicle 22 by use of bolts, welds, brazing or other means well known in the art. The side bar typically extends the majority of the distance underneath a passenger compartment and may extend along the direction between the front and rear wheels of the vehicle. Side bar 20 may be formed from a generally cylindrical tube having a cross section of any a variety of polygonal shapes including, but not limited to, a circle, a square, a rectangle, a triangle, an oval, an ellipse, or any other suitable shape. Side bar 20 may also be any other rigid member that is capable of mounting on a chassis along the underside of the vehicle. Side bar 20 functions as a protective guard for the exterior side surfaces of vehicle 22 and serves as a stable platform for attachment of the smaller U-shaped bar of step assembly 28 . Step assembly 28 may also be made using tubular construction. The invention teaches that a flat bar 29 may be attached on the upper surface of the center of the bar of step assembly 28 to thereby form a step. Alternatively a non-skid surface may be applied to that area of the bar to form a step surface on flat bar 29 .
[0030] In a preferred embodiment of the invention the tubular bar of the step assembly 28 is attached to the side bar 20 by welding; the welds are ground and sanded to a smooth finish prior to polishing and/or painting of the metal surfaces of the invention. Typical side bars 20 and U-shaped tubular bars of the step assembly 28 comprise rugged tubular steel tubing although other materials including but not limited to high tensile strength composites may be used. Similarly, flat bars 29 that form a step are typically stamped steel although other materials may be used. In an alternative embodiment non-skid materials of various kinds can be applied to the top of the center of the tubular bar of the step assembly 28 to form a step.
[0031] On a four-door vehicle, side bar 20 is fitted with tubular bars for step assembly 28 and flat bar 29 positioned below and generally centered below each door. Step assembly 28 is preferably located relative to the doors so that a passenger can easily use the step to enter and exit vehicle 22 . Alternatively, vehicle 22 may have two side doors, a third opening for a mini-club cab or a specialty vehicle with a plurality of doors for the passenger cab; in each case a step assembly and step is positioned below each door. In addition, a step assembly 28 may be located behind the rear door just before the rear tire well to permit step access to the bed of the truck or the rear roof surface of a sport utility vehicle.
[0032] FIG. 1B shows a preferred embodiment of the invention from a side view before being mounted on a vehicle. Step assembly 28 is a U-shaped bar having two ends 21 connected together by a central bar 27 that together attach to side bar 20 to form a step. The angle at which ends 21 attach to central bar 27 may be of any of a variety of angles typically from 0 to 45 degrees to facilitate easy access by a human foot and a stopping point on either side of central bar 27 to inhibit slipping and undesired movement of the person using the step. Ends 21 may be of two different angles on one step assembly depending on the application. Attached to or formed in central bar 27 is flat surface (flat bar 29 of FIG. 1A ) to form a convenient location for a foot to alight.
[0033] FIG. 2 illustrates a side cross sectional view of the invention along the line A-A of FIG. 1 . In the preferred embodiment, side bar 30 is welded to mounting bracket 32 . Mounting bracket 32 is bolted to the vehicle underside chassis 34 to stably secure the side bar below the vehicle body (not shown). Step assembly 36 (consisting of the tubular bar and step previously described) is welded to side bar 30 at an appropriate angle to provide an optimum setback from the vehicle passenger cab and easy to access surface to assist in entering and exiting the vehicle. Preferably, the angle should be approximately 45 degrees from the horizontal plane. There may be applications where the angle could be anywhere from 0 to 90 degrees relative to the horizontal plane depending on vehicle height off the ground and the particular use intended.
[0034] FIGS. 3A through F show each of the component parts of a preferred embodiment in more detail. FIG. 3A shows a top plan view of side bar 40 . During manufacture side bars 40 are cut to lengths customized for each vehicle. After cutting side bar 40 to the desired length, the ends are bent and stylized bent ends 42 and 44 created. One or both of the bent ends may be removed as depicted on the left bent end 44 in shaded outline in the figure to achieve the desired stylized effect. In the preferred embodiment the tubular bar is comprised of mild steel of 3 inch diameter and 14 gauge thickness although other generally cylindrical shapes and materials can be used for side bar 40 .
[0035] FIG. 3B shows a side plan view of side bar 40 and accurately depicts a clean closed appearance of the side bar with the bent ends removed as in outlined bent end 44 from FIG. 3A .
[0036] FIG. 3C shows a top plan view of step assembly tubular bar 50 . During manufacture step assembly tubular bars 50 are cut to lengths customized for each vehicle. The angle at which the bend is applied to bar 50 may be of any of a variety, typically between approximately 0 to 45 degrees to permit easy access of a foot when stepping onto the step assembly. After cutting tubular bar 50 to the desired length the ends are bent and stylized bent ends 52 and 54 created. Bent ends 52 and 54 are then smoothed and recut to provide a surface that can be attached flush to side bar 30 . In the preferred embodiment tubular bar 50 is comprised of mild steel of 1.5 inch diameter and 14 gauge thickness although other generally cylindrical shapes and materials can be used for tubular bar 50 .
[0037] FIG. 3D shows side plan view of flat bar 58 that is used to create a stepping surface in the step assembly. In the preferred embodiment the flat bar is welded to the top portion of the tubular bar shown in FIG. 3C in a manner that creates a step that is horizontal to the ground when the vehicle is parked on a level surface. The flat bar typically consists of stamped steel although other materials well known in the art may be substituted.
[0038] FIG. 3E shows two side plan views of a preferred embodiment of the mounting bracket. The mounting bracket typically consists of stamped steel and is fashioned to each vehicle model to stably hold the side bar in the preferred position below the vehicle body. A typical mounting bracket consists of arms 60 and 62 of varying lengths that hold the side bar in place. With a preferred 3 inch diameter side bar the distance between the top and bottom arms 60 and 62 would be 2.25 inches allowing a secure attachment by means of welding or brazing of the side bar to the arms 60 and 62 . Extension 64 is attached to arms 60 and 62 and is adapted for mounting on the chassis of the vehicle by bolts (not shown) placed in pre-drilled holes on extension 64 .
[0039] FIG. 4 is side view of the preferred embodiment of the invention in a typical installation mounted on high road clearance vehicle 78 . As previously described, side bar 70 and tubular bar of step assembly 72 form an aesthetically pleasing streamlined appearance along the underside of the vehicle body. Bent arm 80 of the side bar complements the bent arms of the step assembly tubular bars and forms a symmetrical visual that is pleasing to the eye and creates a safe edge on the bar that is less likely to be caught on objects or people. Mounting brackets 76 are somewhat hidden in a properly installed installation and do not interfere with ingress or egress from the vehicle. Likewise flat bar 74 for the step assembly forms a step without taking away from the safe application as a step formed by the invention.
[0040] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention; and therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalents of the following claims. Although this invention has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art are also within the scope of this invention, as defined in the claims which follow.
[0041] While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
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An apparatus for assisting entry into high road clearance vehicles having a generally cylindrical side bar adapted for attachment to a vehicle chassis, one or more U-shaped cylindrical bars attached to and suspended from said bar comprised of two end portions and a center bar. The U-shaped bars may be of tubular construction and have a flat surface and are preferably angled from the side bar at an angle of approximately 45 degrees and each U-shaped bar has end portions that meet the center bar at an angle of approximately 0 to 45 degrees. The side bar may be attached to any of a variety of chassis designs and may have a plurality of steps at the doors and at or near the back of the vehicle.
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This application is based on, and claims the benefit of, U.S. Provisional Application No. 60/338,838, filed Nov. 5, 2001.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to ω-cycloalkyl 17-heteroaryl prostaglandin E 2 analogs as EP 2 -receptor agonists. These compounds are potent ocular hypotensive and are particularly suited for the management of glaucoma.
2. Description of Related Art
Ocular hypotensive agents are useful in the treatment of a number of various ocular hypertensive conditions, such as post-surgical and post-laser trabeculectomy ocular hypertensive episodes, glaucoma, and as presurgical adjuncts.
Glaucoma is a disease of the eye characterized by increased intraocular pressure. On the basis of its etiology, glaucoma has been classified as primary or secondary. For example, primary glaucoma in adults (congenital glaucoma) may be either open-angle or acute or chronic angle-closure. Secondary glaucoma results from pre-existing ocular diseases such as uveitis, intraocular tumor or an enlarged cataract.
The underlying causes of primary glaucoma are not yet known. The increased intraocular tension is due to the obstruction of aqueous humor outflow. In chronic open-angle glaucoma, the anterior chamber and its anatomic structures appear normal, but drainage of the aqueous humor is impeded. In acute or chronic angle-closure angle-closure glaucoma, the anterior chamber is shallow, the filtration angle is narrowed, and the iris may obstruct the trabecular meshwork at the entrance of the canal of Schlemm. Dilation of the pupil may push the root of the iris forward against the angle, and may produce pupilary block and thus precipitate an acute attack. Eyes with narrow anterior chamber angles are predisposed to acute angle-closure glaucoma attacks of various degrees of severity.
Secondary glaucoma is caused by any interference with the flow of aqueous humor from the posterior chamber into the anterior chamber and subsequently, into the canal of Schlemm. Inflammatory disease of the anterior segment may prevent aqueous escape by causing complete posterior synechia in iris bombe, and may plug the drainage channel with exudates. Other common causes are intraocular tumors, enlarged cataracts, central retinal vein occlusion, trauma to the eye, operative procedures and intraocular hemorrhage.
Considering all types together, glaucoma occurs in about 2% of all persons over the age of 40 and may be asymptotic for years before progressing to rapid loss of vision. In cases where surgery is not indicated, topical β-adrenoreceptor antagonists have traditionally been the drugs of choice for treating glaucoma.
Certain eicosanoids and their derivatives have been reported to possess ocular hypotensive activity, and have been recommended for use in glaucoma management. Eicosanoids and derivatives include numerous biologically important compounds such as prostaglandins and their derivatives. Prostaglandins can be described as derivatives of prostanoic acid which have the following structural formula:
Various types of prostaglandins are known, depending on the structure and substituents carried on the alicyclic ring of the prostanoic acid skeleton. Further classification is based on the number of unsaturated bonds in the side chain indicated by numerical subscripts after the generic type of prostaglandin [e.g. prostaglandin E 1 (PGE 1 ), prostaglandin E 2 (PGE 2 )], and on the configuration of the substituents on the alicyclic ring indicated by α or β [e.g. prostaglandin F 2α (PGF 2α )].
Prostaglandins were earlier regarded as potent ocular hypertensives, however, evidence accumulated in the last decade shows that some prostaglandins are highly effective ocular hypotensive agents, and are ideally suited for the long-term medical management of glaucoma (see, for example, Bito, L. Z. Biological Protection with Prostaglandins , Cohen, M. M., ed., Boca Raton, Fla, CRC Press Inc., 1985, pp. 231-252; and Bito, L. Z., Applied Pharmacology in the Medical Treatment of Glaucomas Drance, S. M. and Neufeld, A. H. eds., New York, Grune & Stratton, 1984, pp. 477-505. Such prostaglandins include PGF 2α , PGF 1α , PGE 2 , and certain lipid-soluble esters, such as C 1 to C 2 alkyl esters, e.g. 1-isopropyl ester, of such compounds.
Although the precise mechanism is not yet known experimental results indicate that the prostaglandin-induced reduction in intraocular pressure results from increased uveoscleral outflow [Nilsson et. al., Invest. Ophthalmol. Vis. Sci . (suppl), 284 (1987)].
The isopropyl ester of PGF 2α has been shown to have significantly greater hypotensive potency than the parent compound, presumably as a result of its more effective penetration through the cornea. In 1987, this compound was described as “the most potent ocular hypotensive agent ever reported” [see, for example, Bito, L. Z., Arch. Ophthalmol. 105, 1036 (1987), and Siebold et. al., Prodrug 53 (1989)].
Whereas prostaglandins appear to be devoid of significant intraocular side effects, ocular surface (conjunctival) hyperemia and foreign-body sensation have been consistently associated with the topical ocular use of such compounds, in particular PGF 2α and its prodrugs, e.g., its 1-isopropyl ester, in humans. The clinical potentials of prostaglandins in the management of conditions associated with increased ocular pressure, e.g. glaucoma are greatly limited by these side effects.
In a series of co-pending United States patent applications assigned to Allergan, Inc. prostaglandin esters with increased ocular hypotensive activity accompanied with no or substantially reduced side-effects are disclosed. The co-pending U.S. Ser. No. 596,430 (filed Oct. 10, 1990), now U.S. Pat. No. 5,446,041, relates to certain 11-acyl-prostaglandins, such as 11-pivaloyl, 11-acetyl, 11-isobutyryl, 11-valeryl, and 11-isovaleryl PGF 2α . Intraocular pressure reducing 15-acyl prostaglandins are disclosed in the co-pending application U.S. Ser. No. 175,476 (filed Dec. 29, 1993). Similarly, 11,15- 9,15- and 9,11-diesters of prostaglandins, for example 11,15-dipivaloyl PGF 2α are known to have ocular hypotensive activity. See the co-pending patent applications U.S. Ser. No. Nos. 385,645 (filed Jul. 07, 1989, now U.S. Pat. No. 4,994,274), 584,370 (filed Sep. 18, 1990, now U.S. Pat. No. 5,028,624) and 585,284 (filed Sep. 18, 1990, now U.S. Pat. No. 5,034,413). The disclosures of all of these patent applications are hereby expressly incorporated by reference.
SUMMARY OF THE INVENTION
The present invention concerns a method of treating ocular hypertension which comprises administering to a mammal having ocular hypertension a therapeutically effective amount of a compound of formula I
wherein the hatched segment represents an α bond, the solid triangle represents a β bond, the wavy segment represents α or β bond, dashed lines represent a double bond or a single bond, X is hydrogen or a halo radical, e.g. a fluoro or chloro radical, R 3 is heteroaryl or a substituted heteroaryl radical, R 1 and R 2 are independently selected from the group consisting of hydrogen or a lower alkyl radical having up to six carbon atoms, or a lower acyl radical having up to six carbon atoms, R is selected from the group consisting of CO 2 R 4 , CONR 4 2 , CH 2 OR 4 , CONR 4 SO 2 R 4 , P(O)(OR 4 ) and
wherein R 4 is selected from the group consisting of H, phenyl and lower alkyl having from one to six carbon atoms and n is 0 or an integer of from 1 to 4.
In a further aspect, the present invention relates to an ophthalmic solution comprising a therapeutically effective amount of a compound of formula (I), wherein the symbols have the above meanings, or a pharmaceutically acceptable salt thereof, in admixture with a non-toxic, ophthalmically acceptable liquid vehicle, packaged in a container suitable for metered application. In particular, the substituents on the heteroaryl radical may be selected from the group consisting of lower alkyl, e.g. C 1 to C 6 alkyl; OR 4 ; CO 2 R 4 ; halogen, e.g. fluoro, chloro and bromo; trifluoromethyl (CF 3 ); COR 4 , e.g. COCH 3 ; COCF 3 ; SO 2 NR 4 , e.g. SO 2 NH 2 ; NO 2 ; CN; etc.
In a still further aspect, the present invention relates to a pharmaceutical product, comprising
a container adapted to dispense its contents in a metered form; and
an ophthalmic solution therein, as hereinabove defined.
Finally, certain of the compounds represented by the above formula, disclosed below and utilized in the method of the present invention are novel and unobvious.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a schematic of the chemical synthesis of certain compounds related to the compounds of the invention, as specifically disclosed in Examples 12H and L and 13H and L.
FIG. 2 is a schematic of the chemical synthesis of certain compounds related to the compounds of the invention, as specifically disclosed in Examples 16H and L and 17H and L.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to the use of ω-cycloalkyl 17-heteroaryl prostaglandin E 2 analogs as EP 2 -receptor agonists. The compounds used in accordance with the present invention are encompassed by the following structural formula I:
wherein the substituents and symbols are as hereinabove defined. The dotted lines on bonds between carbons 5 and 6 (C-5) and carbons 13 and 14 (C-13) indicate a single or double bond. If two solid lines are used at C-5, or C-13, it indicates a specific configuration for that double bond. Hatched lines used at position C-8, C-9 and C-11 indicate the α configuration. A triangle at position C-12 represents β orientation.
A preferred group of the compounds of the present invention includes compounds that have the following structural formula II:
wherein Z is selected from the group consisting of O and S, A is selected from the group consisting of N, —CH, and C, R 5 is selected from the group consisting of hydrogen, halogen, lower alkyl having from 1 to 6 carbon atoms and lower alkoxy having from 1 to 6 carbon atoms, R 6 and R 7 are selected from the group consisting of hydrogen, halogen, lower alkyl having from 1 to 6 carbon atoms and lower alkoxy having from 1 to 6 carbon atoms, or, together with
R 6 and R 7 forms a condensed aryl ring.
Another preferred group includes compounds having the formula III:
In the above formulae, the substituents and symbols are as hereinabove defined.
The above compounds of the present invention may be prepared by methods that are known in the art or according to the working examples below.
The compounds, below, are especially preferred representative of the compounds of the present invention.
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl)-methyl-cyclobutyl)but-1-enyl]-5-chloro-cyclopentyl}hept-5-enoic acid methyl ester
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl)-methylcyclobutyl)but-1-enyl]-5-chlorocyclopentyl}hept-5-enoic acid
(Z)-7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl)-methylcyclobutyl)but-1-enyl]-5-fluoro-cyclopentyl}hept-5-enoic acid methyl ester
(Z)-7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl-methylcyclobutyl)but-1-enyl]-5-fluoro-cyclopentyl}hept-5-enoic acid
(Z)-7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl)-methylcyclobutyl)but-1-enyl]cyclopentenyl}hept-5-enoic acid methyl ester
(Z)-7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl-methylcyclobutyl)but-1-enyl]cyclopentenyl}hept-5-enoic acid
A pharmaceutically acceptable salt is any salt which retains the activity of the parent compound and does not impart any deleterious or undesirable effect on the subject to whom it is administered and in the context in which it is administered. Of particular interest are salts formed with inorganic ions, such as sodium, potassium, calcium, magnesium and zinc.
Pharmaceutical compositions may be prepared by combining a therapeutically effective amount of at least one compound according to the present invention, or a pharmaceutically acceptable acid addition salt thereof, as an active ingredient, with conventional ophthalmically acceptable pharmaceutical excipients, and by preparation of unit dosage forms suitable for topical ocular use. The therapeutically efficient amount typically is between about 0.0001 and about 5% (w/v), preferably about 0.001 to about 1.0% (w/v) in liquid formulations.
For ophthalmic application, preferably solutions are prepared using a physiological saline solution as a major vehicle. The pH of such ophthalmic solutions should preferably be maintained between 6.5 and 7.2 with an appropriate buffer system. The formulations may also contain conventional, pharmaceutically acceptable preservatives, stabilizers and surfactants.
Preferred preservatives that may be used in the pharmaceutical compositions of the present invention include, but are not limited to, benzalkonium chloride, chlorobutanol, thimerosal, phenylmercuric acetate and phenylmercuric nitrate. A preferred surfactant is, for example, Tween 80. Likewise, various preferred vehicles may be used in the ophthalmic preparations of the present invention. These vehicles include, but are not limited to, polyvinyl alcohol, povidone, hydroxypropyl methyl cellulose, poloxamers, carboxymethyl cellulose, hydroxyethyl cellulose and purified water.
Tonicity adjustors may be added as needed or convenient. They include, but are not limited to, salts, particularly sodium chloride, potassium chloride, mannitol and glycerin, or any other suitable ophthalmically acceptable tonicity adjustor.
Various buffers and means for adjusting pH may be used so long as the resulting preparation is ophthalmically acceptable. Accordingly, buffers include acetate buffers, citrate buffers, phosphate buffers and borate buffers. Acids or bases may be used to adjust the pH of these formulations as needed.
In a similar vein, an ophthalmically acceptable antioxidant for use in the present invention includes, but is not limited to, sodium metabisulfite, sodium thiosulfate, acetylcysteine, butylated hydroxyanisole and butylated hydroxytoluene.
Other excipient components which may be included in the ophthalmic preparations are chelating agents. The preferred chelating agent is edentate disodium, although other chelating agents may also be used in place or in conjunction with it.
The ingredients are usually used in the following amounts:
Ingredient
Amount (% w/v)
active ingredient
about 0.001-5
preservative
0-0.10
vehicle
0-40
tonicity adjustor
1-10
buffer
0.01-10
pH adjustor
q.s. pH 4.5-7.5
antioxidant
as needed
surfactant
as needed
purified water
as needed to make 100%
The actual dose of the active compounds of the present invention depends on the specific compound, and on the condition to be treated; the selection of the appropriate dose is well within the knowledge of the skilled artisan.
The ophthalmic formulations of the present invention are conveniently packaged in forms suitable for metered application, such as in containers equipped with a dropper, to facilitate the application to the eye. Containers suitable for dropwise application are usually made of suitable inert, non-toxic plastic material, and generally contain between about 0.5 and about 15 ml solution.
The invention is further illustrated by the following non-limiting Examples, which are summarized in the reaction schemes of FIGS. 1 and 2, wherein the compounds are identified by the same designator in both the Examples and the Figures.
EXAMPLE 1
Ethyl cyclobutanecarboxylate acid ethyl ester (1).
The named compound was purchased from Aldrich Chemical Co., P.O. Box 2060, Milwaukee, Wis. 53201 USA.
EXAMPLE 2
1-(1-Hydroxy-1-thiophen-2-yl-methyl)cyclobutanecarboxylic acid ethyl ester (2).
Lithium diisopropylamide mono(THF) (1.95 mL of a 2.0M solution in heptane/THF/ethylbenzene, 3.90 mmol) was added to a solution of ester 1 (0.50 g, 3.9 mmol) in THF (6 mL) at −78° C. After stirring 30 min, 2-thiophenecarboxaldehyde (667 mg, 5.95 mmol) was added and the mixture was stirred for 3 h. After the reaction was judged complete by TLC analysis, saturated aqueous NH 4 Cl was added and the reaction was slowly warmed to 23° C. The THF was evaporated and the reaction mixture was extracted with CH 2 Cl 2 (2×). The combined organic layers were washed with brine, dried (Na 2 SO 4 ), filtered and concentrated in vacuo. Purification of the residue by flash column chromatography (FCC) (silica gel, 100% hexane followed by 9:1 hexane/EtOAc) afforded the above named compound 2.
EXAMPLE 3
1-Thiophen-2-yl-methylcyclobutanecarboxylic acid ethyl ester (3).
Trimethylsilyliodide (20 g, 100 mmol) was added to CH 3 CN (10 mL) at 0° C. and the mixture was allowed to stir 5 min. A solution of alcohol 2 (5 g, 20 mmol) in CH 3 CN (10 mL) was added slowly while the temperature was kept between 4-10° C. and the reaction was allowed to warm to 23° C. After stirring for 2 h at 23° C. the reaction was judged complete via TLC analysis. The mixture was poured into 3N NaOH at 0° C. and EtOAc was added. The organic layer was separated, washed with brine, dried (Na 2 SO 4 ), filtered and concentrated in vacuo. FCC (silica gel, 1:1 hexane/CH 2 Cl 2 ) gave 2.3 g of the above named ester 3.
EXAMPLE 4
(1-Thiophen-2-yl-methylcyclobutyl)methanol (4).
Lithium borohydride (435 mg, 20 mmol) was added to a solution of ester 3 (2.3 g, 10 mmol) in Et 2 O (20 mL) at 0° C. After having stirred for 5 min, MeOH (640 mg, 20 mmol) was added dropwise and stirring continued at 0° C. until effervescence ceased. The mixture was warmed to 23° C. and was allowed to stir an additional hour, at which time the mixture was poured into 3N NaOH and stirred an additional 0.5 h. The organic layer was separated and washed with brine, dried (Na 2 SO 4 ), filtered and concentrated in vacuo. The crude alcohol 4 was purified by FCC (silica gel, 1:1 hexane/CH 2 Cl 2 ).
EXAMPLE 5
1-Thiophen-2-yl-methylcyclobutanecarbaldehyde (5).
Oxalyl chloride (50 mL, 0.10 mmol) was added to CH 2 Cl 2 (150 mL) at 23° C. and was cooled to −78° C. DMSO (16 g, 0.20 mmol) was added dropwise to the mixture and stirring was continued for 15 min. A solution of alcohol 4 (7.9 g, 0.041 mmol) in CH 2 Cl 2 (50 mL) was then added dropwise, after which Et 3 N (44 g, 0.44 mmol) was added and the mixture was warmed to 23° C. After 1 h, the mixture was poured into saturated aqueous NaHCO 3 and the organic layer was separated. The aqueous layer was extracted with CH 2 Cl 2 (2×) and the combined organic portions were washed with brine, dried (Na 2 SO 4 ), concentrated in vacuo and purified by FCC (silica gel, 100% hexane followed by 2:1 hexane/CH 2 Cl 2 ) to afford the above named aldehyde 5.
EXAMPLE 6
1-(1-Thiophen-2-yl-methylcyclobutyl)but-2-yn-1-ol (6).
A solution of propylmagnesium bromide (360 mL of a 0.5M solution in THF, 0.180 mmol; 0.5 M in THF) was added dropwise to a solution of aldehyde 5 (7.0 g, 36 mmol) in THF (200 mL) while the mixture was maintained at ambient temperature. After having stirred 3 h at 23° C., the reaction was poured into saturated aqueous NH 4 Cl and extracted with Et 2 O. The organic portion was separated and was washed with saturated aqueous NaHCO 3 , brine, then dried (Na 2 SO 4 ) and concentrated in vacuo. FCC (silica gel, 100% hexane followed by 1:1, hexane/CH 2 Cl 2 ) gave 6.2 g of the above named alkyne 6.
EXAMPLE 7
1-(1-Thiophen-2-yl-methylcyclobutyl)but-3-yn-1-ol (7).
A dry round bottom flask was charged with potassium hydride (5.5 g, 48 mmol; 35% by wt dispersion in oil) and the oil was removed by hexane rinse (3×). Aminopropylamide (39 mL) was added to the mixture and it was stirred until effervescence ceased. The mixture was then cooled to 0° C. and the alkyne 6 (2 g, 9.1 mmol) was added and the reaction stirred at 23° C. for 1 h. The reaction was quenched with MeOH (2 mL) and water. The mixture was extracted with Et 2 O (3×) and the combined organic layer was washed with 1N HCl, brine, dried (Na 2 SO 4 ) and concentrated in vacuo. FCC (silica gel, 1:1 hexane/CH 2 Cl 2 ) gave 570 mg of the above named alkyne 7.
EXAMPLE 8
tert-Butyldimethyl [1-(1-thiophen-2-yl-methylcyclobutyl)but-3-ynyloxy]silane (8).
To a cooled (0° C.) solution of alkyne 7 (200 mg, 0.9 mmol), CH 2 Cl 2 (5 mL) and triethylamine (275 mg, 2.72 mmol) was added tert-butyldimethylsilyl trifluoromethanesulfonate (360 mg, 1.36 mmol) dropwise. After having stirred for 5 min at 0° C., the mixture was warmed to 23° C. and stirred an additional hour. The reaction was then quenched with saturated aqueous NaHCO 3 and extracted with CH 2 Cl 2 (2×). The combined organics were washed with 1N HCl, saturated aqueous NaHCO 3 , brine then were dried (Na 2 SO 4 ), filtered and concentrated in vacuo. FCC (silica gel, 100% hexane) gave 695 mg of the above named compound 8.
EXAMPLE 9
tert-Butyl-[(E)-4-iodo-1-(1-thiophen-2-ylmethylcyclobutyl)but-3-enyloxy]dimethylsilane (9).
Cp 2 ZrHCl (304 mg, 1.18 mmol) was added to a solution of alkyne 8 (263 mg, 0.786 mmol) in CH 2 Cl 2 (5 mL) at 23° C. and stirring was maintained for 20 min. N-iodosuccinimide (247 mg, 1.18 mmol) was added to the mixture and stirring was continued for an additional 30 min. The mixture was concentrated in vacuo, diluted with hexane/Et 2 O, filtered and concentrated in vacuo. FCC (silica gel, 100% hexane) gave 360 mg of the above named compound 9.
EXAMPLE 10
7-[(R)-3-(tert-Butyldimethylsilanyloxy)-5-oxo-cyclopent-1-enyl]heptanoic acid methyl ester (10).
The named compound was purchased from Nissan Chemical Industries, LTD, Tokyo 101-0054 Japan.
EXAMPLE 11
7-{(1R,2R,3R)-2-[(E)-(tert-Butyldimethylsilanyloxy)-(1-thiophen-2-yl-methylcyclobutyl)but-1-enyl]-3-[(dimethylethyl)dimethylsilanyloxy]-5-oxo-cyclopentyl}heptanoic acid methyl ester (11).
To a solution of vinyl iodide 9 (120 mg, 0.259 mmol) in Et 2 O (1.5 mL) at −78° C. was added t-BuLi (0.35 mL of a 1.5M solution in THF, 0.52 mmol). After the mixture had stirred 30 min at −78° C. 2-thienyl(cyano)copper lithium (1.14 mL, 0.285 mmol) was added and stirring was continued for an additional 30 min. The reaction was then treated with a solution of the enone 10 (91.6 mg, 0.259 mmol) in Et 2 O (1 mL). After several minutes had passed, the reaction had solidified and 0.5 mL Et 2 O was added. The reaction was stirred 1 h at −78° C., was poured into saturated aqueous NH 4 Cl and then was extracted with EtOAc (3×). The combined organic portions were washed with brine, filtered and concentrated in vacuo. FCC (silica gel, 100% hexane; 9:1 hexane/EtOAc) gave 63 mg of the above named compound 11.
EXAMPLE 12
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-thiophen-2-yl-methyl-cyclobutyl)but-1-enyl]-5-oxo-cyclopentyl}heptanoic acid methyl ester (12H).
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-thiophen-2-yl-methyl-cyclobutyl)but-1-enyl]-5-oxo-cyclopentyl}heptanoic acid methyl ester (12L).
Hydrogen fluoride-pyridine (0.091 mL) was added to a solution of the bis-TBS ether 11 (63 mg, 0.912 mmol) in CH 3 CN (3 mL) at 23° C. After having stirred for 3 h, the mixture was quenched with saturated aqueous Na 2 CO 3 and extracted with EtOAc (3×). The combined organic portions were washed with 1N HCl, saturated aqueous NaHCO 3 , brine, and were then dried (Na 2 SO 4 ), filtered and concentrated in vacuo. FCC (silica gel, 3:2 hexane/EtOAc followed by 1:1 hexane/EtOAc) gave a higher R f diol (10 mg) and a lower R f diol (30 mg), hereinafter, designated as named compounds 12H and 12L, respectively).
EXAMPLE 13H
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-thiophen-2-yl-methylcyclobutyl)but-1-enyl]-5-oxocyclopentyl}heptanoic acid (13H).
Methyl ester 12H (4.8 mg, 10.4 mmol) and PLE (0.134 mmol, 45 mmol) were stirred in phosphate buffer (2 mL, pH 7.2) at 23° C. over 16 h. After the reaction was complete, the mixture was filtered and the aqueous phase was extracted with EtOAc (3×). The combined organic phases were washed with brine, dried (Na 2 SO 4 ), filtered and concentrated in vacuo. FCC (silica gel, 1:1 hexane/EtOAc; EtOAc) gave of the above named acid 13H.
EXAMPLE 13L
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-thiophen-2-yl-methyl-cyclobutyl)but-1-enyl]-5-oxo-cyclopentyl}heptanoic acid (13L).
Methyl ester 12L was reacted according to Example 13H to yield the above named compound.
EXAMPLE 14
(Z)-7-[(R)-3-(tert-Butyldimethylsilanyloxy)-5-oxo-cyclopent-1-enyl]hept-5-enoic acid methyl ester (14).
The named compound was purchased from Nissan Chemical Industries, LTD, Tokyo 101-0054 Japan.
EXAMPLE 15
(Z)-7-{(1R,2R,3R)-2-[(E)-(tert-Butyldimethylsilanyloxy)-(1-thiophen-2-yl-methylcyclobutyl)but-1-enyl]-3-[(dimethylethyl)dimethylsilanyloxy]-5-oxo-cyclopentyl }hept-5-enoic acid methyl ester (15).
The compound of Example 14, above, was reacted in accordance with the process of Example 11 to yield the above named compound.
EXAMPLE 16
(Z)-7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-thiophen-2-yl-methylcyclobutyl)but-1-enyl]-5-oxo-cyclopentyl}hept-5-enoic acid methyl ester (16H).
(Z)-7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-thiophen-2-yl-methylcyclobutyl)but-1-enyl]-5-oxo-cyclopentyl}hept-5-enoic acid methyl ester (16L).
The compound of Example 15 is reacted in accordance with the process of Example 12 to yield a higher R f diol (6.0 mg) and a lower R f diol (6.0 mg), hereinafter, designated as 16H and 16L, respectively.
EXAMPLE 17H
(Z)-7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-thiophen-2-yl-methylcyclobutyl)but-1-enyl]-5-oxo-cyclopentyl}hept-5-enoic acid (17H).
The compound 16H of Example 16 is reacted in accordance with the process of Example 13H to yield the above named compound.
EXAMPLE 17L
(Z)-7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-thiophen-2-yl-methylcyclobutyl)but-1-enyl]-5-oxo-cyclopentyl}hept-5-enoic acid (17L).
The compound 16L of Example 16 is reacted in accordance with the process of Example 13H to yield the above named compound.
EXAMPLE 18
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl)-methyl-cyclobutyl)but-1-enyl]-5-chloro-cyclopentyl}hept-5-enoic acid methyl ester (18H and 18L).
Examples 14 through 16 is repeated with the appropriate chloro derivative replacing (Z)-7-[(R)-3-(tert-Butyldimethylsilanyloxy)-5-oxo-cyclopent-1-enyl]hept-5-enoic acid methyl ester 14 and the appropriate chlorothienyl derivative replacing 2-thienyl(cyano)copper lithium to yield a product which is separated to provide a higher R f diol and a lower R f diol designated as 18H and 18L, respectively.
EXAMPLE 19H
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl)-methyl-cyclobutyl)but-1-enyl]-5-chloro-cyclopentyl}hept-5-enoic acid (19H).
The compound of Example 18H is reacted according to the process of Example 13H to yield the named compound.
EXAMPLE 19L
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl)-methyl-cyclobutyl)but-1-enyl]-5-chloro-cyclopentyl}hept-5-enoic acid (19L).
The compound of Example 18L is reacted according to the process of Example 13L to yield the named compound.
EXAMPLE 20
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl)-methyl-cyclobutyl)but-1-enyl]-5-fluoro-cyclopentyl}hept-5-enoic acid methyl ester (20H and 20L).
Examples 14 through 16 is repeated with the appropriate fluoro derivative replacing (Z)-7-[(R)-3-(tert-Butyldimethylsilanyloxy)-5-oxo-cyclopent-1-enyl]hept-5-enoic acid methyl ester 14 and the appropriate chlorothienyl derivative replacing 2-thienyl(cyano)copper lithium to yield a product which is separated to provide a higher R f diol and a lower R f diol designated as 20H and 20L, respectively.
EXAMPLE 21H
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl)-methyl-cyclobutyl)but-1-enyl]-5-fluoro-cyclopentyl}hept-5-enoic acid (21H).
The compound of Example 20H is reacted according to the process of Example 13H to yield the named compound.
EXAMPLE 21L
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl)-methyl-cyclobutyl)but-1-enyl]-5-fluoro-cyclopentyl}hept-5-enoic acid (21L).
The compound of Example 20L is reacted according to the process of Example 13L to yield the named compound.
EXAMPLE 22
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl)-methyl-cyclobutyl)but-1-enyl]-cyclopentenyl}hept-5-enoic acid methyl ester.
Examples 14 through 16 is repeated with the appropriate nor keto derivative replacing (Z)-7-[(R)-3-(tert-Butyldimethylsilanyloxy)-5-oxo-cyclopent-1-enyl]hept-5-enoic acid methyl ester 14 and the appropriate chlorothienyl derivative replacing 2-thienyl(cyano)copper lithium to yield a product which is separated to provide a higher R f diol and a lower R f diol designated as 22H and 22L, respectively.
EXAMPLE 23H
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl)-methyl-cyclobutyl)but-1-enyl]-cyclopentenyl}hept-5-enoic acid (23H).
The compound of Example 22H is reacted according to the process of Example 13H to yield the named compound.
EXAMPLE 23L
7-{(1R,2R,3R)-3-Hydroxy-2-[(E)-4-hydroxy-4-(1-(5-chloro-thiophen-2-yl)-methyl-cyclobutyl)but-1-enyl]-cyclopentenyl}hept-5-enoic acid (23L).
The compound of Example 22L is reacted according to the process of Example 13L to yield the named compound.
RADIOLIGAND BINDING
Recombinant EP 2 receptor; transient transfectants COS-7 cells were transiently transfected using Lipofectin (Gibco-BRL life Technologies, Gaitherburg, Md., U.S.A.) according to manufacturer's protocols. For binding studies, 2×10 6 cells were plated onto 150 mm dishes 24 h prior to transfection. Each plate was transfected with 50 μg plasmid DNA and 50 μL lipofectin. Cells were collected and membranes prepared at 48 h post-transfection, and frozen at −80° C. until use.
Plasma membrane preparations were thawed at room temperature and used at a final 1 mg/mL concentration in a 500 μL volume. The binding of [ 3 H]-PGE 2 (specific activity 180 Ci mmol −1 ) were determined in duplicate and experiments were replicated three times. Incubations were for 60 min at 25° C. and were terminated by the addition of 4 mL of ice-cold 50 μM TRIS-HCl, followed by rapid filtration through Whatman GF/B filters and three additional 4 mL washes in a cell harvester (Brandel). Competition studies were performed using a final concentration of 5 nM [ 3 H]-PGE 2 and non-specific binding determined with 10 μM of the respective unlabelled prostanoid.
Certain of the above compounds were tested for activity in the recombinant human EP 2 receptor assay described above and the results are reported in Table 1, below. Note Examples 20 and 21 are the unseparated mixtures of Examples 20H and 20L and 21H and 21L, respectively.
Ex-
am-
ple #
Structure
hEP 2
18H
4300
18L
5500
19H
126
19L
300
22H
NA
22L
NA
23H
700
23L
2500
20H
5100
20L
NA
21H
132
21L
300
20
8100
21
112
EP 2 activity indicates that the compounds of this invention are useful in treating asthma, dysmenorrhea as well as glaucoma and lowering intraocular pressure.
Other potential therapeutic applications are in osteoporosis, constipation, renal disorders, sexual dysfunction, baldness, diabetes, cancer and in disorder of immune regulation.
The compounds of the invention may also be useful in the treatment of various pathophysiological diseases including acute myocardial infarction, vascular thrombosis, hypertension, pulmonary hypertension, ischemic heart disease, congestive heart failure, and angina pectoris, in which case the compounds may be administered by any means that effect vasodilation and thereby relieve the symptoms of the disease. For example, administration may be by oral, transdermal, parenterial, subcutaneous, intravenous, intramuscular, intraperitoneal, transdermal, or buccal routes.
The compounds of the invention may be formulated into an ointment containing about 0.10 to 10% of the active ingredient in a suitable base of, for example, white petrolatum, mineral oil and petroatum and lanolin alcohol. Other suitable bases will be readily apparent to those skilled in the art.
The pharmaceutical preparations of the present invention are manufactured in a manner which is itself known, for example, by means of conventional dissolving or suspending the compounds, which are all either water soluble or suspendable. For administration in the treatment of the other mentioned pathophysiological disorders. The pharmaceutical preparations which can be used orally include push-fit capsules made of gelatin, as well as soft, sealed capsules make of gelatin and a plasticizer such as glycerol or sorbitol. The push-fit capsules can contain the active compounds in liquid form that may be mixed with fillers such as lactose, binders such as starches, and/or lubricants such as talc or magnesium stearate and, optionally, stabilizers. In soft capsules, the active compounds are preferably dissolved or suspended in suitable liquids, such as in buffered salt solution. In addition, stabilizers may be added.
In addition to being provided in a liquid form, for example in gelatin capsule or other suitable vehicle, the pharmaceutical preparations may contain suitable excipients to facilitate the processing of the active compounds into preparations that can be used pharmaceutically. Thus, pharmaceutical preparations for oral use can be obtained by adhering the solution of the active compounds to a solid support, optionally grinding the resulting mixture and processing the mixture of granules, after adding suitable auxiliaries, if desired or necessary, to obtain tablets or dragee cores.
Suitable excipients are, in particular, fillers such as sugars, for example lactose or sucrose, mannitol or sorbitol, cellulose preparations and/or calcium phosphates, for example tricalcium phosphate or calcium hydrogen phosphate, as well as inders such as starch, paste using for example, maize starch, wheat starch, rich starchy, potato starch, gelatin, tragacanth, methyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, and/or polyvinyl pyrrolidone. If desired, disintegrating agents may be added such as the above-mentioned starches and also carboxymethyl-starch, crosslinked polyvinyl pyrrolidone, agar, or algenic acid or a salt thereof, such as sodium alginate. Auxiliaries are, above all, flow-regulating agents and lubricants, for example, silica, talc, stearic acid or salts thereof, such as magnesium stearate or calcium stearate, and/or polyethylene glycol. Dragee cores are provided with suitable coatings which if desired, are resistant to gastric juices. For this purpose, concentrated sugar solutions may be used, which may optionally containing gum arabic, talc, polyvinyl pyrrolidone, polyethylene glycol and/or titanium dioxide, lacquer solutions and suitable organic solvents or solvent mixtures. In order to produce coatings resistant to gastric juices, solutions of suitable cellulose preparations such as acetylcellulose phthalate or hydroxypropylmethyl-cellulose phthalate, are used. Dye stuffs or pigments may be added to the tables or dragee coatings, for example, for identification or in order to characterize combinations of active compound doses.
Suitable formulations for intravenous or parenteral administration include aqueous solutions of the active compounds. In addition, suspensions of the active compounds as oily injection suspensions may be administered. Aqueous injection suspensions may contain substances which increase the viscosity of the suspension include, for example, sodium carboxymethyl cellulose, soribitol, and/or dextran. Optionally, the suspension may also contain stabilizers.
The foregoing description details specific methods and compositions that can be employed to practice the present invention, and represents the best mode contemplated. However, it is apparent for one of ordinary skill in the art that further compounds with the desired pharmacological properties can be prepared in an analogous manner, and that the disclosed compounds can also be obtained from different starting compounds via different chemical reactions. Similarly, different pharmaceutical compositions may be prepared and used with substantially the same result. Thus, however detailed the foregoing may appear in text, it should not be construed as limiting the overall scope hereof, rather, the ambit of the present invention is to be governed only by the lawful construction of the appended claims.
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The invention relates to the use of derivatives of E-type prostaglandins as EP 2 agonists, in general, and, in particular as ocular hypotensives. The PGE derivatives used in accordance with the invention are represented by the following formula I:
wherein the hatched segment represents an α bonds, the solid triangle represents a β bond, the wavy segments represent α or β bond, dashed lines represent a double bond or a single bond, X is selected from the group consisting of hydrogen and halogen radicals, R 3 is heteroaryl or a substituted heteroaryl radical, R 1 and R 2 are independently selected from the group consisting of hydrogen or a lower alkyl radical having up to six carbon atoms, or a lower acyl radical having up to six carbon atoms, R is selected from the group consisting of CO 2 R 4 , CONR 4 2 , CH 2 OR 4 , CONR 4 SO 2 R 4 , P(O)(OR 4 ) and
wherein R 4 is selected from the group consisting of H, phenyl and lower alkyl having from one to six carbon atoms and n is 0 or an integer of from 1 to 4.
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