description
stringlengths 2.98k
3.35M
| abstract
stringlengths 94
10.6k
| cpc
int64 0
8
|
|---|---|---|
PRIORITY OF INVENTION
[0001] This application claims priority under 35 U.S.C. 119(e) from U.S. Provisional Patent Application No. 60/844,020 filed 12 Sep. 2006, and from U.S. Provisional Patent Application No. 60/905,365 filed 7 Mar. 2007.
BACKGROUND OF THE INVENTION
[0002] International Patent Application Publication Number WO 2004/046115 provides certain 4-oxoquinolone compounds that are useful as HIV integrase inhibitors. The compounds are reported to be useful as anti-HIV agents.
[0003] International Patent Application Publication Number WO 2005/113508 provides certain specific crystalline forms of one of these 4-oxoquinolone compounds, 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinoline-3-carboxylic acid. The specific crystalline forms are reported to have superior physical and chemical stability compared to other physical forms of the compound.
[0004] There is currently a need for improved methods for preparing the 4-oxoquinolone compounds reported in International Patent Application Publication Number WO 2004/046115 and in International Patent Application Publication Number WO 2005/113508. In particular, there is a need for new synthetic methods that are simpler or less expensive to carry out, that provide an increased yield, or that eliminate the use of toxic or costly reagents.
SUMMARY OF THE INVENTION
[0005] The present invention provides new synthetic processes and synthetic intermediates that are useful for preparing the 4-oxoquinolone compounds reported in International Patent Application Publication Number WO 2004/046115 and in International Patent Application Publication Number WO 2005/113508.
[0006] Accordingly, in one embodiment the invention provides a compound of formula 3:
[0000]
[0000] or a salt thereof.
[0007] In another embodiment the invention provides a compound of formula 5a:
[0000]
[0000] or a salt thereof.
[0008] In another embodiment the invention provides a method for preparing a compound of formula 3:
[0000]
[0000] or a salt thereof comprising converting a corresponding compound of formula 2:
[0000]
[0000] or a salt thereof to the compound of formula 3 or the salt thereof.
[0009] In another embodiment the invention provides a method for preparing a compound of formula 9:
[0000]
[0000] wherein R is C 1 -C 6 alkyl, comprising cyclizing a corresponding compound of formula 8:
[0000]
[0010] In another embodiment the invention provides a compound of formula 15:
[0000]
[0000] or a salt thereof.
[0011] In another embodiment the invention provides a compound of formula 15a:
[0000]
[0012] In another embodiment the invention provides a compound of formula 16:
[0000]
[0013] In another embodiment the invention provides a method for preparing a compound of formula 15:
[0000]
[0000] or a salt thereof comprising converting a corresponding compound of formula 14:
[0000]
[0000] to the compound of formula 15 or the salt thereof.
[0014] The invention also provides other synthetic processes and synthetic intermediates disclosed herein that are useful for preparing the 4-oxoquinone compounds.
DETAILED DESCRIPTION
[0015] The following definitions are used, unless otherwise described: halo is fluoro, chloro, bromo, or iodo. Alkyl denotes both straight and branched groups, but reference to an individual radical such as propyl embraces only the straight chain radical, a branched chain isomer such as isopropyl being specifically referred to.
[0016] It will be appreciated by those skilled in the art that a compound having a chiral center may exist in and be isolated in optically active and racemic forms. Some compounds may exhibit polymorphism. It is to be understood that the present invention encompasses processes for preparing any racemic, optically-active, polymorphic, tautomeric, or stereoisomeric form, or mixtures thereof, of a compound described herein, it being well known in the art how to prepare optically active forms (for example, by resolution of the racemic form by recrystallization techniques, by synthesis from optically-active starting materials, by chiral synthesis, or by chromatographic separation using a chiral stationary phase).
[0017] Specific and preferred values listed below for radicals, substituents, and ranges, are for illustration only; they do not exclude other defined values or other values within defined ranges for the radicals and substituents.
[0018] Specifically, C 1 -C 6 alkyl can be methyl, ethyl, propyl, isopropyl, butyl, iso-butyl, sec-butyl, pentyl, 3-pentyl, or hexyl.
[0019] A specific value for R a is methyl.
[0020] A specific value for R b is methyl.
[0021] A specific value for R c is 1-imidazolyl.
[0022] A specific value for R is ethyl.
[0023] In one embodiment, the invention provides a method for preparing a compound of formula 3:
[0000]
[0000] or a salt thereof comprising converting a corresponding compound of formula 2:
[0000]
[0000] or a salt thereof to the compound of formula 3 or the a salt thereof. As illustrated below, the reaction can conveniently be carried out by combining Compound 2 with a polar aprotic solvent (e.g., tetrahydrofuran) and cooling the mixture below room temperature (e.g., to about −20° C.).
[0000]
[0000] This mixture can be treated with a first organometallic reagent (e.g., a dialkylmagnesium, dialkylzinc, an alkylmagnesium halide, a trialkylaluminum, or a metal hydride reagent) to form a carboxylate salt. For example, the mixture can be treated with about 0.5 equivalents of dibutylmagnesium or butylethylmagnesium, or about one equivalent of butylethylmagnesium-butanol adduct, to afford Compound A. The resulting mixture can be combined with a second organometallic reagent (e.g., an alkyllithium or alkylmagnesium halide) to form an organometallic compound (Compound B1 or B2). Typically, this is performed at a reduced temperature to affect metal/halogen exchange. For example, the resulting mixture can be combined with about 1.2-2.2 equivalents of an alkyl lithium (e.g., about 1.8 equivalents n-butyllithium or tert-butyllithium) at about −50±50° C. to afford an organo-lithium compound (Compound B1). In one embodiment of the invention metal/halogen exchange reaction can be carried out at a temperature of about −20±20° C. The progress of the metal/halogen exchange reaction can be monitored by any suitable technique (e.g., by HPLC). Upon completion of the reaction, 3-chloro-2-fluorobenzaldehyde (about 1.3. equivalents) can be added. The progress of the addition reaction can be monitored by any suitable technique (e.g., by HPLC). Compound 3 can be isolated by any suitable technique (e.g., by chromatography or crystallization). This method avoids any contamination issues and the cost associated with the use of other reagents (e.g. transition metals such as palladium reagents).
[0024] In one embodiment of the invention the compound of formula 2 or a salt thereof is prepared by brominating 2,4-dimethoxybenzoic acid. The reaction can be carried out using standard bromination conditions.
[0025] In one embodiment of the invention a compound of formula 3 or a salt thereof is converted to a compound of formula 4:
[0000]
[0000] or a salt thereof. About 1 to 5 hydride equivalents of a silane reducing agent (e.g., phenyldimethylsilane, polymethylhydrosiloxane, or chlorodimethylsilane, or a trialkylsilane such as triethylsilane) are combined with a suitable acid (e.g., trifluoroacetic acid, triflic acid or acetic acid). The reaction can conveniently be carried out by using about 1.2 to 2.0 hydride equivalents of triethylsilane and about 5 to 10 equivalents of trifluoroacetic acid. To this mixture is added Compound 3 or a salt thereof. Compound 3 or a salt thereof can conveniently be added to the mixture at a reduced temperature, for example, about 0±10° C. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). Upon completion of the reaction, Compound 4 or a salt thereof can be isolated using any suitable technique (e.g., by chromatography or crystallization). Compound 4 or a salt thereof can also be prepared by adding trifluoroacetic acid to Compound 3 in a suitable solvent and then adding a silane reducing agent to provide Compound 4.
[0026] Alternatively, Compound 4 or a salt thereof can be prepared by forming a corresponding organometallic compound from Compound 2 and reacting the organometallic compound with Compound 11:
[0000]
[0000] wherein R y is a suitable leaving group (e.g., a triflate, mesylate, tosylate, or brosylate, etc.).
[0027] In another embodiment of the invention the compound of formula 4 or a salt thereof is converted to a compound of formula 5′:
[0000]
[0000] or a salt thereof, wherein R c is a leaving group. The carboxylic acid functional group of Compound 4 can be converted to an activated species, for example an acid chloride or an acyl imidazolide (Compound 5′) by treatment with a suitable reagent, such as, for example, thionyl chloride, oxalyl chloride, cyanuric chloride or 1,1′-carbonyldiimidazole in a suitable solvent (e.g., toluene or tetrahydrofuran). Any suitable leaving group R c can be incorporated into the molecule, provided the compound of formula 5′ can be subsequently converted to a compound of formula 6. The reaction can conveniently be carried out using about 1 equivalent of 1,1′-carbonyldiimidazole in tetrahydrofuran.
[0028] In another embodiment of the invention a compound of formula 5′ or a salt thereof can be converted to a compound of formula 6:
[0000]
[0000] or a salt thereof, wherein R is C 1 -C 6 alkyl. For example, a compound of formula 5′ can be combined with about 1 to 5 equivalents of a monoalkyl malonate salt and about 1 to 5 equivalents of a magnesium salt in a suitable solvent. Conveniently, a compound of formula 5′ can be combined with about 1.7 equivalents of potassium monoethyl malonate and about 1.5 equivalents of magnesium chloride. A suitable base, for example triethylamine or imidazole, can be added to the reaction. The reaction can conveniently be carried out at an elevated temperature (e.g., about 100±50° C.) and monitored for completion by any suitable technique (e.g., by HPLC). Upon completion of the reaction, Compound 6 can be isolated using any suitable technique (e.g., by chromatography or crystallization).
[0029] In another embodiment of the invention the compound of formula 6 or a salt thereof, can be converted to a corresponding compound of formula 7:
[0000]
[0000] wherein R a and R b are each independently C 1 -C 6 alkyl; and R is C 1 -C 6 alkyl. Compound 6 can be converted to an activated alkylidene analog, such as Compound 7, by treatment with a formate group donor such as a dimethylformamide dialkyl acetal (e.g., dimethylformamide dimethyl acetal) or a trialkylorthoformate. The reaction can be carried out at elevated temperature (e.g., about 100±50° C.). This reaction may be accelerated by the addition of an acid catalyst, such as, for example, an alkanoic acid, a benzoic acid, a sulfonic acid or a mineral acid. About 500 ppm to 1% acetic acid can conveniently be used. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). Compound 7 can be isolated or it can be used directly to prepare a compound of formula 8 as described below.
[0030] In another embodiment of the invention the compound of formula 7 can be converted to a corresponding compound of formula 8:
[0000]
[0000] wherein R is C 1 -C 6 alkyl. Compound 7 can be combined with (S)-2-amino-3-methyl-1-butanol (S-Valinol, about 1.1 equivalents) to provide compound 8. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). The compound of formula 8 can be isolated or used directly to prepare a compound of formula 9 as described below. In another embodiment, the invention provides a method for preparing a compound of formula 9:
[0000]
[0000] wherein R is C 1 -C 6 alkyl, comprising cyclizing a corresponding compound of formula 8:
[0000]
[0000] Compound 8 can be cyclized to provide Compound 9 by treatment with a silylating reagent (e.g., N,O-bis(trimethylsilyl)acetamide, N,O-bis(trimethylsilyl)trifluoroacetamide or hexamethyldisilazane). The reaction can be conducted in a polar aprotic solvent (e.g., dimethylformamide, dimethylacetamide, N-methylpyrrolidinone or acetonitrile). A salt (e.g., potassium chloride, lithium chloride, sodium chloride or magnesium chloride) can be added to accelerate the reaction. Typically, about 0.5 equivalents of a salt such as potassium chloride is added. The reaction may be conducted at elevated temperature (e.g., a temperature of about 100±20° C.) if necessary to obtain a convenient reaction time. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). During the workup, an acid can be used to hydrolyze any silyl ethers that form due to reaction of the silylating reagent with the alcohol moiety of compound 8. Typical acids include mineral acids, sulfonic acids, or alkanoic acids. One specific acid that can be used is aqueous hydrochloric acid. Upon completion of the hydrolysis, Compound 9 can be isolated by any suitable method (e.g., by chromatography or by crystallization). In the above conversion, the silating reagent transiently protects the alcohol and is subsequently removed. This eliminates the need for separate protection and deprotection steps, thereby increasing the efficiency of the conversion.
[0031] In another embodiment of the invention the compound of formula 9 is converted to a compound of formula 10:
[0000]
[0000] Compound 9 can be converted to Compound 10 by treatment with a suitable base (e.g., potassium hydroxide, sodium hydroxide or lithium hydroxide). For example, about 1.3 equivalents of potassium hydroxide can conveniently be used. This reaction may be conducted in any suitable solvent, such as, for example, tetrahydrofuran, methanol, ethanol or isopropanol, or a mixture thereof. The solvent can also include water. A mixture of isopropanol and water can conveniently be used. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). The initially formed carboxylate salt can be neutralized by treatment with an acid (e.g., hydrochloric acid or acetic acid). For example, about 1.5 equivalents of acetic acid can conveniently be used. Following neutralization, Compound 10 can be isolated using any suitable technique (e.g., by chromatography or crystallization).
[0032] In another embodiment of the invention the compound of formula 10 can be crystallized by adding a seed crystal to a solution that comprises the compound of formula 10. International Patent Application Publication Number WO 2005/113508 provides certain specific crystalline forms of 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinoline-3-carboxylic acid. The entire contents of International Patent Application Publication Number WO 2005/113508 is incorporated herein by reference (in particular, see pages 12-62 therein). The specific crystalline forms are identified therein as Crystal Form II and Crystal Form III. Crystal form II has an X-ray powder diffraction pattern having characteristic diffraction peaks at diffraction angles 2θ(°) of 6.56, 13.20, 19.86, 20.84, 21.22, and 25.22 as measured by an X-ray powder diffractometer. Crystal form III has an X-ray powder diffraction pattern having characteristic diffraction peaks at diffraction angles 2θ(°) of 8.54, 14.02, 15.68, 17.06, 17.24, 24.16, and 25.74 as measured by an X-ray powder diffractometer. International Patent Application Publication Number WO 2005/113508 also describes how to prepare a crystalline form of 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinolone-3-carboxylic acid that have an extrapolated onset temperature of about 162.1° C., as well as how to prepare a seed crystal having a purity of crystal of not less than about 70%. Accordingly, seed crystals of 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinolone-3-carboxylic acid can optionally be prepared as described in International Patent Application Publication Number WO 2005/113508. Advantageously, the process illustrated in Scheme I below provides a crude mixture of Compound 10 that can be directly crystallized to provide Crystal Form III without additional purification (e.g. without the prior formation of another polymorph such as Crystal Form II, or without some other form of prior purification), see Example 6 below.
[0033] In cases where compounds identified herein are sufficiently basic or acidic to form stable acid or base salts, the invention also provides salts of such compounds. Such salts may be useful as intermediates, for example, for purifying such compounds. Examples of useful salts include organic acid addition salts formed with acids, for example, tosylate, methanesulfonate, acetate, citrate, malonate, tartarate, succinate, benzoate, ascorbate, α-ketoglutarate, and α-glycerophosphate. Suitable inorganic salts may also be formed, including hydrochloride, sulfate, nitrate, bicarbonate, and carbonate salts.
[0034] Salts may be obtained using standard procedures well known in the art, for example by reacting a sufficiently basic compound such as an amine with a suitable acid affording an anion. Alkali metal (for example, sodium, potassium, or lithium) or alkaline earth metal (for example calcium or magnesium) salts of carboxylic acids, for example, can also be made.
[0035] The invention will now be illustrated by the following non-limiting Examples. An integrase inhibitor of formula 10 can be prepared as illustrated in the following Scheme 1.
[0000]
EXAMPLE 1
Preparation of Compound 3
[0036] Compound 2 (10 g) was combined with 192 mL of THF and cooled to −20° C. The mixture was treated successively with 21 mL of 1 M dibutylmagnesium solution in heptane and 19.2 mL of 2.5 M n-butyllithium solution in hexane while maintaining the temperature at −20° C. 3-Chloro-2-fluorobenzaldehyde (7.3 g) was added and the mixture allowed to warm to 0° C. After 2 hours at that temperature the reaction was quenched by the addition of 55 mL of 2 M hydrochloric acid. The phases were separated and the organic phase was extracted with 92 mL of ethyl acetate. The combined organic layers were washed with 92 mL of saturated aqueous sodium chloride. The organic phase was concentrated and the product precipitated by the addition of 200 mL heptane. The slurry was filtered and the product air dried to yield Compound 3: 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.15 (br s, 1H), 7.81 (s, 1H), 7.42 (t, J=7.2 Hz, 1H), 7.26 (t, J=6.8 Hz, 1H), 7.15 (t, J=7.8 Hz, 1H), 6.77 (s, 1H), 6.09 (d, J=4.7 Hz, 1H), 5.90 (d, J=4.9 Hz, 1H), 3.84 (s, 3H), 3.80 (s, 3H).
[0037] Alternatively, Compound 3 can be prepared as follows.
[0038] Compound 2 (20 g) was combined with 300 mL of THF and cooled to −20° C. The mixture was treated successively with 75.93 g mL of butylethylmagnesium-butanol adduct (BEM-B) solution in heptane and 35.08 g of 28 wt % t-butyllithium solution in heptane while maintaining the temperature at −20° C. 3-Chloro-2-fluorobenzaldehyde (15.80 g) was added and the mixture allowed to warm to 0° C. After 2 hours at that temperature the reaction was quenched by the addition of 2M hydrochloric acid. The phases were separated and the organic phase was extracted with ethyl acetate. The organic phase was dried over sodium sulfate and the product was precipitated by the addition of MTBE. The slurry was filtered and the product air dried to yield Compound 3 (18.00 g; 69.1% yield): 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.15 (br s, 1H), 7.81 (s, 1H), 7.42 (t, J=7.2 Hz, 1H), 7.26 (t, J=6.8 Hz, 1H), 7.15 (t, J=7.8 Hz, 1H), 6.77 (s, 1H), 6.09 (d, J=4.7 Hz, 1H), 5.90 (d, J=4.9 Hz, 1H), 3.84 (s, 3H), 3.80 (s, 3H).
[0039] Compound 3 can also be prepared as illustrated in the following Scheme.
[0000]
[0040] Compound 14 (10 g) was combined with 28 mL of THF and 9 mL of bisdimethylaminoethyl ether before being cooled to 0° C. Isopropylmagnesium chloride (22.9 mL of a 2.07 M solution in THF) was added and the mixture was allowed to warm to room temperature overnight. Additional isopropylmagnesium chloride (5 mL) was added to improve conversion before 3-chloro-2-fluorobenzaldehyde (4.4 mL) was added. After stirring at ambient temperature for 2 hours 38.6 g of a 14 wt % THF solution of isopropylmagnesium chloride lithium chloride complex was added. After stirring overnight at ambient temperature CO 2 gas was bubbled into the reaction mixture. When conversion was complete the reaction was quenched to pH<3 with 2 M hydrochloric acid. The phases were separated and the organic phase was extracted with ethyl acetate. The combined organic layers were washed with saturated aqueous sodium chloride. The organic phase was concentrated and the product precipitated by the addition of MTBE. The slurry was filtered and the product air dried to yield Compound 3: 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.15 (br s, 1H), 7.81 (s, 1H), 7.42 (t, J=7.2 Hz, 1H), 7.26 (t, J=6.8 Hz, 1H), 7.15 (t, J=7.8 Hz, 1H), 6.77 (s, 1H), 6.09 (d, J=4.7 Hz, 1H), 5.90 (d, J=4.9 Hz, 1H), 3.84 (s, 3H), 3.80 (s, 3H).
[0041] Compound 3 can also be prepared as illustrated in the following Scheme.
[0000]
EXAMPLE 2
Preparation of Compound 4
[0042] Triethylsilane (6.83 g) was added to trifluoroacetic acid (33.13 g) that had been pre-cooled in an ice bath. Compound 3 (10 g) was added to the mixture keeping the temperature below 15° C. After stirring for 2 h MTBE was added to precipitate the product. The slurry was filtered and the product washed with additional MTBE. After drying, 9.12 g of Compound 4 was isolated: 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.11 (br s, 1H), 7.47 (s, 1H), 7.42-7.38 (m, 1H), 7.14-7.08 (m, 2H), 6.67 (s, 1H), 3.87-3.84 (m, 8H).
[0043] Alternatively, Compound 4 can be prepared as follows.
[0044] Triethylsilane (7.50 g) was added to trifluoroacetic acid (49.02 g) that had been pre-cooled in an ice bath. Compound 3 (14.65 g) was added to the mixture keeping the temperature below 15° C. After stirring for 1 h a solution of 17.63 g sodium acetate in 147 mL methanol was added. The mixture was heated to reflux for 3 hours then cooled to 0° C. The slurry was filtered and the product washed with additional methanol. After drying 12.3 g of Compound 4 (89.7% yield) was isolated: 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.11 (br s, 1H), 7.47 (s, 1H), 7.42-7.38 (m, 1H), 7.14-7.08 (m, 2H), 6.67 (s, 1H), 3.87-3.84 (m, 8H).
EXAMPLE 3
Preparation of Compound 5a
[0045] Imidazole (0.42 g) and 1,1′-carbonyldiimidazole (5.49 g) were slurried in 30 mL of THF at ambient temperature. Compound 4 (10 g) was added in one portion and the mixture was stirred at ambient temperature until the reaction was complete by HPLC. The resulting slurry was filtered and the solids washed with MTBE. The solids were dried to yield Compound 5a: 1 H NMR (DMSO-d 6 , 400 MHz) δ 7.99 (s, 1H), 7.52 (s, 1H), 7.41-7.38 (m, 1H), 7.30 (s, 1H), 7.12-7.08 (m, 2H), 7.04 (s, 1H), 6.81 (s, 1H), 3.91 (s, 2H), 3.90 (s, 3H), 3.79 (s, 3H).
EXAMPLE 4
Preparation of Compound 6a
[0046] Imidazole (0.42 g) and 1,1′-carbonyldiimidazole (5.49 g) were slurried in 30 mL of THF at ambient temperature. Compound 5a (10 g) was added in one portion and the mixture was stirred at ambient temperature for 4 hours to form a slurry of compound 5a. In a separate flask, 8.91 g of potassium monoethyl malonate was slurried in 40 mL of THF. Magnesium chloride (4.40 g) was added and the resulting slurry was warmed to 55° C. for 90 minutes. The slurry of Compound 5a was transferred to the magnesium chloride/potassium monoethyl malonate mixture and stirred at 55° C. overnight. The mixture was then cooled to room temperature and quenched by the dropwise addition of 80 mL of 28 wt % aqueous H 3 PO 4 . The phases were separated and the organic phase was washed successively with aqueous NaHSO 4 , KHCO 3 and NaCl solutions. The organic phase was concentrated to an oil and then coevaporated with ethanol. The resulting solid was dissolved in 30 mL ethanol and 6 mL water. Compound 6a was crystallized by cooling. The solid was isolated by filtration and the product was washed with aqueous ethanol. After drying Compound 6a was obtained: 1 H NMR (DMSO-d 6 , 400 MHz) δ 7.51 (s, 1H), 7.42-7.38 (m, 1H), 7.12-7.10 (m, 2H), 6.70 (s, 1H), 4.06 (q, J=7.0 Hz, 2H), 3.89 (s, 8H), 3.81 (s, 2H), 1.15 (t, J=7.0 Hz, 3H).
[0047] Alternatively, Compound 6a can be prepared as follows.
[0048] Carbonyldiimidazole (10.99 g) was slurried in 60 mL of THF at ambient temperature. Compound 4 (20 g) was added in one portion and the mixture was stirred at ambient temperature for 30 min to form a slurry of compound 5a. In a separate flask 15.72 g of potassium monoethyl malonate was slurried in 100 mL of THF. Magnesium chloride (6.45 g) was added and the resulting slurry was warmed to 55° C. for 5 hours. The slurry of Compound 5a was transferred to the magnesium chloride/potassium monoethyl malonate mixture and stirred at 55° C. overnight. The mixture was then cooled to room temperature and quenched onto 120 mL of 28 wt % aqueous H 3 PO 4 . The phases were separated and the organic phase was washed successively with aqueous KHCO 3 and NaCl solutions. The organic phase was concentrated to an oil and then coevaporated with ethanol. The resulting solid was dissolved in 100 mL ethanol and 12 mL water. Compound 6a was crystallized by cooling. The solid was isolated by filtration and the product was washed with aqueous ethanol. After drying 21.74 g Compound 6a (89% yield) was obtained: 1 H NMR (DMSO-d 6 , 400 MHz) δ 7.51 (s, 1H), 7.42-7.38 (m, 1H), 7.12-7.10 (m, 2H), 6.70 (s, 1H), 4.06 (q, J=7.0 Hz, 2H), 3.89 (s, 8H), 3.81 (s, 2H), 1.15 (t, J=7.0 Hz, 3H).
EXAMPLE 5
Preparation of Compound 9a
[0049] Compound 6a (20 g) was stirred with 6.6 g dimethylformamide dimethyl acetal, 66 g toluene and 0.08 g glacial acetic acid. The mixture was warmed to 90° C. for 4 hours. The mixture was then cooled to ambient temperature and 5.8 g (S)-2-amino-3-methyl-1-butanol was added. The mixture was stirred at ambient temperature for 1 hour before being concentrated to a thick oil. Dimethylformamide (36 g), potassium chloride (1.8 g) and bis(trimethylsilyl)acetamide (29.6 g) were added and the mixture was warmed to 90° C. for 1 h. The mixture was cooled to room temperature and diluted with 200 g dichloromethane. Dilute hydrochloride acid (44 g, about 1N) was added and the mixture stirred at ambient temperature for 20 min. The phases were separated and the organic phase was washed successively with water, aqueous sodium bicarbonate and water. The solvent was exchanged to acetonitrile and the volume was adjusted to 160 mL. The mixture was heated to clarity, cooled slightly, seeded and cooled to crystallize Compound 9a. The product was isolated by filtration and washed with additional cold acetonitrile. Vacuum drying afforded Compound 9a: 1 H NMR (DMSO-d 6 , 400 MHz) δ 8.61 (s, 1H), 7.86 (s, 1H), 7.45 (t, J=7.4 Hz, 1H), 7.26 (s, 1H), 7.23-7.14 (m, 2H), 5.10 (br s, 1H), 4.62 (br s, 1H), 4.18 (q, J=7.0 Hz, 2H), 4.03 (s, 2H), 3.96 (s, 3H), 3.92-3.84 (m, 1H), 3.78-3.75 (m, 1H), 2.28 (br s, 1H), 1.24 (t, J=7.0 Hz, 3H), 1.12 (d, J=6.4 Hz, 3H), 0.72 (d, J=6.4 Hz, 3H).
[0050] Alternatively, Compound 9a can be prepared as follows.
[0051] Compound 6a (50 g) was stirred with 17.5 g dimethylformamide dimethyl acetal, 90 g DMF and 0.2 g glacial acetic acid. The mixture was warmed to 65° C. for 3 hours. The mixture was then cooled to ambient temperature and 14.5 g (S)-2-amino-3-methyl-1-butanol and 25 g toluene were added. The mixture was stirred at ambient temperature overnight before being concentrated by distillation. Potassium chloride (4.5 g) and bis(trimethylsilyl)acetamide (80.2 g) were added and the mixture was warmed to 90° C. for 2 h. The mixture was cooled to room temperature and diluted with 250 g dichloromethane. Dilute hydrochloride acid (110 g of ˜1N) was added and the mixture stirred at ambient temperature for 30 min. The phases were separated and the organic phase was washed successively with water, aqueous sodium bicarbonate and water. The solvent was exchanged to acetonitrile by distillation. The mixture was heated to clarity, cooled slightly, seeded and cooled to crystallize Compound 9a. The product was isolated by filtration and washed with additional cold acetonitrile. Vacuum drying afforded 48.7 g (81% yield) of Compound 9a: 1 H NMR (DMSO-d 6 , 400 MHz) δ 8.61 (s, 1H), 7.86 (s, 1H), 7.45 (t, J=7.4 Hz, 1H), 7.26 (s, 1H), 7.23-7.14 (m, 2H), 5.10 (br s, 1H), 4.62 (br s, 1H), 4.18 (q, J=7.0 Hz, 2H), 4.03 (s, 2H), 3.96 (s, 3H), 3.92-3.84 (m, 1H), 3.78-3.75 (m, 1H), 2.28 (br s, 1H), 1.24 (t, J=7.0 Hz, 3H), 1.12 (d, J=6.4 Hz, 3H), 0.72 (d, J=6.4 Hz, 3H).
EXAMPLE 6
Preparation of Compound 10
[0052] Compound 9a (6.02 g) was slurried in 36 mL isopropanol and 24 mL of water. Aqueous potassium hydroxide (2.04 g of 45 wt % solution) was added and the mixture warmed to 40° C. After 3 hours 1.13 g glacial acetic acid was added the mixture seeded with 10 mg of Compound 10. The mixture was cooled in an ice bath for 2 hours and the solid was isolated by filtration. The cake was washed with aqueous isopropanol and dried to give Compound 10: 1 H NMR (DMSO-d 6 , 400 MHz) δ 15.42 (s, 1H), 8.87 (s, 1H), 8.02 (s, 1H), 7.48-7.45 (m, 2H), 7.23 (t, J=6.8 Hz, 1H), 7.17 (t, J=7.8 Hz, 1H), 5.18 (br s, 1H), 4.86 (br s, 1H), 4.10 (s, 2H), 4.02 (s, 3H), 3.97-3.96 (m, 1H), 3.79-3.76 (m, 1H), 2.36 (br s, 1H), 1.14 (d, J=6.3 Hz, 3H), 0.71 (d, J=6.3 Hz, 3H).
EXAMPLE 7
Preparation of Compound 13
[0053] The conversion of Compound 7a to Compound 9a described in Example 5 above produced a second product that was believed to result from the presence of (S)-2-amino-4-methyl-1-pentanol in the (S)-2-amino-3-methyl-1-butanol reagent. As illustrated below, an independent synthesis of Compound 13 was carried out to confirm the identity of the second product.
[0000]
[0054] Compound 13 was prepared from Compound 12 using a procedure analogous to the preparation of Compound 10 in Example 6 above. Following the workup described, the product was extracted into anisole. The desired product was isolated as a foam after removal of the solvent: 1 H NMR (DMSO-d 6 , 400 MHz) δ 8.80 (s, 1H), 8.02 (s, 1H), 7.48-7.44 (m, 2H), 7.23 (t, J=7.2 Hz, 1H), 7.16 (t, J=7.6 Hz, 1H), 5.19 (br s, 1H), 4.09 (s, 2H), 4.00 (s, 3H), 3.77 (br s, 2H), 1.94-1.87 (m, 1H), 1.82-1.75 (m, 1H), 1.43 (hept, J=6.4 Hz, 1H), 0.89 (d, J=6.4 Hz, 3H), 0.85 (d, J=6.8 Hz, 3H).
[0055] The intermediate Compound 12 was prepared as follows.
[0000] a. Compound 12 was prepared from Compound 6a using a procedure analogous to the preparation of Compound 9a, except (S)-(+)-2-amino-4-methyl-1-pentanol was used in place of (S)-2-amino-3-methyl-1-butanol. The desired product was isolated as a foam after concentrating the final acetonitrile solution to dryness: 1 H NMR (DMSO-d 6 , 400 MHz) δ 8.54 (s, 1H), 7.86 (s, 1H), 7.46-7.43 (m, 1H), 7.25 (s, 1H), 7.22-7.14 (m, 2H), 4.97 (br s, 1H), 4.20-4.16 (m, 2H), 4.03 (s, 2H), 3.95 (s, 3H), 3.73 (br s, 2H), 1.83-1.82 (m, 1H), 1.72-1.69 (m, 1H), 1.43 (hept, J=6.4 Hz, 1H), 1.24 (t, J=7.2 Hz, 3H), 0.88 (d, J=6.4 Hz, 3H), 0.84 (d, J=6.4 Hz, 3H).
[0056] Compound 13 is useful as an HIV integrase inhibitor as described in International Patent Application Publication Number WO 2004/046115. Accordingly, the invention also provides Compound 13 or a salt thereof, as well as methods for preparing Compound 13 or a salt thereof. The invention also provides a composition comprising Compound 10 or a salt thereof and Compound 13 or a salt thereof, as well as a compositions comprising Compound 9a or a salt thereof and Compound 12 or a salt thereof. Such compositions are useful for preparing integrase inhibitors described in International Patent Application Publication Number WO 2004/046115.
[0057] Alternatively, Compound 10 can be prepared from Compound 2 as described in the following illustrative Examples 8-12 that are based on 1 kg of starting material.
EXAMPLE 8
Preparation of a Compound of Formula 3
[0058]
[0059] Compound 2 is combined with anhydrous tetrahydrofuran and warmed to form a solution or thin slurry. The mixture is cooled to −20 to −30° C. and butylethylmagnesium in heptane is added. In a separate reactor n-butyllithium in hexane is combined with cold (−20 to −30° C.) tetrahydrofuran. The compound 2/butylethylmagnesium slurry is transferred to the n-butyllithium solution while keeping the mixture at −20 to −30° C. The lithium/halogen exchange reaction is monitored for completion by HPLC. Once complete, a solution of 3-chloro-2-fluorobenzaldehyde in tetrahydrofuran is added. After 1 hour the mixture is warmed to 0° C. and monitored by HPLC for reaction completion. Once complete, the reaction is quenched with aqueous hydrochloric acid to pH 1 to 3. The phases are separated and the aqueous phase is extracted twice with ethyl acetate. The combined organic phases are dried with sodium sulfate at 18 to 25° C. After removing the sodium sulfate by filtration the solvent is exchanged to MTBE and the resulting slurry cooled to 0° C. The product is isolated by filtration, washed with cold MTBE and dried at NMT 40° C. to yield Compound 3.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 2
261.07
1.00
1.00
THF
72.11
11.4
BuEtMg (15% w/w in heptane)
110.48
~1.8
0.55-0.6
n-BuLi (in hexane)
64.06
~1.9
1.8
Aldehyde
158.56
0.79
1.3
2M HCl
36.5
3.8
37% HCl
36.5
0.33
EtOAc
88.11
4.6
Na 2 SO 4
142.04
2
MTBE
88.15
9.5
1. Charge 1.00 kg Compound 2 and 8.7 kg THF to the reactor (1).
2. Heat the mixture to 45-50° C. to dissolve all solids or until a thin, uniform slurry is formed with no heavy solids resting on the bottom of the reactor.
3. Cool the contents of the reactor (1) to −20 to −30° C.
4. Charge BuEtMg (15% w/w in heptane) (˜1.8 kg; 0.6 eq.) to reactor (1) maintaining the temperature of the reaction mixture below −20° C. during the addition.
5. In a separate reactor (2) charge 2.6 kg THF and cool to −20 to −30° C.
6. To reactor (2) charge n-BuLi (in hexane) (1.9 kg, 1.8 eq.) maintaining the temperature below −20° C. during the addition.
7. Transfer the contents of reactor (1) to reactor (2) maintaining the temperature below −20° C. during the addition.
8. To reactor (3) charge 0.5 kg of THF and cool to −20 to −30° C.
9. Transfer contents of reactor (3) to reactor (1) then on to reactor (2) as a wash forward.
10. Approximately 15 minutes after the reactor contents have been combined, sample the reaction mixture and analyze by HPLC to determine completion of lithium/halogen exchange. (Typically there is 1-8% of Compound 2 remaining. If the amount of Compound 2 is greater than 8% sample the reaction again after at least 30 min. before charging additional n-BuLi).
11. In an appropriate container combine 0.79 kg of aldehyde and 0.79 kg THF.
12. Charge contents of the container to the reactor. Maintain the temperature of the reaction mixture below −20° C. during addition.
13. Agitate the reaction mixture at −20° C. for 1 h then warm to 0° C.
14. Quench the reaction mixture by adjusting the pH with 2 M HCl (˜3.8 kg) to a pH of 1 to 3.
15. Separate the phases.
16. Extract the aqueous phase with 2.3 kg EtOAc.
17. Extract the aqueous phase with 2.3 kg EtOAc.
18. Discard the aqueous phase.
19. Combine organic phases and dry with 2 kg of Na 2 SO 4 for at least 1 h. The temperature of the organic phase should be 20-25° C. before Na 2 SO 4 addition.
20. Filter the slurry to remove Na 2 SO 4 .
21. Concentrate the combined organic phases by vacuum distillation to ˜1.5 L (should form a thick slurry).
22. Charge 2.8 kg methyl t-butyl ether (MTBE) to the slurry.
23. Concentrate the mixture to ˜1.5 L.
24. Charge 2.8 kg MTBE to the slurry.
25. Concentrate the mixture to ˜1.5 L.
26. Charge 1.9 kg MTBE to the slurry.
27. Cool the slurry to ˜0° C. and isolate Compound 3 by filtration.
28. Wash forward the distillation vessel with 1.9 kg MTBE pre-cooled to ˜0° C.
29. Deliquor the cake until a granular solid is obtained. The purity of Compound 3 can be improved if necessary by reslurry in 6 volumes of 85:15 toluene:HOAc.
30. Dry the wet cake under vacuum at <40° C.
EXAMPLE 9
Preparation of a Compound of Formula 4
[0090]
[0091] Compound 3 is combined with trifluoroacetic acid and stirred to form a solution. The solution is cooled to −3 to 3° C. and triethylsilane is added while maintaining the temperature at NMT 15° C. The reaction is monitored for completion by HPLC. Once complete, MTBE is added to precipitate Compound 4 and the mixture is cooled to 0° C. The product is isolated by filtration, washed with MTBE and dried at NMT 60° C. to yield Compound 4.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 3
340.73
1.00
1.00
MTBE
88.15
5.6
TFA
114.02
1.7
5
Et 3 SiH
116.28
0.4
1.2
1. Dissolve 1.00 kg Compound 3 in 1.7 kg TFA.
2. Cool the reaction mixture to −3 to 3° C.
3. Charge 0.4 kg triethylsilane to the reaction mixture. Maintain the temperature of the reaction mixture less than 15° C. during this addition.
4. Sample the reaction mixture 30 minutes after the addition of the triethylsilane and analyze by HPLC to verify the complete conversion of Compound 3 to Compound 4.
5. Charge 4.0 kg MTBE to the reaction mixture maintaining the temperature of the mixture below 15° C. during addition.
6. Cool the mixture to 0° C. and agitate for at least 30 min.
7. Isolate Compound 4 by filtration and wash the reaction vessel forward with 1.6 kg MTBE.
8. Dry the Compound 4 obtained under vacuum at <60° C.
Note: The purity of Compound 4 may be improved by reslurry in 4 volumes of acetone. The slurry is warmed to 40° C. for 2 hours and cooled to 18 to 25° C. for 12 hours before filtration and washing with two 1 volume portions of acetone.
EXAMPLE 10
Preparation of a Compound of Formula 6a
[0100]
[0101] Carbonyldiimidazole and imidazole are combined with anhydrous tetrahydrofuran. Compound 4 is added to this mixture to form Compound 5a and the reaction is monitored by HPLC. In a separate reactor potassium monoethylmalonate is combined with tetrahydrofuran before anhydrous magnesium chloride is added while maintaining the temperature NMT 30° C. The resulting slurry is warmed to 50° C. and held for at least two hours before the Compound 5a mixture is added. The reaction is monitored by HPLC. Once the formation of Compound 5a is complete, the mixture is cooled to 18 to 25° C. and added to aqueous phosphoric acid to quench. The organic phase is washed with aqueous sodium bisulfate, brine, potassium bicarbonate and brine solutions before being polish filtered. The solvent is exchanged for anhydrous ethanol. Water is added and the mixture is warmed to dissolve solids, cooled to about 40° C., seeded with Compound 6a and cooled to 0 to 5° C. The product is filtered, washed with cold aqueous ethanol and dried at NMT 40° C. to yield Compound 6a.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 4
324.73
1.000
1.00
THF
72.11
7.11
Imidazole
68.08
0.042
0.20
CDI
162.15
0.55
1.10
KEM
170.2
0.89
1.70
MgCl 2
95.21
0.44
1.50
H 3 PO 4 (85 wt %)
98.00
2.3
NaHSO 4
120.06
0.24
KHCO 3
100.12
0.50
NaCl
58.44
0.48
SDA 2B-2 EtOH (0.5% heptane)
46.07
~10 kg
Procedure:
[0000]
1. Charge 0.55 kg CDI and 0.042 kg imidazole to reactor 1.
2. Charge 2.67 kg THF to reactor 1 and agitate to form a slurry.
3. Charge 1.00 kg Compound 4 to reactor 1 in portions to moderate the CO 2 off gas. This addition is endothermic
4. Charge 0.89 kg KEM to reactor 2.
5. Charge 4.45 kg THF to reactor 2 and agitate to form a slurry.
6. Charge 0.44 kg MgCl 2 to reactor 2 (can be added in portions to moderate exotherm).
7. Warm the contents of reactor 2 to 50° C. and agitate at that temperature for at least two hours.
8. Transfer the contents of reactor 1 to reactor 2. Mixture will become thick temporarily if transferred very rapidly.
9. Agitate the contents of reactor 2 for at least 12 hours at 50° C.
10. Cool the slurry to ambient temperature.
11. Quench the reaction by transferring the reaction mixture onto 7.0 kg of 28 wt % aqueous H 3 PO 4 (2.3 kg 85 wt % H 3 PO 4 dissolved in 4.7 kg H 2 O). This addition is exothermic. Final pH of aqueous layer should be 1-2.
12. Wash the organic (top) phase with 1.2 kg of 20 wt % aqueous NaHSO 4 (0.24 kg of NaHSO 4 dissolved in 0.96 kg H 2 O). Final pH of aqueous layer should be 1-2.
13. Wash the organic (top) phase with 1.2 kg of 20 wt % aqueous NaCl (0.24 kg of NaCl dissolved in 0.96 kg H 2 O)
14. Wash the organic (top) phase with 5.0 kg of 10 wt % aqueous KHCO 3 (0.50 kg of KHCO 3 dissolved in 4.5 kg H 2 O). Final pH of aqueous layer should be 8-10.
15. Wash the organic (top) phase with 1.2 kg of 20 wt % aqueous NaCl (0.24 kg of NaCl dissolved in 0.96 kg H 2 O). Final pH of aqueous layer should be 7-9.
16. Concentrate the organic phase and exchange the solvent to EtOH.
17. Adjust the concentration to ˜3.5 L/kg input.
18. Charge 0.6 volumes of water.
19. Warm 70-80° C. to form a clear solution.
20. Cool to 40° C. and seed with 0.1 wt % Compound 6.
21. Cool slowly to 5° C.
22. Hold for at least 2 hours.
23. Filter and wash the cake with two 1.35 kg volume portions of 50:50 EtOH:H 2 O (1.2 kg EtOH combined with 1.5 kg H 2 O).
24. Dry the cake at less than 50° C.
EXAMPLE 11
Preparation of a Compound of Formula 9a
[0126]
[0127] Compound 6a is combined with toluene, N,N-dimethylformamide dimethyl acetal and glacial acetic acid before being warmed to 100° C. The reaction is monitored by HPLC. Once the formation of Compound 7a is complete the mixture is cooled to 18 to 25° C. before (S)-(+)-valinol is added. The reaction is monitored by HPLC. Once the formation of Compound 8a is complete the mixture is concentrated. The residue is combined with dimethylformamide, potassium chloride and N, O-bistrimethylsilyl acetamide and warmed to 100° C. The reaction is monitored by HPLC. Once complete the mixture is cooled and dichloromethane is added. Aqueous hydrochloric acid is added to desilylate Compound 9a. This reaction is monitored by TLC. Once complete the organic phase is washed with water, aqueous sodium bicarbonate and water. The solvent is exchanged for acetonitrile and the mixture warmed. The mixture is seeded and cooled to crystallize Compound 9a. The product is filtered, washed with cold acetonitrile and dried at NMT 40° C. to yield Compound 9a.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 6a
394.82
1.00
1.00
Toluene
92.14
4.3
Glacial acetic acid
60.05
0.001
0.007
N,N-dimethylformamide dimethyl
119.16
0.33
1.1
acetal
(S)-(+)-Valinol
103.16
0.29
1.1
DMF
73.10
1.8
KCl
74.55
0.09
0.5
N,O-bis(trimethylsilyl)acetamide
203.43
1.13
2.2
1 N HCl
36.5
2.0
DCM
84.93
10
Water
18.02
8
5% Aq. NaHCO 3
84.01
4
CAN
41.05
QS
Compound 9a seeds
475.94
0.005
1. Charge Reactor 1 with 1.00 kg Compound 6a.
2. Charge 0.33 kg N,N-dimethylformamide dimethyl acetal (1.1 eq), 0.001 kg glacial acetic acid and 3.3 kg toluene to Reactor 1.
3. Warm the mixture to ˜100° C. (note that some MeOH may distill during this operation).
4. After 1 h the reaction should be complete by HPLC (˜2% Compound 6a apparently remaining) 1 .
5. Cool the mixture in Reactor 1 to 18-25° C.
[0133] 6. Charge 0.29 kg (S)-(+)-Valinol (1.1 eq) dissolved in 1.0 kg toluene to Reactor 1 and continue agitation at ambient temperature.
7. After 1 h the reaction should be complete by HPLC (<1% Compound 6a). 8. Concentrate the contents of Reactor 1 to ˜2 L/kg. 9. Charge 1.8 kg DMF, 0.09 kg potassium chloride (0.5 eq) and 1.13 kg N, O-bistrimethylsilyl acetamide (2.2 eq.) to Reactor 1. 10. Warm the mixture in Reactor 1 to −100° C. 11. Reaction should be complete in ˜1 h (˜5% Compound 8a remaining). 12. Cool the contents of Reactor 1 to 18-25° C. 13. Charge 10 kg DCM to Reactor 1. 14. Charge 2.0 kg 1 N aqueous HCl to Reactor 1 over ˜15 min, maintaining the temperature of the mixture <35° C. 15. Agitate the mixture for at least 10 min to desilylate Compound 8a. Monitor the progress of desilylation by TLC. 2 16. Separate the phases. 17. Wash the organic phase with 4.0 kg water. 18. Wash the organic phase with 4.0 kg 5% aqueous sodium bicarbonate. 19. Wash the organic phase with 4.0 kg water. 20. Concentrate the organic phase by distillation to ˜1.5 L/kg Compound 6a. 21. Solvent exchange to ACN by distillation until a slurry is formed. Adjust the final volume to ˜8 L/kg Compound 6a. 22. Heat the mixture to reflux to redissolve the solid. 23. Cool the solution to 75° C. and charge Compound 9a seeds. 24. Cool the mixture to 0° C. over at least 2 h and hold at that temperature for at least 1 h. 25. Isolate Compound 9a by filtration and wash the wet cake with 1.6 kg cold ACN. 26. Dry the wet cake at <40° C. under vacuum.
Notes:
[0000]
1. The HPLC AN of remaining Compound 6a is exaggerated by a baseline artifact. The HPLC in step shows only 2% of Compound 6a relative to Compound 8a. Experiments demonstrated that adding more reagent and extending reaction time typically will not further reduce the observed level of Compound 6a.
2. TLC method:
Eluting solvent: 100% ethyl acetate, Silylated Compound 9a Rf: 0.85, Compound 9a Rf: 0.50.
EXAMPLE 12
Preparation of a Compound of Formula 10
[0158]
[0159] Compound 9a is combined with aqueous isopropyl alcohol and warmed to 30 to 40° C. Aqueous potassium hydroxide is added and the reaction is monitored by HPLC. Once complete, glacial acetic acid is added and the mixture warmed to 60 to 70° C. The solution is hot filtered and cooled to 55 to 65° C. The solution is seeded (see International Patent Application Publication Number WO 2005/113508) and cooled to 0° C. The product is isolated by filtration, washed with cold aqueous isopropyl alcohol and dried at NMT 50° C. to yield Compound 10.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 9a
475.94
1.00
1.00
Isopropyl alcohol
60.10
4.7
Water
18.02
4.0
45% KOH
56.11
0.34
1.3
Glacial Acetic Acid
60.05
0.19
1.50
Compound 10 seeds
447.88
0.01
1. Charge 1.00 kg Compound 9a to Reactor 1.
2. Charge 4.7 kg isopropyl alcohol and 4.0 kg water to Reactor 1.
3. Charge 0.34 kg 45% aqueous KOH to Reactor 1.
4. Warm the mixture in Reactor 1 to 30-40° C.
5. When hydrolysis is complete add 0.19 kg of glacial acetic acid.
6. Warm the mixture to 60-70° C. and polish filter the solution to Reactor 2.
7. Cool the mixture in Reactor 2 to 55-65° C.
8. Seed with Compound 10 (see International Patent Application Publication Number WO 2005/113508) as a slurry in 0.28 volumes of 6:4 isopropyl alcohol:water.
9. Cool the mixture to 18-25° C. over at least 2 h and agitate to form a slurry.
10. Cool the mixture to 0° C. and agitate for at least 2 h.
11. Isolate Compound 10 by filtration and wash the cake with 3×1 S cold isopropyl alcohol:water (6:4) solution.
12. Dry the isolated solids at <50° C. under vacuum.
EXAMPLE 13
Preparation of Compound 15
[0172]
[0173] Bisdimethylaminoethyl ether (2.84 g) was dissolved in 42 mL THF and cooled in an ice bath. Isopropylmagnesium chloride (8.9 mL of a 2 M solution in THF) followed by Compound 14 (5 g dissolved in 5 mL THF) were added slowly sequentially. The mixture was allowed to warm to ambient temperature and stirred overnight. Next, 2.1 mL of 3-chloro-2-fluorobenzaldehyde was added. After stirring for ˜1 h, the mixture was quenched to pH 7 with 2N HCl. The product was extracted into ethyl acetate and the organic phase was dried over sodium sulfate. The solvent was exchange to heptane to precipitate the product and a mixture of heptanes:MTBE (4:1) was added to form a slurry. After filtration the solid was slurried in toluene, filtered and vacuum dried to yield compound 15: 1 H NMR (CD 3 CN, 400 MHz) δ 7.47 (s, 1H), 7.41-7.35 (m, 2H), 7.15 (t, J=7.4 Hz, 1H), 6.66 (s, 1H), 6.21 (br s, 1H), 3.90 (s, 3H), 3.87 (br s, 1H), 3.81 (s, 3H).
EXAMPLE 14
Preparation of Compound 15a
[0174]
[0175] Compound 14 (5 g), isopropylmagnesium chloride (8.9 mL of 2M solution in THF) and THF (56 mL) were combined at ambient temperature and then warmed to 50° C. for ˜5 hours. After cooling to ambient temperature and stirring overnight, 2.1 mL of 3-chloro-2-fluorobenzaldehyde was added dropwise to form a slurry. After stirring overnight the solid was isolated by filtration and washing with MTBE to yield compound 15a.
EXAMPLE 15
Preparation of Compound 16
[0176]
[0177] Triethylsilane (1.2 mL) was added to trifluoroacetic acid (2.3 mL) that had been pre-cooled in an ice bath. Compound 15 (1.466 g) was added to the mixture keeping the temperature below 5° C. After stirring for ˜2 h ice was added to quench the reaction. The product was extracted with DCM and the organic phase was washed with aq. NaHCO 3 . The organic phase was dried over Na 2 SO 4 and concentrated to dryness. The product was purified by silica gel column chromatography to provide 1.341 g of Compound 16: 1 H NMR (CDCl 3 , 400 MHz) δ 7.20 (t, J=7.0 Hz, 1H), 6.99-6.91 (m, 3H), 6.46 (s, 1H), 3.91 (s, 3H), 3.81 (s, 5H).
[0178] All publications, patents, and patent documents are incorporated by reference herein, as though individually incorporated by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention.
|
The invention provides synthetic processes and synthetic intermediates that can be used to prepare 4-oxoquinolone compounds having useful integrase inhibiting properties.
| 2
|
FIELD OF THE INVENTION
[0001] The present invention relates to a system and method for detecting distant objects, and more particularly to a system for remote identification and determination of the location of a seaborne vehicle, e.g., a boat. More specifically, the present invention is also concerned with an airborne projectile or missile (hereinafter a “seeker”) head bearing such a system, which may advantageously be equipped with proximity sensors for timely triggering an explosive.
BACKGROUND OF THE INVENTION
[0002] Various lasers are used today as proximity detectors for target seeker heads. Most of the employed systems are fast range finders determining the distance from the seeker head to the target, and when this distance is below a predetermined value, the proximity detectors activate the explosive material.
[0003] The existing proximity detection systems operate effectively in an airborne atmosphere, where no adjacent bodies generate reflections of the laser range finder. In ground applications, greater care must be taken not to be triggered by dust or clatter, and hence targets are identified by their size and shape or by other means such as temperature and magnetism.
[0004] The location of small boats on the sea water surface is a challenge due to the small dimensional features of the boats which are of the same magnitude as the sea waves, and thus, in such cases, a novel approach is required.
SUMMARY OF THE INVENTION
[0005] In accordance with the present invention, there is provided a system for detecting distant seaborne objects by an airborne vehicle, comprising a seeker head having an axis in the direction of flight, at least one sensor mounted on said seeker's head, said sensor being operative to transmit towards the sea surface a laser radiation beam of selected wavelength and to receive from the sea water surface radiation reflected from the sea water surface and from a seaborne object, and computing means for differentiating between the reflection received from the sea water surface and from the seaborne object.
[0006] The invention further provides a method for detecting distant seaborne objects by an airborne vehicle, comprising providing a system according to claim 1 , irradiating said sea water surface with at least one laser beam of a predetermined selectable wavelength, receiving by radiation detectors radiation reflected from the sea water surface and possibly from a seaborne object and converting received radiation into corresponding computable signals, and computing the received signals to differentiate between the reflection received from the sea water and from a seaborne object.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The invention will now be described in connection with certain preferred embodiments with reference to the following illustrative figures so that it may be more fully understood.
[0008] With specific reference now to the figures in detail, it is stressed that the particulars shown are by way of example and for purpose of illustrative discussion of the preferred embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.
[0009] In the drawings:
[0010] FIG. 1 is a schematic representation of a seeker head emitting signals impinging on a sea surface, in accordance with the present invention;
[0011] FIG. 2 is a schematic representation of a seeker head emitting signals, impinging on a seaborne object, according to the embodiment of FIG. 1 ;
[0012] FIG. 3 is a front view of the two sets of proximity sensors shown in FIGS. 1 and 2 , in accordance with the present invention, and
[0013] FIGS. 4A to 4D illustrate intensity versus time curves of reflected pulses as received by the seeker's head.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Referring now to the Figures in detail illustrating a preferred embodiment of a laser object seeker system, and first referring to FIGS. 1 and 3 , there are shown schematic representations of a seeker head 2 , e.g., a cylindrical, tapered or conical head, moving forward in direction 4 , also constituting the seeker's head axis. On the seeker head 2 there are located a plurality of laser proximity sensors (PS's) 6 to 6 ″″ and 8 to 8 ″″ (see FIGS. 1 and 3 ) pointing sideways into the sea water 10 . One or more of the PS's 6 to 6 ″ emit a laser beam 12 in the direction of the sea water 10 . The laser wavelength of the beams is selected so as not to penetrate the sea water 10 and to be reflected from the sea surface 14 , back in direction 16 into at least one of the dedicated detectors of the PS's 6 to 6 ″. Further seen are a plurality of laser PS's 8 to 8 ″″ pointing sideways and emitting laser beams 18 in the direction of the sea water 10 . The laser wavelength of the beams of these PS's is selected to penetrate the sea water 10 , to be partially reflected from the sea water surface 14 and partially reflected by the sea bed 20 , back in directions 22 and 24 respectively, into dedicated detectors of PS's 8 to 8 ″″. As the reflected amplitude and time of the beams are known, they are used to determine the various reflection distances, as per-se known. In this embodiment, the PS 6 ′ serves as a reference measuring distance to the surface 14 and PS 8 ′ measures the depth of the sea bed 20 . While in the shown embodiment, the PS's point sideways, in other embodiments the PS's may be arranged on the seeker's head 2 to point at a downwardly angle forwards in the direction of flight. Also, the seeker's head 2 may be rotatable about its axis.
[0015] Computing means for differentiating between the reflections received from the sea water surface, possibly from the sea bed and from a seaborne object may be included in the seeker's head or in any other part of the airborne vehicle.
[0016] FIG. 2 illustrates a schematic representation of the seeker head 2 , moving forward in direction 4 and having a plurality of PS's 6 to 6 ′ and 8 to 8 ″″ pointing sideways. At least one of the PS's 6 to 6 ′ emits a laser beam 12 in the direction of the sea surface 14 where seaborne object 26 , e.g., a boat is present. The laser wavelength is selected not to penetrate the seawater 10 and to be reflected in direction 16 from the sea water surface 14 or from the seaborne object 26 into the dedicated detectors of PS's 6 to 6 ′. A plurality of laser PS's 8 to 8 ″″ point sideways and emit laser beams 14 towards the sea water 10 . The laser wavelength of the beams is selected to penetrate the sea water 10 and to be partially reflected in direction 22 from sea water surface 14 , and sea bed 20 , into dedicated detectors of the PS's 8 to 8 ″″. As can be seen, in this case, however, the reflection surface of the beam is the reflection from the seaborne object 26 in direction 22 . The reflected amplitude and time of the beam determine the various distances, as per-se known, with the PS 6 serving as a reference measuring distance to the water and the PS 8 measuring the sea depth.
[0017] In FIG. 4A there is illustrated a signal produced by detectors of PS's 6 to 6 ″″, while FIG. 4B shows the signals produced by the detectors of PS's 8 to 8 ″ for sea water.
[0018] In FIG. 4C there is illustrated signal produced by the detectors of PS's 6 to 6 ″″ while FIG. 4D shows a signal produced by the detectors of PS's 8 to 8 ′, which in this case, have equal timing and distance received from a seaborne object.
[0019] The methods of operating the systems described with reference to FIGS. 1 to 4 will now be briefly described.
[0020] According to an embodiment of a method of operation of the present invention, a single laser beam is used, where the laser beam is selected to enhance or reduce seaborne object laser reflection in comparison with the sea waves.
[0021] According to a further embodiment of a method of operation of the present invention, there is provided a laser beam that penetrates the sea water, e.g., green laser light, wherein the impingement on the seaborne object results in a single reflection as compared with a double reflection, one from the sea water surface and one from the sea bed, when the laser radiation impinges on the sea waves.
[0022] A further method of operation of the present invention provides for two laser beams which are selected such that one penetrates the sea water, e.g., green laser light, where the impingement of the laser radiation on the seaborne object forms a single reflection as compared with a double reflection, one from the sea surface and one from the sea bed, when laser radiation impinges on the sea waves, and a second beam of a non-penetrating wavelength, e.g., a red laser, serving as a reference, where the impingement on the seaborne object or the sea waves results in a single reflection.
[0023] According to still a further method of operation of the present invention, two laser beams are selected, one that penetrates the water, e.g., green laser light, and a second, non-penetrating wavelength, e.g., a red laser, where the two laser beams operate simultaneously and share an equivalent optical path using the same single detector, wherein each of the laser beams is modulated by a different RF carrier. The detector's output RF signals are used to differentiate between the seaborne object and the sea, and the impingement on the object will result in a similar reflection pattern for both wavelengths (displayed by similar, highly correlated temporal envelopes of received RF signals), whereas the impingement from the sea will show variations in the reflection pattern between the two wavelengths, displayed by a lower correlation between the correspondingly received RF signals.
[0024] A further method of operation of the present invention provides for multiple laser proximity detectors placed on the circumference of the seeker's head, as shown in FIG. 3 , enabling detection by a rotating seeker and either being redundant, or alternatively, enabling higher computation speed.
[0025] According to a further method of operation of the present invention, laser proximity detectors based on time-of-flight are placed on the seeker, and are continuously utilized. Similarly, laser proximity detectors based on phase detection may be placed on the seeker's head, or laser proximity detectors based on triangulation computations, may be utilized.
[0026] A further method of operation according to the present invention calls for laser proximity detectors data to be analyzed and processed by an on-board computing system and dedicated algorithms, and finally, according to yet a further method, multiple laser proximity detectors are oriented such as to impinge on the sea water surface at a distance higher than the target size, where the similarity or dissimilarity between the signals is used to distinguish between sea water and a target.
[0027] It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrated embodiments and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
|
There is provided a system for detecting distant seaborne objects by an airborne vehicle, including a seeker head having an axis in the direction of flight, a sensor mounted on the seeker's head, the sensor being operative to transmit towards the sea surface a laser radiation beam of selected wavelength and to receive from the sea water surface radiation reflected from the sea water surface and from a seaborne object, and a computing unit for differentiating between the reflection received from the sea water surface and from the seaborne object. A method for detecting distant seaborne objects by an airborne vehicle is also provided.
| 5
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to thermostatic expansion valves for large-capacity refrigeration systems. It particularly relates to improvements in port balance of thermostatic expansion valves.
2. Review of the Prior Art
Thermostatic expansion valves, having an inlet and an outlet, a valve port therebetween, and a valve pin for selectively controlling the valve port, are well known in the art. Such valves generally comprise a compression spring for urging the valve pin or a plurality of push rods upwardly against a diaphragm of a diaphragm motor. On the upper or far side of the diaphragm is a chamber containing a sealed charge of a selected fluid which is exposed within a remote bulb to evaporated refrigerant as a temperature-sensing mechanism. In the lower or near side of the diaphragm is a chamber which is connected to the evaporated refrigerant as a pressure-sensing mechanism.
It has been known for some time that the pressure differential across the valve port produces an extraneous variable bias in the balance of forces that are intended to control the valve pin position. This bias adversely affects valve performance because of valve pin imbalance. The three basic forces intended to control valve pin position and, hence, flow through the valve are: (A) Bulb pressure, which is determined by the evaporator outlet temperature and is exerted on the top side of the valve operating diaphragm, produces a force tending to urge the valve in an opening direction as the remote bulb temperature increases;
(B) The evaporator pressure, which is exerted on the lower side of the operating diaphragm, opposes the bulb pressure and tends to urge the valve in the closing direction; and
(C) The spring force, which also tends to urge the valve in the closing direction, also opposes the bulb pressure.
All other forces affecting the position of the valve pin are extraneous. It is desirable, therefore, to minimize or eliminate them. The undesirable effect of valve pin imbalance is especially significant and troublesome in large-capacity valves with their necessarily large port areas. Several methods exist in the current state of the art to balance or offset the unbalance created by a pressure differential across the port. However, existing methods create other problems such as high manufacturing costs, high valve friction, partial imbalance, high internal leakage rates through the valve port or ports, and leakage from the valve inlet to the underside of the operating diaphragm. Such leakage of inlet pressure into the lower diaphragm compartment is particularly damaging to the performance of the expansion valve.
It is also highly desirable that the valve pin, through its entire stroke, operate uniformly in accordance with the pressures exerted on the diaphragm without being influenced by extraneous pressures and unpredictable unbalance or frictional forces.
SUMMARY OF THE INVENTION
The object of this invention is to provide a thermostatic expansion valve for large-capacity refrigeration systems in which pressures on the valve pin controlling the valve port result substantially entirely from the desired balance of forces.
It is also an object to provide a thermostatic expansion valve in which leak paths from the valve inlet to the underside of the control diaphragm are eliminated.
It is an additional object to provide a thermostatic expansion valve in which flow of high-pressure fluid through leak paths from the valve inlet to the outlet, bypassing the main valve control port, is reduced.
It is further an object to povide a thermostatic expansion valve in which partially unbalancing forces caused by geometry of valve design are eliminated.
It is additionally an object to provide a thermostatic expansion valve in which high-friction seals, used to control leakage from the valve inlet to the outlet, are replaced by low-friction seals.
It is finally an object to provide a thermostatic expansion valve in which excessive valve seat leakage caused by eccentricity or misalignment of assembled parts is reduced.
In satisfaction of these objects and according to the principles of this invention, the large-capacity thermostatic expansion valve as hereinafter described comprises a valve pin having a pair of transversely disposed end faces having equal areas exposed to equal pressure differentials, a coaxial bore extending between the end faces, a cylindrical slide portion near one end face, a centrally disposed reduced-stem portion, a friction-fit portion, and a pair of shoulders at each end of the reduced-stem portion. The valve pin slidingly operates within a bore which is coaxially disposed within the thermostatic expansion valve and which intersects an inlet passage connecting to an inlet fitting.
The coaxial bore in the valve body has a blind upper end and terminates at its other end in an accurately machined circular lip in a circular recess along one wall of an outlet chamber within which a valve pin carrier moves freely. This valve pin carrier is tightly attached to the valve pin and has a circumannular shoulder which is contacted on one side by a compression spring and on the other side by a plurality of push rods. The compression spring also bears against a threadably adjusted lower spring support. The push rods fit closely within rod bores in the valve body and bear against a buffer plate which bears against or is attached to the diaphragm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a large-capacity refrigeration system in which the flow of refrigerant is controlled by the thermostatic expansion valve of this invention in which the remote bulb and the external equalizer are located adjacent to the flow of expanded refrigerant at the evaporator exit.
FIG. 2 is an enlarged sectional elevation of the valve as shown in FIG. 1, with the valve pin in open position.
FIG. 3 is a similar view with the valve pin in closed position.
FIG. 4 is a sectional view taken along lines 4--4 in FIG. 3.
FIG. 5 is a detailed view of another embodiment of the valve pin in which plastic seals are employed in the slide portion thereof.
FIG. 6 is a detailed view of still another embodiment of the valve pin, using a simpler form of retension of the plastic seal in the slide portion thereof.
FIG. 7 is a detailed sectional view showing the valve body with an alternate embodiment for spring adjustment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The refrigeration system shown in FIG. 1 comprises an evaporator 13, a temperature sensing bulb 15 which is positioned to sense the temperature of the evaporated fluid, a pressure tap 16 located nearby, a compressor 17, a condenser 18, a receiver 19, and a thermostatic expansion valve 20. In some instances, a refrigerant distributor 11 is also provided between the valve 20 and the evaporator 13.
The thermostatic expansion valve 20, as shown in FIGS. 1, 2, 3, and 4, comprises an inlet fitting 21, an inlet passage having walls 22, an outlet fitting 23, an outlet chamber 24, a valve body 25, an equalizer fitting 26, a coaxial feed bore having walls 27 in the valve body, a seal cap 28, an inlet strainer 29, a diaphragm motor 30, and a port control means 40. The outlet chamber 24 has sides 24a and is threaded at its lower end. The diaphragm motor 30, as is known in the art, comprises an upper diaphragm support 35, a lower diaphragm support 37, and a diaphragm 34 which is straddled by an opening compartment 31 and a closing compartment 33. The opening compartment 31 is connected with bulb tubing 39 to the temperature sensing bulb 15, and the closing compartment 33 is connected to the pressure tap 16 by means of suitable tubing, the equalizer fitting 26, and an internal passage 26a.
The port control means 40 comprises a lower spring support 41, O-ring seal 43 for the lower spring support 41, valve pin carrier 45, compression spring 44 acting between the lower spring support 41 and the valve pin carrier 45, push rods 49, and valve pin 50. The valve pin carrier 45 has a circular shoulder 47 having parallel, circumannular, and radially disposed sides which are contacted by the compression spring 44 and by push rods 49. The valve pin carrier 45 also has a coaxial bore with sides 46.
The valve pin 50 comprises a cylindrical slide portion 51, a reduced stem portion 52, a cylindrical attachment portion 53, a valve pin body 54, a pair of end faces 55, and a coaxial bore with sides 57. Sides 46 of the coaxial bore in valve pin carrier 45 are pressure fitted to cylindrical attachment portion 53 so that valve pin body 54 and valve pin carrier 45 form a unitary assembly. The reduced stem portion 52 and the walls 27 of the coaxial feed bore in the valve body 25 form an annular port passage 67 which leads to port 69 between shoulder 63 and circular sealing lip 65 in circular recess 64.
Pin shoulder 63 is at one end of reduced stem portion 52; balancing shoulder 61 is at the other end thereof. Shoulder 63 consists of a pressure portion 63a and a dispersal portion 63b, as shown in FIG. 4. Pressure portion 63a is exactly equal to shoulder 61. Approximate balance can be maintained with approximate areas, the degree of unbalance being directly related to the difference in areas 63a and 61. Consequently, when the valve pin 50 is in the position shown in FIG. 3, the inlet pressure to the valve 20 is exerted on the valve pin 50 over identical areas but in opposite directions, thereby balancing the valve pin 50 by causing the valve inlet pressure to be exerted on equal areas of the shoulders 61, 63 and the valve outlet pressure to be exerted on equal areas of both end faces 55 through coaxial bore 57 of the valve pin 50 shown in FIGS. 1-4. However, every surface on the lower portion of valve pin body 54 and on valve pin carrier 45 that is actively exposed to the outlet pressure and has an equivalent projected area in parallel to upper end face 55 provides a longitudinally directed force that balances the force directed against the upper end face 55 so that equality of area for the pair of end faces 55 is irrelevant.
The annular relationship of the shoulder 63 to the surface of the reduced stem portion 52 is preferably measured by the included pin angle 59 which selectively varies from 30° to 180°. A flat seated valve having an included angle of 180° is generally not desirable, because it is difficult to make a tight seal. A 30° angle is at the other limit because the pin tends to stick in the port.
Such adjustment of the included angle for the shoulder 63 can effect a considerable change in valve capacity. For example, a thermostatic expansion valve having a capacity of 30 tons with a 90° included pin angle can be brought to as low as 12 tons by included-angle adjustment.
Because the stroke of a thermostatic expansion valve is fixed, further change in valve capacity must be accomplished in other ways. For example, a parabolic restrictor plug or the like can be inserted into the valve port 69, thereby reducing the capacity to as low as 6 tons. Machining the surface of shoulder 63 or of circular lip 65 to a convex, concave, or parabolic surface is also a practical way to obtain desirable flow characteristics for port 69 and to alter valve capacity and the opening and closing characteristics of the port 69.
Embodiment 70, which is shown in FIG. 5, comprises a valve pin body 71, a cap 73, and a seal ring member 78. The valve pin body 71 has a coaxial bore with sides 72 and terminates in a recess formed by circular shoulder 79 having internal threads 75. The cap 73 has a coaxial bore with sides 74, circular shoulders 77, and external threads 76. The cap 73 is threadably inserted into the recess in valve pin body 71, forming a circular groove into which a plastic seal ring member 78, manufactured from low-friction fluorocarbon polymers, is fitted. Preferably, a U-cap seal (as shown in FIG. 5) or a lip seal is used. This seal embodiment permits employment of conventional manufacturing methods and allows larger machining tolerances for sides 27a of bore 27 to be used for valve body 25 while reducing leakage rates.
The valve pin embodiment 80, which is shown in FIG. 6, comprises a valve pin body 81, a washer disc 84, and a seal ring member 88. The valve pin body 81 has a coaxial bore with sides 82, a cylindrical slide portion 85, a circular terminal lip 86 at the terminal edge of the bore, and a circular recess 87 in the outer terminal edge of the body 81. The cylindrical slide portion 85 need not fit very closely against side 27b of the coaxial bore within body 25 but may be manufactured according to larger machining tolerances. A plastic seal ring member 88, manufactured from low-friction fluorocarbon polymers, is inserted into the recess 87. Preferably, a U-cup seal (as shown in FIG. 6) or a lip seal is used. A washer disc 84 is placed over lip 86, prior to outwardly deforming lip 86, for retaining seal 88 in circular recess 87. This seal embodiment also reduces leakage rates and permits larger machining tolerances and conventional manufacturing methods to be employed.
The alternate embodiment 90 for spring adjustment, shown in FIG. 7, is used with the same body 25 having the same outlet chamber 24 with sides 24a and internal threads 24b into which compression spring 44 fits as it bears against valve pin carrier 45 (not shown in FIG. 7). The embodiment 90 comprises an outwardly threaded cylindrical collar 92, a cap 93 which is screwed onto the lower threads of cylindrical collar 92, a non-rising positioning member 94 fitting within the cylindrical collar 92 and resting upon an internal shoulder thereof, a lower spring support 97, and a pair of O-ring seals 95. The positioning member 94 comprises a turning lug at the lower end, a pair of circular recesses, a circular outer shoulder, and an outwardly threaded upper stem. The lower spring support 94 has a shoulder which engages compression spring 44 and a coaxial bore with internal threads with which it is attached to the stem of positioning member 94. The O-ring seals 95 fit into the pair of circular recesses in the positioning member 94 and bear against the inner side of collar 92. By removing the cap 93, the turning lug of positioning member 94 can be moved to adjust the position of lower spring support 97. Lower spring support 97 is prevented from rotating during adjustment of positioning member 94 because its outer surface 98 is square or hexagonally shaped and is fitted into socket 99 which is similar in shape. This alternate method of spring adjustment provides an optional means for more conveniently adjusting the compression of spring 44 and thus adjusting the pressure on diaphragm 34.
The thermostatic expansion valve as hereinbefore described provides means for causing the inlet pressure to the valve to be exerted on the valve pin over identical areas but in opposite directions, this balancing being accomplished by causing the valve outlet pressure to be exerted on equal areas at both ends of the valve pin 50 through its bore. This invention eliminates the leak path from the valve inlet to the underside of the control diaphragm. Further, it reduces the leak path from the valve inlet to the outlet which bypasses the main valve control port. In addition, it eliminates partial imbalance due to geometry of valve design, reduces high friction seals used to control leakage in the leak paths from the valve inlet to the underside of the control diaphragm and from the valve inlet to the outlet which bypasses the main valve control port. Further, it reduces high manufacturing costs and excessive valve seat leakage caused by eccentricity or misalignment of assembled parts.
If the refrigerant distributor 11 is present in the system, the pressure drop through distributor 11 and the evaporator 13 may be from 10 to 70 psi. Consequently, the pressure tap 16 must necessarily be located beyond the evaporator 13 and fairly close to temperature sensing bulb 15 so that both measure the same conditions. If, however, there is no refrigerant distributor 11 in the system, the pressure tap 16, outlet fitting 26, and connecting tubing can be omitted; instead, passage 26a can be extended to connect with chamber 24 as an internal equalizer.
Push rods 49 must fit with reasonable tightness in their respective bores in valve body 25. However, leakage from outlet chamber 24 to closing compartment 33 is not a serious matter. By this design, there is no possibility of leakage of fluid at inlet pressure to closing compartment 33.
Leakage of fluid at inlet pressure into outlet chamber 24, by way of the fit between cylindrical slide portion 51 and the sides 27 of the coaxial feed bore in the valve body 25, is another matter. As shown in FIGS. 2 and 3, this is a sliding fit, requiring very accurate machining. More practical and less expensive devices for achieving the necessary tightness of sealing are shown in FIGS. 5 and 6. Both embodiments employ conventional methods and permit larger machining tolerances while reducing leakage rates.
It is to be understood that the invention is not to be restricted to the specific embodiments described hereinbefore because numerous other embodiments can be constructed according to the principles of this invention. What is to be construed at the invention according to the scope thereof is defined solely by the accompanying claims.
|
A thermostatic expansion valve for large-capacity refrigeration systems has a pressure-balanced valve pin and no means of communicating inlet pressures to the underside of the diaphragm. The valve pin has a coaxial bore, a pair of end faces, a pair of cylindrical portions fitting slideably in a feed bore leading to an outlet chamber, a reduced stem portion of small diameter between the pair of cylindrical portions, and a pair of shoulders connecting the reduced stem portion to the pair of cylindrical portions. The shoulders are exposed to the same pressure so that the valve pin is balanced.
| 5
|
BACKGROUND OF THE INVENTION
The invention relates to a method and a device for the construction of tunnels according to the precharacterizing parts of the independent claims. They are used when a tunnel is to be driven through soil with parameters expected to have a limited life-time. The word “tunnel”, in this connection, is to be understood in the general sense of the word. It relates to any kind of tubes that are to be driven into the ground, for instance to more or less horizontally extending street tunnels or canals, but also to underground chambers and cavities.
In order to be able to construct tunnels in the above situation it must be prevented that a just finished round collapses before a support has been installed or that loose pieces of rock fall into the tunnel from the tunnel wall. Known methods in this connection are the shotcrete construction method and mechanical tunnel driving with and without a shield structure.
In the shotcrete construction the tunnel is driven by means of excavators or sectional cutting-machines. Deformations of the tunnel tube immediately after driving a round are allowed so that shape changing resistances in the form of a supporting ring become effective. This supporting ring surrounds the cavity and prevents the ground from intruding into the cavity any further. However, the deformation must not become so considerable that this results in a breaking up due to overload. A thin shotcrete protection limits this deformation by providing an increasing spring-like resistance to the deformation as the latter increases. The main field of application for shotcrete constructions is rock material. The latter may be slightly or heavily jointed, or may have worked loose. Cohesive and noncohesive unstable rock formations are possible fields of application.
In the case of the mechanically driven shield tunnel the exploiting system works with mechanical tools, the tools—if provided as a full cutting-machine with a cutting-wheel or a prospecting wheel—being able to process the entire excavation surface simultaneously. If using them in the form of a sectional cutting-machine the working face is removed in several attacks. The shield structure is a support that wanders along with the tunnel machine, under the protection of which the ground support is installed. Tunnel machines including a shield structure and a cutting-wheel are used in loose rock with an unsupported working face, whilst the machines including a prospecting-wheel are employed in the case of a supported working face. The sectional cutting-machine is used for an unsupported working face.
Exploitation at the working face in the case of a mechanically driven tunnel without a shield structure is the same as that with the mechanically driven tunnel including a shield structure. During its use the machine is anchored in the surrounding ground. The supporting work is done at a later time, separately of the advancing work. The field of use of this machine is rock material.
The construction method with shotcrete has the following shortcomings:
Working Safety:
After driving a round the workmen are in the unprotected area and thus in a particularly hazardous position. On account of the heavy rebound and the generation of dust when bringing the shotcrete in the workmen are exposed to considerable health risks.
Costs:
As the shotcrete is not used completely, because of rebounding, the costs for the material employed in this method are high.
Any possibly required advancing measures of protection add to the costs as these cannot be taken into account for the later supporting capacity of the shotcrete shell.
Personnel:
For implementation, the personnel must be well-trained; it is hard to find such personnel nowadays.
Construction Rate:
As the advancing operation and the shotcrete support work must take place one after another the operations cannot be synchronized. The construction rate is therefore low.
Supporting Capacity:
It is difficult to provide static proof of the individual states of construction. If the life-times are short, the section is driven for plural partial excavations, which increases the settings.
The mechanically driven shield tunnel has the following disadvantages:
As the tunnel machine has to be manufactured individually, in accordance with the respective tunnel geometry and geology, it can in most cases be used only for one order and is therefore subject to high costs. Because of the high installation costs the shield machine is not economical for the construction of short tunnels. Only circular sections can be made. The maximal tunnel section at a given clear section is only in exceptional cases circular, so that there are increased costs because of the additional excavation work. Any variations of the tunnel section in the longitudinal direction of the tunnel (for instance for parking bays in road construction or train stations in underground construction) cannot be made by the machine.
In addition to the shortcomings with the mechanically driven shield tunnel the machine without the shield construction has the following shortcoming:
As the supports are installed with a delay and separately of the driving work, it is difficult to react to variations in the ground condition. If supporting work has to be carried out in the area of the machine the driving work is impeded. Moreover, there is the risk of the machine being buried by pieces of rock, etc.
SUMMARY OF THE INVENTION
The object underlying the invention is to provide a method and a device for use in the construction of tunnels, permitting a faster, less expensive and safer driving of a tunnel into the ground.
This object is accomplished by the features of the independent claims. Dependent claims are directed to preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, embodiments according to the invention are described with reference to the drawings, in which
FIGS. 1A-1D show a basic first embodiment of the invention;
FIGS. 2A-2F schematically show individual steps of the method according to the invention;
FIGS. 3A-3B, 4 A- 4 D, and 5 A- 5 B partly schematically show special embodiments of the invention;
FIG. 6 shows a device according to the invention;
FIGS. 7A-7B show a further device according to the invention;
FIG. 8 . shows a further device according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1A shows schematically, and not to scale, the tunnel 10 to be driven in parallel to the longitudinal axis vertically cut, whilst FIGS. 1B and 1C show several sections thereof perpendicular to the longitudinal axis. The tunnel 10 advances in the ground 11 , 12 . 11 denotes the ground surrounding the tunnel, 12 the material to be removed next, reference numeral 13 denotes an artificial supporting layer of a load bearing material such as concrete. 14 denotes the device according to the invention (slotting-machine). 15 is a slot produced by the slotting-machine 14 . 16 is the working face. 17 denotes the tunnel support.
The method according to the invention comprises the following steps, which are schematically shown in FIGS. 2A to 2 F:
(1) Starting at the working face 16 a slot 15 is produced in the area to be supported for the tunnel to be dug, roughly extending in the circumferential and advancing directions of the tunnel 10 to be dug (arrows A and B in FIGS. 2 A and 2 B), with its thickness extending about radially (line C). The slot 15 extends in the circumferential direction at least over the area to be supported and in the tunnel advancing direction as far as allowed by the different construction and/or machine parameters. The slot is located in the area in which the later support 17 will come to lie, or further to the outside.
(2) The slot 15 that has been dug is filled with a load bearing material, preferably quick-setting concrete, thus turning into a supporting layer 13 .
(3) Thereafter, the working face 16 is exploited, protected by the supporting layer 13 , and a further support 17 is installed, if required.
(4) This is followed once again by the sequence of steps (1) to (3).
By steps (1) to (4) the method according to the invention as used in the construction of tunnels is described. In this method, a slot 15 is thus produced in an advancing or preceding manner. This slot is filled with a load bearing material such as concrete. Protected by the load bearing supporting layer 13 formed in this way, the tunnel 10 advances. If one merely looks at the method for building up the supporting layer 13 , only steps (1) and (2) will have to be considered, these being repeated, if necessary. If merely the method for providing the slot 15 is looked at, a repetition of step (1) only, if necessary, will be of relevance.
The method according to the invention is employed particularly advantageously in the construction of tunnels where the ground through which the tunnel is to be driven is of the kind that, on the one side, a sloped working face stands freely, whilst, on the other side, the rigidity is not sufficient so that the tunnel can be driven by applying blasting only.
The method is applicable to varying geometries and geologies. The workmen operate under the protection of the advancing or preceding supporting work. The health hazards for the workmen are reduced, compared to conventional methods. The method facilitates a driving work entailing smaller deformations and thus less damage to the ground surface. If the supporting layer has been designed such that it may be taken into account for the load bearing capacity of the tunnel tube, the inner support to be provided subsequently ( 17 in FIG. 1A) may be designed to be somewhat weaker, or it may be omitted completely, resulting in a definite cost advantage. During the driving work, different tunnel section shapes and/or surfaces may be produced. In this case, all that is necessary is that the device 14 for producing the supporting layer is controlled accordingly.
In the following, variants and further developments of the above steps (1) to (4) are described.
The dimensioning and positioning of the slot 15 to be dug and filled up—and thus also of the supporting layer 13 produced—depends on various parameters. In FIGS. 1A-1D and 2 A- 2 F embodiments are shown in which the slot 15 extends only over a portion of the tunnel circumference. This can make sense if, because of local geological interferences, only portions of the tunnel require support. In this case, the slot 15 is designed such that the supporting layer 13 , following removal of the rock therebeneath, finds a load bearing rest. However, the slot may also be designed in a surrounding or encircling form as shown schematically in FIGS. 3A-3B. This possibility can be chosen, for example, if the tunnel is to be advanced in an environment which, in conventional methods, requires a radially surrounding support. This will result in a through-going surrounding supporting layer 13 , in the following referred to as a supporting ring, which does not have individual abutments to the ground but which is supported over its entire outer surface.
The slot 15 for receiving the supporting layer 13 is produced in a preceding or advancing manner and follows the intended tunnel contour. It can follow a helix if the supporting ring is a closed, circumferential ring (FIG. 4 A). The pitch of the helix corresponds to the processing width of the slotting-machine. The helix may be inclined along the tunnel contour such that, at the top, it is in a more forward position, looking at it in the tunnel advancing direction, than at the bottom (FIGS. 4 B and 4 C). This inclination relative to the vertical will also be experienced by the working face, so that the latter is less prone to collapsing. The angle of inclination is chosen in response to the ground parameters.
Especially in the case of the inclined working face 16 the helix can be optimized under various aspects, particularly under the aspect of the machine structure and the stability of the working face 16 .
In the simplest case for the machine, it is designed such that the variation of curvature of the helix within a turn, at a given inclination of the working face due to the ground conditions (ground parameters), is minimized. This reduces the mobility requirements for the machine.
It can also be optimized in accordance with the stability of the working face. The ground parameters determine the inclination required for the stability of the working face. This also defines the position of the most forward point of the supporting layer to be produced in the respective turn. The shortest connection between the most forward point and the most rearward point would be a straight line in the winding of the helix. The marginal curve resulting from this path has a minimal curvature on the sides of the tunnel, thereby resulting in a working face with an almost constant inclination and thus in a maximal stability.
The apexes of the movement, in this connection, need not contact the roof or the bottom of the tunnel.
Also a through-going ring as a special case of the helix is possible (FIG. 4 D).
By varying the slot width (working width) during one turn, curvatures over the tunnel length can be implemented. To this end, either the working width of the machine is increased, decreased, or, if the working width of the machine is constant, a portion of the supporting layer that has been produced in the previous turn is removed again by the machine.
The material dug loose when producing the slot is transported to the working face by suitable means. To this end, if necessary, an excavation towards the working face is produced. The excavation can run along with the slot-producing machine 14 and be produced either by the latter itself or by a separate unit. Through said excavation the transport of material, energy and signals takes place.
The very first bringing in of the slot-producing device 14 into the ground, in the case of a conventionally produced working face 16 , may simply be effected from the loading space of a transport unit, for instance a truck, provided care is taken that the machine finds an abutment there. From there, it works into the ground, subsequently working its way towards the tunnel circumference, and takes up its regular work there.
Preferably, the slot 15 is filled up with concrete immediately after it has been dug. In this connection, the concrete may be hauled into the free slot either from the side of the working face or from the rear of the machine that is producing the slot. A quick-setting concrete which sets in seconds can be used.
It is pointed out in this connection that, although in the foregoing there is mention of concrete, also other materials may be used, provided they are similar to concrete in their essential parameters (for example, initially deformable, then pressure-resistant).
If the produced supporting layer is to be taken into account for the load bearing capacity of the tunnel to be constructed, the supporting layer must be provided at the location of the tunnel contour. Any other supports as used in the conventional tunnel construction, such as forepoling or current stakes, which do not contribute to the load bearing capacity of the tunnel to be constructed, may be omitted.
The concrete introduced into the slot sets within a few seconds and is additionally held by an accompanying formwork so that it does not flow through the excavation into the tunnel.
Owing to the surrounding supporting rings 13 the tunnel 10 can then be driven continuously, for example in a manner such that the working face 16 is exploited in its sector located in front of the slot producing machine, respectively.
The working face can be exploited by means of conventional tunnel excavators or with the aid of a sectional cutting-machine. Exploitation is effected in synchronism with the production of the supporting layer and the supporting ring, respectively. However, it is delayed such that exploitation of the working face takes place under the protection of the supporting body. It may become necessary in this connection to split exploitation of the working face up into several portions and to spatially shift the exploitation unit. Any overcuts that are possibly required for the supply system of the slotting-machine may be effected together with exploitation of the working face.
Exploitation of the working face, in the tunnel driving direction, may be effected as far as shortly before or right down to the front edge of the supporting layer produced (FIG. 5 A). Yet, depending on the ground for instance, it may also be driven a little further (FIG. 5 B), however not any further than 40% of the working width of the slot producing device 14 . In this case it will not be necessary to supply the slot producing machine 14 through an excavation. In fact, its end on the side of the working face then is visible and more or less freely accessible.
In the following, a device is described that may be used for implementation of individual ones of the above-mentioned method steps. It may be designed as a single unit or as a plurality of units which are working more or less independently of one another. With reference to FIG. 6 a first embodiment is described.
The device comprises several components: On its front side it carries the material removing tool 61 . Behind it there is a means 62 by which the removed material is hauled from the slot. Furthermore, it comprises a moving means 68 , 71 , a concreting means 64 , if required, and a control unit 65 .
Preferably, the material removing tool 61 is connected to the machine 14 for control of its mobility such that it can be swivelled or moved in all directions as required for producing the slot. If necessary, the device may comprise a sealing means 66 which separates the slot producing area from the area of the moving means and of slot filling.
The tool can be designed such that it is capable of producing a slot 15 which has a greater thickness over the entire slot width or a portion thereof than the supporting layer 13 to be produced. Owing to the overcut thus formed as compared to the supporting layer in the previous turn, an access 81 from the slot to the space in front of the working face is produced. Through this access, the supply of the machine with media, the discharge of the exploited material and a linkage to an arm 72 is facilitated.
By a suitable choice of the tool, for instance a screw, the exploited material can be transported into the space in front of the working face directly—through the access 81 produced by means of the overcut. If the overcut is located in the center of the exploiting-tools, for instance, it produces a groove in the direction of the interior of the tunnel for passing the supply lines therethrough.
Alternatively, the access may also be produced by means of a tool provided on the arm 72 .
The advancing force for the tool 61 is transmitted via the linking means 67 on the tool. The reaction force must be taken over by that unit that also enables movement of the machine. A preferred embodiment includes receiving the reaction force and moving the machine as a whole by means of an arm 72 (FIGS. 7A-7B) which extends from a carrier unit 73 that stands in front of the working face and is moved. Via this arm 72 also the supply lines from and to the machine can be guided into the slot. Linking the tool unit 14 to the arm 72 allows a movement in all dimensional directions, independently of the movement of the carrier unit 73 .
The device may comprise, either integrated or separate, a concreting means for filling the excavated slot 13 with concrete. In the following, the integrated embodiment is described. The concreting means 64 comprises a concreting plank 69 which separates the device from the slot that has already been filled with concrete. In order to avoid the forming of a composite between the concrete and the ground to be exploited late on, and also in order to facilitate an exploitation of the working face right into the area of the supporting layer that is just being formed, a formwork 70 may be trailed along the future inside of the supporting ring. This is shown schematically in FIG. 6 .
For introducing the concrete, a nozzle to which the components of the concrete are delivered in dry state is preferably provided. At the nozzle, water and additives, if required, are added.
The concreting means may also be a separately provided conventional means.
A preferred embodiment of the material removing tools 61 is a milling means, which may consist of several units. The units, disposed at—and pointing towards—the flanks of the machine, mill both at the front end and at the circumference. The mill pointing towards the already produced supporting ring ensures, by profiling the same, a good bond between the fresh and the set concrete. The milling head pointing in the tunnel driving direction can be displaced in this direction. This permits a widening of the slot. By varying the slot width in the course of one turn the traveling through curves or gradients or inclines of the tunnel is possible. At least one further mill, which only mills at the circumference, may also be displaced in the longitudinal direction of the tunnel and ensures, together with the two other ones, the material exploitation over the entire slot width required.
A further preferred embodiment of the material removing tools are two counter-rotating or upcut mills, the axes of rotation of which are located approximately radially of the tunnel axis. They offer the advantage that they generate minimal reaction forces transversely of the longitudinal direction of the machine whilst offering the possibility of simultaneously serving as a hauling means.
A further preferred embodiment is a screw. The latter equally is capable not only of exploiting but also of hauling. In a screw geometry, which, on the side pointing towards the existing tunnel, produces an overcut, the removed material can be hauled directly in front of the working face.
Further feasible embodiments are chain-driven, revolving cutting-tools, screws or discs. The material removing tool 61 is driven via a suitable drive (not shown), for example a hydraulic/electric motor disposed in the immediate vicinity of the tool.
The material removing tool produces a through-going processing front over its entire width. In operation, the tool width usually extends about parallel to the tunnel driving direction. On none of the sides the guiding means and the suspension of the tool protrude from this processing front. Therefore, although only in the lateral areas, the supply lines 67 are nevertheless flanged on from underneath (facing the interior of the tunnel in operation).
Discharge of the material can ensue with or without a transport medium. Preferred transport media are air and water. Possible mechanical transport means are brushes or screws.
In a further preferred embodiment, the counter-force is generated by the machine body 14 itself, which holds itself in the surrounding ground by suitable devices 68 . The inventive device, in this case, is mechanically decoupled from units in front of the work face. Merely the supply and discharge lines are still required. Holding can be accomplished via hydraulic presses or struts (anchors). Through use of a plurality of supporting members the advance of the machine can be decoupled from the advance of the tool. This allows for a continuous exploitation. From the braced base body of the device the tool 61 is advanced in the forward direction. This advancing can ensue via hydraulic, pneumatic or motordriven means.
Preferably, the machine is supported such that it does not impart a load on the working face 16 that would be apt to endanger the stability of the working face. It may rest laterally on the already finished supporting layer 13 and on the ground 11 , or find an anchoring in the ground in an upward or downward direction, or in the rear through abutting the already introduced concrete, or make use of a combination of the possibilities mentioned.
There also is possible an embodiment wherein the required advancing forces and the forces for moving the machine are applied in a combination of holding in the ground and linking from outside.
The machine is divided into several segments. These segments, assuming a machine height of about 200 mm, a slot thickness of 250 mm and a tunnel diameter of about 6000 mm, may have a length of up to 1000 mm. The processing width of the machine is about 1 m-2 m.
The advancing segment consists of at least two members that are coupled to one another with the aid of extension means 71 . By alternatingly anchoring and releasing the individual members the machine is moved forward in a screwlike manner.
The extension means 71 may, for example, be four hydraulic cylinders. Through extending the individual cylinders for different periods of time, the members of the advancing segment can be tilted towards one another. This facilitates travelling in every dimensional direction, particularly also along the tunnel circumference.
In the preferred embodiment with a separate driving means the production of an additional shaft in synchronism with production of the slot is feasible. The shaft extends parallel to the helix of the slot and is offset towards the tunnel axis. In this shaft the supply lines may run. This facilitates to a certain degree a separation of the preceding provision of the supporting means from exploitation of the working face.
The machine can be protected from the entry of material, particularly in the area of the moving means 68 , 71 . This is ensured, for example, with a cover with a shape and length that can be varied so as to adapt to the variation in length or the internal winding of the machine in the construction process, for instance by folding or in the form of a sheet which is fitted by means of a mechanism resembling a window-shade.
As carrier unit 73 a heavy crawler-type excavator basic unit may be used. If, on account of its heavy weight, the unit cannot stand on the still young bottom concrete, the bottom is filled with debris or muck after the slot has been produced.
The unit may be modified such that both the removing tool and, depending on the method, the loom of cables or the arm 72 for the slotting-machine 14 can be fitted.
In order for the carrier unit to be able to stand in any place in front of the working face 16 , and for the slotting-machine 14 and exploitation of the working face to be executed geometrically independently of one another, the removing tool ( 75 ) must be connectable to the slotting-machine alternatively on both sides of the arm ( 42 ).
On the carrier unit 73 a shotcrete means may be provided, with the aid of which a quick protection can be applied in the case of an inrush of water or a collapse of the working face.
Alternatively, a castor 81 may be provided as carrier unit, which is supported by the circumference of the existing tunnel. To this castor the arm 72 , which guides the machine and possibly advances it, is fixed. The arm can move over the entire circumference.
The castor consists of a steel structure 82 , mobile in the advancing direction and adapting to the respective tunnel section. This is achieved by means of steel sections of different radii, which are extended by means of extension units.
In the castor a platform 83 is provided, the position of which in the tunnel can be changed in all dimensional directions. On it, excavators or sectional cutting-machines can stand, which, with the aid of this extension unit, reach all areas concerned, even if large tunnel sections are to be made.
The castor can take over the function of the resistance of lining as long as the supporting material (for instance concrete), even if having set in the supporting layer 13 , has not yet reached its full carrying capacity.
As a reference for control of the machine, a groove can be produced in the concrete shell with the aid of a respective formwork. This groove, in the next turn, serves the machine as a point of reference.
When the slotting-machine 14 works independently of a carrier unit, it moves either through remote control or fully automatically. Remote control may e.g. be effected by a workman who stands in front of the work face, watches the working progress and moves the slotting-machine 14 on accordingly, via a line-borne or wireless remote control. For fully automatic travelling, a suitable navigation system must be provided, by means of which the slot machine 14 is able to spatially orient itself. As technical aids for the measuring and control technique inter alia gyroscopic devices, laser devices, optical structural elements for use of laser light, or also inclinometers may be used.
|
The present invention relates to a tunneling method starting from the working face in the driving direction, a bearing layer being laid as the working face progresses and then carried away together with the debris. The inventive system includes at the front an excavating tool capable of removing broken rock up to a certain width and a certain height, and an advancing device for moving forward and steering the system, and a control and setting device for controlling and regulating the operation of the excavating tool and the advancing device.
| 4
|
TECHNICAL FIELD
The present invention relates to a printing apparatus and is particularly concerned with thermal printing apparatus which receives tape holding cases housing a tape to be printed.
BACKGROUND ART
Printing apparatus of the general type with which the present invention is concerned are known. They operate with a supply of tape arranged to receive an image and a means for transferring the image onto the tape. In one known device, there is a tape holding case which holds a supply of image receiving tape and a supply of an image transfer ribbon, the image receiving tape and the transfer ribbon being passed in overlap through a printing zone of the printing device. At the print zone, a thermal print head cooperates with a platen to transfer an image from the transfer ribbon to the tape. A printing device operating with a tape holding case of this type is described for example in EP-A-0267890 (Varitronics, Inc.). Other printing devices have been made in which letters are transferred to an image receiving tape by a dry lettering or dry film impression process. In all of these printing devices, the construction of the image receiving tape is substantially the same. That is, it comprises an upper layer for receiving an image which is secured to a releasable backing layer by a layer of adhesive.
The upper layer can either receive an image on its top surface, its lower surface being secured to the releaseable backing layer by a layer of adhesive or alternatively the upper layer can be transparent and can receive an image on one of its faces printed as a mirror image so that it is viewed the correct way round through the other surface of the tape. In this case, a double sided adhesive layer can be secured to the upper layer, this double sided adhesive layer having a releaseable backing layer. This latter arrangement is described for example in EP-A-0322918 (Brother Kogyo Kabushiki Kaisha).
With such printing devices, it is important to be able to determine when the tape holding case used with the device has exhausted its supply of image receiving tape so that a new tape holding case can be inserted into the device. If the printing device is run with no image receiving tape there is a danger that the print head or platen will be damaged by overheating. Damage to the platen can also result if an image is transferred to it by the print head operating with no image receiving tape.
Furthermore, it is desirable for printing apparatus of this type to be able to operate with image receiving tapes of different widths. For this, the apparatus should include a way of identifying the width of tape within the tape holding case automatically so that the user does not have to concern himself with setting the apparatus for different tape widths. There is a danger if the user is called upon to set the tape width that the tape width will be incorrectly set.
The present invention seeks to provide a printing apparatus in which these problems are both overcome.
According to the present invention there is provided a printing device comprising a zone for receiving tape for printing so that said tape passes along a predetermined path in the printing device; an optical sensing arrangement comprising first and second optical sensing assemblies each comprising a light emitter and a light receiver arranged to receive light emitted from the light emitter, the optical sensing arrangement being located so that when there is no tape in said predetermined path the light receivers of the first and second assemblies receive light from their respective light emitters and when there is tape present in the predetermined path it obstructs light from at least one of said light emitters so preventing it from reaching its light receiver; and a controller for receiving signals from said light receivers and for controlling operation of the printing device in response to said signals.
The tape for printing is conveniently housed in a tape holding case. Tape holding cases for use with the printing device can be supplied holding tapes of respective differing widths. The tape holding cases have similar external dimensions for reception by said zone but are arranged to accommodate internally tapes of respective differing widths. In one embodiment of the present invention a tape holding case is provided with a tape guide arrangement comprising a plurality of sets of tape guides, each set fitting a particular tape width. Thus, only one type of tape holding case needs to be manufactured and can accommodate reels of tape of different widths as desired. The sets of guides are located to guide the tape in cooperation with the optical sensing assemblies. Where two tape holding cases are arranged to supply tape of different widths along said predetermined path with a common centre line the optical sensing arrangement can be such that the first optical sensing assembly is located below the second. With this arrangement, with a tape holding case holding a narrow tape it will obstruct light only in the second optical sensing assembly and not in the first. With a wide tape, however, both of the optical sensing assemblies will be affected. The controller thus receives signals informing it either that there is no tape (where neither of the light emitters is obstructed), or that there is narrow tape present (where only the second of the light emitters is obstructed) or that there is wide tape present (where both of the light emitters are obstructed).
More than two widths of tape can be taken into account by providing further optical sensing assemblies located suitably. In one particular arrangement, a tape holding case can be arranged to accommodate tape narrower than the narrow width tape already mentioned. Where this tape is centered about the centre line the optical sensing arrangement requires a third optical sensing assembly located above the second assembly so that only the third optical assembly is affected by the tape when present. In another arrangement, the narrower tape is located in a tape holding case so that its lower edge corresponds to the lower edge of the widest tape so that it obstructs only the first light emitter and not the second light emitter. Thus, a different combination of signals is then supplied to the controller to indicate that there is this narrow tape, namely that only the first light emitter is obstructed.
The invention also contemplates the combination of a printing device and a cooperable tape holding case. A tape holding case can be provided with a housing which accommodates the tape and which has an aperture for receiving the optical sensing arrangement.
Typical tape widths are 19 mm, 12 mm and 6 mm although it will readily be appreciated that different tape widths can be used with the present invention.
It will be appreciated that in practice tape holding cases will be manufactured holding a single reel of tape of a predetermined width. When this is inserted into the device the device is immediately informed through the controller of the width of tape which is present and can thus set itself to appropriate label composition parameters. Thus, a user is not required to input into the machine what tape width is being used.
Moreover, when the tape in a tape holding case runs out the device will be advised through the controller and operation will be inhibited to prevent damage to the print head and platen.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention and to show how the same may be carried into effect reference will now be made by way of example to the accompanying drawings in which:
FIG. 1 is a plan view showing two cassettes inserted into a printing device;
FIG. 2 is a plan view showing the upper cassette and the optical sensing arrangement in more detail;
FIG. 3 is a side view of one embodiment of the optical sensing device;
FIG. 3a is a side view of another embodiment of the optical sensing device; and
FIG. 4 is a plan view of the lower half of a cassette showing the tape guides.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows in plan view two cassettes arranged in a printing device. The upper cassette 2 contains a supply of image receiving tape which passes through a print zone 3 of the printer to an outlet 5 of the printer. The image receiving tape 4 comprises an upper layer for receiving a printed image on one of its surfaces and having its other surface coated with an adhesive layer to which is secured a releaseable backing layer. The cassette 2 has a recess 6 for accommodating a platen 8 of the printer. The platen 8 is mounted for rotation within a cage moulding 10.
The lower cassette 7 contains a thermal transfer ribbon which extends from a supply spool to a take-up spool within the cassette 7. The thermal transfer ribbon 12 extends through the print zone 3 in overlap with the image receiving tape 4. The cassette 7 has a recess 14 for receiving a print head 16 of the printer. The print head 16 is movable between an operative position, shown in FIG. 1, in which it is in contact with the platen and holds the thermal transfer ribbon 12 and the image receiving tape 4 in overlap between the print head and the platen and an inoperative position in which it is moved away from the platen to release the thermal transfer ribbon and image receiving tape. In the operative position, the platen is rotated to cause image receiving tape to be driven past the print head and the print head is controlled to print an image onto the image receiving tape by thermal transfer of ink from the ribbon 12. The print head is a conventional thermal print head having an array of pixels each of which can be thermally activated in accordance with the desired image to be printed.
FIG. 2 shows a plan view of the cassette 2 with the cover of the cassette housing having been removed. The supply of image receiving tape 4 takes the form of a reel 18 from which is fed along a tape path defined by a plurality of guide pins or guide rollers. A first guide pin 20 is located as the tape 4 leaves the reel 18. Second and third guide pins 22, 24 are located within the cassette housing to guide tape 4 through an optical sensing assembly 26 to be described in more detail hereinafter. A fourth guide pin 28 guides the tape 4 past an outlet of the optical sensing assembly 26 and a fifth guide pin 30 guides the tape 4 through the print zone 3 and thence to an outlet 32 of the cassette.
The optical sensing arrangement 26 comprises a housing 34 mounted on the printing device and containing a first support 41 which carries two light emitting diodes 42, 44. Arranged opposite the first support 41 is a second support 36 which carries two photo transistors 38, 40 located to receive light from the light emitting diodes 44 and 42 respectively.
Each light emitting diode and photo transmitter constitute an optical sensing assembly. As shown in FIG. 3 one optical assembly 38, 44 is arranged vertically below the other optical assembly 40, 42.
The cassette housing has an aperture 46 for receiving the supports 36 and 42 when the cassette is inserted into the printing device. The tape path in the cassette is such that when the cassette is loaded into the printing device the tape passes between the light emitting diodes and their respective photo transistors with the image receiving surface disposed vertically (i.e. perpendicular to the floor of the printing device).
As shown most clearly in FIG. 3, the optical assemblies 38, 44 and 40, 42 are spaced apart vertically to allow for the sensing of tapes of different widths. In FIG. 3, the centre line of tape is denoted by a dot-dash line and FIG. 3 thus illustrates tape 4, 4' of two different tape widths, w1 which is typically 12 mm and w2 which is typically 19 mm.
Signals from the photo transistors 38, 40 are fed from the optical sensing arrangement 26 to a controller 50 for controlling the printing device.
With no tape present in the path between the guide pins 22 and 24 through the optical sensing arrangement 26 light from each photo diode 42, 44 is sensed by its respective photo transistor 38, 40 which provide respective "0" signals to the controller 50 to indicate that there is no tape present. If a cassette holding tape 4 of the narrower width w1 is inserted, light from the upper of the two diodes 42 is prevented from reaching its corresponding photo transistor 40 while light from the lower diode 44 is unobstructed. This then provides respective "0" and "1" signals to the controller to indicate that narrow tape is present. If a cassette holding tape 4' of the wider width w2 is inserted, not only is light from the upper diode 42 obstructed but also light from the lower diode 44. This provides respective "1", "1" signals to the controller to indicate that wide tape is present.
When a cassette is inserted therefore the controller is notified automatically what width of tape is present and sets its criteria accordingly for the composition of labels. In use of the device when the tape runs Out the signals identifying "no tape present" are passed to the controller 50 to indicate that the device should cease to operate and the cassette requires replacement. In the preferred arrangement, this signal automatically inhibits further operation of the device, with the possibility of allowing the device to continue to operate for a short time to take into account the path length of tape from the optical sensing arrangement 26 through the print zone and through the outlet of the cassette 32. The controller can inhibit further operation of the device by preventing further rotation of the plates and/or terminating print signals to the print head. A light can be illuminated on the device to indicate no tape present.
Thus, the described arrangement provides a simple sensing assembly which not only indicates when tape has run out but also enables the device to be aware of the width of tape which is being used.
It will readily be appreciated that the described arrangement can be modified to take into account more than two different widths of tape. For example, to accommodate a further width w3, narrower than w1 and typically 6 mm could be done in one of two ways. This tape could be positioned about the centre line and a third diode 50 could be provided above the diode 42 to discriminate for this size, as shown in FIG. 3a. As an alternative, the narrow tape could be positioned with its lower edge corresponding to the lower edge of the wide tape of width w2 so that it affects only the lower of the two sensing assemblies 38, 44 and not the upper sensing assemblies 40, 42. The controller 50 would then be required to discriminate as to which photo transistors had been obstructed. A table showing the logic arrangement is set out below where 0 indicates unobstructed photo transistors and 1 indicates obstructed photo transistors.
______________________________________Top (40,42) 1 0 1 0Bottom (38,44) 0 1 1 0 12 mm 6 mm 19 mm Tape out______________________________________
Reference is now made to FIG. 4 which illustrates in plan view the lower part of the cassette. Reference numerals in FIG. 4 indicate like parts as in FIG. 3 but FIG. 4 shows in addition a modified guiding arrangement to replace the guide pins designated by reference numerals 22 and 24 in FIG. 2.
There is a plurality of guide elements designated by reference numerals 52, 54 (for guiding the tape as it enters the optical assembly 26) and 56, 58 (for guiding the tape as it leaves the optical assembly 26). Each guide element is constructed to have a vertical surface for guiding tape of a wide width and a vertical surface for guiding tape of a narrower width, the construction of the guide element being such that the tape of narrower width is automatically located against its guide surface. Taking the guide element 52 as an example, there is a guide surface 52a for guiding the tape 4 of wide width and a guide surface 52b for guiding tape of a narrower width. The guide element has a horizontal surface 52c for locating tape of a narrower width against the guide surface 52b. Each of the guide elements 52, 54, 56, 58 are similarly constructed. In this way, a common tape holding case can be manufactured to receive reels of different width tapes according to choice. It will be apparent that the guide elements can be modified so as to receive tapes of more than two widths.
Each tape guide element extends from a base of the tape holding case in a direction widthwise of the tape 4 and comprises two lateral tape guide surfaces 52a, 52b spaced apart in the direction of the tape width.
The base provides a support for a longitudinal edge of tape of a first width such that the centre line of said tape is located along a line spaced from the base. The tape guide elements provide respective support surfaces 52c, 56c for the longitudinal edge of tape of a second width whereby its centre line lies along the centre line of tape of said first width.
A top part is used to construct the tape holding case, the top fitting onto the lower part of the tape holding case to provide a secure unit. The tape holding case then has the same external dimensions whether it is holding tape of the first, second or third width. The optical sensing arrangement enables the width of tape to be ascertained.
|
A printing device comprises a zone for receiving tape for printing so that said tape passes along a predetermined path in the printing device; and an optical sensing arrangement comprising first and second optical sensing assemblies which enable an end of tape state to be detected and also allow discrimination between tapes of different widths.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. §119 of German Patent Application No. DE 10 2011 009 092.4, filed Jan. 21, 2011, the disclosure of which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a rotor box for a ground milling machine, having at least one milling roller (or milling rotor) accommodated thereon, which is provided for loosening and/or removing soil material. Furthermore, the present invention relates to a ground milling machine, such as a road milling machine or a trench milling machine in particular, which has at least one such rotor box.
BACKGROUND OF THE INVENTION
[0003] At least partially housing a milling roller on a ground milling machine through a so-called rotor box is known from the prior art. Reference is made in this regard to EP 1 070 788 A2, for example.
[0004] Such a rotor box has an ejection opening, through which the soil material (milled material) milled by the milling roller can be ejected from the interior onto a conveyor belt to transport the milled material away, for example. This ejection opening typically does not extend over the entire axial length of the milling roller, so that the milled material must be conveyed in the interior or in the inner chamber of the rotor box out of the side areas to the ejection opening, for example. This is performed in the prior art by arranging the milling cutters in screw-shaped or spiraling (coiled) rows on the milling roller, as known from DE 698 24 340 T2, for example. However, it is disadvantageous in this case that strong wear occurs on the milling roller and in particular on the milling cutters and the milling cutter holders, as well as on the rotor box itself, due to this conveyance of the milled material in the interior of the rotor box, in particular if a large amount of material is present in the rotor box.
SUMMARY OF THE INVENTION
[0005] The present invention is therefore based on the object of improving the transport of milled material in the interior of the rotor box to the ejection opening and thus reducing the wear in particular.
[0006] The rotor box according to one embodiment of the present invention for a ground milling machine comprises at least one milling roller, which is at least partially accommodated therein, for loosening and/or removing soil material and an ejection opening that allows for the transport of the milling material out of the interior of the rotor box. It is provided that at least one guide device is arranged in the interior of the rotor box, which, in cooperation with the rotating milling roller, causes conveyance of the loosened milled material in the axial direction of the milling roller towards the ejection opening or at least supports such a conveyance. A purpose of the present invention is to achieve an improved milling material transport with at least one guide device in addition to the rotary movement of the milling drum.
[0007] Milled material is understood in the scope of the present invention as the soil material which is pulverized and removed by the engagement of the milling cutters in the soil material. The at least one guide device is used as a passive device for conveying or transporting the loosened milled material with the predominant goal of conveying the milled material in an axial direction of the milling roller to the ejection opening of the rotor box, the energy required for the conveyance being provided by the rotating milling roller. The guide device is advantageously stationary relative to the rotor box and fixedly connected to the rotor box.
[0008] The rotor box according to one embodiment of the present invention has many advantages. For example, one advantage is that less wear occurs on the milling roller and on the rotor box or its walls. A further advantage is that fundamentally, more milled material can be moved in the rotor box according to one embodiment of the present invention due to the improved milling material transport, whereby the milling performance of the ground milling machine is increased. A further advantage is that because of the improved conveyance of the milled material relative to the milling roller, less motor power is required for driving the milling roller (reduction of the drive torque).
[0009] The guide device is preferably formed by a plurality of guide plates, which protrude from the inner wall of the rotor box in the direction of the milling roller. Multiple guide devices can also be provided within the scope of the present invention, which are each formed from a plurality of guide plates. A guide plate is a planar structural element, which is implemented as flat in particular and whose thickness is low in relation to the area extension. A guide plate is preferably, but not necessarily, formed from a sheet-metal material, as are the housing parts of the rotor box.
[0010] It can preferably be provided that the guide plates are arranged diagonally in relation to the axial direction of the milling roller. This is to be understood to mean that the plane of a guide plate intersects the longitudinal axis or the rotational axis of the milling roller at an acute angle, as described in greater detail hereafter in connection with the figures. Ideally, the diagonal arrangement is oriented towards the ejection opening (with respect to the rotational movement of the milling drum).
[0011] It has proven to be advantageous if the guide plates, i.e., at least some and preferably all of the guide plates belonging to the plurality, are arranged surface-parallel and having equal spacing to one another.
[0012] According to another embodiment of the present invention, it is provided that the guide plates, i.e., at least some and preferably all of the guide plates belonging to the plurality, are implemented having the same or identical contour in a side view.
[0013] It can preferably be provided that the guide plates, i.e., at least some and preferably all of the guide plates belonging to the plurality, are at least coarsely adapted to the contour of the milling rotor or to the shape of the cutting circle in the side view toward the milling rotor (view in axial direction). For this purpose, for example, the guide plates can have at least one curved contour section, in particular in the form of a circular arc, facing toward the milling roller. This curved or concave contour section is used as a recess for the milling roller, so that the guide plates can be implemented having a comparatively large area in spite of the cramped space conditions in the interior of the rotor box. It can also preferably be provided that the guide plates have at least one linear contour section facing toward the milling roller in the side view. In one embodiment, it is ideal if at least two linear contour sections are provided in the guide plate, the two linear contour sections also being adapted to the milling roller or the cutting circle of the milling roller in their angle to one another. Of course, it is also possible to provide more than two linear contour sections in the above-described way on the guide plate.
[0014] According to another embodiment of the present invention, it is provided that the guide plates, i.e., at least some and preferably all of the guide plates belonging to the plurality, are arranged in two groups, the guide plates in the first group having an opposite orientation to the guide plates in the second group. Orientation is understood as the direction (positive angle or negative angle) of the surface orientation with respect to the axial direction or with respect to the rotational axis of the milling roller. Through the proposed measure, conveyance of the milled material in opposing axial directions can be obtained, as described in greater detail hereafter in connection with the figures. The two groups are preferably both oriented in the direction of the ejection opening. Accordingly, the two groups of guide plates move the milling material towards each other inside the rotor box with regard to the axial direction.
[0015] It can preferably be provided that the guide plates, i.e., at least some and preferably all of the guide plates belonging to the plurality, are arranged on the inner wall of the rotor box opposite to the ejection opening in relation to the milling roller. This is approximately the area between the rotor box cover and the rotor box rear wall.
[0016] According to another embodiment of the present invention, it is provided that the milling roller accommodated in the rotor box has at least one conveyor device in addition to the milling cutters, which also causes a conveyance of the detached milled material in the axial direction of the milling roller or at least supports such a conveyance when the milling rotor is rotating. The at least one conveyer device is preferably a conveyer scoop having a conveyer surface. Additionally or alternatively, the at least one conveyor device is preferably also arranged on the outer shell of the milling roller main body, like the milling cutters.
[0017] This refinement is based on the concept of a task division between the milling cutters, which are to cause the loosening and/or the removal of the soil material, and the at least one conveyor device, which is to cause or at least support the conveyance of the milled material, preferably in an axial direction of the milling roller. Support is to be understood in particular to mean that the conveyance of the milled material in the axial direction of the rotating milling roller occurs in cooperation with the milling cutters and/or the milling cutter holders. In combination with the guide device or the guide plates arranged in the interior of the rotor box, as a result, outstanding conveyance of the milled material in the interior of the rotor box can be achieved.
[0018] Furthermore, the following advantages result through this refinement. On the one hand, the milling cutters and the milling cutter holders are relieved, which results in significantly reduced wear. Furthermore, the conveyance of the loosened milled material relative to the milling roller is improved, whereby the milling performance can be increased further. The improved conveyance of the milled material relative to the milling roller also has the result, however, that the motor power required for driving the milling roller can be reduced still further (reduction of the drive torque). This is not an exhaustive list.
[0019] It is preferably provided that such a conveyor device is a conveyor scoop having at least one conveyor surface, which is arranged on the outer shell of the roller main body. Such a conveyor scoop primarily has a conveying function or transport function for the milled material. This is not opposed by the fact that the conveyor scoop can also have a milling function, for example, through a milling cutter additionally fastened thereon, which is secondary in relation to the conveyance function, however. Ideally, the conveying function pertains to the transport of the milling material in the rotary direction of the milling drum and, at the same time, in the axial direction of the milling drum towards the ejection opening.
[0020] The conveyor scoop is preferably arranged protruding outward on the outer shell of the roller main body, in particular in a radial direction. A conveyor scoop is preferably fixedly connected to the milling drum main body, preferably welded or screwed onto the milling drum main body. It is particularly preferably provided that the conveyor scoop is replaceably arranged on the roller main body. This replaceability can be produced similarly to the replaceable milling cutters by a conveyor scoop quick-change tool holder. Furthermore, a conveyor scoop can be implemented in one piece or multiple parts. A conveyor scoop (or at least its scoop blade) is particularly a forged product made of a wear resistant metal alloy.
[0021] According to another embodiment of the present invention, a plurality of conveyor scoops is provided, which are arranged distributed in the peripheral direction and/or in the axial direction on the outer shell of the roller main body. Through a plurality of conveyor scoops, the conveyance of the milled material can be significantly improved and/or adapted to special requirements in individual areas or longitudinal sections of the milling roller. Thus, for example, the conveyance can be set to be stronger in the middle section of the milling roller and/or close to the ejection opening than on the axial outer sections.
[0022] The concrete arrangement of the conveyor scoops can also be varied in various ways. Outstanding operating results are obtained, however, if the conveyor surfaces of the conveyor scoops have a different and in particular an opposite orientation in one defined longitudinal section of the milling roller than the conveyor surfaces of the remaining conveyor scoops. An orientation of the conveyor surface is understood in particular as its direction (or the direction of a compensation surface in the case of a curved or concave surface). In this way, a different axial conveyance direction for the milled material can be caused in the associated longitudinal sections, as described in greater detail hereafter in connection with the figures.
[0023] In addition, it is preferably provided that the conveyor scoops having identical or different orientation of the conveyor surface are arranged between adjacent milling cutter rows. This is described in greater detail hereafter in connection with the figures.
[0024] Furthermore, it can preferably be provided that at least one conveyor scoop has a conveyor surface which is oriented parallel to the axial direction of the milling roller. Alternatively and/or additionally, it is provided that at least one conveyor scoop has a conveyor surface which is oriented diagonally (i.e., in particular at an acute angle) to the axial direction of the milling roller.
[0025] According to another embodiment of the present invention, it is provided that at least one conveyor scoop is also implemented as a thrower. A thrower has the function of throwing off the milled material in the radial direction from the milling roller, in order to eject it through the ejection opening in the rotor box, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The present invention is described in greater detail hereafter on the basis of the figures. In the schematic figures:
[0027] FIG. 1 shows a top view of a rotor box according to the present invention looking partially into the interior;
[0028] FIG. 2 shows a sectional view through the rotor box of FIG. 1 , according to the section line B-B indicated in FIG. 1 ;
[0029] FIG. 3 shows an alternative embodiment of a rotor box in a sectional view, according to the section line B-B indicated in FIG. 1 ;
[0030] FIG. 4 shows various possible embodiments for the guide plates arranged in the rotor box of FIG. 2 or FIG. 3 ;
[0031] FIG. 5 shows a top view of a milling roller, which is preferably used in the rotor box of FIG. 1 ;
[0032] FIG. 6 shows a top view of another milling roller, which is preferably used in the rotor box of FIG. 1 ;
[0033] FIG. 7 shows a top view of a further milling roller, which is particularly preferably used in the rotor box of FIG. 1 ; and
[0034] FIG. 8 shows a perspective view of a conveyor scoop, which is arranged on a milling roller according to FIGS. 3 to 4 .
DETAILED DESCRIPTION
[0035] FIG. 1 shows a top view of a rotor box 100 . The rotor box cover 110 is shown partially cut away, in order to expose the view into the interior. A milling roller 10 is arranged in the interior of the rotor box 100 . The milling roller 10 has a roller main body 12 , on whose outer shell a plurality of milling cutters (not shown in detail) is arranged. The rotational axis of the milling roller 10 is indicated by L, via which the axial direction of the milling roller is also indicated. The external diameter of the milling roller 10 formed by the milling cutter tips is indicated by 11 , which forms a milling circle 11 ′ in milling operation, as indicated in FIG. 2 . The rotor box 100 has a wall formed from a sheet metal material, which comprises a rotor box cover 110 , a rotor box rear wall (back wall) 120 , and an ejector 130 having an ejection opening 131 . The ejection opening is at least partially arranged within a rotor box front wall 121 . The side wall is identified by 140 .
[0036] FIG. 2 shows a section through the rotor box 100 according to section line B-B indicated in FIG. 1 , the section plane E extending in the area of the ejection opening 131 . The milling circle (cutter engagement circle) of the milling cutters fastened on the outer shell of the roller main body 12 is identified by 11 ′. In milling operation, the milling roller 10 rotates in the indicated direction R, the milling cutters loosening the soil material (not shown) to be removed and transporting it as milled material. A fraction of the transported milled material is ejected through the ejection opening 131 , which is indicated by the arrow A. So-called throwers can be arranged on the milling roller 10 as a support for this purpose.
[0037] However, the soil material (milled material) removed by the milling roller 10 in the side sections has to be conveyed inside the rotor box 100 to the ejector 130 and the ejection opening 131 , respectively. This is caused in a known way by a spiral arrangement of the milling cutters on the outer shell of the roller main body 12 , as described in greater detail hereafter, which results in strong wear in particular on the milling cutters and the milling cutter holders, however. According to one aspect of the present invention, it is therefore provided that a plurality of planar guide plates 150 a and 150 b, which protrude from the inner wall of the rotor box 100 in the direction of the milling roller 10 , is arranged on the rotor box 100 in the interior of the rotor box 100 , whereby in cooperation with the rotating milling roller 10 , a conveyance of the loosened milled material in the axial direction L of the milling roller 10 towards the ejection opening 131 is caused or at least supported. In this way, the wear on the milling cutters and the milling cutter holders can be significantly reduced. Furthermore, the milling performance can be increased, as already described above. Depending on the embodiment, the guide plates 150 a and 150 b can also be spatially shaped, i.e., not planar. The guide plates 150 a and 150 b can additionally be laterally braced.
[0038] The guide plates 150 a and 150 b are arranged on the inner wall opposite to the ejection opening 131 and are preferably fastened, in particular fixedly welded, on both the rotor box rear wall 120 and also on the rotor box cover 110 , as is shown in FIG. 2 . The rigidity of the rotor box design is also increased in this way. The guide plates 150 a and 150 b have a vertical orientation, for example. Alternatively, the guide plates 150 a and 150 b can also be arranged inclined in the interior.
[0039] The guide plates 150 a and 150 b are arranged diagonally in relation to the longitudinal axis L of the milling roller 10 (which corresponds to the rotational axis). The angle between the plane of a guide plate 150 b and the longitudinal axis L is indicated by a. The guide plates 150 a are arranged at the same angle, but having opposite orientation. Furthermore, as can be inferred from FIG. 2 , the guide plates 150 a (this is also true for the guide plates 150 b ) have a concave contour section 151 facing toward the milling roller 10 , which is adapted to the outer contour ( 11 ′) of the milling roller 10 formed by the milling cutter tips. A scraping effect for milled material adhering to the milling roller 10 can be caused by the implementation and arrangement of the guide plates 150 a or 150 b shown.
[0040] In one particularly preferred embodiment, the guide plates are arranged in two groups, as shown in FIG. 1 , the guide plates 150 a in the first group having an opposite orientation to the guide plates 150 b in the second group. In this way, a conveyance of the milled material in opposite axial directions, concretely towards each other, can be caused, which is indicated by the arrows IIa and IIb. In particular, the milled material can be conveyed in a targeted manner from both side sections of the milling roller 10 in the direction of the plane E (plane of the ejection opening) towards the ejection opening 131 that is located axially spaced with regard to the side walls 140 . Within a group, the guide plates 150 a or 150 b are arranged surface-parallel and having equal spacing to one another.
[0041] FIG. 3 shows an alternative possible embodiment for a rotor box 100 , in which the rotor box cover 110 and the transition to the rotor box rear wall 120 are formed by flat plates. The arrangement of the guide plates 150 a and 150 b is essentially unchanged.
[0042] FIG. 4 shows, in multiple partial figures a to f, various possible embodiments for the guide plates 150 a and 150 b in a side view corresponding to FIG. 2 or FIG. 3 . A differentiating feature of the various guide plates is the contour facing toward the milling roller 10 (or the milling circle 11 ′). The possible embodiments shown in FIG. 4 are in no way exhaustive but rather are to illustrate the different design possibilities. In addition to tapered embodiments oriented toward the milling roller 10 (or the milling circle 11 ′), as shown in FIGS. 4 c and 4 d , for example, it is also possible to adapt the contour of the guide plates 150 a/b facing toward the milling circle 11 ′ to the rounded shape of the cutting or milling circle 11 ′. The coarsest shape of the adaptation is achieved by a linear implementation, which extends diagonally toward the circumference of the milling circle 11 ′, of the contour of the guide plates 150 a/b facing toward the milling circle, as indicated in FIG. 4 b , for example. The extent of the adaptation can be improved by contours, which have at least two linear contour sections. Such embodiments are shown in FIGS. 4 e and 4 f , for example. Alternatively, the contour of the guide plates 150 a/b facing toward the milling circle 11 ′ can also be implemented as rounded, for example, so as to be adapted to the rounding of the milling circle 11 ′, as illustrated in greater detail in FIG. 4 a.
[0043] Milling rollers 10 are described hereafter in connection with FIGS. 5 to 7 , which are preferably used in a rotor box 100 according to the present invention and which advantageously extend the concept of the present invention.
[0044] FIG. 5 shows a first exemplary embodiment of such a milling roller 10 in a schematic top view. The rotational axis of the milling roller 10 (milling drum) is indicated by L, via which the axial direction of the cylindrical milling roller 10 is also indicated. The rotational direction is indicated by R. A plurality of milling rollers is fastened in a spiral arrangement on the outer shell of the roller main body 12 of the milling roller 10 in a known way. The spiral arrangement line is indicated by 13 . The milling cutters are not shown in detail. The external diameter of the milling roller 10 , which is formed by the milling cutter tips, is indicated by 11 , which forms the milling circle 11 ′ (see FIG. 2 ) in milling operation.
[0045] Furthermore, multiple conveyor scoops 20 , which are shown in simplified form as rectangles, are arranged on the outer shell of the roller main body 12 of the milling roller 10 between the adjacent milling cutter rows, which result through the spiral arrangement of the milling cutters. The conveyor scoops 20 protrude outward and in particular radially outward from the roller main body 12 , but typically do not protrude beyond the milling cutter tips (contour 11 ).
[0046] Each conveyor scoop 20 has one conveyor surface 21 . By means of the conveyor surface 21 , in milling operation, the milled material detached by the milling cutters from the soil material to be processed is initially moved in the peripheral direction, according to arrow I. A conveyance of the milled material in the axial direction L results, according to the arrow II, from the superposition of this movement in the peripheral direction with the rotational movement of the milling cutters arranged in a spiral (because of the milling roller rotation). An advantage resulting from the conveyor scoops 20 in relation to the solutions known from the prior art is lower wear on the milling cutters and the milling cutter holders.
[0047] FIG. 6 shows a second exemplary embodiment of such a milling roller. In contrast to the first exemplary embodiment of FIG. 1 , the conveyor scoops 20 or their conveyor surfaces 21 are oriented diagonally to the axial direction L of the milling roller 10 . In this way, the conveyance of the milled material in the axial direction L, especially towards the ejection opening 131 , can be improved.
[0048] FIG. 7 shows a third exemplary embodiment of such a milling roller. In contrast to the first exemplary embodiment of FIG. 1 and the second exemplary embodiment of FIG. 2 , the milling cutters are arranged in two opposing spirals, which intersect in axial direction in the plane E that runs through the ejection opening 131 . This is preferably the plane of the ejection opening 131 of the rotor box 100 , as described above. The conveyor scoops 20 a (according to the illustration in the upper section) have a different orientation (direction) than the conveyor scoops 20 b (according to the illustration in the lower section). As a result, in the sections separated by the plane E, an opposing conveyance of the milled material is caused, which is indicated by the arrows IIa and IIb. In this way, for example, the milled material can be conveyed from both side sections in a targeted manner in the direction of the plane E (plane of the ejection opening). In particular, additional throwers can be arranged in the plane Eon the main body 12 of the milling roller 10 , which eject the milled material through the ejection opening 131 in the rotor box 100 .
[0049] FIG. 8 schematically shows an exemplary embodiment of a conveyor scoop 20 in a perspective view looking toward the conveyor surface 21 . It is preferably provided that the conveyor surface 21 is implemented on a separate and in particular replaceable scoop blade 22 , as shown. A quick-change tool holder is identified by 23 .
[0050] The features described above can also be combined with one another in embodiments other than the embodiments shown in the figures and described accordingly, if no technical contradiction results therefrom.
[0051] While the present invention has been illustrated by description of various embodiments and while those embodiments have been described in considerable detail, it is not the intention of Applicants to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and modifications will readily appear to those skilled in the art. The present invention in its broader aspects is therefore not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of Applicants' invention.
|
The present invention relates to a rotor box for a ground milling machine, in particular for a road milling machine or a trench milling machine, having at least one milling roller accommodated therein for loosening and/or removing soil material. It is provided that at least one guide device is arranged in the interior of the rotor box, which, in cooperation with the rotating milling roller causes a conveyance of the loosened milled material in the axial direction (L) of the milling roller or at least supports such a conveyance. The present invention also relates to a ground milling machine, in particular a road milling machine or trench milling machine, which has at least one such rotor box.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/275,565, filed Mar. 14, 2001.
FIELD OF THE INVENTION
[0002] This invention is directed to improving the adhesion of nylon coatings on substrates of nylon and polyester. More specifically this invention is directed to the use of select formaldehyde resins with high imino content or partially alkylated or non-alkylated derivatives thereof to improve the adhesion of mixed nylon polymers to filaments, films, parts and the like made from nylons and polyesters.
BACKGROUND OF THE INVENTION
[0003] Nylon “multi-polymers” are nylons made from a mixture of nylon forming monomers such that the nylon polymer contains a mixture of at least two types of nylon structural units. These types of nylons are sold commercially for a variety of coatings and adhesive applications. Generally these nylons are readily soluble in organic solvents and are generally applied as solutions. See for example brochures entitled “Elvamide® Nylon Multipolymer Resins, Properties and Uses” (September 1977) and “Elvamide® Nylon Multipolymer Resins for Thread Bonding” (October 1977), both published by E. I. DuPont de Nemours and Company, Inc.
[0004] Typically, sewing threads are coated with polymeric materials (and with lubricants added in most cases) to protect them from abrasion during the sewing operation. Furthermore, with twisted multi-filament sewing threads the polymeric coatings (also referred to as thread bonding) also prevent fraying and unraveling (untwisting) of the individual filaments. See generally, the December 1990 DuPont brochure and Kohan, M. I., “Nylon Plastics Handbook” Hansen/Gardner Publications, Inc. (1995) pages 283-290.
[0005] Nylon multi-polymers have been used for thread bonding applications for several decades. However, there is increasing demand for improved adhesion of the coating to the thread, as for example in highly demanding modern applications. This is also of paramount importance for applications relying upon tightly woven fabric, for example in luggage and automotive air bags, leather, and the like. In such applications abrasion of the thread is high and the operating needle temperature is much higher compared to more loosely woven fabric applications such as those used in apparel. The poor adhesion of coatings results in a ‘snake skin” effect where the coating comes off the surface of the thread. This results in loose coating material that jams the needle requiring stoppage of the operation. Further, poor aesthetics are associated with loose coating material as can be seen on inspection of the surface of the thread.
[0006] In the case of sewing threads and fabrics, nylon copolymers, terpolymers, and higher multi-polymers are used for coatings applications. These polymers are usually soluble in organic solvents, especially alcohols. The nylon coating is typically applied by dipping the thread in a solution of the nylon multi-polymer and then subsequently passing the thread through a drying chamber and then to a fusing chamber generally at a temperature above the melting point of the nylon mixed polymer. Melting of the nylon multi-polymer coating on the thread promotes adhesion. Nylon mixed polymers are generally favored for this use because of their toughness, good abrasion resistance, and ready solubility in solvents. For more information on these procedures and the benefits associated with nylon mixed polymers, see the Elvamide® (October 1977) brochure and the “Nylon Plastics Handbook” mentioned above.
[0007] The brochures mentioned above describe the ability of thermosetting resins such as epoxy, phenol-formaldehyde, and melamine-formaldehyde to cross-link nylon multi-polymers and improve the adhesion of the coating. The nylon multi-polymer reacts with these thermosetting resins to form thermoset-thermoplastic compositions.
[0008] U.S. Pat. No. 4,992,515 describes the use of Cymel® 1135 available from Cytek Industries, Inc., a fully alkylated melamine-formaldehyde resin, and strong acid catalyst to cross-link nylon 6/66/69, nylon 6/66/610, and nylon 6/66/612 terpolymers. The extent of cross-linking achieved was measured by the insolubility in the original solvent of the coating material after cross-linking. The cross-linked nylon coating becomes insoluble in the solvent. However, no data was provided as to how much improvement in adhesion and resistance to unraveling were achieved.
[0009] Various types and re-activities of formaldehyde derived cross-linking agents are disclosed in a brochure entitled “High Solids Amino Crosslinking Agents” (September 1994) available from Cytec. For example, Cymel® 325 used in several examples described below has free formaldehyde of 1.0 weight percent. Other grades of Cymel® can contain up to 3.5 weight percent free formaldehyde and are useful in the practice of the instant invention. These and other cross-linking agents are prepared by the reaction of amine functionalities with formaldehyde resulting in the replacement of the hydrogen on the amine functionality by a hydroxymethyl group. The hydroxymethy function is reacted with an alcohol to convert the hydroxy function to an alkoxy. Many classes of these crosslinking agents are possible depending on the extent of reaction. For example, there are commercially available types in melamine-formaldehyde cross-linking resins. Partial reaction of the amino functionalities in melamine (Structure 1 below)
[0010] where only some of the hydrogens have been replaced by the hydroxymethyl groups. Alkylation reaction of Structure 2 with an alcohol results in the conversion of the hydroxy group to alkoxy group as shown in Structure 3.
[0011] Melamine-formaldehyde resins containing the type of functionality as in Structure 3 are classified as high imino-type resins. Complete replacement reaction of melamine with formaldehyde and subsequent partial alkylation results in Structure 4.
[0012] Again resins containing this type of functionality are classified as partially alkylated. If the reaction with alcohol is allowed to reach completion the fully alkylated derivative (Structure 5)
[0013] is obtained. Those having skill in the art will readily appreciate that different classes of functionalities (eg, amino or alkoxy groups) may be designed into the molecule. Each class is chemically distinct and has different characteristics and re-activities. The fully alkylated resins such as Cymel® 1135 require catalysis by strong acids to initiate their reaction.
[0014] There is a longstanding need for a technique to improve the overall adhesion of nylon coatings to substrates of nylon and polyester. Improvements in such adhesion will promote better aesthetic qualities to the article formed, and also provide an economic benefit in that less material is rejected as nonconforming for the intended final product.
[0015] An object of the instant invention is to develop a processing technique and coating solutions to improve the adhesion of nylon coatings to nylons, polyesters, and mixtures thereof. This development applies not only to threads but in general to any substrates where such adhesion is desirable. A further object of the instant invention is to provide such techniques and solutions that are readily adaptable and useful for a variety of applications including monofilaments, multifilaments, films, tubings, shaped parts and the like. A feature of the present invention is the durability of the adhesive bond itself making it suitable for rigorous applications in which the material is extensively handled and manipulated. An advantage of the present invention is that the procedure may utilize any of a variety of solvents. These and other objects, features and advantages of the invention will become better understood upon having reference to the following descriptions of the invention.
SUMMARY OF THE INVENTION
[0016] Coating solutions to promote the adhesion of polyamides to substrates of polyamides, polyesters or mixtures thereof are disclosed herein. These solutions comprise:
[0017] (a) polyamide having a solubility of at least 0.5 weight percent in select organic solvents, and
[0018] (b) 1 to 100 weight percent based on the weight of the polyamide of high imino, partially alkylated or non-alkylated formaldehyde resins selected from the group consisting of melamine-formaldehyde, glycoluril-formaldehyde, benzoguanamine-formaldehyde, and mixtures thereof.
[0019] Optionally, 0-20 weight percent based on the weight of the formaldehyde resin of a catalyst may be added. Additionally, fully alkylated melamine-formaldehyde, glycoluril-formaldehyde, or benzoguanamine-formaldehyde resins may be added. The resins (b) function as adhesion promoters. The resins (b) are preferably incorporated in the range of 1-40 weight percent (most preferably 1-20 weight percent) based on the weight of the polyamide.
[0020] There are also disclosed herein processes for the coating of these substrates with the coating solutions of the invention. Such processes are readily appreciated by those having skill in the art. See for example the thread coating procedures described herein.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Nylons suitable as coating materials for purposes of the instant invention are polyamides derived from a lactam containing 6-12 carbon atoms, polyamides derived from 2-12 carbon diamines and 6-12 carbon diacids , polyamides derived from polypropylene glycol diamine or polyethylene glycol diamine and 6-12 carbon atom diacids and mixed polymers of the aforementioned polyamides with the proviso that these polyamides must have a solubility of at least 0.5 weight percent in alcohols, phenols, cresols, or mixtures of these solvents. . Preferably the polyamide suitable as coating material is a multi-polymer such as 6/66 copolymer or 6/66/X where X is a polyamide derived from lactam containing 7-12 carbon atoms or polyamide derived from 2-12 carbon diamines and 6-12 carbon diacids.
[0022] Suitable solvents of the instant invention are methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, furfuryl alcohol, benzyl alcohol, phenols, and m-cresols or combinations of these solvents. The selected solvent or combination of solvents may also contain water. Additionally, chlorinated solvents may be added as diluent. The selection of suitable solvent will also depend on several factors as is appreciated by those of skill in the art, such as geometry of the substrate, thickness of the article, and the like.
[0023] Examples of polyamides suitable as substrates herein for mono-filaments, multi-filaments, films, or tubings are those derived from 4-12 carbon diamines and 6-12 carbon diacids, lactams with 6-12 carbon atoms and mixed polymers of the aforementioned monomers. Examples of polyesters suitable for mono-filaments, multi-filaments, films, or tubings are polyethylene terephthalate, polypropylene terephthalate, or polybutyleneterephthalate, and their copolymers. It is recognized by those familiar with the art that adhesion and compatibility between polymers are favorable when the two polymers are of the same class or type ie polar polymers will tend to have better adhesion with other polar polymers. Thus, nylon is inherently more adherent to other nylons than to polyesters.
[0024] The melamine-formaldehyde resins suitable for these inventions are those that contain imino and hydroxymethyl moieties such as Cymel® 325, 1158, 385, 1172, and 1123. These are commercial grades of materials available from Cytek Industries, Inc. The melamine-formaldehyde resins, with or without the catalyst, preferably is added to the nylon multi-polymer solution and applied to the substrate as a single solution. However, with comparable effectiveness, the melamine-formaldehyde resins, with or without the catalyst, can be pre-coated to the substrate.
[0025] Suitable catalysts are inorganic acids such as phosphoric acid, organic acids such as p-toluenesulfonic acid, acetic acid, oxalic acid, and phthalic acid.
[0026] Materials other than threads such as mono-filaments, tubings, fabrics, films and other extruded or molded parts, in many cases, also could be coated with nylon polymer to enhance surface properties. These properties include for example abrasion resistance, barrier properties or the modification of the surface of a polymer such as polyester to make the surface more polar for a subsequent operations where the modified surface may be more amenable.
[0027] Articles to which the instant coating solutions have been applied are also disclosed and claimed herein. A coated article comprising a substrate of polyamides, polyesters, or mixtures thereof is first provided. Then a coating solution is applied thereto to form a precoated substrate. The coating solution comprises at least 0.5 weight percent of high imino, partially alkylated, or non-alkylated formaldehyde resins selected from the group consisting of melamine-formaldehyde, glycoluril-formaledhyde, benzoguanamine-formaldehyde and mixtures thereof. Finally a polyamide with a solubility of at least 0.5 weight percent in select organic solvents is applied to the precoated substrate.
[0028] The invention will become better understood and appreciated upon having reference to the following examples.
EXAMPLES
Thread Coating Procedure
[0029] The thread coating was conducted in a laboratory coating unit similar to the one described in the DuPont brochure relating to Elvamide® (October 1977) and the “Nylon Plastics Handbook”, both referenced earlier. The drying and fusing sections are heated with hot nitrogen passed through electrical tube heaters provided with controllers to allow independent temperature control of the two sections. In a typical coating experiment the thread is passed between cheesecloth saturated with the coating solution by continuously dripping the coating solution onto the cloth from a dropping funnel. The residence time of the thread in the drying section is six seconds and also six seconds in the fusing section. The residence time is controlled by the take up speed of the spool motor. To provide a basis for accurate comparisons, the specified threads were always selected from the same spool.
Abrasion Resistance & Interply Adhesion
[0030] After coating the thread is conditioned in a 50% Relative Humidity (RH) chamber for six days before testing. One end of the thread is attached to a reciprocating arm driven by an electric motor (at a rate of 44 cycles/minute) and the other end to a 230.0 g weight ( such that the thread abraids against the nylon 66 mono-filament ). The thread hangs over a nylon 66 mono-filament with a diameter of 0.025-inch to 0.030-inch. There is provided a counter that records the number of cycles. During the test, the appearance of the thread is observed visually through a 50X magnifying lens. The point where the coating has abraded is observed as the number of cycles. Increased number of cycles reflects increased abrasion resistance.
[0031] The interply adhesion of the samples is compared qualitatively by twisting the coated thread opposite the original twist direction. A qualitative grading system from 0 to 3 was used. Zero is when the plies completely separate from each other; 1 is when the plies separate but some portion of the plies are still attached to each other; 2 is when only a small portion of the plies separate from each other; and 3 is when there is no visible separation of the plies. In close cases, gradations in units of 0.5 were used (for example, “1.5” and “2.5”).
Examples 1 & 2
[0032] An 11.0 percent by weight solution of Elvamide® 8061 was made by heating Elvamide® 8061 and methanol in a flask fitted with a magnetic stirrer and a condenser. The amount of solution required depends on the amount of thread to be coated. In a typical experiment a 100-gram solution is made by heating 11.0 grams of Elvamide® 8061 and 89.0 grams of methanol.
[0033] A 210-denier, 3-ply nylon thread was coated as described above using 6 seconds residence time in the drying section and 6 seconds in the fusing section. Results are shown in the table below.
DRY- ING WT. % CYCLES EXAM- TEMP., FUSION COAT- TO INTERPLY PLE C. TEMP. C. ING ABRASION ADHESION Comp. 1 80 120 4.5 24 3 Comp. 2 120 170 4.7 53 3
Examples 3 & 4
[0034] A methanol solution containing 1.0 weight percent Elvamide® 8061, 2.0 30 weight percent Cymel® 1135, and 0.2 weight percent p-toluenesulfonic acid was prepared as in Example 1. This solution was used to coat a 210-denier, 3-ply nylon thread as in Example 1. This example is in accordance with U.S. Pat. No. 4,992,515 using a fully alkylated melamine-formaldehyde cross-linking agent and a strong acid catalyst.
WT. % p- TOLUENE- SULFONIC DRYING FUSION WT. % CYCLES TO INTERPLY EXAMPLE WT. % CYMEL ® ACID TEMP., C. TEMP. C. COATING ABRASION ADHESION Comp. 3 2% Cymel(R) 0.2 80 120 3.7 32 2 1135 Comp. 4 2% Cymel(R) 0.2 120 170 4.1 >200 1 1135
[0035] The results show that at the lower fusion temperature (Example 3) the abrasion resistance is not significantly different than Elvamide® 8061 by itself (Example 1). The abrasion resistance at the higher fusion temperature (Example 4) was significantly improved but the interply adhesion was very poor.
Examples 5 to 16
[0036] Solutions for coating were prepared as in the previous examples using a ration of 11.0 weight percent Elvamide® 8061 in combination with various Cymel® cross-linking agents. These solutions were used to coat 210-denier, 3-ply nylon thread as in Example 1.
WT. % p- TOLUENE- SULFONIC DRYING FUSION WT. % CYCLES TO INTERPLY EXAMPLE WT. % CYMEL ® ACID TEMP., C. TEMP. C. COATING ABRASION ADHESION Comp. 5 2% Cymel(R) 303 0.2 80 120 3.4 53 2.5 Comp. 6 2% Cymel(R) 303 0.2 120 170 4.4 >200 0.5 7 2% Cymel(R) 325 0.2 80 120 4.1 20 3 8 2% Cymel(R) 325 0.2 120 170 5.6 >200 2 9 2% Cymel(R) 325 0 80 120 2.9 148 3 10 2% Cymel(R) 325 0 120 170 4.9 75 3 11 2% Cymel(R) 385 0.2 80 120 3.4 28 3 12 2% Cymel(R) 385 0.2 120 170 4.4 >200 1.5 13 2% Cymel(R) 385 0 80 120 4.4 42 3 14 2% Cymel(R) 385 0 120 170 4.7 45 3 15 2% of 1/1 Cymel(R) 0 80 120 4 74 3 303/325 16 2% of 1/1 Cymel(R) 0 120 170 1.2 150 3 303/325
[0037] Comparative Examples 5 and 6 illustrate the use of another fully alkylated melamine-formaldehyde resin in accordance with U.S. Pat. No. 4,992,515. At the lower fusion temperature (Comp. Example 5) the abrasion resistance was slightly better than with Elvamide® 8061 alone (Comp. Example 1) and with good interply adhesion. However, at the higher fusion temperature although the abrasion resistance was improved, the interply adhesion was poor (Comp. Example 6). On the other hand, the use of both Cymel® 325 a high imino cross-linking agent (Examples 7 to 10) and 385 a partially alkylated cross-linking agent (Examples 11 to 14) and mixtures with fully alkylated Cymel® 303 (Examples 15 and 16) afforded both good abrasion resistance and interply adhesion.
Examples 17 to 36
[0038] Solutions for coating were prepared as in the previous examples using a concentration of 11.0 weight percent Elvamide® 8061 in combination with various Cymel® cross-linking agents. These solutions were then used to coat 220-denier, 3-ply polyethyleneterephthalate thread as in Comp. Example 1.
WT. % WT. % DRYING FUSION WT. % CYCLES TO INTERPLY EXAMPLE CYMEL ® CATALYST TEMP., C TEMP. C COATING ABRASION ADHESION Comp. 17 0 0 80 120 3.2 14 2 Comp. 18 0 0 120 170 0.6 14 2 Comp. 19 1.1% 0.11% 80 120 3.2 23 2 Cymel(R) 1135 PTSA Comp. 20 1.1% 0.11% 120 170 1.9 9 2 Cymel(R) 1135 PTSA Comp. 21 1.1% 0.11% 80 120 1.9 25 1.5 Cymel(R) 303 PTSA Comp. 22 1.1% 0.11% 120 170 2.9 8 2 Cymel(R) 303 PTSA 23 1.1% 0.11% 80 120 2.8 40 2 Cymel(R) 325 PTSA 24 1.1% 0.11% 120 170 0.4 14 2.5 Cymel(R) 325 PTSA 25 1.1% 0.11% Ac 80 120 4.6 55 2 Cymel(R) 325 ACID 26 1.1% 0.11% Ac 120 170 2.5 46 2 Cymel(R) 325 ACID 27 0.5% 0 80 120 4.6 37 2.5 Cymel(R) 325 28 0.5% 0 120 170 0.2 48 2.5 Cymel(R) 325 29 1.0% 0 80 120 2.2 47 2.5 Cymel(R) 325 30 1.0% 0 120 170 0.9 57 2 Cymel(R) 325 31 4.0% 0 80 120 6.4 >200 2 Cymel(R) 325 32 4.0% 0 120 170 2.9 109 2.5 Cymel(R) 325 33 2.2% 0 80 120 5 44 2.5 Cymel(R) 1158 34 2.2% 0 120 170 2.23 44 2.5 Cymel(R) 1158 35 2.2% 0.022% 80 120 4.6 66 2.5 Cymel(R) 1158 PTSA 36 2.2% 0.022% 120 170 1.9 39 2 Cymel(R) 1158 PTSA
[0039] Comp. Examples 17 and 18 using Elvamide® 8061 alone showed abrasion resistance of only 14 which is much lower than those obtained with nylon thread Comp. Examples 1 and 2. This difference in abrasion resistance exemplifies the inherently low adhesion between dissimilar polymers such as nylon and polyester. The interply adhesion is still fairly good. The use of a fully alkylated melamine-formaldehyde cross-linking agent such as Cymel® 1135 or 303 and p-toluene sulfonic acid catalyst as described in U.S. Pat. No. 4,992,515 did not result in significant improvement in abrasion resistance (Comp. Examples 19 to 22). On the other hand, the use of high imino melamine-formaldehyde cross-linking agents such as Cymel® 325 and 1158 resulted in significant improvement in both abrasion resistance and interply adhesion.
Examples 37 to 40
[0040] A 220-denier, 3-ply polyethyleneterephthalate thread was pre-coated with a 6.0 weight percent Cymel® 350 and 1.0 weight percent p-toluenesulfonic acid catalyst in methanol usining 6 seconds residence time at 80 C. in the drying section and 6 seconds at 170 C. in the fusion section. The pre-coated thread is then coated as in Example 1 with an 11.0 weight percent solution of Elvamide® 8061 in methanol without additional catalyst (Examples 37 & 38) and with an 11.0 weight percent Elvamide® 8061 and 1.0 weight percent p-toluenesulfonic acid solution in methanol (Examples 39 & 40).
WT. % p- TOLUENE- DRYING FUSION WT. % CYCLES TO INTERPLY EXAMPLE SULFONIC ACID TEMP., C TEMP., C COATING ABRASION ADHESION 37 0 80 120 5.5 41 2.5 38 0 120 170 4.3 Over 80 2.5 39 1.0 80 120 6.9 54 2 40 1.0 120 170 3.4 Over 100 2.5
[0041] The results show that pre-coating the polyester thread with the Cymel® 350, a fully alkylated resin, afforded very good abrasion resistance and interply adhesion in contrast to Comparative Examples 19 to 22. The presence of catalyst in the subsequent coating with the Elvamide® 8061 was found not to have significant adverse or beneficial effects.
|
Novel coating solutions are disclosed that promote desirable adhesion to substrates formed from nylon, polyester, or a combination thereof. These coating solutions include nylons having specific solubility together with select formaldehyde resins and resin mixtures. The solutions provide superior adhesion and are therefore attractive to thread applications as well as formed structures.
| 3
|
FIELD OF THE INVENTION
This invention relates to apparatus and a method to predict the discharge capacity of a battery by predicting the reserve time remaining in a discharging battery to a specified end-voltage and, in particular, to an adaptive reserve time prediction system that is active in real time to respond to changing conditions of a discharging battery.
BACKGROUND OF THE INVENTION
One process of determining the capacity of a discharging battery is based on the ampere hour capacity of the battery; that is the number of hours that the battery can supply a given current, assuming a constant current, or supply a given ampere hour area if the current varies. Capacity evaluation is based on current because it is a reliable indication of the ability of the battery to power a load. The discharge of the battery is generally considered complete when the battery voltage drops to some voltage level which is a bare minimum requirement of the load network. Typical discharge characteristics of new batteries are shown in FIG. 1 in which discharge curves relating battery voltage and time are shown for various constant value discharge currents. It is readily apparent that the value of the discharge current significantly affects the time of discharge until a particular battery discharge voltage is reached. These discharge curves characteristically reflect the capacity of the battery when these measurements were made and would not necessarily reflect true battery capacity at a later stage in the battery's life.
Prior art methods of predicting the available reserve time remaining in a discharging battery were based on the assumption that all the battery cells retain their original discharge characteristics. The duration of a discharge to a specified end voltage was essentially predicted from power data-sheet information based on the experimental measured discharge characteristics of a new battery.
One widely used method of predicting the available reserve time of a discharging battery is based on the Peukert parameters, which are based on measured constants that depend on the end voltage of interest of a discharging battery and which are included in an exponential equation. Plotted logrithmically the discharge characteristic of a battery is a straight line with a separate straight line for each end voltage value. Implicit in this method and other prior art methods is the premise that the battery discharge characteristic is fixed and does not vary with the age of the battery. Furthermore the prior art methods assume that the discharge current is a constant value for the entire discharge and do not accommodate varying discharge currents. These discharge prediction methods accordingly permit only rough approximations of the available reserve time of a discharging battery.
In reality the discharge characteristics of the battery cells deviate from their original behavior with age and these initial characteristics are retained for only a few initial charge/discharge cycles. Discharge characteristics also typically deviate substantially from those theoretically predicted by the Peukert relation. Hence it has not been feasible to provide reliable predictions of remaining reserve time for a mature discharging battery.
SUMMARY OF THE INVENTION
A reliable technique of predicting the available reserve time remaining to a selected end voltage of a discharging battery is based on an adaptive state-of-charge algorithm that is active in real time to respond to changing conditions of a battery system. The adaptive state-of-charge algorithm is based on measured discharge characteristics of the battery whose reserve time is to be predicted. These discharge characteristics, according to the invention, have been reduced to two parameters plotted as a single canonical curve invariant to discharge current levels and having a linear and an exponential region. These discharge characteristics defined by the single curve are combined with dynamic parameters of the battery system which are monitored and processed in real time to provide a continuous evaluation and reevaluation of the reserve time remaining under changing conditions. As the battery discharge proceeds there is a continual improvement in the prediction of reserve time available due to the adaptive nature of the prediction.
This predictive feature embodying the principles of the invention is included in a stored program controller for a lead acid battery plant in a central office in the illustrative embodiment of the invention disclosed herein. In such applications it is highly desirable to be able to predict the available reserve time of a discharging battery until a final end voltage level is reached.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a graph of discharge characteristics of a typical battery at varying discharge currents;
FIG. 2 is a graph of normalized discharge characteristics limited to two variable parameters of the discharge;
FIG. 3 is a schematic of a battery system including apparatus operable according to the invention to predict a remaining reserve time of discharge for a battery to a final specified end voltage;
FIG. 4 is a flow diagram of a stored program for managing the battery system of FIG. 1 including detecting and predicting the remaining reserve time of a discharging battery;
FIG. 5-8 contain a flow diagram of the reserve time prediction portion of the operating control system of FIG. 4: and
FIG. 9 shows how FIGS. 5-8 are combined.
DETAILED DESCRIPTION
The discharge characteristics of a battery at various constant discharge currents are shown in FIG. 1. As shown the battery voltage drops during the discharge process and the time of discharge to a particular voltage level is dependent on the value of the constant discharge current. At a low current as shown by current discharge curve 101 the drop in voltage of the battery is gradual for a substantial time until a first voltage level V 1 is attained after which the discharge to a final voltage level V 4 is very rapid. As is shown by curve 101 the time duration of discharge is rather long. At a high discharge current as shown by curve 102 the time of discharge until the final voltage V 4 is attained is relative short being less than 20% of the discharge time of the current of curve 101. These characteristics can be measured in the laboratory, however they are only accurate for the battery at the stage of its life at which the measurements are made.
These discharge curves can also be expressed analytically in the form of an exponential equation (the Peukert equation) to relate discharge time and current:
t.sub.ev =a·I(t).sup.b (1)
in which:
t ev =total reserve time to the final voltage level for discharge at current I(t);
I(t)=discharge current at time (t);
a,b=Peukert parameters or constants;
Peukert parameters are determined by experimental measurements made on a discharging battery. Predictive accuracy of the equation (1) is dependent on the measured Peukert parameters which are accurate only for a battery in the life stage in which the parameters were measured.
The discharge behavior of batteries is known to change with the age of the battery and to change during discharge as the discharge current varies. These factors are not taken into account by the prior art discharge time prediction techniques considered above.
Analysis of the many factors related to the discharge characteristics of a discharging battery in accord with the invention permits the discharge time prediction to be based on two defined parameters of the battery. These parameters are V p , the plateau voltage of the battery, and t* a dimensionless time ratio representing a ratio of battery charge removed to battery charge available at a discharged battery end voltage. The discharge characteristics of a battery defined in terms of those two parameters are illustrated by the single curve 201 shown in FIG. 2 in which the dimensionless time ratio scale of the abcissa is plotted against a logrithmic scale of a difference between the battery plateau voltage and its instantaneous terminal voltage.
As a battery discharges, its terminal voltage fluctuates shortly after the discharge has begun. A temporary initial maximum value is attained and then terminal voltage of the battery begins to decrease. This decrease may have a cyclic nature, but the overall trend is for the battery terminal voltage to decrease in value. For a given battery, this initial maximum value of the terminal voltage consistently occurs at a fixed elapsed time after discharge begins and this voltage magnitude is a fixed value for a given battery. This maximum voltage value is technically known as the plateau voltage V p and is an important parameter in estimating the reserve time of a discharging battery.
This discharge curve 201 in FIG. 2 exhibits a linear portion 202 and an exponential portion 203 with the transition from one to the other at line 205 which in the example has the value 0.4 as the dimensionless time ratio. If the dimensionless time ratio is less than 0.4 the discharge behavior is characterized by a linear portion 202 of the curve 201. When the dimensionless time ratio equals or exceeds 0.4 the discharge behavior is characterized by the exponential portion 203 of the curve 201.
The overall discharge curve 201 is invariant with respect to the magnitude of discharge current within a defined operating range in contrast to the discharge curves of FIG. 1 each of which have a different trajectory for each different magnitude of discharge current. The linear portion 202 of the discharge relationship defined by curve 201 is characterized by the following linear equation:
V(t)=V.sub.p (I)-c-d·t*;for(t*<0.4) (2)
and the exponential portion of the discharge relationship defined by curve 201 is characterized by the following exponential equation
V(t)=V.sub.p (I)-g·exp (h·t*);for(t*≧0.4)(3)
where
V(t)=battery terminal voltage at time t
V p (I) is the battery plateau voltage at a certain discharge
current I as defined by the second degree empirical
equation
V.sub.p (I)=e+f·I+j·I.sup.2 (4)
The constants c, d, e, f, g, h and j of equations (2), (3) and (4) are determined by experimentally discharging a battery of the type to be monitored, graphing its discharge characteristics corresponding to the equations (2), (3) and (4) and obtaining the values of the constants from the plotted graphs. Here c, d, g and h are measured constants of the battery which are independent of the battery discharge current and end voltage; c, d and g are measured in volts and h is dimensionless. e, f and j are also battery constants independent of battery discharge current and end voltage. Here e is measured in volts and represents the plateau voltage, f is measured in ohms and j is measured in terms of ohms/ampere.
The dimensionless time ratio t* discussed above with reference to FIG. 2, is represented by: ##EQU1## Where q t is the battery charge removed at time t and
q d is the battery charge available to the default end discharge voltage.
A typical illustrative battery system arrangement in which it is desirable to predict the remaining discharge reserve time of a discharging battery is shown in FIG. 3, which discloses a simple battery plant arrangement. This battery plant arrangement may include a lead acid battery although it is to be understood that the invention is not limited to this type of battery. A battery 301 is connected for energizing a load 302 and is continuously recharged by a rectifier 303 connected to a commercial AC line power input 304. Operation performance and status of the battery is monitored by a monitoring circuit 305 which is connected to current sensing shunts 321 and 322 and terminals 323 and 324 to determine the battery input charging current, the battery output current and the battery terminal voltage, respectively. While a monitoring of the whole battery is shown in FIG. 3, it is to be understood that in actual application individual battery cell voltages and other subassemblies may be specifically monitored. The monitored signal variables are applied to a digital multimeter 306 which in turn is connected to a data bus 307.
A microprocessor controller 310 including a stored program control for the battery plant is also connected to the bus. It continuously analyzes data acquired by the digital multimeter 306 and controls the management of the battery plant through the management function control unit 311 which is connected via lead 325 to control functioning of the rectifier and other subassemblies and switches of the plant. Temperature of the battery 301 is sensed by a thermo sensing device 330 whose output is connected directly to the microprocessor controller 310, via lead 331.
The stored program of the microprocessor control 310 includes an operating system 401 such as shown in the flow chart of FIG. 4 and further includes a stored program management function 402. It periodically loops through the management function 402 and periodically checks to determine if the battery is discharging in a decision function 403 which queries--is the battery discharging? If no battery discharge activity is occurring, the normal management function loop continues, via flow line 404, to return to the operating system function 401. If occurrence of a battery discharge is detected through evaluation of the data supplied by the digital multimeter 306, the discharge parameters are periodically evaluated by the stored program during the interval of discharge in function block 405 in order to determine the reserve time remaining until the battery voltage attains some specified final end voltage value. The end voltage value may be some pre-specified default value contained in the stored program or it may be another value presently specified by the user of the management system.
The stored program includes stored data that reflects the canonical battery discharge characteristics as shown in the graph of FIG. 2. A predictive operation to calculate a reserve time is performed in the function block 405 and a reserve time value is calculated representing a reserve time remaining from the present instant until the battery voltage attains the default or specified end voltage value. It is determined in subsequent decision block 406 if the battery has fully discharged; (i.e., has the default or specified end voltage been attained)? If the battery is still discharging and its voltage is greater than the end voltage, the process proceeds by flow line 407 to the decision block 403 and from there to a subsequent prediction evaluation of reserve time in function block 405. If the battery has fully discharged in that its terminal voltage is equal to the default or specified end voltage, the process returns by flow line 408 to the operating system function 401 and the periodic prediction of discharge reserve time remaining is terminated.
The predictive technique embodied in the blocks 405 and 406 in FIG. 4 is shown in detail in the flow chart shown in FIGS. 5-8. This flow chart shows in detail the portion of the stored program concerned with predicting the reserve time remaining until a discharging battery attains an end voltage value.
The battery predictive technique for predicting available reserve time of a battery begins at the start terminal 1001 which is activated by turning on the management system and proceeds to the function block 1002 which allows the battery plant user to specify status and operating parameters of the battery system. Such information specifically includes an end voltage at which the battery is considered to be fully discharged, and certain measured parameters or constants of the battery as indicated above and also data as to the past charging and discharging history of the battery. The system architecture and other physical characteristics of the battery such as cell voltage and cell storing values and various plant parameters are additionally specified.
The prediction evaluation technique includes instructions in function block 1003 to monitor the battery operation state for variables that are related to charging and discharging of the battery. A determination is made in subsequent decision function 1004 as to whether a battery discharge condition has occurred. If there is no existing battery discharge the control flow returns, via flow line 1005, to continue to monitor the battery condition. If the occurrence of a battery discharge is detected the control flow continues to function block 1006 in which a time variable t representing elapsed time of discharge is set to zero and a discharge variable q defining discharge in accumulated ampere hours is set to zero. The end voltage at which discharge is considered complete, has also been specified as either the default voltage V d or a user specified end voltage V ev and is set as the voltage at which a discharge is considered complete.
The stored program control begins measuring the elapsed time of discharge in the function block 1007. This is a running time of discharge and is utilized in subsequent calculations during discharge to determine a remaining battery reserve time to a particular end voltage.
Subsequent decision block 1008 measures the elapsed time to ascertain if the discharging battery has attained its plateau voltage value. In the initial moments after discharge the battery voltage for any particular battery increases in value and attains a maxima voltage value after a short but definite interval of discharge. The plateau voltage of a discharging battery is this maxima of voltage that occurs at a specific elapsed time after a discharge of the battery has begun. Its specific value is a function of the discharge current and other battery characteristics. In the illustrative example the plateau voltage V p occurs at 14 elapsed minutes after the discharge of the battery has begun.
If the battery has not attained its plateau voltage value, the process proceeds to function block 1009 where standard Peukert equations are utilized to predict the reserve time remaining until an end voltage is attained. This standard Peukert equation is typically expressed as equation (1) with modifications to accommodate the measured battery operating temperature where the total discharge time t ev is defined as
t.sub.ev =a·I(t).sup.b ·[1+0.005·(T-77)](6)
where
T is temperature °F.
a and b are the measured Peukert factors; and
I(t) is the present discharge current.
By evaluating this equation, the stored program can determine the remaining reserve time t r for the battery to reach the end voltage. This remaining reserve time t r is estimated by equation ##EQU2## where I(t) is the discharge current, and q t is the amount of charge (ampere hours) removed from the battery by the elapsed time t and which in turn is expressed as: ##EQU3##
If enough time has elapsed for the discharging battery to attain its plateau voltage; its plateau voltage and discharge current is or has been measured in response to a command in function block 1010 which measurement takes place at the time t p . The value of the constant e which is related to the plateau voltage is also determined.
After a predetermined time delay the control flow proceeds to the function block 1011 where the present battery voltage V(t) and discharge current I(t) is measured and these values are stored in memory. A preliminary calculation of the batteries overall reserve time of discharge to attainment of the default voltage is calculated by calculating available battery charge at the default end voltage in function block 1012 according to the equation ##EQU4## where q d is the total battery charge available to the default end
voltage
V p (I) is the measured plateau voltage for the present discharge current
V(t) is the present battery voltage and
c is a measured battery constant expressed in voltage
This equation (9) assumes that the discharge characteristic of the battery is at this time within the linear region 202 of the curve 201 in FIG. 2 and assumes the standard default voltage in estimating the discharge reserve time.
The control flow now inquires in decision block 1013 if the end voltage at which the discharge is considered complete is the default voltage or if a user specified end voltage has been entered. If the default voltage, specified by the system, is the voltage of interest as an end voltage the time remaining to attainment of that voltage is calculated in process block 1016 by the formula
t.sub.r =(q.sub.ev -q.sub.t)/I(t) (10)
where
t is the elapsed time
q ev is the total charge available until the default end voltage is attained
t r is the time remaining until the end voltage will be attained
If, on the other hand, the user has specified an end voltage in place of the default voltage the total discharge time for that specified end voltage is calculated in process block 1017 by equation ##EQU5## where g and h are measured constants
q d is the charge available to the default voltage
The flow then proceeds from function block 1017 to function block 1016 wherein the time remaining until the final discharge end voltage is calculated by equation (10).
Determination of the instantaneous battery voltage is made in decision block 1020 to determine if the end voltage value of discharge has been attained. If the end voltage value has been attained the control flow proceeds to the termination terminal 1021 where a state of discharge is declared and the attainment of the end voltage may be alarmed or the load may be disconnected. If the end voltage is not attained a time delay interval is instituted in subsequent function block 1022 and the prediction system continues to recalculate a discharge reserve time after expiration of this time delay.
At the next time increment a new dimensionless time ratio is calculated in function block 1024 as per equation (5). This calculation based on a history of the discharge determines a ratio of the discharge ampere hours already expended q t with the total ampere hours q d which will be removed at the time the default end voltage of discharge is achieved.
The newly calculated dimensionless time ratio is reviewed in decision block 1026 to determine if present discharge characteristic is operating within a linear region 202 or an exponential region 203 of the discharge characteristic curve 201 graphed in FIG. 2.
If it is determined in decision function 1026 that the present discharge characteristic is operating in the linear region, the process flow proceeds to the function block 1028 in which the charge q d available until the attainment of the default voltage is calculated by solving the equation (9). Subsequent decision function 1030 ascertains if the default voltage or a user specified voltage is the end voltage at which the battery discharge is supposed to be complete.
If the default voltage of the system is the designated end voltage at which discharge of the battery is considered complete the remaining discharge reserve time to the end voltage is calculated in function block 1032 by applying q d to equation (10) as detailed in function block 1032. Control flow then proceeds to node 1019 via flow line 1033.
If the user has specified an end voltage other than the default voltage the available charge q ev until the attainment of the specified end voltage is calculated in function block 1034 by using equation (11) in which the value q d is an input as a variable. The actual reserve time remaining until the end voltage is determined in function block 1036 using the equation (10). The control flow then returns, via flow line 1037, to node 1019.
If the present discharge characteristic is operating in the exponential region as determined in decision block 1026 the process proceeds to function block 1040 in which the available charge q d until the attainment of the default voltage is calculated by solving the following equation. ##EQU6##
Decision function 1042 determines if the default voltage or a user specified voltage has been selected as the end voltage at which the battery discharge is considered complete.
If the default voltage of the system is the designated end voltage at which discharge of the battery is considered complete the remaining reserve time to the end voltage is calculated by applying q d to equation (10) as detailed in function block 1044. The control flow then returns, via flow line 1045, to node 1019. If an end voltage other than the default voltage is specified the available charge q ev , until the attainment of the specified end voltage, is calculated in function block 1046 by using equation (11). The actual reserve time remaining until the end voltage is determined in function block 1048 using the equation (10).
At the end of each determination of the remaining reserve time for both the linear region and the exponential region the flow process returns to node 1019. The calculation of this battery discharge reserve time is continuously recycled until the end voltage indication of completion of the discharge is attained.
|
A reliable technique of predicting the available reserve time remaining to a selected end voltage of a discharging battery is based on an adaptive state-of-charge algorithm that is active in real time to respond to changing conditions of a battery system. The adaptive state-of-charge algorithm is based on measured discharge characteristics of the battery whose reserve time is to be predicted which have been reduced to two parameters plotted as a single curve with a linear and an exponential region. These discharge characteristics are combined with dynamic parameters of the battery system which are monitored and processed in real time to provide a continuous evaluation and reevaluation of the reserve time remaining under changing conditions. As the discharge proceeds there is a continual improvement in the prediction of reserve time available.
This predictive feature embodying the principles of the invention is included in a stored program controller for a battery plant in a central office in the illustrative embodiment of the invention disclosed herein. In such applications it is highly desirable to be able to predict the available reserve time of a discharging battery until a final end voltage level is reached.
| 8
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/643616, filed Dec. 21, 2009, titled “WATER CONTROL FIXTURE HAVING BYPASS VALVE”, which is a continuation of U.S. patent application Ser. No. 11/827926, filed Jul. 12, 2007, issued as U.S. Pat. No. 7,648,078 issued Jan. 19, 2010, which is a continuation of U.S. patent application Ser. No. 11/173,572, filed Jul. 1, 2005, issued as U.S. Pat. No. 7,287,707 issued Oct. 30, 2007, which is a continuation of U.S. patent application Ser. No. 10/006,970, filed Dec. 4, 2001, issued as U.S. Pat. No. 6,929,187 on Aug. 16, 2005, which patent is a continuation-in-part of U.S. patent application Ser. No. 09/697,520 filed Oct. 25, 2000, issued as U.S. Pat. No. 6,536,464 issued Mar. 25, 2003, and claimed priority to U.S. Provisional Application No. 60/251,122 filed Dec. 5, 2000, each of which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to faucets and bypass valves for use in home or industrial water distribution systems that supply water to various fixtures at different temperatures through different pipes. More particularly, the present invention relates to faucets having bypass valves that are thermostatically controlled so as to automatically bypass water that is not at the desired temperature for use at the fixture. Even more particular, the present invention relates to faucets having an integral thermostatically controlled bypass valve.
[0003] Home and industrial water distribution systems distribute water to various fixtures, including sinks, bathtubs, showers, dishwashers and washing machines, that are located throughout the house or industrial building. The typical water distribution system brings water in from an external source, such as a city main water line or a private water well, to the internal water distribution piping system. The water from the external source is typically either at a cold or cool temperature. One segment of the piping system takes this incoming cold water and distributes it to the various cold water connections located at the fixture where it will be used (i.e., the cold water side of the faucet at the kitchen sink). Another segment of the piping system delivers the incoming cold water to a water heater which heats the water to the desired temperature and distributes it to the various hot water connections where it will be used (i.e., the hot water side of the kitchen faucet). At the fixture, cold and hot water either flow through separate hot and cold water control valves that are independently operated to control the temperature of the water into the fixture by controlling the flow rate of water from the valves or the water is mixed at a single valve that selectively controls the desired temperature flowing into the fixture.
[0004] A well known problem common to most home and industrial water distribution systems is that hot water is not always readily available at the hot water side of the fixture when it is desired. This problem is particularly acute in water use fixtures that are located a distance from the hot water heater or in systems with poorly insulated pipes. When the hot water side of these fixtures is left closed for some time (i.e., overnight), the hot water in the hot water segment of the piping system sits in the pipes and cools. As a result, the temperature of the water between the hot water heater and the fixture lowers until it becomes cold or at least tepid. When opened again, it is not at all uncommon for the hot water side of such a fixture to supply cold water through the hot water valve when it is first opened and for some time thereafter. At the sink, bathtub or shower fixture located away from the water heater, the person desiring to use the fixture will either have to use cold or tepid water instead of hot water or wait for the distribution system to supply hot water through the open hot water valve. Most users have learned that to obtain the desired hot water, the hot water valve must be opened and left open for some time so that the cool water in the hot water side of the piping system will flow out ahead of the hot water. For certain fixtures, such as dishwashers and washing machines, there typically is no method of “draining” away the cold or tepid water in the hot water pipes prior to utilizing the water in the fixture.
[0005] The inability to have hot water at the hot water side of the fixture when it is desired creates a number of problems. One problem is having to utilize cold or tepid water when hot water is desired. This is a particular problem for the dishwasher and washing machine fixtures in that hot water is often desired for improved operation of those fixtures. As is well known, certain dirty dishes and clothes are much easier to clean in hot water as opposed to cold or tepid water. Even in those fixtures where the person can let the cold or tepid water flow out of the fixture until it reaches the desired warm or hot temperature, there are certain problems associated with such a solution. One such problem is the waste of water that flows out of the fixture through the drain and, typically, to the sewage system. This good and clean water is wasted (resulting in unnecessary water treatment after flowing through the sewage system). This waste of water is compounded when the person is inattentitive and hot water begins flowing down the drain and to the sewage system. Yet another problem associated with the inability to have hot water at the hot water valve when needed is the waste of time for the person who must wait for the water to reach the desired temperature.
[0006] The use of bypass valves and/or water recirculation systems in home or industrial water distribution systems to overcome the problems described above have been known for some time. The objective of the bypass valve or recirculation system is to avoid supplying cold or tepid water at the hot water side of the piping system. U.S. Pat. No. 2,842,155 to Peters describes a thermostatically controlled water bypass valve, shown as FIG. 2 therein, that connects at or near the fixture located away from the water heater. In his patent, the inventor discusses the lack of hot water problem and describes a number of prior art attempts to solve the problem. The bypass valve in this patent comprises a cylindrical housing having threaded ends that connect to the hot and cold water piping at the fixture so as to interconnect these piping segments. Inside the housing at the hot water side is a temperature responsive element having a valve ball at one end that can sealably abut a valve seat. The temperature responsive element is a metallic bellows that extends when it is heated to close the valve ball against the valve seat and contracts when cooled to allow water to flow from the hot side to the cold side of the piping system when both the hot and cold water valves are closed. Inside the housing at the cold water side is a dual action check valve that prevents cold water from flowing to the hot water side of the piping system when the hot water valve or the cold water valve is open. An alternative embodiment of the Peters' invention shows the use of a spiral temperature responsive element having a finger portion that moves left or right to close or open the valve between the hot and cold water piping segments. Although the invention described in the Peters' patent relies on gravity or convection flow, similar systems utilizing pumps to cause a positive circulation are increasingly known. These pumps are typically placed in the hot water line in close proximity to the faucet where “instant” hot water is desired.
[0007] U.S. Pat. No. 5,623,990 to Pirkle describes a temperature-controlled water delivery system for use with showers and eye-wash apparatuses that utilize a pair of temperature responsive valves, shown as FIGS. 2 and 5 therein. These valves utilize thermally responsive wax actuators that push valve elements against springs to open or close the valves to allow fluid of certain temperatures to pass. U.S. Pat. No. 5,209,401 to Fiedrich describes a diverting valve for hydronic heating systems, best shown in FIGS. 3 through 5 , that is used in conjunction with a thermostatic control head having a sensor bulb to detect the temperature of the supply water. U.S. Pat. No. 5,119,988 also to Fiedrich describes a three-way modulating diverting valve, shown as FIG. 6 . A non-electric, thermostatic, automatic controller provides the force for the modulation of the valve stem against the spring. U.S. Pat. No. 5,287,570 to Peterson et al. discloses the use of a bypass valve located below a sink to divert cold water from the hot water faucet to the sewer or a water reservoir. As discussed with regard to FIG. 5 , the bypass valve is used in conjunction with a separate temperature sensor.
[0008] A recirculating system for domestic and industrial hot water heating utilizing a bypass valve is disclosed in U.S. Pat. No. 5,572,985 to Benham. This system utilizes a circulating pump in the return line to the water heater and a temperature responsive or thermostatically actuated bypass valve disposed between the circulating pump and the hot water heater to maintain a return flow temperature at a level below that at the outlet from the water heater. The bypass valve, shown in FIG. 2 , utilizes a thermostatic actuator that extends or retracts its stem portion, having a valve member at its end, to seat or unseat the valve. When the fluid temperature reaches the desired level, the valve is unseated so that fluid that normally circulates through the return line of the system is bypassed through the circulating pump.
[0009] Despite the devices and systems set forth above, many people still have problems with obtaining hot water at the hot water side of fixtures located away from the hot water heater or other source of hot water. Boosted, thermally actuated valve systems having valves that are directly operated by a thermal actuator (such as a wax filled cartridge) tend not to have any toggle action. Instead, after a few on-off cycles, the valves tend to just throttle the flow until the water reaches an equilibrium temperature, at which time the valve stays slightly cracked open. While this meets the primary function of keeping the water at a remote faucet hot, leaving the valve in a slightly open condition does present two problems. First, the lack of toggle action can result in lime being more likely to build up on the actuator because it is constantly extended. Second, the open valve constantly bleeds a small amount of hot or almost hot water into the cold water piping, thereby keeping the faucet end of the cold water pipe substantially warm. If truly cold water is desired (i.e., for brushing teeth, drinking, or making cold beverages), then some water must be wasted from the cold water faucet to drain out the warm water. If the bypass valve is equipped with a spring loaded check valve to prevent siphoning of cold water into the hot water side when only the hot water faucet is open, then the very small flow allowed through the throttled-down valve may cause chattering of the spring loaded check valve. The chattering can be avoided by using a free floating or non-spring loaded check valve. It is also detrimental to have any noticeable crossover flow (siphoning) from hot to cold or cold to hot with any combination of faucet positions, water temperatures, or pump operation.
[0010] U.S. Pat. No. 6,536,464 the disclosure of which is incorporated herein as fully set forth and having some of the same inventors and the same assignee as the present invention, describes an under-the-sink thermostatically controlled bypass valve and water circulating system with the bypass valve placed at or near a fixture (i.e., under the sink) to automatically bypass cold or tepid water away from the hot water side of the fixture until the temperature of the water reaches the desired level. The system described in U.S. Pat. No. 6,536,464 includes a single small circulating pump that is placed between the water heater and the first branching in the hot water supply line which supplies the fixture having a bypass valve so as to pressurize the hot water piping system and facilitate bypassing of the cold or tepid water.
[0011] The public is accustomed to purchasing faucets for lavatories, bathtubs, showers, kitchen sinks and etc. that can be readily repaired, usually by removing a top-mounted handle and bonnet, and replacing a faucet washer or other seal or seat. In recent designs, the sealing action occurs within a replaceable cartridge, which can be easily replaced by the home repair person. None of the known prior art devices include the use of an integral thermostatically controlled bypass valve to bypass water as described above. However, for a thermal bypass valve to be included in a faucet, it is necessary that it meet the same expectation for ease of repair as the standard faucet. There are several advantages to location of the thermal bypass valve within the faucet itself and being accessible from the top, which include: (1) elimination of the clutter resulting from extra hoses located below the sink and the need to do plumbing and maintenance below the sink; (2) elimination of the under-the-sink hoses, which by their very presence add potential leak paths at each end of each hose; (3) a new feature that a faucet manufacturer can use to define its top-of-the-line faucet, which can stimulate sales to those customers who like to have the latest in convenience; and (4) the bypass valve can be serviced by the home repair person or, if desired, professional plumber in a standing position in a manner which is already learned from the maintenance of existing design faucets.
BRIEF DESCRIPTION OF THE INVENTION
[0012] In an exemplary embodiment, a water control fixture is provided including a housing having a plurality of ports defining a hot water inlet port, a bypass port, and a fixture outlet port, wherein water is dispensed via the fixture outlet port. At least one operating valve is disposed in the housing for controlling a flow of water from the hot water inlet port to the fixture outlet port. A bypass valve is disposed in the housing for controlling a flow of water from the hot water inlet port to the bypass port.
[0013] Optionally, the plurality of ports includes a cold water port configured to be in fluid communication with a cold water supply line, wherein the at least one operating valve may control a flow of water from the cold water port to the fixture outlet port. The bypass valve may control a flow of water from the hot water inlet port to the cold water port. Optionally, the bypass valve may opens to permit a flow of water from the hot water inlet port to the bypass port based on an activation condition. The bypass valve may be thermostatically controlled and may control the flow of water from the hot water inlet port to the bypass port until the temperature of the water at the hot water inlet port is at a preset level. Optionally, the bypass port may be configured to be in fluid communication with one of a dedicated return line and a cold water supply line. Optionally, the housing may represent a faucet and include at least one handle provided on the housing, wherein the handle is joined to the at least one operating valve to control the flow of water from the hot water inlet port and the fixture outlet port.
[0014] In another embodiment, a water control fixture is provided including a housing having a plurality of ports defining a hot water inlet port, a bypass port, and a fixture outlet port, wherein water is dispensed via the fixture outlet port. At least one handle is attached to the housing for controlling the flow of water from the hot water inlet port to the fixture outlet port. A bypass member is disposed in the housing for controlling a flow of water from the hot water inlet port to the bypass port.
[0015] In a further embodiment, a water control fixture is provided including a housing having a chamber and a plurality of ports in fluid communication with the chamber. The plurality of ports define a hot water inlet port, a bypass port, and a fixture outlet port, wherein water is dispensed via the fixture outlet port. A flow control unit is received within the chamber and is configured to be selectively positioned in fluid communication with the plurality of ports for controlling the flow of water from the hot water inlet port to the fixture outlet port and for controlling the flow of water from the hot water inlet port to the bypass port.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows a water distribution system that utilizes a water control fixture (faucet) having a thermostatically controlled bypass valve of the present invention;
[0017] FIG. 2 is a side view of the preferred thermally sensitive actuating element, shown in its unmodified condition, for use in the bypass valve of the present invention;
[0018] FIG. 3 is a front view of a typical fixture body for a single handle faucet;
[0019] FIG. 4 is a side view of the single handle faucet in FIG. 3 ;
[0020] FIG. 5 is a top view of the faucet body housing for the faucet of FIG. 3 ;
[0021] FIG. 6 is a side cross-sectional view of the faucet body housing for the faucet of FIG. 3 ;
[0022] FIG. 7 is a bottom view of the faucet body housing of the faucet of FIG. 3 ;
[0023] FIG. 8 is a sectional view of a bypass valve cartridge body for use with the present invention;
[0024] FIG. 9 is a sectional view of the bypass valve cartridge body taken at 90 degrees to FIG. 8 ;
[0025] FIG. 10 is a sectional view of the bypass valve cartridge body of FIG. 8 with a bypass valve and other components place therein;
[0026] FIG. 11 is a cross-sectional view of the side of a shower faucet that utilizes a cartridge insert (not shown) for controlling the flow of water through the faucet showing the placement of a bypass valve therein;
[0027] FIG. 12 is a cross-sectional view of the side of a modified ball control mechanism for use in single handle faucets;
[0028] FIG. 13 is a top view of the ball of FIG. 12 ;
[0029] FIG. 14 is a side view of the ball of FIG. 12 ;
[0030] FIG. 15 is a cross sectional view of modified replaceable cylindrical valving cartridge used in some faucets as adapted for the present invention;
[0031] FIG. 16 is a side view of a valve member used with dual handle, single spout faucets;
[0032] FIG. 17 is side cross-sectional view of the upper half of a cartridge placed in the valve member of FIG. 16 ;
[0033] FIG. 18 is chart showing the operational characteristics of the bypass valve of the present invention when in use with a water distribution system; and
[0034] FIG. 19 is a side cross-sectional view of a modified thermal actuator showing modifications to reduce problems with lime buildup.
DETAILED DESCRIPTION OF THE INVENTION
[0035] With reference to the figures where like elements have been given like numerical designations to facilitate the reader's understanding of the present invention, the preferred embodiments of the present invention are set forth below. The enclosed figures and drawings are illustrative of the preferred embodiments and represent a preferred way of configuring the present invention. Although specific components, materials, configurations and uses are illustrated, it should be understood that a number of variations to the components and to the configuration of those components described herein and in the accompanying figures can be made without changing the scope and function of the invention set forth herein.
[0036] In the accompanying drawings of the various preferred embodiments of a water control fixture of the present invention, the water control fixture is shown as faucet 10 . However, other water control fixtures may be adaptable to the thermal bypass valve features described herein (i.e., solenoid valve used on home laundry washing machines). A typical water distribution system 12 utilizing faucet 10 of the present invention is illustrated in FIG. 1 . The water distribution system 12 typically comprises a supply of cold water 14 , such as from a city main or water well, that supplies cold water directly to faucet 10 through cold water line 16 and water to hot water heater 18 so that it may heat the water and supply hot water to faucet 10 through hot water line 20 . Cold water line 16 connects to faucet 10 through cold water inlet 22 and hot water line 20 connects to faucet 10 through hot water inlet 24 , as explained in more detail below.
[0037] The preferred system 12 of the present invention utilizes a small circulating pump 26 of the type used in residential hot water space heating. A very low flow and low head pump is desirable because a larger (i.e., higher head/higher flow) pump mounted at the typical domestic water heater 18 tends to be noisy. This annoying noise is often transmitted by the water pipes throughout the house. In addition, if the shower (as an example) is already in use when pump 26 turns on, whether the first start or a later cyclic turn-on, the sudden pressure boost in the hot water line 20 from a larger pump can result in an uncomfortable and possibly near-scalding temperature rise in the water at the shower head or other fixture in use. The smaller boost of a “small” pump (i.e., one with a very steep flow-head curve) will result in only a very small and less noticeable increase in shower temperature. In the preferred embodiment, the single, small pump 26 needs to provide only a flow of approximately 0.3 gpm at 1.0 psi pressure. In accordance with pump affinity laws, such a “small” pump requires a very small impeller or low shaft speed. The inventors have found that use of a very small impeller or low shaft speed also precludes formation of an air bubble in the eye of the impeller, which bubble may be a major cause of noise. Such a small steep curve pump may, however, constitute a significant pressure drop in the hot water line 20 when several fixture taps are opened simultaneously (such as a bathtub and the kitchen sink). To avoid reduced flow in those installations having a relatively low volume pump, a check valve 28 can be plumbed in parallel with pump 26 or incorporated within the pump housing, to pass a flow rate exceeding the pump's capacity around pump 26 . When pump 26 is powered and flow demand is low, check valve 28 prevents the boosted flow from re-circulating back to its own inlet. With check valve 28 plumbed around pump 26 , it is advantageous to place an orifice 30 in the pump discharge to provide a simple manner to achieve the desired very steep flow-head curve from available stock pump designs. A single pump 26 located at or near the water heater 18 in its discharge piping will boost the pressure in the hot water pipes somewhat above that in the cold water pipes (i.e., perhaps one to three feet of boost). With this arrangement only one pump 26 per plumbing system (i.e., per water heater 18 ) is required with any reasonable number of remote faucets 10 (i.e., the typical number used in residences) equipped with bypass valves. This is in contrast to those systems that require multiple pumps, such as a pump at each fixture where bypassing is desired.
[0038] If desired, pump 26 can operate twenty-four hours a day, with most of the time in the no flow mode. However, this is unnecessary and wasteful of electricity. Alternatively, pump 26 can have a timer 32 to turn on the pump 26 daily at one or more times during the day just before those occasions when hot water is usually needed the most (for instance for morning showers, evening cooking, etc.) and be set to operate continuously for the period during which hot water is usually desired. This still could be unnecessary and wasteful of electricity. Another alternative is to have the timer 32 cycle pump 26 on and off regularly during the period when hot water is in most demand. The “on” cycles should be of sufficient duration to bring hot water to all remote fixtures 10 that are equipped with a bypass valve, and the “off period” would be set to approximate the usual time it takes the water in the lines to cool-down to minimum acceptable temperature. Yet another alternative is to equip pump 26 with a normally closed flow switch 34 sized to detect significant flows only (i.e., those flows that are much larger than the bypass valve flows), such as a shower flowing. For safety purposes, the use of such a switch 34 is basically required if a cyclic timer 32 is used. The switch 34 can be wired in series with the motor in pump 26 . If the switch 34 indicates an existing flow at the moment the timer calls for pump 26 to be on, the open flow switch 34 will prevent the motor from starting, thereby avoiding a sudden increase in water temperature at the fixture 10 (i.e., particularly if it is a shower) being utilized. The use of such switch 34 accomplishes several useful objectives, including reducing electrical power usage and extending pump life if hot water is already flowing and there is no need for the pump to operate, avoiding a sudden temperature rise and the likelihood of scalding that could result from the pump boost if water is being drawn from a “mixing” valve (such as a shower or single handle faucet) and allowing use of a “large” pump (now that the danger of scalding is eliminated) with its desirable low pressure drop at high faucet flows, thereby eliminating the need for the parallel check valve 28 required with a “small” pump.
[0039] By using a time-of-day control timer 32 , pump 26 operates to maintain “instant hot water” only during periods of the day when it is commonly desired. During the off-cycle times, the plumbing system 12 operates just as if the faucet 10 having bypass valves and pump 26 were not in place. This saves electrical power usage from pump operation and, more importantly, avoids the periodic introduction of hot water into relatively un-insulated pipes during the off-hours, thereby saving the cost of repeatedly reheating this water. The time-of-day control also avoids considerable wear and tear on pump 26 and the bypass valve in faucet 10 . Considerable additional benefits are gained by using a cyclic timer 32 , with or without the time-of-day control. In addition to saving more electricity, if a leaky bypass valve or one not having toggle action is used, there will be no circulating leakage while the pump 26 is cycled off, even if the valve fails to shut off completely. Therefore, a simple (i.e., one not necessarily leak tight) valve may suffice in less demanding applications. Having the leakage reduced to just intermittent leakage will result in reduced warming of the cold water line 16 and less reheating of “leaking” re-circulated water.
[0040] The bypass valve assemblies 36 utilized with the present invention have a thermally sensitive actuating element 38 , an example of which is shown in FIG. 2 , for thermostatically controlling bypass valve 36 . Actuating element 38 is preferably of the wax filled cartridge type, also referred to as wax motors, having an integral poppet rod member 40 , as best shown in FIG. 2 . Rod member 40 comprises poppet 42 attached to piston 44 with an intermediate flange 46 thereon. The end of poppet 42 is configured to seat directly against a valve seat or move a shuttle (i.e., spool or sleeve valves) so as to close a passage. These thermostatic control elements 38 are well known in the art and are commercially available from several suppliers, such as Caltherm of Bloomfield Hills, Mich. The body 48 of actuating element 38 has a section 50 of increased diameter, having a first side 52 and second side 54 , to seat against a shoulder or like element in a valve body. Piston 44 of rod member 40 interconnects poppet 42 with actuator body 48 . Actuating element 38 operates in a conventional and well known manner. Briefly, actuating element 38 comprises a blend of waxes or a mixture of wax(es) and metal powder (such as copper powder) enclosed in actuator body 48 by means of a membrane made of elastomer or the like. Upon heating the wax or wax with copper powder mixture expands, thereby pushing piston 44 and poppet 42 of rod member 40 in an outward direction. Upon cooling, the wax or wax/copper powder mixture contracts and rod member 40 is pushed inward by a bias spring until flange 46 contacts actuator body 48 at actuator seat 56 . Although other types of thermal actuators, such as bimetallic springs and memory alloys (i.e., Nitinol and the like) can be utilized in the present invention, the wax filled cartridge type is preferred because the wax can be formulated to change from the solidus to the liquid state at a particular desired temperature. The rate of expansion with respect to temperature at this change of state is many times higher, resulting in almost snap action of the wax actuating element 38 . The temperature set point is equal to the preset value, such as 97 degrees Fahrenheit, desired for the hot water. This is a “sudden” large physical motion over a small temperature change. As stated above, this movement is reacted by a bias spring that returns rod member 40 as the temperature falls.
[0041] Because the bypass valve 36 has little or no independent “toggle action,” after a few cycles of opening and closing, the valve tends to reach an equilibrium with the plumbing system, whereby the bypass valve 36 stays slightly cracked open, passing just enough hot water to maintain the temperature constantly at its setting. In particular plumbing systems and at certain ambient conditions, this flow is just under that required to maintain a spring loaded check valve cracked continuously open. In such a situation, the check valve chatters with an annoying buzzing sound. To avoid this occurrence, the spring may be removed from the check valve, leaving the poppet free floating. In the event that the hot water is turned full on at a time when the bypass valve 36 is open, thereby lowering the pressure in the hot water line 20 , and so inducing flow from the cold water line 16 through the open bypass valve 36 to the hot side, the free floating poppet will quickly close. There is no necessity for a spring to keep this check valve closed prior to the reversal in pressures.
[0042] Although not entirely demonstrated in early tests, it is believed that beneficial “toggle” action can be achieved with a bypass valve 36 of very simple mechanical design. If the motion of the thermal actuator 38 is made to lag behind the temperature change of the water surrounding it by placing suitable insulation around the actuator 38 or by partially isolating it from the water, then instead of slowly closing only to reach equilibrium at a low flow without reaching shutoff, the water temperature will rise above the extending temperature of the insulated actuator 38 as the valve approaches shutoff, and the piston 44 will then continue to extend as the internal temperature of the actuator 38 catches up to its higher surrounding temperature, closing the valve 36 completely. It is also believed that an insulated actuator 38 will be slow opening, its motion lagging behind the temperature of the surrounding cooling-off water from which it is insulated. When actuating element 38 finally begins to open the valve 36 and allow flow, the resulting rising temperature of the surrounding water will again, due to the insulation, not immediately affect it, allowing the bypass valve 36 to stay open longer for a complete cycle of temperature rise. Such an “insulated” effect may also be accomplished by use of a wax mix that is inherently slower, such as one with less powdered copper or other thermally conductive filler. An actuator 38 to be installed with insulation can be manufactured with a somewhat lower set point temperature to make up for the lag, allowing whatever valve 36 closing temperature desired.
[0043] An additional benefit of utilizing pump 26 in system 12 is that shut-off of a toggle action valve upon attainment of the desired temperature is enhanced by the differential pressure an operating pump 26 provides. If pump 26 continues to run as the water at the faucet 10 cools down, the pump-produced differential pressure works against re-opening a poppet type bypass valve 36 in faucet 10 . If pump 26 operates cyclically, powered only a little longer than necessary to get hot water to faucet 10 , it will be “off” before the water at valve 36 cools down. When the minimum temperature is reached, the thermal actuator 38 will retract, allowing the bias spring to open valve 36 without having to fight a pump-produced differential pressure. By-pass flow will begin with the next pump “on” cycle. An additional benefit to the use of either a time-of-day or cyclic timer 32 is that it improves the operating life of thermal actuator 38 . Because use of either timer 32 causes cyclic temperature changes in valve 36 (as opposed to maintaining an equilibrium setting wherein temperature is constant and the actuator 38 barely moves), there is frequent, substantial motion of the piston 44 in thermal actuator 38 . This exercising of actuator 38 tends to prevent the build-up of hard water deposits and corrosion on the cylindrical surface of actuator piston 44 and face of poppet 42 , which deposits could render the valve 36 inoperable.
[0044] Also inside valve 36 can be an over-travel spring (not shown) disposed between the first side 52 of the actuator body 48 and a stop located inside valve 36 to prevent damage to a fully restrained actuator 38 if it were heated above the bypass valve's maximum operating temperature and to hold the actuator 38 in place during operation without concern for normal tolerance. Use of an over-travel spring, which is not necessary for spool-type valves, allows movement of the actuator body 48 away from the seated poppet 42 in the event that temperature rises substantially after the poppet 42 contacts its seat. Without this relief, the expanding wax could distort its copper can, destroying the calibrated set point. The over-travel spring also holds the bias spring, rod member 40 and actuator body 48 in place without the need to adjust for the stack-up of axial tolerances. Alternatively, actuator 38 can be fixedly placed inside valve 36 by various mechanisms known in the art, including adhesives and the like. Over-travel spring, if used, can be held in place by various internal configurations commonly known in the art, such as a molded seat.
[0045] As there are a great many configurations and brands of faucets 10 , there are several different preferred designs of bypass valve 36 placement and arrangement to accommodate these many faucet configurations. For purposes of illustrating the present invention, various specific examples are set forth below. The following examples are representative of the types of uses to which the integral or in-faucet bypass valve 36 is suitable. The examples are for illustrative purposes only and are not intended to restrict the invention to particular uses, sizes or materials used in the examples.
[0046] For instance, there are several basic types of faucet assemblies, including those that have a single handle faucet assembly that mixes the hot and cold water and delivers a flow of water out the single spout based on the user's movement of the faucet's valve assembly. Another common type of faucet assembly is the dual handle, single spout faucet assembly that has separate handles for the hot and cold water. As with the single handle assembly, the hot and cold water are mixed prior to the spout based on the user's selection of the amount of flow of hot and/or cold water. A third, older arrangement is the use of completely separate faucets for hot and cold water. Although the different manufacturers of faucets may utilize different arrangements of valving components, different valving mechanisms and/or different valves to water supply line connections, the bypass valve system of the present invention is adaptable to all such known configurations. As set forth below, the primary selection in the use of the bypass faucet assembly of the present invention is whether to place the bypass valve in a stationary portion of the faucet, such as the hot water piping leading to the faucet or in a housing or block portion of the faucet, or to place the bypass valve in the moveable valving of the faucet. Selection of which location to place the bypass valve assembly will often be dictated by economics, preferences, limitations on the amount of space available, the current design of the faucet and/or the willingness to change.
Example 1
Single Handle Faucets w/Bypass Valve in Stationary Block
[0047] As is well known, single handle faucets, an example of which is shown as fixture body 60 , faucet 10 without its decorative covering, in FIGS. 3 and 4 , have both hot 24 and cold 22 water inlets connected to a housing or block 62 . Various internal valving means, such as pivoting and rotating ball 64 , selectively and adjustably control the volume and temperature of the flow of water by connecting the hot 20 and cold 16 lines, through hot and cold conduits 66 and 68 respectively (as shown in FIGS. 5 and 7 ), to a single outlet spout 70 through spout outlet 72 . In such designs, the thermal bypass valve 36 is preferably assembled into an easily replaceable cartridge 74 , shown best in FIGS. 8 , 9 and 10 , that can be located within the hot water conduit 66 of fixture body 60 (if the design provides such access) or in an added cavity 76 placed between and connected to the hot 24 and cold 22 inlets, as shown in FIG. 7 . In either case, the bypass valve 36 senses and is controlled by the temperature of the “hot” water in the fixture body 60 . When the “hot” water is cooled off due to long disuse, the bypass valve 36 will open, providing a conduit between the hot 24 and cold 22 inlets. If the hot water line pump 26 is then turned on, the boosted pressure in the hot water line 20 will produce flow through the open bypass valve 36 , bringing “hot” water to the fixture body 60 . In the above-mentioned arrangements, the flow of water from both hot 20 and cold 16 lines remains unimpeded due to the previously mentioned internal valving arrangement of the fixture body 60 . The flow from the hot line 20 through the bypass valve cartridge 74 to the cold line 16 is provided through molded or cast passages or cross-drilled holes, discussed below.
[0048] The single handle faucet body 60 with spherical ball valving means 64 , shown in FIGS. 3 and 4 , is a good example of a faucet design that can be easily and economically re-designed to include a bypass valve cartridge 74 in the stationary housing 62 . Use of this approach requires a new fixture body 60 to be installed, with a top-accessible, suitably sized cavity 76 to hold the bypass cartridge 74 and connect conduits 66 and 68 built into the fixture body 60 to accommodate the bypassed flow from the hot 20 to the cold 16 lines. FIGS. 5 through 7 show a modified and lengthened version of a Delta housing 62 that is used with the standard Delta faucet outer housing. The portion 78 above line AA (i.e., to the left of in FIG. 6 ) it is essentially an original Delta housing, with the addition of bore 76 . Below AA (i.e., to the right of in FIG. 6 ) is extension 80 . In the preferred use of the present invention, these sections 78 and 80 would be made in a single, integral housing 62 . Cavity 76 and the drilled and plugged cross passages 82 and 84 are added, and the top bore 86 is extended inward if and as much as is needed to accommodate any necessary devices, such as a ring or washer to hold cartridge assembly 74 in place in cavity 76 . Drilled passage 82 connects the cold water supply to cavity 76 near its top and drilled passage 84 connects the hot water line 20 to cavity 76 near its bottom.
[0049] FIGS. 8 and 9 show the bypass valve cartridge 74 , without its internal components, that is designed and configured to fit in cavity 76 . FIG. 10 shows the components, including thermal actuator 88 , assembled together as they would fit into cavity 76 . The thermal actuator 88 is a modified version of the actuator 38 that is used in U.S. Pat. No. 6,536,464 and shown in. FIG. 2 herein. Water from hot water line 20 is carried through drilled hole 84 to the lower end of cavity 76 and flows up around and through the cartridge 74 to and through the open valve seat 90 (poppet 42 is shown closed into against O-ring 92 forming seat 90 in FIG. 10 ) into the check valve chamber 94 housing check valve 96 and out through the cross drilled hole 98 into an annulus 100 on the cartridge 74 . From annulus 100 , between O-rings 102 and 104 , the water flows through drilled passage 82 to the cold water supply. When sufficient water has flowed through the bypass valve 36 to exhaust the cooled-off water in the hot water supply line 20 and bring hot water to the bypass valve 36 , the thermal actuator 88 will cause piston 44 to extend, forcing poppet 42 into seat 90 to close off the flow. The seat O-ring 92 is held in place by spring 106 , which doubles as the bias or poppet return spring. In the preferred embodiment, thermal actuator 88 is held in place by a snap fit into the split cartridge 74 , which is designed to be easily moldable. The check valve 96 is included to prevent flow of cold water into the hot side when the hot water is turned full on in the system, or the equivalent usage of hot water, resulting in a lowered pressure on the hot side. The cartridge 74 can be held down in cavity 76 by a brass ring, or the like, which is in turn held down by the screw-on bonnet, which also captures the existing ball valving assembly 64 .
[0050] Another example of a single handle water control fixture is shown as 110 in FIG. 11 . This fixture 110 is a modified Moen shower valve that comprises a rear housing 112 attached to the rear 114 of Moen housing 116 . Housing 116 has a hot water inlet port 118 and a cold water inlet port 120 for receiving hot and cold water, respectively, from the hot 20 and cold 16 water lines and a valve cavity 122 for receiving the operating valve (not shown) through valve opening 124 . The operating valve controls the flow of hot and cold water out of the spout associated with valve 110 . Rear housing 112 has a cavity 126 configured to hold cartridge 127 and hot 128 and cold 130 water channels to allow passage of water around valve cavity 126 until the hot water reaches the desired temperature to cause actuator 38 to push piston 44 rearward until poppet 42 engages valve seat 90 to shut-off hot water flow through hot water channel 128 , thereby ending the diversion of “hot” water to the cold water channel 130 . Elastomeric washer shaped diaphragm 125 acts as a check valve to prevent back flow of cold to hot when hot water line pressure is reduced. Conical washer shaped screens 129 filers detritus and other trash from passing water. Screens 129 are self-cleaning due to the high water velocities encountered when the shower valve is running hot water.
Example 2
Single Handle Faucets w/Bypass Valve in Moveable Valving
[0051] This family of valves may utilize either a moveable perforated hollow spherical ball 64 , as shown in FIGS. 3 and 4 , or an internally moveable valve cartridge, that have a common internal flow area to selectively and adjustably connect the hot 20 and cold 16 lines to the discharge spout 70 . It is possible to place the same thermal valve system 36 (in a more compact form) inside of a replacement one inch diameter ball 134 for the moveable ball type or inside the replaceable faucet cartridges with internally moveable valving parts.
[0052] The previous simple hollow sphere, now 134 (shown in FIGS. 12 , 13 and 14 ), is structurally divided into two separate compartments inside ball body 135 , an outer annular compartment 136 , coaxial with the centerline of the actuating stem 138 , and a cylindrical inner compartment 140 , also coaxial with the centerline of the actuating stem 138 . Passage 162 , connected to annulus 159 , and passage 164 , connected to central bore 157 , are separated by the valving action of the bypass valve 36 installed in compartment 140 . Ball 134 is made in two parts, an upper half 142 and a lower half 144 (relative to the stem 138 which normally extends upward), which screw together for convenience in development work. The thermal actuator 88 is enclosed in the inner compartment 140 is the same as the actuator discussed above, but with a shortened guide length and a cut-off piston 44 with no poppet. The radially squeezed O-ring 146 seals the two halves 142 and 144 of ball 134 , and is held in place by the spring 148 , which also functions as the bias or return spring. The piston 44 is cut off short to conserve space, and bears on the upper end of drilled hole 150 . Unlike the above-mentioned actuators, this piston 44 remains stationary and it's the thermal actuator body 48 that moves against spring 148 to push the elastomer poppet disc 152 , which doubles as a check valve, against the stationary seat 154 as the valve 134 heats up.
[0053] The two inlet ports on ball body 135 , shown as 156 for the hot water inlet port and 158 for the cold water inlet port on FIGS. 13 and 14 , selectively and adjustably communicate with the hot 20 and cold 16 lines. The ball discharge port 160 communicates in all ball positions with the faucet spout to discharge water from faucet 10 . Ports 156 , 158 and 160 are located in exactly the same locations on the ball body 135 as the prior art ball 64 previously. However all three ports are connected within the ball to annular compartment 136 instead of to the entire inner volume of the hollow prior art ball 64 . In the shut-off mode, the hot and cold inlet ball ports 156 and 158 , respectively, of ball 134 are shifted away from the hot 20 and cold 16 lines, as with prior art ball 64 . However, ball 134 includes two added small ports 162 and 164 to the un-perforated spherical surface that previously blocked off the hot 20 and cold 16 lines. Ports 162 and 164 connect the hot 20 and cold 16 lines to the central bore 157 and annulus 159 , which are valved by action of poppet disc 152 . When the ball 134 is cold due to a cooled-off hot water line 20 , the bypass valve 36 opens, allowing communication between the annulus 159 and central bore 157 . With the faucet 10 in the shut-off position, the two added ports 162 and 164 thus allow communication between a cooled-off “hot” line 20 and the cold line 16 , and consequently a flow of water from the boosted “hot” line 20 to the cold line 16 . Positioning slot 165 in ball 134 , also in ball 64 , is used to position ball 134 in the faucet. The bypass action described above is accomplished without change to any part of the faucet 10 except the replaceable valving ball 134 . It is thus very easy to retrofit an existing faucet to the bypass function by simply replacing the existing “standard” design hollow ball 64 with the new ball 134 , as described.
[0054] There are several major advantages to this arrangement. These advantages include: (1) the complete ball 134 is easily replaced to fix a malfunctioning bypass valve 36 ; (2) for retrofit, the original ball 64 can be removed and replaced with the new valve-in-ball 134 . No other changes need be made to the existing faucet 10 (however, a booster pump 26 located near the hot water heater 18 in the hot water line 20 does of course need to be installed). This is particularly advantageous where it would be very difficult or impractical to replace an existing complete faucet valve, such as a shower valve installed behind a tiled wall.
[0055] While the hollow ball 64 of the Delta faucet (and other clone faucets) provides an adequate space in a convenient location for installation of the bypass valve 36 , a miniaturized version of the bypass valve 36 can also be fitted into the replaceable cylindrical valving cartridges of other brands of single handle faucets with an action characterized by oscillating movement about a vertical centerline to adjust water temperature. Such a valving action to control mixing is commonly used in Price-Pfister, Sterling, American Standard, Moen, and Kohler faucets, among others. These faucets use a push-pull or tipping lever action to operate the on-off function within the same (usually) cylindrical cartridge. On some configurations, it is likely that space would have to be made by lengthening these cylindrical faucet cartridges, which would in turn call for a compensating change to the faucet central housing.
[0056] FIG. 15 shows a modification of a widely used Moen designed faucet 200 as an example of a fixture that utilizes a replaceable cylindrical valving cartridge 202 . The modifications to the faucet 200 include adding a hot water bypass valve 36 within the moving valving spool 204 of the Moen design. This valve design is of the type wherein on/off and metering adjustment is accomplished by axial motion of the center spool 204 (off is all the way inward). Hot/cold mixing adjustment is by angular positioning of the center spool 204 when it is wholly or partially pulled out to the on position. The faucet 200 typically has a brass housing 206 connected to the cold water inlet 208 and hot water inlet 210 . A spout connection 212 allows water to exit the fixture 200 . FIG. 15 shows the spool 204 in its outward or “full on” position (slot 214 axially aligns with spout port 212 and slot 216 axially aligns with cold 208 and hot 210 inlet ports) and angularly rotated so that the hot port 210 is open to slot 216 but cold port 208 is blocked off.
[0057] In the position shown in FIG. 15 , hot water from port 210 can enter through slot 216 to the interior of tubular spool 204 and proceed through hollow shuttle 218 to slot 214 and exit out spout port 212 . Arrows 220 indicate the length of travel of the spool 204 . Tubular member 222 is a stationary (preexisting) sleeve incorporated within the housing 206 to allow placement and retention of the three elastomer seals 224 to bear against and dynamically seal with spool 204 . It also provides a vent path around its exterior for the space at the “bottom” of the valve 200 to allow axial (piston) motion of spool 204 without encountering hydraulic lock. Spool 204 is shown in a simplified one-piece configuration for clarity.
[0058] The bypass valve 36 components (consisting of bias spring 226 , shuttle 218 , actuator piston 228 and actuator 230 ) are enclosed within the tubular portion of spool 204 . Shuttle 218 is located (floats) between bias spring 226 and actuator 230 . Shuttle 218 has a central cruciform shaped member with an integral elastomer sleeve 232 attached to the four legs of the cruciform. Four axial passages within the sleeve 232 and around the cruciform are thus provided. This elastomer sleeve 232 is in contact with and seals against the inner surface of tubular spool 204 . When thermal actuator 230 is heated to its actuation temperature, it “suddenly” extends piston 228 outward, moving shuttle 218 (to the left in FIG. 15 ) against bias spring 226 .
[0059] Two bleed holes 234 and 236 are so located through the wall of tubular spool 204 as to line up with hot water inlet 210 and cold water inlet 208 , respectively, when the manually operated spool 204 is pushed all the way into housing 206 (the off position). Further, bleed hole 236 is axially located slightly closer to the bias spring end of spool 204 . O-rings 238 seal spool 204 and retaining clip 240 holds sleeve 222 within housing 206 .
[0060] In FIG. 15 , the bypass valve 36 components are shown in their “cold” positions. Hot bleed hole 234 is covered by the end of the elastomer sleeve 232 on shuttle 218 , but cold bleed hole 236 is uncovered. With spool 204 pushed all the way in (off position) bleed hole 234 communicates with hot water inlet 210 and boosted hot water pressure communicates through hot bleed hole 234 . this pressure deflects elastomer sleeve 232 inward locally to allow flow from the boosted hot water line 20 (presumably cooled off from a period of disuse) into the interior of tubular spool 204 and out through uncovered cold bleed hole 236 , which by virtue of the spool 204 being in the off position is in communication with cold water inlet 208 . A bypass of cooled off water from the hot water line 20 to the cold water line 16 is thus accomplished.
[0061] When sufficient cooled off water has passed through the valve 200 to bring “hot” water to and through the valve 200 , actuator 230 will be warmed to its actuation temperature and will expand, forcing shuttle 218 against bias spring 226 . This axial movement will result in elastomer sleeve 232 covering cold bleed hole 236 . Boosted hot water pressure internal to sleeve 232 will hold sleeve 232 outward against the inner wall of tubular spool 204 , effectively sealing bleed hole 236 , and stopping the bypass flow until the valve cools down, causing bias spring 226 to force shuttle 218 back against piston 10 into contracting actuator 230 , again opening cold bleed hole 236 .
[0062] The elastomer sleeve 232 has a second function, that of acting as a check valve. When any faucet in the plumbing system is opened, the resulting flow may induce a substantial pressure drop in the associated plumbing line (either hot 20 or cold 16 , depending on which faucet was opened). If a bypass valve 36 is open at such a time, such a pressure difference may cause sufficient water to leak through so as to constitute a nuisance. If the lowered pressure is on the hot water line 20 , no “leak” will occur as the higher pressure of the cold water inside the sleeve 232 will hold it against the inner wall of tubular spool 204 in the vicinity of hot bleed hole 234 , effecting a seal. If the lowered pressure is on the cold side, the valve 200 will allow cooled off water from the hot water line 20 to bypass into the cold water line until warm water arrives at the valve 200 , at which time the shuttle 218 will shift and cut off the bypass.
Example 3
Dual Handle, Single Spout Faucets
[0063] Although two handle, single spout faucets might have been expected to fade out of demand in favor of the more convenient single handle faucets, the two handle faucets (shown as 10 in FIG. 1 ) seem more amenable to elegant cosmetic design than their single handle cousins, which have an inherently more utilitarian look. Apparently for this reason, most double handle faucets on display are for lavatory use. The same requirements for ease of maintenance by allowing access to the bypass valve 36 from the top apply to this faucet type. It is convenient that the prior art faucet design utilizing a rotating threaded stem with a faucet washer and a hard seat has become a thing of the past, as the newer designs with replaceable cartridges are more adaptable to this modification.
[0064] Most modern two handle faucets utilize a cartridge design in a pair of valve member 166 , shown in FIG. 16 , wherein the valving function is accomplished within the cartridge that is positioned inside the housing section 168 of valve member 166 . This allows complete re-conditioning of the faucet by simply replacing a single assembly on each side. These cartridges are accessible in the housing section 168 from the top by removing the faucet handles and bonnets that attach to the upper threaded portion 170 . The cartridge assembly then simply lifts out, exposing its open cavity inside housing section 168 , with a side port 172 leading to confluence with the like port from the other side of the faucet, which confluence flows on through the single spout of such faucets. Below the mentioned cavity for the faucet valving cartridge there is an open one-half inch (typically) threaded pipe 174 for the hot or cold conduit into the faucet. This externally threaded pipe is substantially longer than needed for valving or connection purposes to allow for overly thick lavatory counters and to get the lower end of these threaded pipes far enough down behind the sink for reasonable access by the installer. This “extra” space on the hot water side is a top accessible, hydraulically appropriate place to locate a thermal valve cartridge similar to the type described for inclusion in or adjacent to the hot water conduit in the central housing 62 of a single handle faucet. Side port 175 is added to housing section 168 and a line is run to a like port on the other, opposing faucet. Addition of a thermal bypass valve 36 requires additional machining and the addition of a bypass line connecting the hot and cold lines. An existing two handle single spout valve thus could not be retrofitted, but modifications to the design are relatively minor and the existing replaceable valve cartridge would fit the new design.
[0065] The major difference of concern in this matter between single handle single spout and two handle single spout faucet designs is that in the single handle central block, it is possible to create the connecting passages (bypass) by simply drilling cross holes, as discussed above. With two separate hot and cold faucet valves located four inches apart, some kind of cross conduit for the bypass must be added. There seem to be two approaches to directing the water from the hot and cold faucets to a confluence and out to the single spout. American-Standard, Oasis, La Bella and some Price-Pfisters use a large brass casting that includes the spout, both hot and cold faucet housings, and a cored east passage connecting all of this together. Adding a thermal bypass valve 36 to such a two handle faucet set would require the addition of an additional cored cast passage to accomplish the bypass function between hot and cold lines. Delta, Moen, Kohler, and some Price Pfister two handle single spout valves use brazed-in copper tube manifolds instead of cored cast passages. These would require the addition of a tubular cross passage brazed in. The Delta two handle single spout valve has a somewhat different valving action which makes it much more difficult to fit in a thermal valve cartridge. This new passage (cored or brazed tubular) needs to connect to the vertical hot and cold “pipe” members below their existing side port to the spout. These faucet sets generally do not have sufficient vertical space under the polished bezel to accommodate the extra passage. This will require addition of some vertical length to the skirt of the valve bezel.
[0066] FIG. 17 shows a modified “hot” side of a Kohler two handle faucet 176 , with the housing shown as 178 . The housing 178 is identical to the standard existing Kohler housing 178 above (to the right of) line AA. The housing 178 must be bored out in several steps to accommodate the new thermal valve cartridge 180 , which can be a molded plastic cartridge identical in function to that already described for the center block of the Delta single handle valve. It varies from the previously described cartridge in the configuration of the passage to bring the hot water past the thermal valve 36 to the faucet, and the configuration of the snap fit for the thermal actuator 88 . It also has an upper extension 182 with a through hole 184 . The extension 182 fits into a recess in the bottom of the existing Kohler faucet cartridge and the through hole 184 is for engagement of a hook to allow removal of the thermal valve cartridge 180 for replacement of the thermal bypass valve 36 .
[0067] The operation of the bypass valve 36 inside of faucet 10 of the present invention is summarized on the chart shown as FIG. 18 which indicates the results of the twenty combinations of conditions (pump on/pump off; hot water line hot/hot water line cooled off; hot faucet on, or off, or between; cold faucet on or off, or between) that are applicable to the operation of valve 36 . The operating modes IVB, IVC, IVD, IIIB, & IIID are summarized detailed in the immediately following text. The operation of the remaining fifteen modes are relatively more obvious, and may be understood from the abbreviated indications in the outline summarizing FIG. 18 . Starting with the set “off” hours (normal sleeping time, and daytime when no one is usually at home) pump 26 will not be powered. Everything will be just as if there were no pump 26 and no bypass valve 36 installed in faucet 10 (i.e., both the cold and hot water lines will be at the same city water pressure). The hot water line 20 and bypass valve 36 will have cooled off during the long interim since the last use of hot water. The reduced temperature in the valve results in “retraction” of rod member 40 of the thermally sensitive actuator 88 . The force of bias spring 106 pushing against flange 46 on rod member 40 will push it back away from valve seat 90 , opening valve 36 for recirculation. Although the thermal actuating element 88 is open, with pump 26 not running, no circulation flow results, as the hot 20 and cold 16 water piping systems are at the same pressure. This is the mode indicated as IVB in the outline on FIG. 18 . If the cold water valve at faucet 10 is opened with the thermal element 88 open as in mode IVB above, pressure in the line 16 to the cold water side of faucet 10 will drop below the pressure in the hot water line 20 . This differential pressure will siphon tepid water away from the hot side to the cold side, which is the mode indicated as IVD in the outline on FIG. 18 . The recirculation of the “hot” water will end when the tepid water is exhausted from the hot water line 20 and the rising temperature of the incoming “hot” water causes the thermal element 88 to close.
[0068] If the hot water valve is turned on with the thermal element 88 open as in mode IVB above, pressure in the line 20 to the hot water side of faucet 10 will drop below the pressure in the cold water line 16 . This differential pressure, higher on the cold side, will load check valve 96 in the “closed” direction allowing no cross flow. This is mode IVC in the outline on FIG. 18 . In this mode, with the hot water line 20 cooled and the pump off, a good deal of cooled-off water will have to be run (just as if valve 36 were not installed), to get hot water, at which time the thermal element 88 will close without effect, and without notice by the user. With the thermal element 88 open and the hot water line 20 cooled-off as in mode IVB above, at the preset time of day (or when the cyclic timer trips the next “on” cycle) the pump 26 turns on, pressurizing the water in the hot side of faucet 10 . Pump pressure on the hot side of faucet 10 results in flow through the open thermal element 88 , thereby pressurizing and deflecting the check valve 96 poppet away from its seat to an open position. Cooled-off water at the boosted pressure will thus circulate from the hot line 20 through the thermal element 88 and check valve 96 to the lower pressure cold line 16 and back to water heater 18 . This is the primary “working mode” of the bypass valve 36 and is the mode indicated as III b in the outline on FIG. 18 . If the cold water valve is turned on during the conditions indicated in mode IIIB above (i.e., pump 26 operating, hot line 20 cooled off, the hot valve at faucet 10 off) and while the desired recirculation is occurring, mode IIID will occur. A pressure drop in the cold water line 16 due to cold water flow creates a pressure differential across valve 36 in addition to the differential created by pump 26 . This allows tepid water to more rapidly bypass to the cold water inlet 22 at faucet 10 . When the tepid water is exhausted from the hot water line 20 , thermal element 88 will close, ending recirculation.
Explanation of FIG. 18 Table
[0069] MODE I: Water In Hot Water Supply Line Hot, Pump On.
A. Hot and cold faucet valves full open
Pressure drops from hot and cold flow about equal. Actuator element 26 stays closed. No leak or recirculation in either direction.
B. Hot and cold faucet valves fully closed
Thermal actuator 88 keeps valve 36 closed. No recirculation.
C. Hot faucet valve fully open, cold faucet valve closed
Actuator element 88 closed. Check valve 96 closed. No recirculation. No leak.
D. Hot faucet valve closed, cold faucet valve fully open
Actuator element 88 closed. No recirculation. No leak.
E. Hot and cold faucet valves both partially open in any combination
Actuator element 88 closed. No recirculation. No leak.
[0080] MODE II: Water in Hot Water Supply Line Hot, Pump Off.
A. Hot and cold faucet valves full on
Pressure drops from hot and cold flow about equal. Actuator element 88 stays closed.
B. Hot and cold faucet valves fully closed
Thermal actuator 88 keeps valve 36 closed. No recirculation.
C. Hot faucet valve fully open, cold faucet valve closed
Thermal actuator 88 closed. Check valve 96 closed. No recirculation. No leak.
D. Hot faucet closed, cold faucet fully open
Thermal actuator 88 closed. No recirculation. No leak.
E. Hot and cold faucets both partially open in any combo
Thermal actuator 88 closed. No recirculation. No leak.
[0091] MODE III: Water in Hot Water Line Cooled Off, Pump On.
A. Hot and cold faucet valves full open
Flow-induced pressure drops about equal, valve 36 stays open and allows recirculation hot to cold until tepid water is exhausted and hotter water closes thermal actuator 88 . If both faucet valves are at same sink, they are mixing hot and cold anyway. If faucet valves being manipulated are at remote sinks on the same plumbing branch, this short time tepid-to-cold leak will probably not be noticeable. If faucet valves being manipulated are on remote branches of plumbing, the mixing would have no effect.
B. Hot and cold faucet valves fully closed
Thermal actuator 88 open, get desired tepid-to-cold recirculation until hot line heats up.
C. Hot faucet valve fully open, cold faucet valve closed
Thermal actuator 88 open but pressure drop in hot line may negate pump pressure, stopping recirculation. Check valve 96 stops cold to hot leak.
D. Hot faucet valve closed, cold faucet valve fully open
Thermal actuator 88 open, get tepid to cold recirculation until hot line heats up.
E. Hot and cold faucets both partially open in any combination
Could get tepid to cold leak. If faucet valves at same sink don't care as mixing hot and cold anyway. If at remote sinks probably not noticeable. Tepid to cold leak would be short term.
[0102] MODE IV: Water In Hot Water Supply Line Cooled Off, Pump Off.
A. Hot and cold faucet valves full open
[0104] Flow-induced pressure drops about equal, valve 36 stays open and may allow recirculation (leak) hot to cold until tepid water is exhausted and hotter water a long shallow groove 190 in or a reduced diameter of piston 44 that would extend from just inside the guide bore 186 (at full extension) to just outside the guide bore 186 at full retraction would provide a recess to contain buildup for a long period. Once this recessed area filled up with lime, the edge 188 of guide bore 186 could scrape off the incrementally radially extending soft build up relatively easily, as compared to scraping off the surface layer that bonds more tenaciously to the metal.
[0105] The most direct method to overcome sticking due to mineral buildup is to optimize actuator force in both directions. Buildup of precipitated minerals on the exposed outside diameter of the extended piston 44 tends to prevent retraction, requiring a strong bias spring 106 . This high bias spring force subtracts from the available extending force however, thereby limiting the force available to both extend the piston 44 against the mineral sticking resistance and to effect an axial seal between poppet and seat.
[0106] When water temperature is high, the piston 44 is extended so that its surface is exposed. Deposition also occurs primarily at high temperatures, so that buildup occurs on the piston outside diameter, resulting in sticking in the extended position when the growth on the piston outside diameter exceeds the guide 186 interior diameter. Significantly more than half of the available actuator force thus can most effectively be used to compress the bias spring 106 , resulting in a maximum return force.
[0107] While there is shown and described herein certain specific alternative forms of the invention, it will be readily apparent to those skilled in the art that the invention is not so limited, but is susceptible to various modifications and rearrangements in design and materials without departing from the spirit and scope of the invention. In particular, it should be noted that the present invention is subject to modification with regard to the dimensional relationships set forth herein and modifications in assembly, materials, size, shape, and use. While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope.
[0108] It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means—plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
|
A water control fixture includes a fixture body in fluid communication with a pressurized supply of hot water and a pressurized supply of cold water. The fixture body interconnects the supply of hot water and the supply of cold water. The fixture body has a spout outlet configured to dispense water from the fixture body. At least one operating valve is coupled to the fixture body for controlling a flow of water to the spout outlet. A bypass valve is disposed in the fixture body for controlling a recirculating flow of water through the fixture body. The bypass valve blocks and permits recirculating flow from the supply of hot water to the supply of cold water based on a temperature of the water.
| 8
|
FIELD OF INVENTION
[0001] The invention concerns the use of bleaching solutions.
BACKGROUND OF THE INVENTION
[0002] Raw cotton (gin output) is dark brown in colour due to the natural pigment in the plant. The cotton and textile industries recognise a need for bleaching cotton prior to its use in textiles and other areas. The object of bleaching such cotton fibres is to remove natural and adventitious impurities with the concurrent production of substantially whiter material.
[0003] There have been two major types of bleach used in the cotton industry. One type is a dilute alkali or alkaline earth metal hypochlorite solution. The second type of bleach is a peroxide solution, e.g., hydrogen peroxide solutions. This bleaching process is typically applied at high temperatures, i.e. 80 to 95° C. Controlling the peroxide decomposition due to trace metals is key to successfully using hydrogen peroxide. Often Mg-silicates or sequestering agents such as EDTA or analogous phosphonates are applied to reduce decomposition. A problem with the above types of treatment is that the cotton fibre is susceptible tendering.
[0004] Wood pulp produced for paper manufacture either contains most of the originally present lignin and is then called mechanical pulp or it has been chiefly delignified, as in chemical pulp. Mechanical pulp is used for e.g. newsprint and is often more yellow than paper produced from chemical pulp (such as for copy paper or book-print paper). Further, paper produced from mechanical pulp is prone to yellowing due to light- or temperature-induced oxidation. Whilst for mechanical pulp production mild bleaching processes are applied, to produce chemical pulp having a high whiteness, various bleaching and delignification processes are applied. Widely applied bleaches include elemental chlorine, hydrogen peroxide, chlorine dioxide and ozone.
[0005] Whilst for both textile bleaching and wood pulp bleaching, chlorine-based bleaches are most effective, there is a need to apply oxygen-based bleaches for environmental reasons. Hydrogen peroxide is a good bleaching agent, however, it needs to be applied at high temperatures and long reaction times. For industry it is desirable to be able to apply hydrogen peroxide at lower temperatures and shorter reaction times than in current processes. Towards this end, the use of highly active bleaching catalysts would be desirable.
[0006] As a particular class of active catalysts, the azacyclic molecules have been known for several decades, and their complexation chemistry with a large variety of metal ions has been studied thoroughly. The azacyclic molecules often lead to transition-metal complexes with enhanced thermodynamic and kinetic stability with respect to metal ion dissociation, compared to their open-chain analogues.
[0007] United States Application 2001/0025695, discloses the use of a manganese transition metal catalyst of 1,4,7-Trimethyl-1,4,7-triazacyclononane (Me 3 -TACN); the transition metal catalyst has as a non-coordinating counter ion PF 6 − . United States Application 2001/0025695A1 also discloses a manganese transition metal catalyst of 1,2,-bis-(4,7,-dimethyl-1,4,7,-triazacyclonon-1-yl)-ethane (Me 4 -DTNE); the transition metal catalyst has as a non-coordinating counter ion ClO 4 − . The solubility, in water at 20° C., of the Me4-DTNE complex having non-coordinating counter ion ClO 4 − is about 16 gram/Liter. The solubility, in water at 20° C., of the Me4-DTNE complex having non-coordinating counter ion PF 6 − is about 1 gram/Liter.
[0008] US 2002/0066542 discloses the use of a manganese transition metal complex of Me 3 -TACN in comparative experiments and makes reference to WO 97/44520 with regard to the complex; the non-coordinating counter ion of the manganese transition metal complex of Me 3 -TACN is PF 6 − . The X groups as listed in paragraph [021] of US 2002/0066542 are coordinating.
[0009] EP 0458397 discloses the use of a manganese transition metal complex of Me 3 -TACN as bleaching and oxidation catalysts and use for paper/pulp bleaching and textile bleaching processes. Me 3 -TACN complexes having the non-coordinating counter ion perchlorate, tetraphenyl borate (BPh 4 − ) and PF 6 − are disclosed. The solubility, in water at 20° C., of the Me 3 -TACN complex having non-coordinating counter ion ClO 4 − is between 9.5 to 10 gram/Liter. The solubility, in water at 20° C., of the Me 3 -TACN complex having non-coordinating counter ion BPh 4 − is less then 0.01 gram/Liter.
[0010] WO 95/27773 discloses the use of manganese transition metal catalysts of 1,4,7-Trimethyl-1,4,7-triazacyclononane (Me 3 -TACN); the transition metal catalysts have as a non-coordinating counter ion ClO 4 − and PF 6 − .
[0011] 1,4,7-Trimethyl-1,4,7-triazacyclononane (Me 3 -TACN) has been used in dishwashing for automatic dishwashers, SUN™, and has also been used in a laundry detergent composition, OMO Power™. The ligand (Me 3 -TACN) is used in the form of its manganese transition-metal complex, the complex having a counter ion that prevents deliquescence of the complex. The counter ion for the commercialised products containing manganese Me 3 -TACN is PF 6 − . The Me 3 -TACN PF 6 − salt has a water solubility of 10.8 g per litre at 20° C. Additionally, the perchlorate (ClO 4 − ) counter ion is acceptable from this point of view because of its ability to provide a manganese Me 3 -TACN that does not appreciably absorb water. Reference is made to U.S. Pat. No. 5,256,779 and EP 458397, both of which are in the name of Unilever. One advantage of the PF 6 − or ClO 4 − counter ions for the manganese Me 3 -TACN complex is that the complex may be easily purified by crystallisation and recrystallisation from water. In addition, for example, the non-deliquescent PF 6 − salt permits processing, e.g., milling of the crystals, and storage of a product containing the manganese Me 3 -TACN. Further, these anions provide for storage-stable metal complexes. For ease of synthesis of manganese Me 3 -TACN highly deliquescent water soluble counterions are used, but these counterions are replaced with non-deliquescent, much less water soluble counter ions at the end of the synthesis. During this exchange of counter ion and purification by crystallisation loss of product results. A drawback of using PF 6 − is its significant higher cost compared to other highly soluble anions.
[0012] U.S. Pat. Nos. 5,516,738 and 5,329,024 disclose the use of a manganese transition metal catalyst of 1,4,7-Trimethyl-1,4,7-triazacyclononane (Me 3 -TACN) for epoxidizing olefins; the transition metal catalyst has as a non-coordinating counter ion ClO 4 − . U.S. Pat. No. 5,329,024 also discloses the use of the free Me 3 -TACN ligand together with manganese chloride in epoxidizing olefins.
[0013] WO 2002/088063, to Lonza AG, discloses a process for the production of ketones using PF 6 − salts of manganese Me 3 -TACN.
[0014] WO 2005/033070, to BASF, discloses the addition of an aqueous solution of Mn(II)acetate to an aqueous solution of Me 3 -TACN followed by addition of a organic substrate followed by addition of hydrogen peroxide.
[0015] Use of a water-soluble salt negates purification and provides a solution, which may be used directly, and reduces loss by purification.
SUMMARY OF INVENTION
[0016] We have found that there is an advantage in using a preformed transition metal complex of azacyclic molecules over in situ generation, for example by mixing the appropriate ligand with the MnCl 2 , MnSO 4 or Mn(OAc) 2 salts in an industrial process. Further, the addition of one product to a reaction vessel reduces errors in operation.
[0017] We have found that for certain applications the use of a highly water-soluble salt of the manganese azacyclic complex is preferable. We have found that the dominant factor in the solubility of these transition metal complexes is the non-coordinating counter ion(s). In the solubilities given herein for (Me 3 -TACN) the co-ordinating counter ions are three O 2− and for Me 4 -DTNE the co-ordinating counter ions are two O 2− and one acetate.
[0018] The invention is particularly applicable to industrial bleaching of paper/pulp, cotton-textile fibres, and the removal or degradation of starches. By using a transition metal catalyst that is significantly water soluble the synthesis negates the preparation of significantly water insoluble salts and hence reduces cost. The transition metal catalyst may be shipped in solution or as a solid form of transition metal catalyst which is easily dissolved in water.
[0019] In order to avoid the use of costly non-coordinating counter ions required for isolation, formulation and stabilisation, one might form the transition metal catalyst in situ. U.S. Pat. No. 5,516,738 discloses the use of free Me 3 -TACN ligand with Mn(II) Cl 2 in epoxidizing olefins. However the in situ preparation has some drawbacks, for example, it is a more complicated process and uncontrolled side reactions occur which result in less efficient formation of the catalyst and undesirable side products like MnO 2 . Fast decomposition of hydrogen peroxide, catalysed by some of the undesirable side products might occur, reducing the efficiency of the bleach process.
[0020] In one embodiment the present invention provides a method of catalytically treating a substrate, the substrate being a cellulose-containing substrate or starch containing substrate, with a preformed transition metal catalyst salt, the preformed transition metal catalyst salt having a non-coordinating counter ion, the method comprising the following steps:
[0000] (i) optionally dissolving a concentrate or solid form of a preformed transition metal catalyst salt in an aqueous medium to yield an aqueous solution of the preformed transition metal catalyst salt;
(ii) adding the aqueous solution of the preformed transition metal catalyst salt to a reaction vessel; and,
(iii) adding hydrogen peroxide to the reaction vessel,
wherein the preformed transition metal catalyst salt is a mononuclear or dinuclear complex of a Mn (III) or Mn(IV) transition metal catalyst for catalytically treating the substrate with hydrogen peroxide, the non-coordinating counter ion of said transition metal selected to provide a preformed transition metal catalyst salt that has a water solubility of at least 30 g/l at 20° C. and wherein the ligand of the transition metal catalyst is of formula (I):
[0000]
[0000] wherein:
p is 3;
R is independently selected from: hydrogen, C1-C6-alkyl, CH 2 CH 2 OH, and CH 2 COOH, or one of R is linked to the N of another Q via an ethylene bridge;
R1, R2, R3, and R4 are independently selected from: H, C1-C4-alkyl, and C1-C4-alkylhydroxy, and the substrate is bought into contact with a mixture of the aqueous solution of the preformed transition metal catalyst salt and the hydrogen peroxide. The dinuclear complex may have two manganese in same or differing oxidation states.
[0021] R is preferably C1-C6-alkyl, most preferably Me, and/or one of R is an ethylene bridge linking the N of Q to the N of another Q.
[0022] The reaction vessel may be part of a continuous flow apparatus or a vessel used in a batch process. Preferably pulp and cotton are treated in a continuous flow process. Steps (ii) and (iii) provide a mixture of the aqueous solution of the preformed transition metal catalyst salt and the hydrogen peroxide; the substrate is bought into contact with this mixture and hence is treated with such within the reaction vessel.
[0023] The preformed transition metal catalyst salt is one which has been provided by bringing into contact the free ligand or protonated salt of the free ligand and a manganese salt in solution followed by oxidation to form a Mn (III) or Mn(IV) transition metal catalyst. Preferred protonated salts of the ligand are chloride, acetate, sulphate, and nitrate. The protonated salts should not have undesirable counterions such as perchlorate or PF 6 − . The contact and oxidation step is preferably carried out in an aqueous medium, at least 24 hours before use, preferably at least 7 days before use.
[0024] The rate of formation of the transition metal catalyst depends upon the ligand. The formation of a transition metal catalyst from Me 3 -TACN ligand is typically complete within 5 min. The formation of a transition metal catalyst from Me 4 -DTNE ligand requires about 20 to 30 min for optimal complexation. After complex formation an aqueous solution of H 2 O 2 /NaOH may be slowly added to form a desired Mn(IV)/Mn(IV) or Mn(IV)/Mn(III) species. This second step, the oxidation step, provides a sufficiently stable complex for storage.
[0025] In another aspect the present invention provides the preformed transition metal catalyst salt as defined herein, wherein the preformed transition metal catalyst salt has been formed by a contact and oxidation step that is carried out at least 24 hours previously, preferably 7 days previously, and is stored in a closed, preferably sealed, container.
[0026] The present invention also extends to the substrate treated with preformed transition metal catalyst and hydrogen peroxide.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The solubility, in water at 20° C., of the Me 3 -TACN complex having non-coordinating counter ion acetate is more than 70 gram/Liter. The solubility, in water at 20° C., of the Me 3 -TACN complex having non-coordinating counter ion sulphate is more than 50 gram/Liter. The solubility, in water at 20° C., of the Me 3 -TACN complex having non-coordinating counter ion chloride is 43 gram/Liter. It is most preferred the preformed transition metal catalyst salt is a dinuclear Mn(III) or Mn(IV) complex with at least two O 2− bridges.
[0028] The method of treating paper/pulp, cotton-textile fibres, or starch containing substrate is most applicable to industrial processes. Other examples of such processes are laundry or mechanical dish washing applications, fine chemical synthesis. Most preferably the method is applied to wood pulp, raw cotton, or industrial laundering. In this regard, the wood pulp is bleached which has not been processes into a refined product such as paper. The raw cotton is in most cases treated/bleached after preparation of the raw cotton cloths or bundled fibres. Preferably the method of treatment is employed in an aqueous environment such that the liquid phase of the aqueous environment is at least 80 wt % water, more preferably at least 90 wt % water and even more preferably at least 95 wt % water. After treatment of the substrate the reactants may be recycled back into the reaction vessel.
[0029] In addition, poly-cotton may also advantageously be treated in the form of a thread or a woven garment. Another preferred utility is in the industrial bleaching market of laundry, for example, the bleaching of large amounts of soiled white bed linen as generated by hospitals and gaols.
[0030] Preferably R is independently selected from: hydrogen, CH 3 , C 2 H 5 , CH 2 CH 2 OH and CH 2 COOH; least preferred of this group is hydrogen. Most preferably R is Me and/or one of R is an ethylene bridge linking the N of Q to the N of another Q. Preferably R1, R2, R3, and R4 are independently selected from: H and Me. Preferred ligands are 1,4,7-Trimethyl-1,4,7-triazacyclononane (Me 3 -TACN) and 1,2,-bis-(4,7-dimethyl-1,4,7,-triazacyclonon-1-yl)-ethane (Me 4 -DTNE) of which Me 3 -TACN is most preferred. The manganese ion is most preferably Mn(III) or Mn(IV), most preferably Mn(IV).
[0031] The water solubility of the preformed transition metal catalyst salt is at least 30 g/l at 20° C., more preferably at least 50 g/l at 20° C. Even more preferably the water solubility of the preformed transition metal catalyst salt is at least 70 g/l at 20° C. and most preferably the salt is deliquescent. The high solubility provides for concentrates whilst avoiding precipitation or crystallisation of the preformed transition metal catalyst salt. The preformed transition metal catalyst salt (cationic) used in the method is most preferably a single species. In this regard, the aqueous solution used comprises at least 90% of a single species. The non-coordinating counter ions may, for example, be a mixture of acetate and chloride.
[0032] The non-coordinating anion of the transition metal catalyst salt is preferably selected from the group consisting of chloride, acetate, sulphate, and nitrate. Most preferably the salt is acetate. The salt is other than the perchlorate.
[0033] Co-ordinating counter ions for the transition metal complexes are O 2− and/or carboxylate (preferably acetate). It is preferred that the transition metal complexes have at least one O 2− coordinating counter ion. In particular, for Me 3 -TACN three O 2− co-ordinating counter ions are preferred or one O 2− co-ordinating counter ion and two carboxylate co-ordinating counter ions are preferred, with two acetate moieties as co-ordinating counter ions being most preferred. For Me 4 -DTNE two O 2− coordinating counter ions and one acetate co-ordinating counter ion are preferred.
[0034] It is preferred that the transition metal catalyst salt is present in a buffer system that maintains the solution in the pH range 2 to 7, and preferably in the pH range 4 to 6. The buffer systems is preferably phosphate or carboxylate containing buffers, e.g., acetate, benzoate, citrate. The buffer system most preferably keeps the transition metal catalyst salt in the range pH 4.5 to 5.5.
[0035] The catalyst solution may also be provided in a reduced volume form such that it is in a concentrate, solid or slurry which is then dispatched to its place of use. Removal of solvent is preferably done by reduced pressure rather than the elevation of temperature. Preferably the solution, solid or slurry is stored over an inert atmosphere, e.g., nitrogen or argon, with little or no headspace at 4° C. For storage purposes a preformed transition metal catalyst salt concentration range of 0.1 to 10% is desirable, more desirable is between 0.5 and 8%, and most desirable is between 0.5 and 2%. The concentrate or solid or solid most preferably has the pH means as described above before reduction of water volume.
[0036] In the bleaching process it is preferred that the substrate is contacted with between from 0.1 to 100 micromolar of the preformed transition metal catalyst and from 5 to 1500 mM of hydrogen peroxide.
[0037] Preferably the preformed transition metal catalyst salt and hydrogen peroxide are mixed just before introduction to the substrate.
EXPERIMENTAL
[0038] Examples on the syntheses of Mn 2 O 3 (Me 3 -TACN) 2 complexes with different anions are provided. Synthesis of the Mn 2 O 3 (Me 3 -TACN) 2 PF 6 salt is disclosed in U.S. Pat. No. 5,153,161, U.S. Pat. No. 5,256,779, and U.S. Pat. No. 5,274,147. The solubility of the Mn 2 O 3 (Me 3 -TACN) 2 PF 6 salt in water at 20° C. is 1.08% (w/w).
Preparation of Aqueous Solution of [Mn 2 O 3 (Me3-TACN) 2 ].(Cl) 2
[0039] To 10 mmol (1.71 gram Me3-TACN in 10 ml water was added 10 mmol (1.98 gram) solid MnCl 2 .4H 2 O while stirring under nitrogen flow. The mixture turned white/bluish. After 5 minutes stirring a freshly prepared mixture of 10 ml 1 M hydrogen peroxide and 2 ml of 5 M (20%) NaOH was added drop-wise over 5 minutes. The mixture turned immediately dark brown/red. At the end of the addition some gas evolution was observed. After completion of the addition the nitrogen flow was stopped and the stirring was continued for 5 minutes and pH was set with to neutral/acidic (pH 5 paper) with 1 M hydrochloric acid. The mixture was filtered through G4 glass frit, washed with water and the collected red filtrate and wash diluted to 50.00 ml in a graduated flask. From this solution a 1000× dilution was made and from the absorption in the UV/Vis spectrum at 244, 278, 313, 389 and 483 nm the concentration in the stock was calculated and the yield (based on extinction of the PF 6 analogue in water) Extinction of 1000× diluted sample gave
[0000] 244 nm 1.692 278 nm 1.619 313 nm 1.058 389 nm 0.108 485 nm 0.044
Calculated yield 91%, solution contains 5.2% (on weight basis) of the catalyst.
Preparation of Aqueous Solution of [of [Mn 2 O 3 (Me 3 -TACN) 2 ].(OAc) 2
[0040] To 10 mmol (1.71 gram Me 3 -TACN in 10 ml water was added 10 mmol (2.47 gram) solid MnCl 2 .4H 2 O while stirring under nitrogen flow. The mixture turned to a bluish solution. After 5 minutes stirring a freshly prepared mixture of 10 ml 1 M hydrogen peroxide and 2 ml of 5 M (20%) NaOH was added drop-wise over 5 minutes. The mixture turned immediately dark brown/red. At the end of the addition some gas evolution was observed. After completion of the addition the nitrogen flow was stopped and the stirring was continued for 5 minutes and pH was set with to neutral/acidic (pH 5 paper) with 1 M acetic acid. The mixture was filtered through a G4 glass frit, washed with water and the collected red filtrate and wash diluted to 50.00 ml in a graduated flask. From this solution a 1000× dilution was made and from the absorption in the UV/Vis spectrum at 244, 278, 313, 389 and 483 nm the concentration in the stock was calculated and the yield (based on extinction of the PF 6 analogue in water)
[0000] 244 nm 1.689 278 nm 1.626 313 nm 1.074 389 nm 0.124 485 nm 0.051
Calculated yield 88%; solution contains 5.2% (on weight basis) of the catalyst.
Preparation of Aqueous Solution of [Mn 2 O 3 (Me 3 -TACN) 2 ].SO 4
[0041] To 10 mmol (1.7 gram Me 3 -TACN in 10 ml water was added 10 mmol (1.98 gram) solid MnCl 2 .4H 2 O while stirring under nitrogen flow. The mixture turned to a white suspension. After 5 minutes stirring a freshly prepared mixture of 10 ml 1 M hydrogen peroxide and 2 ml of 5 M (20%) NaOH was added drop-wise over 5 minutes. The mixture turned immediately dark brown/red. At the end of the addition some gas evolution was observed. After completion of the addition the nitrogen flow was stopped and the stirring was continued for 5 minutes and pH was set with to neutral/acidic (pH 5 paper) with 1 M sulphuric acid. The mixture was filtered through a G4 glass frit, washed with water and the collected red filtrate and wash diluted to 50.00 ml in a graduated flask. From this solution a 1000× dilution was made and from the absorption in the UV/Vis spectrum at 244, 278, 313, 389 and 483 nm the concentration in the stock was calculated and the yield (based on extinction of PF 6 analogue in water)
[0000] 244 nm 1.648 278 nm 1.572 313 nm 1.022 389 nm 0.103 485 nm 0.042
Calculated yield 98%; solution contains 5.2% (on weight basis) of the catalyst.
Stability Experiments
[0042] Stability of aqueous solutions of chloride, sulphate and acetate salts are provided. Solutions of the bleach catalyst with chloride, sulphate and acetate anion were brought to pH 2, 3, 4 and 5 by hydrochloric acid, sulphuric acid and acetic acid respectively. For the acetate this could only give pH 5. For the lower pH values sulphuric acid was used in the case of acetate. The solutions were kept at 37° C. and after 2 weeks the stability was monitored from the absorptions in the UV/Vis spectra of 1000× diluted solutions.
[0000]
2 week results at 37° C.
pH 2
pH 3
pH 4
pH 5
Chloride
% (UV/Vis)
100
100
97
94
(Precipitate is formed at all pH's)
Acetate
% (UV/Vis)
87
91
93
95
(No precipitate is formed)
Sulphate
% (UV/Vis)
78
96
94
98
Precipitate only at pH = 5)
[0043] For the two weeks results it is clear within experimental error (ca 5%) at pH 3 and higher no instability issue occurs.
[0044] Softwood chemical mill pulp obtained after the D0 bleaching stage (abbreviated as softwood D0 pulp) was used. The bleaching experiments were conducted on small scale in 100 ml vessels using the pulps at 5% consistency (i.e., 5% oven dry wood pulp; 95% aqueous bleaching liquor). The mixture contained 2.5 microM of the catalyst (as chloride, sulfate, acetate and PF 6 salts—see Table), 1 kg/t of MgSO 4 , 8 kg/t of NaOH and 10 kg/t of H 2 O 2 (kg/t: kg chemicals per ton oven dry pulp). The mixture was manually stirred to ensure good distribution of the bleaching chemicals. Then the vessel was placed in a water bath and stirred regularly at 50° C. for 1 h. All experiments were carried out at least 6 times. As a reference the experiment was conducted without catalyst. The dosages and exact reaction conditions are given in the sections below. After the allocated bleaching times the pulp batches were removed from the vessels, filtered using a Buchner funnel, and washed with 100 ml of water. From the resultant samples of bleached pulp 4×4 cm discs were made having a flat surface on one side. The softwood D0 pulp samples were dried using a L&W Rapid Dryer (Lorentzen and Wetter) at 90° C. for 20 minutes. Whiteness of the bleached pulps was determined using L, a*, b* values as defined by CIE (Commission Internationale de l'Eclairage) of the dried pad was measured using a Minolta spectrophotometer.
[0045] Results (all whiteness values show a standard deviation of 0.3 points.
[0000]
Complex
Whiteness
[Mn 2 O 3 (Me 3 -TACN) 2 ]•(PF 6 ) 2
84.4
comparative example
[Mn 2 O 3 (Me 3 -TACN) 2 ]•Cl 2
84.3
[Mn 2 O 3 (Me 3 -TACN) 2 ]•(OAc) 2
84.0
[Mn 2 O 3 (Me 3 -TACN) 2 ]•SO 4
84.1
Blank (only H 2 O 2 )
77.0
[0046] The data presented in the table show clearly that the bleaching effect is the same for all different catalyst-salt complexes.
|
The present invention concerns bleaching of substrates with an aqueous solution of a water soluble salt of a preformed transition metal catalyst together with hydrogen peroxide.
| 3
|
PRIORITY CLAIM
[0001] This application is a divisional of U.S. patent application Ser. No. 12/279,472, filed on Oct. 16, 2008, which is the U.S. national stage designation of International Application No. PCT/EP07/051,448 filed Feb. 14, 2007, which claims priority to EP06101690.3 filed Feb. 15, 2006, the entire disclosures of which are incorporated by reference.
BACKGROUND
[0002] This invention relates to a method for the prevention and treatment of inflammation.
[0003] In the recent past, certain strains of bacteria have attracted considerable attention because they have been found to exhibit valuable properties for man if ingested. In particular, specific strains of the genera Lactobacillus and Bifidobacterium have been found to be able to establish themselves in the intestinal tract and transiently colonise the intestine, to reduce the adherence of pathogenic bacteria to the intestinal epithelium, to have immunomodulatory effects and to assist in the maintenance of well-being. Such bacteria are commonly called probiotics.
[0004] Extensive studies have been carried out to identify new probiotic strains. For example, EP 0 199 535, EP 0 768 375, WO 97/00078, EP 0 577 903 and WO 00/53200 disclose specific strains of lactobacilli and bifidobacteria and their beneficial effects.
[0005] Inflammation is a complex reaction of the innate immune system that involves the accumulation and activation of leucocytes and plasma protein at sites of infection, toxin exposure or cell injury. Although inflammation serves as a protective function in controlling infections and promoting tissue repair, it can also cause tissue damage and disease. Gastrointestinal diseases such as inflammatory bowel disease (for example Crohn's disease, ulcerative colitis, and pouchitis), food allergies and atopic dermatitis resulting from food allergies are always accompanied by aberrant intestinal inflammatory responses at different levels. The alleviation of this intestinal inflammation by balancing pro- and anti-inflammatory cytokines or induction of regulatory cytokines has been suggested as a possible treatment for these chronic diseases. There are numerous such cytokines of which IFN-γ, IL1, IL8, IL12 and TNF-α for example are regarded as pro-inflammatory and IL10 and TGF-β for example are regarded as anti-inflammatory.
[0006] Macrophages are tissue based phagocytic cells derived from monocytes which play an important role in the innate immune response. They are activated by microbial components and, once activated can themselves secrete both pro- and anti-inflammatory cytokines. In “Stimulation of the Secretion of Pro-Inflammatory Cytokines by Bifidobacterium Strains” (Microbiol. Immunol., 46(11), 781-785, 2002) He et al investigated the ability of different bifidobacteria strains to affect the production of macrophage derived cytokines. They discovered that “adult type” bifidobacteria such as Bifidobacterium adolescentis and Bifidobacterium longum induced significantly more pro-inflammatory cytokine secretion than did “infant type” bifidobacteria such as Bifidobacterium bifidum, Bifidobacterium breve and Bifidobacterium infantis . In addition they noted that B. adolescentis in particular did not stimulate production of the anti-inflammatory cytokine IL-I0. They concluded that adult-type bifidobacteria may be more potent to amplify, but less able to down-regulate, the inflammatory response.
[0007] More recently, attempts to identify the most promising anti-inflammatory probiotic strains for human use have indicated that the generalizations made by He et al are likely to prove unreliable as it has now been demonstrated that the properties of a specific strain—for example its anti-inflammatory properties—cannot be accurately predicted by reference to its taxonomic classification.
SUMMARY
[0008] The present inventors have surprisingly discovered that a specific probiotic strain of B. longum , namely Bifidobacterium longum ATCC BAA-999, has exceptional anti-inflammatory properties.
[0009] Accordingly, the present invention provides the use of Bifidobacterium longum ATCC BAA-999 in the manufacture of a medicament or therapeutic nutritional composition for preventing or reducing inflammation in a mammal.
[0010] The invention further extends to a method of preventing or reducing inflammation in a mammalian patient in need thereof which comprises administering to the patient a therapeutic amount of Bifidobacterium longum ATCC BAA-999.
[0011] The present invention may be used in circumstances where it is desired to prevent or reduce intestinal inflammation irrespective of the underlying condition which may be, for example, a reaction to a food allergen, chronic or acute intestinal inflammation caused by a disease of the gastrointestinal tract such as inflammatory bowel disease or colitis, post-infective inflammation or chronic sub-clinical inflammation in the elderly as well as in circumstances where it is desired to prevent inflammation in the sense of prophylaxis i.e. where there is no underlying condition giving rise to inflammation.
[0012] An advantage of the present invention is that it may be used to reduce or prevent inflammation in a mammal by oral administration of a therapeutic nutritional composition or medicament incorporating the probiotic. It will be appreciated that such oral administration is more acceptable and convenient for the patient than a composition requiring intravenous or subcutaneous administration which not only requires specially trained personnel, but also is neither as safe nor as convenient.
[0013] Additional features and advantages are described herein, and will be apparent from, the following Detailed Description.
DETAILED DESCRIPTION
[0014] In the present specification, the following words are given a definition that must be taken into account when reading and interpreting the description, examples and claims.
[0015] “Infant”: child under the age of 12 months;
[0016] “Infant formula”: foodstuff intended for the complete nutrition of infants during the first four to six months of life and as a complement to other foodstuffs up to the age of 12 months.
[0017] “Probiotic”: microbial cell preparations or components of microbial cells with a beneficial effect on the health or well-being of the host. (Salminen S, Ouwehand A. Benno Y. et al “Probiotics: how should they be defined” Trend Food Sci. Technol. 1999:10 107-10).
[0018] The mammal may be a human or a companion animal such as a dog or cat.
[0019] The Bifidobacterium longum ATCC BAA-999 (“BL999”) may be administered on its own, for example enclosed in capsules each containing, for example, 10 8 colony forming units (cfu) or incorporated in a nutritional composition such as a nutritionally complete formula (for example an infant formula or a clinical nutrition product), a dairy product, a beverage powder, a dehydrated soup, a dietary supplement, a meal replacement, a nutritional bar, a cereal, a confectionery product or a dry pet food. When incorporated in a nutritional composition, BL999 may be present in the composition in an amount equivalent to between 10 4 and 10 12 cfu/g (dry weight). These expressions of quantity include the possibilities that the bacteria are live, inactivated or dead or even present as fragments such as DNA or cell wall materials or as metabolites. In other words, the quantities of bacteria are expressed in terms of the colony forming ability of that quantity of bacteria as if all the bacteria were live irrespective of whether they are, in fact, live, inactivated or dead, fragmented or a mixture of any or all of these states. Preferably the BL999 is present in an amount equivalent to between 10 5 to 10 10 more preferably 10 7 to 10 10 cfu/g of dry composition.
[0020] BL999 may be obtained from Morinaga Milk Industry Co. Ltd. of Japan under the trade mark BB536. It may be cultured according to any suitable method and prepared for encapsulation or addition to a nutritional composition by freeze-drying or spray-drying for example. Alternatively, it may be purchased already prepared in a suitable form for addition to food products.
[0021] A nutritionally complete formula for use in the present invention may comprise a source of protein, preferably a dietary protein such as an animal protein (for example milk, meat or egg protein), a vegetable protein (for example soy, wheat, rice or pea protein); mixtures of free amino acids; or combinations thereof. Milk proteins such as casein and whey protein and soy proteins are particularly preferred. The composition may also contain a source of carbohydrates and a source of fat.
[0022] If the formula includes a fat source, it preferably provides 5% to 55% of the energy of the formula; for example 20% to 50% of the energy. The lipids making up the fat source may be any suitable fat or fat mixture. Vegetable fats such as soy oil, palm oil, coconut oil, safflower oil, sunflower oil, corn oil, canola oil, and lecithins are particularly suitable. Animal fats such as milk fat may also be added if desired.
[0023] If the formula includes a carbohydrate source, it preferably provides 40% to 80% of the energy of the formula. Any suitable carbohydrate may be used, for example sucrose, lactose, glucose, fructose, corn syrup solids, maltodextrins, and mixtures thereof. Dietary fibre may also be added if desired. The dietary fibre may be from any suitable origin, including for example soy, pea, oat, pectin, guar gum, gum Arabic, fructooligosaccharides, galacto-oligosaccharides, sialyl-lactose and oligosaccharides derived from animal milks. Suitable vitamins and minerals may be included in the nutritional formula in an amount to meet the appropriate guidelines.
[0024] One or more food grade emulsifiers may be incorporated into the nutritional formula if desired; for example diacetyl tartaric acid esters of mono- and di-glycerides, lecithin and mono- and di-glycerides. Similarly suitable salts and stabilisers may be included.
[0025] The nutritionally complete formula may be prepared in any suitable manner. For example, the protein source, the carbohydrate source, and the fat source may be blended together in appropriate proportions. If used, the emulsifiers may be included in the blend. The vitamins and minerals may be added at this point but are usually added later to avoid thermal degradation. Any lipophilic vitamins, emulsifiers and the like may be dissolved into the fat source prior to blending. Water, preferably water which has been subjected to reverse osmosis, may then be mixed in to form a liquid mixture.
[0026] The liquid mixture may then be thermally treated to reduce bacterial loads. For example, the liquid mixture may be rapidly heated to a temperature in the range of about 80° C. to about 110° C. for about 5 seconds to about 5 minutes. This may be carried out by steam injection or by heat exchanger; for example a plate heat exchanger.
[0027] The liquid mixture may then be cooled to a temperature in the range from about 60° C. to about 85° C.; for example by flash cooling. The liquid mixture may then be homogenised; for example in two stages at about 10 MPa to about 30 MPa in the first stage and about 2 MPa to about 10 MPa in the second stage. The homogenised mixture may then be further cooled to add any heat sensitive components; such as vitamins and minerals. The pH and solids content of the homogenised mixture is conveniently standardised at this point.
[0028] The homogenised mixture may then be transferred to a suitable drying apparatus such as a spray drier or freeze drier and converted to powder. The powder should have a moisture content of less than about 5% by weight. The BL999 may be added to the powder in the desired quantity by dry mixing.
[0029] A dry pet food for use in the present invention may include anyone or more of a carbohydrate source, a protein source and lipid source.
[0030] Any suitable carbohydrate source may be used. Preferably the carbohydrate source is provided in the form of grains, flours or starches. For example, the carbohydrate source may be rice, barley, sorghum, millet, oat, corn meal or wheat flour. Simple sugars such as sucrose, glucose and corn syrups may also be used. The amount of carbohydrate provided by the carbohydrate source may be selected as desired. For example, the pet food may contain up to about 60% by weight of carbohydrate.
[0031] Suitable protein sources may be selected from any suitable animal or vegetable protein source; for example muscular or skeletal meat, meat and bone meal, poultry meal, fish meal, milk proteins, corn gluten, wheat gluten, soy flour, soy protein concentrates, soy protein isolates, egg proteins, whey, casein, gluten, and the like. For elderly animals, it is preferred for the protein source to contain a high quality animal protein. The amount of protein provided by the protein source may be selected as desired. For example, the pet food may contain about 12% to about 70% by weight of protein on a dry basis.
[0032] The pet food may contain a fat source. Any suitable fat source may be used. Preferably the fat source is an animal fat source such as tallow. Vegetable oils such as corn oil, sunflower oil, safflower oil, rape seed oil, soy bean oil, olive oil and other oils rich in monounsaturated and polyunsaturated fatty acids, may also be used. In addition to essential fatty acids (linoleic and alpha-linoleic acid) the fat source may include long chain fatty acids. Suitable long chain fatty acids include, gamma linoleic acid, stearidonic acid, arachidonic acid, eicosapentanoic acid, and docosahexanoic acid. Fish oils are a suitable source of eicosapentanoic acids and docosahexanoic acid. Borage oil, blackcurrant seed oil and evening primrose oil are suitable sources of gamma linoleic acid. Rapeseed oil, soybean oil, linseed oil and walnut oil are suitable sources of alpha-linolenic acid. Safflower oils, sunflower oils, corn oils and soybean oils are suitable sources of linoleic acid. Olive oil, rapeseed oil (canola), high oleic sunflower oil, safflower oil, peanut oil, and rice bran oil are suitable sources of monounsaturated fatty acids. The amount of fat provided by the fat source may be selected as desired. For example, the pet food may contain about 5% to about 40% by weight of fat on a dry basis. Preferably, the pet food has a relatively reduced amount of fat.
[0033] The choice of the carbohydrate, protein and lipid sources is not critical and will be selected based upon nutritional needs of the animal, palatability considerations, and the type of product produced. Further, various other ingredients, for example, sugar, salt, spices, seasonings, vitamins, minerals, flavoring agents, gums, and probiotic micro-organisms may also be incorporated into the pet food as desired.
[0034] For elderly pets, the pet food preferably contains proportionally less fat than pet foods for younger pets. Further, the starch sources may include one or more of oat, rice, barley, wheat and corn.
[0035] The pet food may be produced by extrusion cooking, although baking and other suitable processes may be used. When extrusion cooked, the pet food is usually provided in the form of a kibble. The BL999 is preferably coated onto or filled into the dried pet food. A suitable process is described in European Patent Application No 0862863.
[0036] The invention will now be further described by the reference to the following examples. In the Figures:—
[0037] FIG. 1 compares the percentage of NFκB activity after stimulation of intestinal cells in vitro with LPS in the presence of four different bifidobacteria (cell based NFκB reporter gene assay);
[0038] FIG. 2 compares the fecal score observed in a mouse colitis model mimicking IBD pathologies (DSS induced colitis) with and without intervention with BL999;
[0039] FIG. 3 compares the macroscopic inflammation scores observed in a mouse colitis model mimicking IBD pathologies (DSS induced colitis) with and without intervention with BL999;
[0040] FIG. 4A to E compare the individual Wallace scores (A), the mean Wallace scores (B), the percentage protection (C), the myeloperoxidase activity (D) and the two day weight loss (E) observed in a TNBS-induced model of colitis wherein two groups received an intervention with BL999 at different dosage levels and the control group received no bacteria; and
[0041] FIG. 5 compares the protective capacity of BL999 in the same mouse colitis model to those of B. longum NCC2705, L. rhamnosus ATCC 53103, L. johnsonii CNCM I-1225, L. plantarum NCIMB8826, L. lactis NZ9000 and MG 1363; and to the protective effect of the medicament prednisolone.
EXAMPLE 1
[0042] An example of the composition of an infant formula for use in the present invention is given below. This composition is given by way of illustration only.
[0000]
Nutrient
Per 100 kcal
per litre
Energy (kcal)
100
670
Protein (g)
1.83
12.3
Fat (g)
5.3
35.7
Linoleic acid (g)
0.79
5.3
α-Linolenic acid (mg)
101
675
Lactose (g)
11.2
74.7
Minerals (g)
0.37
2.5
Na (mg)
23
150
K (mg)
89
590
Cl (mg)
64
430
Ca (mg)
62
410
P (mg)
31
210
Mg (mg)
7
50
Mn (μg)
8
50
Se (μg)
2
13
Vitamin A (μg RE)
105
700
Vitamin D (μg)
1.5
10
Vitamin E (mg TE)
0.8
5.4
Vitamin K1 (μg)
8
54
Vitamin C (mg)
10
67
Vitamin B1 (mg)
0.07
0.47
Vitamin B2 (mg)
0.15
1.0
Niacin (mg)
1
6.7
Vitamin B6 (mg)
0.075
0.50
Folic Acid (μg)
9
60
Panothenic acid (mg)
0.45
3
Vitamin B12 (μg)
0.3
2
Biotin (μg)
2.2
15
Choline (mg)
10
67
Fe (mg)
1.2
8
I (μg)
15
100
Cu (mg)
0.06
0.4
Zn (mg)
0.75
5
B. longum BB 536
10 8 cfu/g of powder, live bacteria
EXAMPLE 2
[0043] This example compares the inhibitory activity of BL999 with the inhibitory effects of other probiotic bacterial strains in a nuclear factor kappa B (NFκB) cell-based reporter gene assay.
[0044] An abundance of literature has been published on the central role that the transcription factor NFκB plays in the induction and perpetuation of inflammatory events. NFκB is activated in response to entero-invasive pathogenic bacteria and other inflammatory stimuli which lead to the production of inflammatory molecules, such as tumor necrosis factor-α (TNF-α), interleukin-8 (IL-8), intracellular adhesion molecule-1 (ICAM-1), and inducible cyclo-oxygenase (COX-2).
[0045] A human intestinal epithelial cell line (HT29 NFκB) stably expressing a reporter gene construct (secreted alkaline phosphatase) under the control of the endogenous NFκB promoter was used in this study (Blum S et al.; Riedel C. et al. World J Gastroenterol. 2006 in press). The ability of four bifidobacteria strains to inhibit lipopolysaccharide (LPS)-induced NFκB activity in these cells was measured. Cells were incubated with freshly prepared B. bifidum (NCC 189, CNCM 1-2333), B. infantis (NCC 200, CNCM I-2334), B. pseudocatenulatum (NCC 291), and B. longum (NCC 3001, ATCC BAA-999) at a cell to bacteria ratio of 1:100. Following 1 hr pre-incubation of cells with bacteria, LPS at 10 ng/ml was added for an additional 4 hrs and spent culture supernatants were collected for measurement of NFκB-mediated reporter activity. The assay was done in duplicate and repeated at least 3 times with each repetition normalized to LPS stimulation without bacteria, no bacteria control. The data are shown in FIG. 1 as the mean percentage of LPS-stimulated NFκB activity±SEM.
[0046] It may be seen that cells treated with LPS had a 10-fold induction in NFκB activity following 4 hrs of incubation. All four bifidobacteria strains down-modulated NFκB activity, however, BL999 had the greatest inhibitory activity in this assay. In conclusion, BL999 is an excellent candidate strain for applications where inhibition of inflammatory activity is of great value.
EXAMPLE 3
[0047] This example demonstrates the capability of BL999 and its metabolites to prevent inflammation in a mouse model of IBD.
[0048] A dextran sodium sulphate (DSS)-induced mouse model of colitis recognized as a relevant model for IBD pathologies was used in this experiment (Blumberg R S et al, Current Opin. Immunol. 1999; 11(6):648-56). Administration of DSS induces histopathological damage in the large intestine similar to that observed in ulcerative colitis patients. The DSS treatment was administered so as to induce acute intestinal inflammation.
[0049] Experimental Groups and Diets:
“Control-MRS”: mice fed the control diet (Table 1) ad libitum, with free access to tap water during the whole experiment, and receiving a daily intra-gastric gavage of MRS from day 1 to day 14 “DSS-MRS”: mice fed the control diet ad libitum during the whole experiment, with free access to tap water containing 1% DSS from day 7 to day 14, and receiving a daily intra-gastric gavage of MRS from day 1 to day 14 “DSS-BL”: mice fed the control diet during the whole experiment, from day 1 to day 14, with free access to tap water containing 1% DSS from day 7 to day 14, and receiving a daily intragastric gavage of BL999 (NCC3001) (10 9 cfu/mouse/day) from day 1 to day 14
[0000]
TABLE 1
Control diet
Components
Percentage in the diet (wt %)
Resistant starch (Cerestar SF 12018)
40.0
Soluble casein
20.0
Saccharose
27.3
DL-methionine
0.3
Corn Oil
5.0
Cellulose
2.0
Mineral premix AIN 93
4.4
Vitamin premix AIN 93
1.0
[0053] The animal experiment was conducted as follows. Male BALBc/J mice (8 weeks, Janvier, France) were randomised into 4 experimental groups (n=10 mice per group). During a 7 days acclimatisation period, mice had free access to tap water and received the control diet. Then, mice in Group DSS-BL received a daily intra-gastric gavage of BL999 (10 9 cfu/mouse/day) with the culture supernatant for 14 days whilst mice in the other two groups received a daily intra-gastric gavage of MRS. In addition, from day 7 to day 14, mice in both the DSS-MRS and DSS-BL groups received 1% DSS in their drinking water while the Control group received normal tap water.
[0054] Every 2 days during the experiment, fecal samples from each mouse were examined and the consistency, and presence or absence of blood was recorded (Hemoccult II, SKD, Roissy, France). A fecal score was calculated as indicated in Table 2 and the results are shown in FIG. 2 .
[0000]
TABLE 2
Scale followed to score mice clinical symptoms.
Intensity scores
Stool scores
Observations
0
Normal, hard
1
Soft, well formed, sticky
2
Not formed
3
Liquid, diarrhea
[0055] At the end of the 14 day period, mice were sacrificed by cervical dislocation. The caeco-colic segments were rapidly removed from the animal, gently washed with a physiological saline buffer, and scored for macroscopic inflammatory signs following adaptation of the scale previously published by Appleyard and Wallace (Appleyard C. B and Wallace J. L. “Reactivation of hapten-induced colitis and its prevention by anti-inflammatory drugs” Am J. Physiol 269, G119-125) (Table 3). The results are shown in FIG. 3 .
[0000]
TABLE 3
Criteria for macroscopic scoring of caeco-
colonic damage (Appleyard and Wallace)
Score
Appearance
Thickening
0
Normal mucosa
1
Moderate thickening
2
Severe thickening
Ulcerations
0
None
1
Redness
2
Slight ulcerations
3
Strong ulcerations
Caeco-colic contents
0
No blood
1
Slightly bloody
2
Bloody
[0056] From FIGS. 2 and 3 , it may be seen that the BL999 effectively normalizes the stool characteristics and significantly reduces inflammation in the caecum and proximal and distal colon compared with that observed in the DSS-MRS group. Thus it may be seen that BL999 is effective in preventing the DSS-induced inflammation as the mice in group DSS-BL received bacteria both before and during administration of the DSS.
EXAMPLE 4
[0057] In this example, the anti-inflammatory potential of BL999 bacteria was investigated and compared with that of other strains of lactic acid bacteria as well as prednisolone, a commonly used anti-inflammatory drug, using a mouse model of acute colitis induced by TNBS.
[0058] The following strains bacterial strains were investigated:—
[0000]
NCC No
Strain
Official Deposit No.
NCC 3001
Bifidobacterium longum
ATCC BAA-999
NCC 2705
Bifidobacterium longum
CNCM I-2618
NCC 3003
Lactobacillus rhamnosus
ATCC 53103
NCC 533
Lactobacillus johnsonii
CNCM I-1225
Lactobacillus plantarum
NCIMB8826
Lactococcus lactis
NZ9000
Lactococcus lactis
MG1363
[0059] Lactobacillus strains were grown aerobically at 37° C. in MRS medium (Difco). Bifidobacteria were grown anaerobically at 37° C. in MRS supplemented with 0.05% L-cysteine hydrochloride (Sigma). Lactococcus lactis MG1363 and Lactococcus lactis NZ9000 were grown at 30° C. in M17 medium supplemented with 0.5% glucose. The number of bacteria (cfu) was estimated at stationary growth phase by measuring the 30 absorbance at 600 nm (A 600 ), with respective calibration curve for each strain. For routine in vivo experiments, bacteria were grown for 18 h, washed twice in sterile PBS pH 7.2 and re-suspended at 10 8 and 2. 10 9 cfu/ml in 0.2 M NaHCO 3 buffer containing 2% glucose.
[0060] Adult female BALB/C mice aged 7 to 8 weeks were purchased from Charles River. The mice were randomised into experimental groups with 10 mice per group. Mice were group housed (8 to 10 per cage) and had free access to water and standard rodent chow. They underwent at least 1 week of acclimatization before any intervention. Mice in the groups treated with bacteria received bacterial suspensions (corresponding to 10 8 cfu/mouse/day) by intra-gastric gavage in 0.2M NaHCO3 buffer at pH 8.5 with 2% glucose from the fourth day before induction of colitis to the day of induction of colitis. Mice in the group treated with prednisolone received 10 mg/kg body weight/day. Mice in the control group received no bacteria or prednisolone. Further, the effect of dosage level was investigated by treating one group with BL999 at 2.10 9 cfu/mouse/day.
[0061] Prior to induction of colitis, all mice were anaesthetized by intraperitoneal injection of 3 mg of ketamine (Imalgene 1000, Mérial, Lyon, France), 46.7 μg of diazepam (Valium, Roche Diagnostics, France) and 15 μg of atropine (Aguettant Laboratory, Lyon, France) dissolved in 0.9% sodium chloride. Then colitis was induced by intra-rectal administration of 50 μl of trinitrobenzene sulphonic acid (TNBS, Fluka, France) dissolved in 0.9% NaCl/ethanol (50/50 v/v) at a dose of 100-120 mg/kg of body weight. Mortality rate and inflammation scores were assessed 48 hours after TNBS administration. Mice were weighed prior to administration of TNBS and at sacrifice which was performed by cervical dislocation.
[0062] The colon was removed, dissected free of fat and mesenterium, carefully opened and cleaned with PBS. Colonic damage and inflammation were assessed according to the Wallace criteria (Wallace J. L. et al, Inhibition of leukotriene synthesis markedly accelerates healing in a rat model of inflammatory bowel disease” Gastroenterology 96:29-36, 1989). These criteria for macroscopic scoring have been well established in mouse studies and reflect the intensity of inflammation, the thickening of colonic mucosa and the extent of ulceration. Colonic damage and inflammation were scored blind by two researchers.
[0063] In addition, myeloperoxidase (MPO) activity, a marker of polymorphonuclear neutrophil primary granules, was determined according to a modified method of Bradley et al. (“Measurement of cutaneous inflammation: estimation of neutrophil content with an enzyme marker” J Invest Dermatol. 60(3):618-22). Protein concentration was determined by the method of Lowry, and MPO activity expressed as U MPO/cm of intestine.
[0064] MPO activity was determined in proximal colon tissue, immediately after sacrifice. A colonic sample (1 cm long) was taken at 3 cm from the caeco-colonic junction, suspended in potassium phosphate buffer (50 mmol/L, pH 6.0) and homogenized in ice using a polytron. Three cycles of freezing and thawing were performed and suspensions were centrifuged at 10,000 g for 15 min at 4° C. Supernatants were discarded and pellets were re-suspended in the detergent hexadecyl trimethylammonium bromide buffer 10 (HTAB 0.5%, w/v, in 50 mmol/L potassium phosphate buffer, pH 6.0), inducing the release of MPO from the polymorphonuclear neutrophil primary granules. Suspensions obtained were sonicated on ice, and again centrifuged for 15 min at 4° C. Supernatants were diluted in potassium phosphate buffer (PH 6.0) containing 0.167 mg/mL of O-dianisidine dihydrochloride and 0.0005% of hydrogen peroxide (H2O2). MPO from human neutrophils (0.1 U/100 mL, Sigma) was used as a standard. Changes in absorbance at 450 nm, over 5 and 10 min, were recorded with a microplate spectrophotometer (ELX808, Bio-Tek Instrument, CA). One unit of MPO activity was defined as the quantity of MPO degrading 1 mmol hydrogen peroxide/min/mL at 25° C.
[0065] Results were analyzed by the non-parametric one-way analysis of variance, Mann-Whitney ∪ test. Differences were judged to be statistically significant when the p value was <0.05.
[0066] The results are shown in FIG. 4 , A to E and FIG. 5 . FIGS. 4 A and B compare the individual Wallace scores and the mean Wallace scores of mice treated with BL999 at the two dosage levels, 10 8 cfu/mouse/day and 2.10 9 cfu/mouse/day with the control group who received no bacteria. It may be seen that mice from both the groups which received BL999 had substantially lower Wallace scores than mice in the control group.
[0067] FIG. 4C shows the percentage protection provided by the BL999. This corresponds to the reduction of the mean macroscopic inflammation of bacteria-treated mice (n=10) in relation to the mean score of TNBS-treated control mice (NaOHCO3 buffer-treated mice, (n=10).
[0068] FIG. 4D compares the mean MPO activity of mice treated with BL999 at the two dosage levels with the control group. It may be seen that mice from both the groups which received BL999 had substantially lower MPO activity than mice in the control group.
[0069] FIG. 4E compares the 2 day weight loss of mice treated with BL999 at the two dosage levels with the control group. It may be seen that mice from both the groups which received BL999 had substantially lower weight loss than mice in the control group.
[0070] FIG. 5 compares the percentage protection provided by the various strains of lactic acid bacteria tested and by administration of prednisolone. It may be seen that BL999 provides a markedly greater degree of protection than the other bacterial strains tested and a comparable level of protection to the medicament.
[0071] It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.
|
The invention relates to the use, in the manufacture of a medicament or a therapeutic nutritional composition for preventing or reducing inflammation in a mammal, of bifidobacterium longum ATCC BAAA-999.
| 0
|
BACKGROUND
1. Field
The embodiments described herein relate to point-of-sale (POS) transactions and more specifically to systems and methods that enable integrated and secure POS transactions using low cost tablet devices.
2. Description of the Related Art
A conventional POS system comprises a large cash register. Early Electronic Cash Registers (ECRs) were controlled by proprietary software and had limited functionality. Eventually these ECR's were able to interface with a backend system that provided accounting, reporting and other functionality. But these earlier systems in addition to being physically bulky were also typically proprietary systems in that there were no uniform standards across the industry. Often, these systems were server-client systems that were costly to own and operate.
More recently, the availability of local processing power, local data storage, networking, and graphical user interface made it possible to develop flexible and highly functional POS systems. Cost of such systems has also declined, as all the components can now be purchased off-the-shelf. A conventional retail POS system now typically includes a computer, monitor, cash drawer, receipt printer, customer display and a barcode scanner, and the majority of retail POS systems also include a debit/credit card reader. It can also include a weight scale, integrated credit card processing system, a signature capture device and a customer pin pad device. At the core of the modern POS system is some type of CPU that runs the POS system. The other components are then peripherals that can be interfaced with the CPU as needed.
More and more POS monitors use touch-screen technology for ease of use and a computer is built in to the monitor chassis for what is referred to as an all-in-one unit. All-in-one POS units liberate counter space for the retailer. The POS system software can typically handle myriad customer based functions such as sales, returns, exchanges, layaways, gift cards, gift registries, customer loyalty programs, BOGOF (buy one get one free), quantity discounts and much more. POS software can also allow for functions such as pre-planned promotional sales, manufacturer coupon validation, foreign currency handling and multiple payment types.
In the retail environment, the POS unit handles the sales to the consumer but it is only one part of the entire POS system used in a retail business. “Back-office” computers typically handle other functions of the POS system such as inventory control, purchasing, receiving and transferring of products to and from other locations. Other typical functions of a POS system are to store sales information for reporting purposes, sales trends and cost/price/profit analysis. Customer information may be stored for receivables management, marketing purposes and specific buying analysis. Many retail POS systems include an accounting interface that “feeds” sales and cost of goods information to independent accounting applications.
Moreover, recently new applications have been introduced that enable POS transactions to be conducted using mobile phones and tablets. New entrants include Square, Intuit's GoPayments, and NCR Inc.'s Silver platform, ezyMART POS, ShopKeep POS, and GoPago. This is an important development, because in the United States alone, there are over 5 million small merchants who do not handle a large amount of transaction. As a result, they are very price sensitive toward the POS system and the payment system.
A major problem with these newer, mobile device centric systems is that they lack the necessary security. The more conventional systems described above suffer from higher cost, and limited flexibility. Another issue with these conventional systems the material flow, e.g., the process around reading the bar code on an item, and the payment process are two separate processes run by different applications.
SUMMARY
The embodiments described herein are related to system and methods for a tablet or mobile based POS system that provides the necessary security and integrated material and payment processing.
One aspect provides a system for processing transactions, comprising: at least one mobile device comprising a housing having a processor, and a Wi-Fi Communication module disposed therein; and a base station comprising a base station housing, wherein the base station housing houses an embedded system comprising: a processor, and a Wi-Fi communication module configured to communicate with the Wi-Fi communication module of the at least one mobile device, a support stand configured to support the at least one mobile device, wherein the support stand comprises at least one arm having an adjustable position and configured to move to adjust the size of the support stand based on a size of the at least one mobile device; and at least one peripheral device connected to the base station.
BRIEF DESCRIPTION OF THE DRAWINGS
The details of the present invention, both as to its structure and operation, may be gleaned in part by study of the accompanying drawings, in which like reference numerals refer to like parts, and in which:
FIG. 1 illustrates a first perspective view of base station according to a first embodiment of the present application.
FIG. 2 illustrates a second perspective view of the base station.
FIG. 3 illustrates a front view of the base station with a mobile device;
FIG. 4 illustrates a back view of the base station and mobile device;
FIG. 5A-5E illustrates several enlarged views of various portions of the base station;
FIG. 6 illustrates a block diagram of the electronic hardware of the base station; and
FIG. 7 illustrates a block diagram illustrating an example wired or wireless system that may be used as or in conjunction embodiments of the present application.
FIG. 8 illustrates a flow chart of a payment process using the base station and mobile device.
FIG. 9 illustrates a flow chart of an inventory process using the base station and the mobile device.
FIG. 10 provides a block diagram showing a first embodiment of the software level architecture, and interaction between, an embodiment of the base station and one or more mobile devices.
FIG. 11A provides a block diagram showing a second embodiment of the software level architecture, and interaction between, an embodiment of the base station and one or more mobile devices.
FIG. 11B provides a block diagram showing a third embodiment of the software level architecture, and interaction between, an embodiment of the base station and one or more mobile devices.
FIGS. 12A-12D provide perspective views of a case for the tablet having a card reader incorporated directly into the case.
DETAILED DESCRIPTION
The embodiments described herein have several aspects that will be described. These aspects include the hardware designs, e.g., the physical stand, base, interconnections, etc.; the electronic hardware design; the software design; and the communication processes. Each of these aspects is described in detail below.
Hardware
The embodiments described herein include a base stations and a mobile device such as a tablet device. FIGS. 1 and 2 illustrate an example base station 102 configured in accordance with on example embodiment. As can be seen, base station 102 can comprise or act as a base to hold the mobile device or tablet. Thus, base station 102 can include a base portion 104 and a support portion 106 for holding the mobile or tablet device. The base station 102 can also provide charging function for the mobile or tablet device, as well as connection to an external wireless router. In certain embodiments, the base station can include a router. The base station 102 can also include a processor and memory as described in more detail below.
Using a mobile device or tablet allows the device to be removed from support portion 106 so that it can be moved throughout a store or retail location. The tablet can provide the user interface needed to process transactions, the base station's processor can be configured to then process the transaction. Other peripherals can then be added in a modular fashion to base station 102 . For example, a scanner(s), printer, register, card reader, etc., can be added to or interfaced with base station 102 . Thus, base station 102 can include various Input-Output (I/O) ports, such as a RJ12 24V cash register port, RS232 ports with 5V/12V support for printer and VFD display, one USB port for a bar code scanner and three other USB expansion ports, e.g., one on the front and the other in the rear, a 10/100M Ethernet interface, a stereo audio port, or some combination thereof. It will be understood that these are just examples.
In certain embodiments, the support portion 106 can swivel as illustrated in FIGS. 3 and 4 . As can be seen in FIGS. 3 and 4 , which provide front and back views, the base 108 of support 106 can swivel in these implementations.
FIG. 5A is a diagram with another support portion 106 that can adjust to fit different sized tablets or mobile devices via adjustable arms 110 and 112 , which can slide in and out. Also, support portion 106 can be configured such that it can be elongated or collapsed in order to move top arms 110 up and down. FIGS. 5B and 5C illustrate an alternative embodiment of base station 102 that use the support portion 106 of FIG. 5A . As can be seen, base station 102 sits on base portion 113 . The I/O ports can be seen on the back of base station 102 in FIG. 5C . Also, a scanner or card reader 107 can be built into base station 102 as illustrated in both FIGS. 5B and 5C . The adjustable portion 105 of support portion 106 can be seen in FIG. 5C .
FIG. 5D illustrates the base station 102 and adjustable support portion 106 of FIGS. 5A-C integrated with a cash register 120 and a printer 122 .
In the embodiment of FIG. 5E , support portion 106 includes arms 112 that can slide outward or inward as needed.
While not illustrated, certain embodiments can include a casing for the tablet through which the tablet can interface with base station 102 . The case can either be a water resistant design or a basic version. The casing can allow for charging through a standard port on the base station allowing the same base station to support multiple tablet models despite the various connector designs and locations. The charging port will also allow for the base station 102 to sense that the tablet is physically present for cash transactions preventing the cash drawer from inadvertently deploying when the sales associate is not present. Further, a cash drawer may be opened accidentally where the cashier may complete the transaction on the floor but he or she is not present at the cash drawer. Therefore, by adding a physical detection of the tablet being on the stand by adding the contact pin or RFID reader, this error can be prevented. The cashier has to physically go back to the cash drawer and install the stand before he or she can open the cash drawer. In some embodiments, the application can support multiple tablets on one station by assigning each tablet a unique identification number through the use of an RFID tag adhered to the back of each tablet. A reader installed on the stand connected to the base station will allow the base station to authenticate that the tablet performing the transaction is physically located at the base station.
FIGS. 12A-12D provide perspective views of a case 1400 for a tablet 1404 having a card reader 1410 incorporated directly into the case 1400 . The case 1400 includes a front frame 1402 , a rear inner case 1406 , and a rear outer case 1414 . The front frame 1402 and the rear inner case 1406 surround the tablet 1404 from the front and back sides respectively. The front frame 1402 and the rear inner case 1406 are configured to engage each other and create a seal around the tablet 1404 within the case 1400 . The rear inner case 1406 may also include a hinged stand 1412 that can be opened to support tablet in an upright orientation. The rear inner case 1406 also may have a card reader receiving portion 1416 to hold the card reader 1410 . In the embodiment shown in FIG. 12A , the card reader receiving portion 1416 may include a slot or groove configured to receive the card reader 1410 . Further, a locking member 1408 may be provided to hold the card reader 1410 in the card reader receiving portion 1416 . The rear outer case 1414 is configured to attach to the rear of the rear inner case 1406 after the card reader 1410 has been inserted in to the card reader receiving portion 1416 .
Electronic Hardware
FIG. 6 is a diagram illustrating the electronic hardware components of a base station 102 configured in accordance with one embodiment. As can be seen, from an electronic hardware perspective, base station 102 can include a processor or CPU as well as main program memory, DDR RAM, FLASH, etc., in hardware block 202 . This block 202 can also include an EMV processing and encryption capability as described in more detail below.
Block 202 can be interfaced with a Wi-Fi module 204 , a non-volatile memory such as an Electrically Erasable Programmable Memory (EEPROM) 206 , a POS function block 208 , and a transaction function block 210 . A unique identifier (VID/PID) and other information can be stored in the non-volatile memory 206 inside base station. The tablet can use this data for authentication between the tablet and the base station 102 .
POS block 208 can include a secured storage 212 . All confidential customer data, business data and transaction data can be password-protected and DES/AES encrypted and stored in this drive. Only with the correct password and matched base station can the stored data be accessed. POS block 208 can also include various interface modules including a RJ12 port 214 , a RS232 transceiver 216 can port 218 , a USB to Ethernet controller 220 , transformer 222 , and RJ45 port 224 , and a plurality of USB ports such as ports 226 and 228 .
Transaction function block 210 can comprise magnetic stripe card reader, a secured magnetic strip card reader and a smartcard reader module 230 as well as interfaces for a contactless reader 232 and PINpad (Personal Identification Number Pad) 234 . The architecture of a secured magnetic stripe reader includes a magnetic stripe reader head, a flexible PCB and a 8-bit Micro CPU. The magnetic stripe reader head has three tracks and has six pins out from the reader head. A three layer flexible PCB is soldered to the six pins on the reader head. An epoxy is used to pot the connection between the reader head and the flexible PCB to provide it with security. The flexible PCB has three layers and the top and the bottom layers are designed with electronic fence to prevent any thief from tapping the magnetic stripe traces. The micro CPU is soldered on a small PCB and is potted with epoxy and protected with a PCB based electronic fence to prevent anyone from probing the CPU. This gives the base station a physical security protection for the magnetic stripe reader. The CPU will encrypt the magnetic stripe data in the potted area and will send the encrypted data to the base station to complete the transaction.
Base station 102 can also include a tablet interface block 236 through which power can be supplied to the tablet. In certain embodiments, an audio port 238 can also be interfaced with tablet interface block 236 . Base station 102 can also include a power input 240 and a power converter 242 configured to convert the, e.g., 24V input from power input 240 into various voltage signals for use by the modules and blocks that comprise base station 102 .
The hardware components can be used by multiple applications, or multiple tablets. For example, the WTA application, described in detail below, can require hardware device management functionality to handle resource allocation arrangement. The WTA can compensate for the capability of the associated tablet, e.g., an iPad without the use of Jailbreak to control multiple peripherals in the base station 102 without requiring the user to disconnect and connect to the various components. Initial setup of base station 102 can be performed through connecting the base station 102 to the network via an Ethernet port 224 . Once configured the base station 102 can operate wirelessly or via Ethernet connection.
It will be understood that the diagram of FIG. 6 is a high level diagram and that other or fewer components can be included. Thus the illustration of FIG. 6 should not be seen as limiting in any way. It will also be understood that any of the components illustrated can be implemented using multiple devices and our distributed resources.
More generically, FIG. 7 is a block diagram illustrating an example wired or wireless system 550 that may be used in connection with various embodiments described herein. For example the system 550 may be used as or in conjunction with one or more of the mechanisms or processes described above, and may represent components of processors 202 , user system(s), and/or other devices described herein. The system 550 can be a server or any conventional personal computer, or any other processor-enabled device that is capable of wired or wireless data communication. Other computer systems and/or architectures may be also used, as will be clear to those skilled in the art.
The system 550 preferably includes one or more processors, such as processor 560 . Additional processors may be provided, such as an auxiliary processor to manage input/output, an auxiliary processor to perform floating point mathematical operations, a special-purpose microprocessor having an architecture suitable for fast execution of signal processing algorithms (e.g., digital signal processor), a slave processor subordinate to the main processing system (e.g., back-end processor), an additional microprocessor or controller for dual or multiple processor systems, or a coprocessor. Such auxiliary processors may be discrete processors or may be integrated with the processor 560 . Examples of processors which may be used with system 550 include, without limitation, the Pentium® processor, Core i7® processor, and Xeon® processor, all of which are available from Intel Corporation of Santa Clara, Calif.
The processor 560 is preferably connected to a communication bus 555 . The communication bus 555 may include a data channel for facilitating information transfer between storage and other peripheral components of the system 550 . The communication bus 555 further may provide a set of signals used for communication with the processor 560 , including a data bus, address bus, and control bus (not shown). The communication bus 555 may comprise any standard or non-standard bus architecture such as, for example, bus architectures compliant with industry standard architecture (ISA), extended industry standard architecture (EISA), Micro Channel Architecture (MCA), peripheral component interconnect (PCI) local bus, or standards promulgated by the Institute of Electrical and Electronics Engineers (IEEE) including IEEE 488 general-purpose interface bus (GPIB), IEEE 696/S-100, and the like.
System 550 preferably includes a main memory 565 and may also include a secondary memory 570 . The main memory 565 provides storage of instructions and data for programs executing on the processor 560 , such as one or more of the functions and/or modules discussed above. It should be understood that programs stored in the memory and executed by processor 560 may be written and/or compiled according to any suitable language, including without limitation C/C++, Java, JavaScript, Pearl, Visual Basic, .NET, and the like. The main memory 565 is typically semiconductor-based memory such as dynamic random access memory (DRAM) and/or static random access memory (SRAM). Other semiconductor-based memory types include, for example, synchronous dynamic random access memory (SDRAM), Rambus dynamic random access memory (RDRAM), ferroelectric random access memory (FRAM), and the like, including read only memory (ROM).
The secondary memory 570 may optionally include an internal memory 575 and/or a removable medium 580 , for example a floppy disk drive, a magnetic tape drive, a compact disc (CD) drive, a digital versatile disc (DVD) drive, other optical drive, a flash memory drive, etc. The removable medium 580 is read from and/or written to in a well-known manner. Removable storage medium 580 may be, for example, a floppy disk, magnetic tape, CD, DVD, SD card, etc.
The removable storage medium 580 is a non-transitory computer-readable medium having stored thereon computer executable code (i.e., software) and/or data. The computer software or data stored on the removable storage medium 580 is read into the system 550 for execution by the processor 560 .
In alternative embodiments, secondary memory 570 may include other similar means for allowing computer programs or other data or instructions to be loaded into the system 550 . Such means may include, for example, an external storage medium 595 and an interface 590 . Examples of external storage medium 595 may include an external hard disk drive or an external optical drive, or and external magneto-optical drive.
Other examples of secondary memory 570 may include semiconductor-based memory such as programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable read-only memory (EEPROM), or flash memory (block oriented memory similar to EEPROM). Also included are any other removable storage media 580 and communication interface 590 , which allow software and data to be transferred from an external medium 595 to the system 550 .
System 550 may include a communication interface 590 . The communication interface 590 allows software and data to be transferred between system 550 and external devices (e.g. printers), networks, or information sources. For example, computer software or executable code may be transferred to system 550 from a network server via communication interface 590 . Examples of communication interface 590 include a built-in network adapter, network interface card (NIC), Personal Computer Memory Card International Association (PCMCIA) network card, card bus network adapter, wireless network adapter, Universal Serial Bus (USB) network adapter, modem, a network interface card (NIC), a wireless data card, a communications port, an infrared interface, an IEEE 1394 fire-wire, or any other device capable of interfacing system 550 with a network or another computing device.
Communication interface 590 preferably implements industry promulgated protocol standards, such as Ethernet IEEE 802 standards, Fiber Channel, digital subscriber line (DSL), asynchronous digital subscriber line (ADSL), frame relay, asynchronous transfer mode (ATM), integrated digital services network (ISDN), personal communications services (PCS), transmission control protocol/Internet protocol (TCP/IP), serial line Internet protocol/point to point protocol (SLIP/PPP), and so on, but may also implement customized or non-standard interface protocols as well.
Software and data transferred via communication interface 590 are generally in the form of electrical communication signals 605 . These signals 605 are preferably provided to communication interface 590 via a communication channel 600 . In one embodiment, the communication channel 600 may be a wired or wireless network, or any variety of other communication links. Communication channel 600 carries signals 605 and can be implemented using a variety of wired or wireless communication means including wire or cable, fiber optics, conventional phone line, cellular phone link, wireless data communication link, radio frequency (“RF”) link, or infrared link, just to name a few.
Computer executable code (i.e., computer programs or software) is stored in the main memory 565 and/or the secondary memory 570 . Computer programs can also be received via communication interface 590 and stored in the main memory 565 and/or the secondary memory 570 . Such computer programs, when executed, enable the system 550 to perform the various functions of the present invention as previously described.
In this description, the term “computer readable medium” is used to refer to any non-transitory computer readable storage media used to provide computer executable code (e.g., software and computer programs) to the system 550 . Examples of these media include main memory 565 , secondary memory 570 (including internal memory 575 , removable medium 580 , and external storage medium 595 ), and any peripheral device communicatively coupled with communication interface 590 (including a network information server or other network device). These non-transitory computer readable mediums are means for providing executable code, programming instructions, and software to the system 550 .
In an embodiment that is implemented using software, the software may be stored on a computer readable medium and loaded into the system 550 by way of removable medium 580 , I/O interface 585 , or communication interface 590 . In such an embodiment, the software is loaded into the system 550 in the form of electrical communication signals 605 . The software, when executed by the processor 560 , preferably causes the processor 560 to perform the inventive features and functions previously described herein.
In an embodiment, I/O interface 585 provides an interface between one or more components of system 550 and one or more input and/or output devices. Example input devices include, without limitation, keyboards, touch screens or other touch-sensitive devices, biometric sensing devices, computer mice, trackballs, pen-based pointing devices, and the like. Examples of output devices include, without limitation, cathode ray tubes (CRTs), plasma displays, light-emitting diode (LED) displays, liquid crystal displays (LCDs), printers, vacuum florescent displays (VFDs), surface-conduction electron-emitter displays (SEDs), field emission displays (FEDs), and the like.
The system 550 also includes optional wireless communication components that facilitate wireless communication over a voice and over a data network. The wireless communication components comprise an antenna system 610 , a radio system 615 and a baseband system 620 . In the system 550 , radio frequency (RF) signals are transmitted and received over the air by the antenna system 610 under the management of the radio system 615 .
In one embodiment, the antenna system 610 may comprise one or more antennae and one or more multiplexors (not shown) that perform a switching function to provide the antenna system 610 with transmit and receive signal paths. In the receive path, received RF signals can be coupled from a multiplexor to a low noise amplifier (not shown) that amplifies the received RF signal and sends the amplified signal to the radio system 615 .
In alternative embodiments, the radio system 615 may comprise one or more radios that are configured to communicate over various frequencies. In one embodiment, the radio system 615 may combine a demodulator (not shown) and modulator (not shown) in one integrated circuit (IC). The demodulator and modulator can also be separate components. In the incoming path, the demodulator strips away the RF carrier signal leaving a baseband receive audio signal, which is sent from the radio system 615 to the baseband system 620 .
If the received signal contains audio information, then baseband system 620 decodes the signal and converts it to an analog signal. Then the signal is amplified and sent to a speaker. The baseband system 620 also receives analog audio signals from a microphone. These analog audio signals are converted to digital signals and encoded by the baseband system 620 . The baseband system 620 also codes the digital signals for transmission and generates a baseband transmit audio signal that is routed to the modulator portion of the radio system 615 . The modulator mixes the baseband transmit audio signal with an RF carrier signal generating an RF transmit signal that is routed to the antenna system and may pass through a power amplifier (not shown). The power amplifier amplifies the RF transmit signal and routes it to the antenna system 610 where the signal is switched to the antenna port for transmission.
The baseband system 620 is also communicatively coupled with the processor 560 . The central processing unit 560 has access to data storage areas 565 and 570 . The central processing unit 560 is preferably configured to execute instructions (i.e., computer programs or software) that can be stored in the memory 565 or the secondary memory 570 . Computer programs can also be received from the baseband processor 610 and stored in the data storage area 565 or in secondary memory 570 , or executed upon receipt. Such computer programs, when executed, enable the system 550 to perform the various functions of the present invention as previously described. For example, data storage areas 565 may include various software modules (not shown).
Various embodiments may also be implemented primarily in hardware using, for example, components such as application specific integrated circuits (ASICs), or field programmable gate arrays (FPGAs). Implementation of a hardware state machine capable of performing the functions described herein will also be apparent to those skilled in the relevant art. Various embodiments may also be implemented using a combination of both hardware and software.
Furthermore, those of skill in the art will appreciate that the various illustrative logical blocks, modules, circuits, and method steps described in connection with the above described figures and the embodiments disclosed herein can often be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled persons can implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the invention. In addition, the grouping of functions within a module, block, circuit or step is for ease of description. Specific functions or steps can be moved from one module, block or circuit to another without departing from the invention.
Moreover, the various illustrative logical blocks, modules, functions, and methods described in connection with the embodiments disclosed herein can be implemented or performed with a general purpose processor, a digital signal processor (DSP), an ASIC, FPGA or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor can be a microprocessor, but in the alternative, the processor can be any processor, controller, microcontroller, or state machine. A processor can also be implemented as a combination of computing devices, for example, a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
Additionally, the steps of a method or algorithm described in connection with the embodiments disclosed herein can be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module can reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium including a network storage medium. An exemplary storage medium can be coupled to the processor such the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium can be integral to the processor. The processor and the storage medium can also reside in an ASIC.
Communication Process Overview
Software running on the mobile device may allow the mobile device to interact with the base station and perform both payment POS activities as well perform activities related to monitoring and maintaining inventory. FIG. 8 illustrates a process for performing a payment operation using the mobile device and base station according to an embodiment of the present application. FIG. 9 illustrates a process for performing a POS operation using the mobile device and base station according to an embodiment of the present application.
In the payment operation (i.e. a payment transaction) shown in FIG. 8 , the system must first be initialized and the user (i.e. a sales representative, for example) must login as shown by S 801 . In some embodiments, this involves authenticating by the base station of the mobile device and authenticating by the mobile device the base station in order to ensure that a secure transaction in a commercial environment. Thus, an embedded system within the base station may communicate with a mobile device using a Wi-Fi Transportation Authority (WTA). The WTA is made up of a pair of applications, one residing on the mobile device, and one residing on the base station. In some embodiments, the WTA application residing on the mobile device may be replaced with a thin-client application running on a host server and accessed through a browser. Thus, in the case of a thin client application, the WTA is made up of a pair of applications, one residing on the host server which is accessed through the browser on the mobile device, and one application residing on the base station.
Together the pair of applications facilitates communication between the mobile device and the system embedded within the base station. Through the WTA, the mobile device and the base station authenticate each other prior to any sales transactions being processed to ensure that only authorized mobile devices working in conjunction with authorized base stations can execute sales transactions. Without the proper authenticated WTA application installed, a mobile device cannot communicate with the base station. Additionally, a unique identifier (VID/PID) may be stored by the system embedded in the base station and to complete authentication a user may be required to enter the identifier through the mobile device.
Additionally, a separate POS application may be used to perform the POS operations. In other words, a separate POS application running in parallel with the WTA application is used to perform the POS transactions. The POS application uses the WTA application to communicate with the base station and thus must be authenticated by the WTA application to communicate with the base station. Further, the data may be transmitted between the WTAs may be further encrypted using Wi-Fi WEP/WPA encryption.
Additionally, a Terminal Management System (TMS) download tool may be used to download authentication information so that a payment application can be downloaded to the base station to perform the base station side of POS transactions. The TMS also locks the payment application to prevent unauthorized downloading of applications into the base station.
Additionally, in some embodiments a pin pad may be used in combination with base station and mobile device to allow a customer to key in personal identification information for payment transactions. In such embodiments, the pin pad is authenticated by the base station during the authentication of S 801 to ensure that only the approved pin pad can be used with the base station.
Once the system has self-authenticated and a user (i.e. sales representative) has logged in, the system enters an idle state in S 802 . During the idle state, the system waits for the user to initiate a payment transaction. During S 802 , the system monitors how long the system has been in an idle state. If the system determines it has been in an idle state for an amount of time that exceeds a threshold (i.e. 5 minutes, 10 minutes, etc.), the system may automatically logout in S 803 so that login and authentication of S 801 must be repeated to prevent access by an unauthorized person.
In S 804 , the authorized user (i.e. sales representative) selects a payment transaction function using the POS application to begin a payment transaction. This may be done through any method of interface apparent to a person of ordinary skill in the art. For example, an authorized user may touch a control button on a displayed user interface.
In some embodiments, the user may be provided with an interface for entry of customer information (i.e. customer name, mailing address, email address, telephone, zip code, etc.) in S 805 once the payment transaction has been selected. The user may enter the customer information using the displayed interface. In some embodiments, the user may elect to bypass the customer information and proceed to payment information entry in S 806 .
In S 806 , the authenticated user enters payment information using the mobile device. In some embodiments, the user may enter payment information by swiping a credit card through a card reader in communication with the mobile device or the base station. Connection between the mobile device or base station and the credit card reader can be achieved through either wired or wireless communication.
After the credit card information has been entered, a customer can be requested to provide a pin number associated with card information in S 807 using the authenticated pin pad device discussed above.
Once the pin number has been provided, payment transaction information indicating the purchase value amount and the payment information is provided to the authorized user (i.e. the sales representative) in S 808 so that any errors can be detected prior to transmission to the financial institution associated with the credit card. After the payment transaction information is provided to the authorized user, the user confirms the accuracy of the information in S 809 .
Once the payment transaction has been confirmed, the payment module on the base station connects to a gateway server through the base station and sends a request for payment confirmation of the transaction in S 810 . Once the request for payment confirmation is sent in S 810 , the payment module on the base station goes into an idle state awaiting a reply from the Gateway server in S 811 .
Once a reply or result is received from the gateway server in S 811 , the transaction data, including the payment information and the confirmation result returned by the gateway server, is stored in the secured storage device of the embedded system of the base station in S 812 . Additionally, once the result is returned by the gateway server, a merchant receipt may be printed using a printer in communication with the base station (communication may be wired or wireless) in S 813 . Additionally, a customer receipt may also be printed using the printer in S 814 .
Finally, the payment module on the base station may store the payment transaction information in batches with other payment transactions in S 815 . Once the payment transaction is successfully stored in batch, the system returns to the idle state of S 802 awaiting another transaction to be initiated. Again, if the system is idle for a period of time exceeding a threshold, the system may automatically logout to prevent unauthorized access.
FIG. 9 illustrates a process for performing an POS operation using the mobile device and base station according to an embodiment of the present application.
In the POS operation (i.e. a payment transaction) shown in FIG. 9 , the system must first be initialized and the user (i.e. a sales representative, for example) must login as shown by S 901 . In some embodiments, this involves authenticating by the base station of the mobile device and authenticating by the mobile device the base station in order to ensure that a secure transaction in a commercial environment. Thus, an embedded system within the base station can communicate with mobile device using a Wi-Fi Transportation Authority (WTA). The WTA is made up of a pair of applications, one residing on the mobile device, and one residing on the base station or host for the thin-client application accessed through the browser.
Together the pair of applications facilitates communication between the mobile device and the system embedded within the base station. Through the WTA, the mobile device and the base station authenticate each other prior to any transactions being processed to ensure that only authorized mobile devices working in conjunction with authorized base stations can execute sales transactions. Without the proper authenticated WTA application installed or securely accessed to the host through a browser, a mobile device cannot communicate with the base station. Additionally, a unique identifier (VID/PID) may be stored by the system embedded in the base station and to complete authentication a user may be required to enter the identifier through the mobile device.
Additionally, a separate POS application may be used to perform the POS operations. In other words, a separate POS application running in parallel with the WTA application is used to perform the POS transactions. The POS application uses the WTA application to communicate with the base station and thus must be authenticated by the WTA application to communicate with the base station.
Additionally, a Terminal Management System (TMS) download tool may be used to download authentication information to the base station so that a payment application can be downloaded to perform the base station side of POS transactions. The TMS also locks the payment application to prevent unauthorized downloading of applications into the base station.
Additionally, in some embodiments a pin pad may be used in combination with base station and mobile device to allow a customer to key in personal identification information for payment transactions. In such embodiments, the pin pad is authenticated by both the mobile device and the base station during the authentication of S 901 to ensure that only the approved pin pad can be used with the base station.
Once the system has self-authenticated and a user (i.e. sales representative) has logged in, the system enters an idle state in S 902 . During the idle state, the system waits for the user to initiate a POS transaction (i.e. access the inventory application). During S 902 , the system monitors how long the system has been in an idle state. If the system determines it has been in an idle state for an amount of time that exceeds a threshold (i.e. 5 minutes, 10 minutes, etc.), the system may automatically logout in S 903 so that login and authentication of S 901 must be repeated to prevent access by an unauthorized person.
Once the authorized user (i.e. sales representative) initiates an inventory transaction, the POS application is activated to access the inventory information through the POS application in S 904 . Thus, the inventory may be updated to reflect any items being purchased and the pricing information for purchased items may be retrieved from secured storage located within the base station. Once the inventory is updated and the pricing is retrieved, the POS data is re-saved to the secured storage located within the base station in S 905 .
Once the POS data is accessed, retrieved, and updated to the secured storage, the retrieved pricing information is transmitted to the payment application in S 906 and a payment process is performed according to the process discussed above with respect to FIG. 8 . Once the payment transaction is completed, the payment data is saved to the secured storage of the base station in S 907 .
Once the payment process has been completed in S 906 and the payment data is saved to the secured storage of the base station in S 907 , a payment receipt may be printed for a customer records using a printer in communication with the base station (i.e. a printer connected through wired or wireless connection with the base station). Further, a sales receipt for store records may also be printed using the printer in S 909 . Once the sales receipt is printed in S 909 , the system may return to an idle state in S 902 and await subsequent transactions. Again, if the system is in an idle state for a period of time exceeding a threshold, the system may automatically log out in S 903 to prevent unauthorized access.
Thus, as indicated, the transaction information is stored in base station 102 . Moreover, the base station and whatever peripheral but in particular the mobile device must co-authenticate each other before the device or peripheral will be granted access to the transaction information. The TMS ensures that only valid and authorized processing applications are loaded onto the base station. All of this ensures that the data can be safely maintained on the base station, which in turn allows the base station to communicate with several devices and store the aggregate transaction information. Moreover, if a device is stolen, it will not include the transaction information.
Software Architecture
FIG. 10 provides a block diagram showing the software level architecture, and interaction between, an embodiment of the base station 1000 and one or more mobile devices 1100 , 1200 , 1300 . Though different mobile devices (i.e. an Apple IPAD 1100 , a Samsung Galaxy Tab 2 1200 , a Microsoft RT Surface 1300 ) may be used, a number of features can still be common to the mobile device used regardless of what type of mobile device is selected. Specifically, in mobile device 1100 , 1200 , 1300 includes a POS application 1101 , 1201 , 1301 that is used to perform the POS transactions, a Payment User interface application 1102 , 1202 , 1301 and a WTA application 1103 , 1203 , 1303 , which is configured to interface with the individual operating systems 1104 , 1204 , 1304 of the different mobile devices 1100 , 1200 , 1300 . Additionally, each of the different mobile devices 1100 , 1200 , 1300 may also have a Wi-Fi driver 1105 , 1205 , 1305 configured to allow each of the individual operating systems 1104 , 1204 , 1304 to control a Wi-Fi device 1106 , 1206 , 1306 integrated into the mobile devices 1100 , 1200 , 1300 to allow wireless communication with the base station 1000 .
As discussed above, the base station 1000 includes an embedded system (Best terminal (BT)) that is independent from the mobile device 1000 , 1200 , 1300 . The embedded system includes its own software that can include a payment application 1001 , EMV L2 application 1002 , and a terminal management system 1003 that each interface with a WTA application 1004 . The WTA Application 1004 allows the payment application 1001 , EMV L2 application 1002 , and terminal management system (TMS) 1003 to interface with the embedded operating system 1005 of the embedded system (BT OS). In some embodiments, the embedded operating system 1005 may be a Linux based system, but is not particularly limited to a Linux based operating system. The embedded operating system 1005 communicates with a plurality of drivers to allow the embedded system to control a plurality of peripheral devices. Specifically, the embedded system may include a Wi-Fi driver 1006 to allow the operating system 1005 to communicate with a Wi-Fi device 1007 , through which the base station 1000 can communicate with the mobile devices 1100 , 1200 , 1300 .
The authentication between the base station 1000 and one of the mobile devices 1100 , 1200 , 1300 is done through the base station WTA application 1004 and the WTA application of the respective mobile devices (or host accessed by the respective mobile devices) 1103 , 1203 , 1303 . In other words, one WTA application resides on each of the mobile devices (host securely accessed by each mobile device through a browser) 1100 , 1200 , 1300 , and one WTA application resides on the base station 1000 . Further, each of the WTA applications 1103 , 1203 , 1303 of the mobile devices 1100 , 1200 , 1300 authenticate the WTA application 1004 of the base station 1000 and the WTA application 1004 of the base station 1000 authenticates the WTA applications 1103 , 1203 , 1303 of the respective mobile devices 1100 , 1200 , 1300 .
Further, there is also additional authentication between the POS applications 1101 , 1201 , 1301 of the mobile devices 1100 , 1200 , 1300 and the WTA application 1004 of the base station 1000 . The POS applications 1101 , 1201 , 1301 may be readily available third party POS applications available through various mobile device application stores (i.e. iTunes App store, Android Play store, etc.). However, only POS applications 1101 , 1201 , 1301 of the mobile devices that have been authenticated by the WTA application of the base station 1000 can use the WTA applications 1103 , 1203 , 1303 to communicate with the base station 1000 . Thus, even if a user downloads the correct POS application into a mobile device, the POS application cannot use the base station 1000 until it is authenticated because the WTA applications 1004 , 1103 , 1203 , 1303 control the data flow between the mobile devices 1100 , 1200 , 1300 and the base station 1000 .
Additionally, the Terminal Management System (TMS) 1003 includes a download tool that is used for download authentication for the base station 1000 when downloading and installing the payment application 1001 on the base station 1000 . Thus, though the POS applications 1101 , 1201 , 1301 of the mobile devices 1100 , 1200 , 1300 may be directly downloadable through online app stores, the TMS 1003 locks down the payment application 1001 to prevent unauthorized downloading of applications into the base station 1000 .
Further, the embedded system of the base station 1000 may also include a driver 1008 to allow the base station 1000 to communicate with a cash drawer 1009 to facilitate making change for cash purchases. A secured storage driver 1010 may be used to communicate with the secured storage device 1011 embedded within the base station 1000 . A bar code scanner driver 1012 may also be provided to allow the base station to interface with a bar code scanner or reader 1013 . Further, a print driver 1014 may also be provided to allow the base station to communicate with a printer 1015 , either wirelessly or through a wired connection.
Further, a non-volatile memory driver 1016 may be provided to allow the base station to control a non-volatile memory such as an Electrically Erasable Programmable Memory (EEPROM) 1017 . A unique identifier (VID/PID) and other information can be stored in the non-volatile memory 1017 inside base station 1000 . The portable devices 1100 , 1200 , 1300 can use this data for authentication between the portable devices 1100 , 1200 , 1300 and the base station 1000 . Additionally, one or more card reader drivers 1018 , 1019 may be provided to control one or more card reader modules 1020 , 1021 . Further, a contactless reader driver 1022 and an external PIN pad driver 1023 may be provided to control an external contactless reader 1024 and an external PIN pad 1025 . The mobile devices 1100 , 1200 , 1300 and base station 1000 will authenticate the pin pad so that only an approved PIN pad can be used with the base station 1000 and mobile devices 1100 , 1200 , 1300 . Additionally, in some embodiments, the embedded system of the base station 1000 may also include a customer or shopper display driver 1026 to interface with a display 1027 for a shopper or customer to view the transaction as it is being processed. Additionally, in some embodiments the base station 1000 may include an Ethernet driver 1028 to interface with an Ethernet controller.
FIG. 11A provides a block diagram showing a second embodiment of the software level architecture, and interaction between, an embodiment of the base station and one or more mobile devices. The second embodiment of the software level architecture shown in FIG. 11A is substantially similar to the embodiment shown in FIG. 10 . Thus, similar components are labeled with the same reference numerals and redundant description is omitted.
In the embodiment shown in FIG. 10 , a payment application 1001 was provided in the base station 1000 and a payment User Interface Application 1102 , 1202 , 1302 was provided on each of the mobile devices 1100 , 1200 , 1300 . However, embodiments of the present application need not include a payment application 1001 provided in the base station 1000 . Instead, as shown in the embodiment of FIG. 11A , a payment application 1107 , 1207 , 1307 may be separately provided on each of the mobile devices 1100 , 1200 , 1300 . By running a payment application 1107 , 1207 , 1307 on the mobile devices 1100 , 1200 , 1300 , the payment user interface application 1102 , 1202 , 1302 may be omitted from the mobile devices 1100 , 1200 , 1300 and the payment application 1001 may be omitted from the base station 1000 .
Further, FIG. 11B provides a block diagram showing a third embodiment of the software level architecture, and interaction between, an embodiment of the base station and one or more mobile devices. The third embodiment of the software level architecture shown in FIG. 11B is substantially similar to the embodiment shown in FIG. 10 . Thus, similar components are labeled with the same reference numerals and redundant description is omitted.
In the embodiment shown in FIG. 10 , a payment application 1001 was provided in the base station 1000 and a payment User Interface Application 1102 , 1202 , 1302 was provided on each of the mobile devices 1100 , 1200 , 1300 . However, embodiments of the present application need not include a payment application 1001 provided in the base station 1000 . Instead, as shown in the embodiment of FIG. 11B , a thin-client application or browser based application 1108 , 1208 , 1308 may be separately provided on each of the mobile devices 1100 , 1200 , 1300 . By running a thin-client application or browser based application 1108 , 1208 , 1308 on the mobile devices 1100 , 1200 , 1300 , the payment user interface application 1102 , 1202 , 1302 may be omitted from the mobile devices 1100 , 1200 , 1300 and the payment application 1001 may be omitted from the base station 1000 .
Any of the software components described herein may take a variety of forms. For example, a component may be a stand-alone software package, or it may be a software package incorporated as a “tool” in a larger software product. It may be downloadable from a network, for example, a website, as a stand-alone product or as an add-in package for installation in an existing software application. It may also be available as a client-server software application, as a web-enabled software application, and/or as a mobile application.
The above description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles described herein can be applied to other embodiments without departing from the spirit or scope of the invention. Thus, it is to be understood that the description and drawings presented herein represent a presently preferred embodiment of the invention and are therefore representative of the subject matter which is broadly contemplated by the present invention. It is further understood that the scope of the present invention fully encompasses other embodiments that may become obvious to those skilled in the art and that the scope of the present invention is accordingly not limited.
|
A system for processing transactions, having at least one mobile device having a housing having a processor, and a Wi-Fi Communication module disposed therein; a base station having a base station housing, wherein the base station housing houses an embedded system including a processor; and a Wi-Fi communication module configured to communicate with the Wi-Fi communication module of the at least one mobile device; a support stand configured to support the at least one mobile device, wherein the support stand comprises at least one arm having an adjustable position and configured to move to adjust the size of the support stand based on a size of the at least one mobile device; and at least one peripheral device connected to the base station.
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
Trichothecenes are a closely related group of biologically active secondary metabolites produced by certain species of Fusarium and by related fungal genera in the class Hyphomycetes. Production of the toxins in agricultural commodities has led to a variety of mycotoxicoses in man and animal. The Fusaria occur widely in nature on many hosts and substrates and are among the most common of all the fungi.
It is well established that the trichothecene skeleton is formed by mevalonate via farnesyl pyrophosphate and trichodiene [Ciegler, J. Food Protec. 42: 825-828 (1979)]. All toxic trichothecenes possess a 12,13-epoxy-Δ.sup. 9 nucleus, which is believed to be formed via oxygenation of trichodiene. Desjardins et al. [Appl. Environ. Microbiol. 51: 493-497 (1986)] have shown that the oxygens of the pyran nucleus, the 12,13-epoxide, and the various hydroxyl groups are all derived from molecular oxygen. It may be concluded that these six oxygenations are catalyzed by aliphatic hydroxylases which are either dioxygenases or monooxygenases. These enzyme mechanisms can be distinguished by their sensitivity to a variety of inhibitors. In the course of studying the effects of several known and presumptive monooxygenase inhibitors and analogous compounds on trichothecene biosynthesis in Fusarium sporotrichioides, which produces T-2 toxin as the end product, and Fusarium sambucinum, which produces diacetoxyscirpenol as the end product, I have arrived at the subject invention.
2. Description of the Prior Art
One such inhibitor I have investigated is ancymidol. Ancymidol has been reported in the literature as having plant growth regulator activity at concentrations less than 10 -6 M (0.2 μg./ml.). Inhibition of plant growth by ancymidol was first demonstrated by Tschabold et al. [Plant Physiol. 46: 19 (1970)]. Leopold [Plant Physiol. 48: 537-540 (1971)] and Shive and Sisler [Plant Physiol. 57: 640-644 (1976)] determined that gibberellin relieved the growth retardation by ancymidol in lettuce hypocotyls, green bean plants, and corn seedlings. Coolbaugh et al. [Plant Physiol. 57: 245-248 (1976) and Plant Physiol. 69: 707-711 (1982)] found that ancymidol blocked three oxidative reactions in the gibberellin biosynthetic pathway in higher plants.
Ancymidol is also weakly fungitoxic. Shive and Sisler, supra, found ancymidol at 100 μg./ml. to inhibit dry weight increase of Gibberella fujikuroi by 23%. However, no concentration was found where dry weight was not affected and gibberellin activity produced was affected. Ali [Can. J. Bot. 57: 458-460 (1979)] showed ancymidol at 4 μg./ml. to inhibit radial growth of Fusarium graminearum by 50%. Coolbaugh et al. [Plant Physiol. 69: 712-716 (1982)] found ancymidol at 10 -3 M (250 μg./ml.) to inhibit dry weight increase of Gibberella fujikuroi by 88%. They also showed that ancymidol was much less effective in inhibiting gibberellin biosynthesis in the fungus than in higher plants. Effects of ancymidol on other fungal enzyme systems were not studied.
SUMMARY OF THE INVENTION
I have now discovered that the compound ancymidol inhibits the biosynthesis of trichothecene toxins on substrates susceptible to growth of tricothecene-producing fungal species when the compound is applied to the substrate in amounts substantially less than that needed to block fungal growth itself.
In accordance with this discovery, it is an object of the invention to define a previously unrecognized trichothecene toxin control agent.
It is also an object of the invention to provide a new and unobvious use for ancymidol.
It is a further object of the invention to control trichothecene toxins in cereal grains and other crops by addition of extremely low levels of ancymidol safe for human and animal consumption.
Other objects and advantages of this invention will become readily apparent from the ensuing description.
DETAILED DESCRIPTION OF THE INVENTION
The name "ancymidol" is generic for α-cyclopropyl-α-(p-methoxyphenyl)-5-pyrimidinemethanol and identifies the compound represented by the structural formula I, below. ##STR1##
Pure ancymidol is characterized as a white crystalline solid having a melting point of 110°-111° C. Ancymidol is freely soluble in DMSO, acetone, methanol, chloroform, and other polar solvents; moderately soluble in aromatic hydrocarbons such as benzene; and only slightly soluble in saturated hydrocarbon solvents. In water it is soluble at levels of approximately 650 p.p.m. at 25° C.
Ancymidol is relatively nontoxic as indicated by oral feeding studies over a 3-month period with rats and dogs. In the studies, all test animals survived without significant changes at 8000 p.p.m. of the feed, corresponding to a dose in the dogs of 20 mg./kg. body weight ("Technical Report on `A-REST`," Lilly Research Laboratories).
In accordance with the objective of the invention, it is envisioned that ancymidol may be applied to any liquid or solid substrate susceptible to contamination with trichothecenes. As secondary fungal metabolites, the toxins are associated with the senescent fungus. All substrates susceptible to growth of the fungus are therefore targets for treatment. Of particular interest are cereal grains, forage crops, and potatoes, especially those which are stored for extended periods. It is sufficient to commence treatment at any time during the primary phase of fungal growth. However, as a practical matter, it would be efficacious to treat the grain or other crop material at the time of storage.
Ancymidol may be formulated with one of the aforementioned solvents or with any suitable carrier or vehicle as known in the art. Solutions of ancymidol in DMSO are readily miscible with water. The compound is unstable under acidic conditions, and it is therefore important to maintain the formulation at pH 4 or greater. The ancymidol formulation may be sprayed onto the substrate or otherwise applied by any conventional means.
In accordance with this invention, ancymidol finds utility in virtually all fungal systems known to produce trichothecenes. Included in this category, without limitation, are species of Fusarium, Acremonium, Trichoderma, Trichothecium, Myrothecium, and Stachybotrys, all belonging to the class Hyphomycetes. The end product of the trichothecene biosynthetic pathway may vary from species to species. It is now known that blockage of only the end product in the natural pathway will lead to accumulation of other trichothecene toxins which are otherwise intermediates to the end product. However, of those species studied, all produce trichothecenes via the nontoxic, trichodiene intermedite. I have discovered that ancymidol blocks the epoxidation of trichodiene, presumably by inhibition of the cytochrome P-450 monooxygenase. Thus, biosyntheses of all trichothecene intermediates and end products are blocked.
The principal advantage of this invention relates to the specificity of ancymidol when applied at the proper rate to a substrate susceptible to contamination by trichothecene toxins. On a given substrate the effective amount of ancymidol required for trichothecene inhibition is consistently at least one or two orders of magnitude less than that required to achieve a comparable degree of fungal growth inhibition. The expression "specific effective amount" is defined herein to mean that amount of ancymidol which will achieve the desired response in terms of trichothecene inhibition without substantial inhibition of fungal growth. The actual amount will vary depending upon the substrate, the specific fungal organism, the level of fungal contamination, and the conditions of growth. Typically, by application of a specific effective amount of ancymidol, it will be possible to inhibit 50-100% of the toxin production.
The following examples are intended only to further illustrate the invention and are not intended to limit the scope of the invention which is defined by the claims.
EXAMPLES 1-2
Inhibitor Screening Experiment. Fusarium sambucinum isolate R-6380 (Pennsylvania State University Fusarium Research Center) was grown on "V-8" juice agar. Conidial suspensions were prepared and frozen in 50% v/v glycerol at -90° C. A 2800-ml. Fernback flask containing 1 liter of 5% glucose, 0.1% peptone, and 0.1% yeast extract was inoculated with thawed conidia to a final concentration of 10.sup. 5 per ml. The culture was incubated at 28° C. in the dark on a gyrotory shaker at 200 r.p.m. After 24 hours, 10-ml. aliquots were removed to measure dry weight and toxin levels. Twenty-five ml. volumes of the culture were transferred to 50-ml. Erlenmeyer flasks with metal caps. Twenty-three test compounds to be screened were added to the cultures in DMSO to a final concentration of 1% v/v. All compounds were tested in duplicate cultures. At 48 hrs., the test compounds were again added to the cultures. Incubation as above continued for a total of 5 days, at which time 5-ml. aliquots were collected to measure dry weight. Total cultures were extracted twice with 25 ml. ethylacetate and evaporated to dryness. The residue was dissolved in acetonitrile-water (9:1), applied to a charcoal cleanup column, eluted with acetonitrile-water, and evaporated to dryness. The residue was dissolved in toluene:acetone:methanol (2:1:1), evaporated to dryness under nitrogen, derivatized with "TBT" (Pierce Chemical Co.), diluted in hexane, and analyzed for diacetoxyscirpenol using a Spectro-Physics gas chromatograph.
The results of the ancymidol assay are reported in Table I, below. Data are expressed as follows: net fungal growth was determined by subtracting the dry weight at 24 hrs. from the dry weight at 5 days, and normalized by dividing by net growth of the DMSO-treated control. Net diacetoxyscirpenol production was determined by subtracting diacetoxyscirpenol at 24 hrs. from toxin at 5 days and normalized by dividing by the net toxin of the DMSO-treated control.
EXAMPLE 3
The procedure of Examples 1-2 was repeated except that at 24 hrs. after inoculation, ancymidol was added to a final concetration of 1 mM to the 1-liter culture. After extracting the culture four times with 500 ml. ethylacetate and evaporating to dryness, the sample was redissolved in ethylacetate and analyzed by GC-MS. The hydrocarbon in the sample was determined, by comparison to an authentic standard, to be trichodiene. This experiment established that no significant amounts of epoxide intermediates or end products were produced by the fungus in the presence of ancymidol.
TABLE I______________________________________Effects of Ancymidol on F. sambucinum Net DAS.sup.b Ancymidol Net fungal growth productionExample level (mM) (% of controls).sup.a (% of control).sup.a______________________________________1 2 62 32 0.2 74 13______________________________________ .sup.a Values represent average of duplicate cultures. .sup.b DAS = diacetoxysciropenol.
EXAMPLES 4-8
The Effect of Ancymidol on Trichothecene Biosynthesis in Rice. F. sambucinum R-6380 (Pennsylvania State University Fusarium Research Center) was used for this study. The inoculum was a conidial suspension obtained by washing the surface of 1-week old "V-8" grown cultures with sterile distilled water. Five ml. of inoculum at 3×10 -7 conidia per ml. were added to each 300-ml. Erlenmeyer flask containing 30 g. rice autoclaved with 13 ml. water. The cultures were incubated at 28° in the dark for 4 days, at which time the rice was evenly colonized. Ancymidol was added to the cultures as 100-mM solution in DMSO. After 10 days further incubation, the cultures were extracted three times by homogenization with 100 ml. ethylacetate. The ethylacetate extract was concentrated and analyzed by GC/MS. The results are reported in Table II, below.
EXAMPLES 9-12
Fungicide Screening Protocol. Each of two strains of F. sambucinum and F. sporotrichioides was grown on "V-8" juice agar. Conidial suspensions were prepared by washing the surface of a 1-week old culture with sterile distilled water. A 300-ml. flask, containing 150 ml. of 5% glucose, 0.1% peptone, and 0.1% yeast extract was inoculated with conidia of each strain to a final concentration of 10.sup. 5 per ml. The culture was incubated at 28° C. in the dark on a gyrotory shaker at 200 r.p.m. After 24 hrs., 10-ml. aliquots were removed to measure dry weight and toxin levels. Twenty-five ml. volumes of the culture were transferred to 50-ml. Erlenmeyer flasks with metal caps. Ancymidol was added to duplicate cultures in DMSO (to a final concetration of 1% v/v). At 48 hrs., ancymidol was again added to the culture such that the final concentration of ancymidol was 2 mM. Incubation as above continued for a total of 7 days, at which time 5-ml. aliquots were collected to measure dry weight. Total cultures were extracted twice with 25 ml. ethylacetate and evaporated to dryness. The residue was dissolved in 1 ml. ethylacetate and analyzed by GC/MS.
TABLE II______________________________________Diacetoxysciropenol in Ancymidol-TreatedCultures of F. sambucinum on Rice Ancymidol DiacetoxyscirpenolExample (μmoles/g. rice) (μg./g. rice).sup.a______________________________________4 0 2525 0.33 1606 1.0 1407 2.0 1438 3.3 143______________________________________ .sup.a Values represent average of duplicate cultures.
The results are reported in Table III, below. Data are expressed as follows: net growth was determined by subtracting the dry weight at 24 hrs. from the dry weight at 7 days, and normalized by dividing by net growth of the DMSO-treated control. Net toxin production was determined by subtracting toxin at 24 hrs. from toxin at 7 days and normalized by dividing by net toxin of the DMSO-treated control.
EXAMPLES 13-22
F. sambucinum isolate R-6380 (Pennsylvania State University Fusarium Research Center) was grown on "V-8" juice agar. A conidial suspension was prepared by washing the surface of a 1-week-old culture with sterile distilled water. A 2800-ml. Fernbach flask containing 750 ml. of 5% glucose, 0.1% peptone, and 0.1% yeast extract was inoculated with conidia to a final concentration of 10.sup. 5 per ml. The culture was incubated at 28° C. in the dark on a gyrotory shaker at 200 r.p.m. After 24 hrs., 10-ml. aliquots were removed to measure dry weight and toxin levels. Twenty-five ml. volumes of the culture were transferred to 50-ml. Erlenmeyer flasks with metal caps. Ancymidol was added to duplicate cultures according to the regime set forth in Table IV. Incubation as above continued for a total of 7 days, at which time 5-ml. aliquots were collected to measure dry weight. Total cultures were extracted twice with 25 ml. ethylacetate and evaporated to dryness. The residue was dissolved in 1 ml. ethylacetate and analyzed by GC/MS.
Diacetoxyscirpenol production was determined by dividing toxin at 7 days by toxin of the DMSO-treated control at 7 days. The results are reported in Table IV, below.
EXAMPLES 23-30
Fusarium sporotrichioides strain 3299 was grown on "V-8" juice agar. Conidial suspensions were prepared by washing the surface of a 1-week-old culture with sterile distilled water. A 50-ml. flask containing 25 ml. of 5% glucose, 0.1% peptone, and 0.1% yeast extract was inoculated with
TABLE III__________________________________________________________________________Effects of Ancymidol on F. sporotrichioides and F. sambucinum Net toxin Net fungal growth as % of DMSO-treated as % of DMSO-treated control.sup.aExampleFungus control.sup.a DAS.sup.b T-2__________________________________________________________________________9 Fusarium sporotrichioides 51 -- 0strain #329910 F. sporotrichioides 57 14 --strain #MB 1716.sup.c11 F. sambucinum 54 3 --strain #638012 F. sambucinum 63 0 --strain #278-34__________________________________________________________________________ .sup.a Values represent average of duplicate cultures. .sup.b DAS = diacetoxyscirpenol. .sup.c This UVinduced mutant makes only diacetoxyscirpenol.
TABLE IV__________________________________________________________________________Effect of Ancymidol on Diacetoxyscirpenol (DAS) Production by F.sambucinum Ancymidol addition (mM) DAS at day 7 as % of Net DAS toxin as % ofExample Day 1 Day 2 Day 3 Day 4 Day 5 DMSO-treated control DMSO-treated control.sup.a__________________________________________________________________________13 0 0 0 0 0 100 --(DMSO control)14 1 1 0 0 0 10 315 2 0 0 0 0 13 616 1 1 1 0 0 14 717 0 1 1 0 0 61 018 0 2 0 0 0 58 019 0 1 1 1 0 55 020 0 0 1 1 0 103 3321 0 0 2 0 0 89 1922 0 0 1 1 1 76 6__________________________________________________________________________ .sup.a Computed as the toxin at day 7 minus the toxin level prior to the first treatment with ancymidol.
conidia to a final concentration of 10.sup. 5 per ml. The cultures were incubated at 28° C. in the dark on a gyrotory shaker at 200 r.p.m. At 24 hrs., ancymidol was added to duplicate cultures in DMSO to a final concentration of 1% v/v. At 48 hrs., ancymidol was again added to the cultures such that the final concentration was as indicated in Table V. Incubation as above continued for a total of 7 days, at which time 5-ml. aliquots were collected to measure dry weight. T-2 in culture filtrates was assayed using monoclonal antibodies.
Net growth was determined by subtracting the dry weight at 24 hrs. from the dry weight at 7 days, and normalized by dividing by net growth of the DMSO-treated control. Net T-2 was determined by subtracting T-2 at 24 hrs. from T-2 at 7 days and normalized by dividing by net T-2 of the DMSO-treated control.
It is understood that the foregoing detailed description is given merely by way of illustration and that modifications and variations may be made therein without departing from the spirit and scope of the invention.
TABLE V______________________________________Dose Response of Fungal Growth and T-2 Toxin to Ancymidolin F. sporotrichioidesEx- Net fungal growth Net T-2 toxinam- Ancymidol as % of DMSO- as % of DMSO-treatedple (mM) treated control.sup.a control.sup.a,b______________________________________23 2 87 2024 1 90 2125 0.2 97 3826 0.1 95 5727 0.02 98 7328 0.01 99 8529 0.002 100 9030 0.001 97 100______________________________________ .sup.a Values represent average of quadruplicate cultures. .sup.b T2 of control = 90 μg./ml.
|
The compound ancymidol, a known potent plant growth retardant and weak fungicide, has now been found to inhibit biosynthesis of trichothecene toxins on substrates susceptible to growth of trichothecene-producing fungi. These fungi are known to contaminate cereal grains, forage crops, and potatoes. The effective level of ancymidol addition for toxin inbibition is substantially less than that required for control of fungal growth.
| 8
|
FIELD OF THE INVENTION
The invention relates to a device to detect various states such as deformation states, movements and loading states of a component, having a transmitter and a receiver that are arranged independently and at a distance from each other on at least one component, and the invention also relates to an evaluation unit.
BACKGROUND
A transducer of deformation states of a component is already known from U.S. Pat. No. 5,170,366. This transducer emits acoustic signals by means of a transmitter provided in or on the component and it receives acoustic signals with a receiver arranged on or in another place on the component. The various loading states of the component such as, for example, deformation due to stretching, compression or torsion result in various delay time differences of the acoustic signals. In the case of stretching of the component, the propagation rate decreases while in the case of a compression, the propagation rate of the acoustic signals increases. In order to obtain a correlation between the measured delay times and the component load, it is necessary to determine the possible loading states and thus the various delay times between the transmitter and the receiver in a simulation phase. Moreover, it is necessary to equalize and evaluate all of the parameters that have an influence on the propagation rate and that cannot be ascribed to a loading of the component such as, for instance, the temperature or fault signals.
U.S. Pat. No. 3,708,231 shows a device to detect angular changes of a component, whereby the reflection behavior of a light beam on a slanted, plane surface is evaluated. Component deformations such as, for example, bending, cannot be detected with this arrangement. French Patent No. 2,578,974 relates to a device to determine a force or the movement resulting from said force. Here, inside a flexible housing, there is a light transmitter and, opposite from it in the housing, an optical receiver. Due to the optical property or characteristic of the light that propagates in the housing, a deformation of the housing can be detected. A small, dynamic relative movement between the transmitter and the receiver cannot be detected with such a device.
SUMMARY OF THE INVENTION
The invention is based on the objective of creating and configuring a deformation transducer in such a way that a rapid and simple determination of various loading states of the component is possible.
This objective is achieved according to the invention in that the transmitter emits a focused or punctiform electromagnetic wave or a focused acoustic wave or a focused particle beam outside of the component towards the receiver. The result of this is that the transmitter and the receiver are effectively linked to each other via the light beam so that, for example, deformations of the component have an effect on the relative position between the transmitter and the receiver and thus also on the path of the light beam relative to the receiver. This device is suitable as a weighing device since the deformation of a component allows a conclusion to be drawn about the force acting upon it. However, other influencing variables that entail a deformation of the component such as, for example, dynamic loads or an unbalance, can also be ascertained. For such a position determination, it is also conceivable to use a pressure wave or sound wave or else a water jet.
In this context, it is also advantageous for the transmitter and the receiver to each be arranged in a holder on the component in such a way that a deformation of the component is equivalent to the position shift of the electromagnetic wave or of the light beam on the receiver. Thus, every deformation of the component leads to a change in the light beam path relative to the receiver. This change serves to determine the component deformation or the component oscillation or else it is equivalent thereto. This also offers the possibility—via the deformation state of the component—to detect the force that causes the deformation; that is to say, for example, the weight of a load like that of a train on a railway track that is deformed under its load can be determined. The dynamic weighing of a train is also an option.
According to an embodiment, an additional possibility is that, within the beam path of the light beam, there is at least one reflector or one reflective surface and that the light beam is reflected by the reflector or by the reflective surface towards the receiver, whereby the reflector is connected to the component via a holder. For this purpose, it is also advantageous for the transmitter and the receiver to be arranged on a shared side of the housing opposite from the reflector or from the reflective surface. Therefore, the beam path of the light beam is lengthened two-fold, four-fold or multiple-fold depending on the number of reflectors. Thus, the deviation of the light beam resulting from the component deformation is increased by this lengthening factor, which leads to a considerable resolution of the component deformation. Consequently, any slight deformation can be resolved and determined. The arrangement of the reflector on the component has the advantage that the transmitter-receiver unit in its entirety is arranged on the component by means of a separate holder.
Finally, according to a preferred embodiment of the solution according to the invention, it is provided that the receiver has a light-sensitive surface such as a PSD transducer or an image processing element and the light-sensitive surface ensures a resolution of at least 3000 d to 6000 d. This value, which is common in weighing technology, is determined from the quotient of the length ratios of the maximum measurable deviation of the light beam to the light-sensitive surface and the diameter of the smallest optical unit. In this manner, the deviations of the reflected light beam relative to its starting position and thus the component deformation can be determined on the basis of the above-mentioned resolution. Here, it must be noted that the deviation of the light beam is already enlarged by the corresponding factor due to the multiple reflection of the beam path.
An especially important aspect for the present invention is that the transmitter should emit at least one light beam such as a laser beam. Thus, it is also possible that the component deformation can be evaluated by means of two or three light beams whose frequency and/or position differ. The use of a laser beam is extremely advantageous in terms of the scatter or the position detection. The use of another medium such as, for example, water, for generating a beam path is also conceivable.
In conjunction with the design and arrangement according to the invention, it is advantageous for the transmitter, the receiver and the reflector to be arranged in a flexible housing. The housing serves to protect the beam path from external influences. By designing the housing so as to be flexible, it is possible to prevent the relative movements between the various elements due to component deformation.
Regarding the beam path lengthening, it is advantageous for at least one semi-transparent layer to be arranged inside the beam path leading from the transmitter to the receiver. In this manner, one part of the intensity of the emitted light beam is reflected and the other part of the intensity of the beam path continues further. Thus, a position image of the beam path on the receiver is obtained which indicates various resolution stages of the component deformation corresponding to the number of reflections.
For this purpose, it is also advantageous for the transmitter and/or the receiver and/or the housing to be round or rectangular in shape. Depending on the potential component deformation or on the area of application, an optimal utilization of the available surfaces can be achieved in this manner. The round housing shape serves essentially for the use of the transducer in the form of a drill core or as a drill core substitute. This core is inserted into a bore or received by it in order to determine the component deformations there. Thus, the transducer can be used, for instance, in a foundation in order to determine the deformations or oscillations present there.
It is also advantageous for the receiver or the PSD transducer to be associated with an evaluation logic circuit in order to determine the deformation of the component. The component deformation manifested by the deviation of the reflected light is determined by means of an evaluation logic circuit. Consequently, the transducer can also be employed as a weighing member.
In conjunction with the design and arrangement according to the invention, it is advantageous for the transmitter and the receiver to be arranged together on a plate that is clamped to a component by means of at least one clamping element, whereby the clamping element has two pointed or round contact parts and at least one bore that matches the plate. Via these bores, the clamping element is put into contact, on the one hand, with the plate and, on the other hand, with the railway track, so that the deformations of the component are transmitted to the transmitter and to the receiver. The resultant contact surface is linear here, as a result of which a non-redundant support is achieved. This avoids the need for complicated drilling or gluing to the component.
Finally, it is advantageous for the transmitter and the receiver—together in one holder—and for the reflector—independent of and at a distance from them in another holder—to be arranged on the component in a shared housing.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional advantages and details of the invention are explained in the patent claims and in the description, and they are illustrated in the figures, which show the following:
FIG. 1 —a cross sectional representation of the transducer from the side in the unstressed component,
FIG. 2 —a cross sectional representation of the transducer from the side in the stressed component,
FIG. 3 —a receiver in a front view,
FIG. 4 —a sectional view of the transducer as a drill core,
FIG. 5 —a sectional view of the transducer with a screwed connection to the component,
FIG. 6 —the sectional view A—A according to FIG. 5,
FIG. 7 —the representation according to FIG. 1 with the light beam reflected multiple times,
FIG. 8 —a sectional view of a holding means.
DETAILED DESCRIPTION
FIG. 1 uses reference numeral 1 to designate a component on whose side or side surface a load or deformation transducer 11 is arranged. This component can be a railway track, an axle or a support bar. The deformation transducer 11 can be clamped, screwed or glued onto the component.
The transducer 11 is equipped with a transmitter 2 and a receiver 3 on the right-hand side of its housing 8 ′. The transmitter 2 emits a light or laser beam 5 towards a left-hand housing side 8 , where said beam strikes a reflector 6 and is reflected. A reflected light beam 10 then strikes the receiver 3 that is provided on the transmitter side. Depending on the degree of parallelism of transmitter 2 and reflector 6 , the transmitted light beam 5 is identical to the reflected light beam 10 or it deviates somewhat as shown in FIG. 1, in other words, an exit point 13 of the transmitted light beam and a striking point 14 of the reflected light beam are at a slight distance. This position is now selected as the reference for all other loading states of the component. The force that caused the deformation such as, for example, the weight of a freight train, is determined on the basis of the deformation of the component.
The transmitter-receiver unit on the right-hand side as well as the reflector 6 on the left-hand side are each firmly attached to the component 1 by means of a holder 12 , 12 ′.
Both holders 12 , 12 ′ are surrounded by a shared flexible housing 7 that shields the transducer against external influences and that ensures the freedom of motion of both sides during a component deformation according to FIG. 2 .
FIG. 2 shows the component deformed due to an external load. The left-hand and right-hand holders 12 , 12 ′ are thus positioned slanted towards each other corresponding to the deformation. The result is that the angle of incidence of the transmitted light or laser beam 5 and the emergent angle of the reflected laser beam 10 differ from the reference position as shown in FIG. 1 and the exit point 13 of the transmitted laser beam and the striking point 14 of the reflected laser beam are at a distance that diverges from the reference position.
FIG. 3 shows the receiver 3 with the emerging laser beam 5 and the exit point 13 as well as the striking point 14 of the reflected laser beam. The receiver is circular in shape and has a light-sensitive surface 19 by means of which the position of the incident laser beam is determined.
FIG. 4 shows the transducer in the form of a drill core, that is to say, it is guided through a bore 15 provided in the component to be tested. Due to the holder 12 , 12 ′ provided on both sides, the deformation caused in the component by the external load has an effect on the transducer or on the parallelism of the receiver 3 and the reflector 6 . The housing 7 ensures the guidance properties needed for introducing the transducer 11 so that the parallelism of the receiver 3 and of the reflector 6 in the reference state is virtually assured. In this embodiment, the transmitter 2 is arranged opposite from the receiver 3 . In the case of component deformation, the light beam 5 is deflected from its reference position. Therefore, a deflected light beam 5 ′ strikes the receiver 3 at a position that diverges from the reference position, and the component deformation can be determined.
FIG. 5 shows another possibility for arranging or attaching the transducer 11 to the component 1 . For this purpose, the two holders 12 , 12 ′ each have a fixed connection 18 , 18 ′ with a stud bolt 16 , 16 ′. The stud bolts 16 , 16 ′ are screwed to the component 1 or threaded into it. The housing 7 surrounds the transmitter 2 and the receiver 3 . The attachment strength or form-fit between the stud bolts 16 , 16 ′ and the component 1 is ensured by a pin connection 17 , 17 ′ that prevents torsion around the center axis of the stud bolt in question.
FIG. 6 shows the section A—A according to FIG. 5 . The receiver 3 is rectangular in shape, whereby the transmitter 2 is arranged on the edge in the vicinity of a corner or on the upper left, and the reflected laser beam 10 in the reference state likewise strikes in the vicinity of this corner, that is to say, the exit point 13 and the striking point 14 of the laser beam are both arranged in the vicinity of a corner of the rectangular transmitter-receiver unit 2 , 3 .
According to FIG. 7, it is also possible to place a semi-transparent layer 9 in front of the receiver 3 so as to allow part of the reflected laser beam 10 to pass through, i.e. part of the intensity of the laser beam strikes the receiver, while the remaining part of its intensity is reflected once again in the direction of the reflector 6 , which then allows it to strike the receiver 3 a second time.
In FIG. 8, the reference numeral 1 designates a railway track that is connected via a plate 20 and two bridge-shaped or U-shaped clamping elements 21 to the transmitter 2 and the receiver 3 . For this purpose, the plate 20 has at least one bore 24 in the area of both ends, said bore being located coaxially to a bore 23 of the clamping element 21 in question. Moreover, the clamping element 21 has two semi-circular contact parts 22 , 22 ′ that lie linearly against the plate 20 as well as against the railway track 1 . The transmitter 2 and the receiver 3 are located underneath the plate. Here, the clamping element 21 rests with a short leg 26 on a foot 25 of the railway track 1 and with a long leg 26 ′ on the plate 20 . Thus, the plate 20 is brought into contact with the railway track 1 and a deformation of the railway track can be determined.
|
A device for detecting different conditions of a component, such as distorted conditions, movements and loaded conditions. Said device comprises a transmitter and a receiver which are located independently on at least one component at a distance from one another and an evaluation unit. The transmitter emits an electromagnetic wave (such as e.g. a laser beam), or a focused particle beam to the receiver. The spatial resolution can be increased by multiple reflections from a mirror and a semi-transparent mirror.
| 6
|
TITLE OF THE INVENTION
This is a continuation of application No. 08/104,113, filed on Aug. 16, 1993, which was abandoned.
BACKGROUND OF THE INVENTION
The invention relates to a process for dispersing, blending or homogenizing of solid/liquid and/or liquid/liquid mixtures, and to a device for executing this process, having a grinding chamber in which grinding bodies are disposed.
In accordance with a previous proposal Austrian Letters Patent 395,544 a device for blending, homogenizing or reacting of at least two components was already known, wherein it was possible to omit separate mixing tools. Thus, in contrast to known stirring apparatus which dip into a container, the intent of this previous proposal had been to bring the material to be mixed into motion in respect to itself, so that at adjoining partial areas a strong relative movement of the material to be mixed is generated. The mixing zone formed in this way was intended to lead to blending as homogeneously as possible in the area of the mixing zone. To vary the mixing results, it was furthermore proposed to put the mixing zone under pressure by changing the volume of the rotating container, in which connection the use of such compression pressure was of importance, in particular in view of the possibility to achieve desired chemical reactions of individual components with each other. Continuous operation was possible in the previous proposal in that the blended material could be drawn off in the axial direction of the container, i.e. in the direction of the axis of rotation, wherein the partial section in which the most intense mixing took place was limited to the front faces, located opposite from each other, of oppositely directed, open, cylindrical containers.
OBJECTS OF THE INVENTION
Now, it is the object of the invention to improve an installation of the previously mentioned type in such a way that with small structural dimensions it is possible to increase the mixing zone substantially, and wherein furthermore the possibility is created to improve homogenization, even when using substances which are hard to mix with each other, in particular solid/liquid mixtures and liquid/liquid mixtures, for obtaining a dispersion or an emulsion. By means of the process of the invention it is simultaneously intended to create the possibility to counteract effectively the possible formation of clumps, which might occur in the course of producing such dispersions, and to split up assuredly agglomerations of the smallest size. Besides the assured blending, it is intended by means of the process of the invention to perform wet grinding and intense dispersion successfully even in cases where liquids of relatively high viscosity are used and where, because of the high viscosity, the separation of the grinding bodies from the liquid component is difficult with conventional processes. In accordance with the invention it is intended at the same time that an assured and easy separation of the grinding bodies is successful in spite of high viscosity, even if grinding bodies are used which have an extremely small diameter and where there are extremely slight differences in density in respect to the dispersion to be produced. Due to the employment of basic materials of higher viscosity it is also intended to process concentrates, wherein the throughput can be considerably reduced, for example when producing dilutable dyes on the basis of synthetic resin pigment.
SUMMARY OF THE INVENTION
To attain this object, the process of the invention essentially consists in introducing the dispersion or emulsion to be homogenized into a rotating grinding chamber which is at least partially filled with grinding bodies and is bounded by at least two rotatable wall elements, and in moving or guiding the dispersion or emulsion to be homogenized through the annular chamber in a direction crosswise to the axis (axes) of rotation of the wall elements. Due to the fact that the dispersion or emulsion to be homogenized is introduced into a rotating grinding chamber which is at least partially filled with grinding bodies and is bounded by at least two rotatable wall elements, a mixing zone is formed between the rotating wall elements, which with small dimension altogether assures a relatively large partial section of intense blending. At the same time intense wet grinding is assured because of the at least partial filling of the grinding chamber with grinding bodies, wherein an intense acceleration of the grinding bodies and blending takes place at the interface between the rotating areas of the grinding chamber. Because of the rotation of the rotatable wall elements and thus the rotation of the grinding chamber, a centrifugal force is simultaneously exercised on the grinding bodies which leads to the grinding bodies moving against each other under high pressure over a greater diameter of the grinding chamber and for this reason a high compression pressure and thus an improved wet grinding result is achieved in this partial area of the grinding chamber. But, simultaneously with this directed movement of the grinding bodies in the direction of the centrifugal force, the separation of the grinding bodies from the prepared emulsion or the prepared dispersion is now also improved, so that it is possible to draw off the finished material to be ground in a simple way over a reduced diameter, for example on the side of the grinding chamber located opposite this compression of the grinding bodies, without there being a need here for conventional separating techniques, such as the use of filters or screens, which tend to become clogged. Thus it is possible to improve the separation of the grinding bodies from the dispersion or the emulsion considerably by means of the process of the invention, the improvement being, amongst other things, that it is possible to eliminate the use of screens or filters when drawing off the mixture, for which purpose the process of the invention is executed in such a way that the dispersion or emulsion to be homogenized is moved or guided through the grinding chamber crosswise to the axis (axes) of rotation of the wall elements.
With wall elements which rotate in relation to each other, the partial area of intense blending between the rotating partial areas of the grinding chamber or mixing chamber is formed by an annular plane which essentially extends normally in respect to the axes of rotation. With an appropriate design of the rotating wall elements, however, the separation plane and thus the zone of the most intense blending can also be located in a plane corresponding to the surface area of a cone. Blending or swirling is a function of the relative speed existing between adjoining areas of the mixing chamber or grinding chamber. With opposite rotation of the wall surfaces this relative speed, and thus the dispersing effect becomes particularly high, where in connection with this a resulting centrifugal force in the grinding chamber for separating the grinding bodies should altogether be taken into consideration. Thus, the process can be advantageously executed in such a way that the mixing process is performed between wall elements which rotate in relation to each other with different rpm and/or direction of rotation.
The axes of rotation of the wall elements which are rotatable in relation to each other can be different from each other and essentially extend parallel to each other, by means of which it is possible to achieve a certain amount of eccentricity of the rotational movement in relation to the interface between the particles which rotate in relation to each other, and thus a particularly intense blending.
If the axes of rotation extend inclined toward each other, it is additionally possible to achieve a kneading effect to improve the blending over the entire radial extent of the grinding chamber. When employing wall elements with axes of rotation which are inclined toward each other, the wall elements can be driven at the same speed and in the same direction of rotation, the result of which is that a total movement of the mixture of material to be ground--grinding bodies is produced during each revolution, in spite of a small relative movement between the disks or wall elements and the material to be ground. This means that the energy supply can take place optimally and that the danger of local overheating, especially when processing materials of higher viscosity, does not exist. The possibility of being able to drive both wall elements at the same rpm and still to achieve an optimum grinding/mixing effect, also means a considerably simplification of the entire structure and in the end improves the centrifugal effects on all grinding bodies.
In this case the process is preferably executed in such a way that the material to be mixed or the mixture of grinding bodies/material to be ground is put into rotation at the same rotational speed as the two wall elements, and that the material to be mixed or the mixture of grinding bodies/material to be ground are moved at least once in the direction of the axis of rotation and once in the direction away from the axis of rotation during each revolution. The total result of this is that the relative movement in the direction of rotation between the grinding bodies/material to be ground and the driving disks or wall elements is practically zero and the exclusive mixing and grinding effects are achieved through the displacement of the mixture in the radial direction. It is achieved by means of this to set the pressure forces and separation effects exclusively as a function of the common rpm of these disks.
However, to simplify sealing and to simplify construction of a corresponding device it is easily possible to dispose the axes of rotation coaxially in respect to each other. There is the additional possibility to provide, outside of the grinding chamber bounded by the rotating wall elements, an additional possibility of pre-blending under high shearing stress. For this purpose the process of the invention is advantageously performed in such a way that the dispersion or emulsion to be homogenized is subjected, prior to its entry into the grinding chamber, to a shearing stress between rotating surfaces at the outside of the wall elements of the grinding chamber, wherein such a performance of the process by means of a structurally relatively simple device results in an additional intense blending.
Good separation of the grinding bodies from the dispersed or homogenized ground material without an expensive separation technique can be achieved in that the dispersion or emulsion to be homogenized is conveyed through the grinding chamber in a direction opposite to the direction of movement generated by the centrifugal force.
The material to be homogenized or dispersed can be advantageously fed in the radial direction from the outside to the inside, wherein the process can be performed continuously in a particularly simple manner in that the homogenized mixture is drawn off via an axial conduit. To set the appropriate pressure requirements and flow conditions, the outflow via the axial conduit can be appropriately throttled. As a whole, because of the possibility of being able to freely select the rpm and/or the direction of rotation of the wall elements which rotate in respect to each other, over a large range and the possibility of setting the respective flow speed and pressure conditions, an adaptability to different basic materials results, and homogenizing and blending even of difficult to mix, highly viscous substances, along with a simultaneous improvement of homogenization and of fine distribution or dispersion can be achieved. In the course of this the advantageous process is to fill the grinding chamber up to maximally 75% by volume, preferably 60% by volume with grinding bodies of an effective diameter of less than 0.5 mm, preferably less than 0.1 mm.
The device in accordance with the invention for executing this process, requiring little space and a small structural and installation outlay, and which in particular assures the adaptability to different basic materials, along with improved homogenization and blending at the same time, is advantageously embodied in such a way that the grinding chamber is bounded by at least two wall elements which can be rotatably driven, and that the grinding chamber has at least one feed and/or draw-off opening on its sides facing towards and away from the axis (axes) of rotation. In this case the feed opening can be connected to the front of the grinding chamber located radially on the outside, while the draw-off opening can terminate into an axial conduit in an area close to the axis. In a particularly simple manner, both of these openings can be formed by slits extending over the circumference of the grinding chamber, wherein the embodiment advantageously is made in such a way that the slits are located in a common separation plane of the grinding chamber which essentially extends normally in respect to the axis (axes) of rotation of the wall elements. With an embodiment of this type the result is a relatively large zone of intense blending with, at the same time, small dimensions in the area of the annular plane defined between the rotating partial areas. In place of the formation of a slit in the near-axial area for a draw-off opening by means of appropriate axial extensions of the wall elements, it is of course also possible to form the draw-off opening by means of an axial conduit formed in at least one wall element, wherein appropriate throttling means can be provided in this conduit. The grinding chamber has a generally circular exterior circumferential surface and, in the case of being embodied with slit-shaped openings in the near-axial area, is embodied as a toroid or annular chamber.
A further improvement of the ability to set the pressure conditions and the intensity of wet grinding can of course be achieved in the case were the grinding bodies in their movement in the direction of the centrifugal force are subjected to a particularly close proximity to each other with the simultaneous increase of the pressure forces which become effective when they near each other. This is made advantageously possible by a structural design in which the grinding chamber, bounded by the wall elements of the grinding chamber, is embodied, in a cross-sectional plane containing at least one axis of rotation, tapering crosswise in respect to this axis of rotation. In the course of the movement in accordance with centrifugal force of the grinding bodies in a cone tapering in this way, intensive blending is also assured outside of the surface where the primary blending takes place, because of which the effect of homogenization and the splitting of the smallest agglomerates is even more successful.
The embodiment is advantageously made in such a way that the wall elements are formed by half-shells, which are rotatably seated around a common axis and connected with separate drives, which results in a simple construction with simple seating. Premixing becomes advantageously possible on the outside of the mixing chamber or grinding chamber by means of the application of large shear forces in that the embodiment is provided in such a way that a wall element is connected, fixed against relative rotation, with a part which extends over the second wall element and forms a gap, and that the feed line terminates in this gap.
Intense blending, during which it might be possible to omit shear stress, can be achieved with an embodiment of the device in which the axes of rotation of the wall elements are disposed inclined in relation to each other and adjoin each other, enclosing an obtuse angle. If such a device is operated at the same rpm and the same direction of rotation of the wall elements, in particular disks, the relative movement of the wall elements is reduced to a cyclic squeezing, and generates a kneading effect, on which a shear stress at the boundary surfaces can also be superimposed, if differences in rpm or direction of rotation are permitted.
For further setting and adaptability of the conditions to different mixtures, the embodiment is preferably such that the angle between the axes of rotation of the wall elements can be continuously changed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described below by means of an exemplary embodiment schematically shown in the drawings. Shown therein are: in FIG. 1 a partial section through a first embodiment of a device in accordance with the invention for executing the process of the invention; and in FIG. 2 a variant embodiment of the device of the invention with wall elements having axes of rotation inclined towards each other.
DETAILED DESCRIPTION OF THE INVENTION
Only one half of the rotationally symmetrical embodiment of the device is shown in section in FIG. 1, the entire device ensuing from the reflection along the common axis of the two wall elements which delimit the grinding chamber.
The device for dispersing, blending or homogenizing of solid/liquid and/or liquid/liquid mixtures consists of a housing, generally identified by 1, in which a first wall element 2 in the shape of a half-shell is seated, rotatable around an axis of rotation 3 by means of a drive, not shown in detail. The shell-shaped wall element 2, together with a second, also rotatably seated shell-shaped wall element 4, delimits a grinding chamber 5 embodied as an annular chamber, wherein the grinding chamber in the second half of the drawings is indicated by dashed lines and 5' for making clear the symmetrical design. In the embodiment shown, the second wall element 4 is also rotated around the axis 3 by means of a drive, not shown in detail. A bearing for the wall element 4 in the housing 1 has been indicated by 6. A part 7, which extends over the outer surface of the second wall element 4, is connected, fixed against relative rotation, with the first rotating wall element 2, as indicated by 8, wherein the bearings for the first wall element 2 and the part 7 connected therewith are indicated by 9 and 10.
In this case the two shell-shaped wall elements 2 and 4 which delimit the grinding chamber 5 rotate around the common axis 3 at different rpm and/or different directions of rotation. The material to be blended, or the solid/liquid and/or liquid/liquid mixtures, enters the gap 12 between the outside wall 13 of the second wall element 4 and the inside wall 14 of the part 7 connected with the first wall element 2 via a feed line or a connector 11, wherein a strong shear stress of the introduced material is caused in this gap 12 by means of the elements 4 and 7, which rotate at different speeds and/or different direction of rotation. Then the material reaches the grinding chamber or annular chamber 5 via a slit or a feed opening 15, in which up to 75% by volume of grinding bodies, not shown, having an effective diameter of less than 0.5 mm, are disposed to assist dispersion, blending or homogenizing of the fed-in materials. In the grinding chamber 5, the fed-in materials are also subjected to a shear and mixing stress in that the two wall elements 2 and 4 which delimit or define the grinding chamber are driven at different rpm and/or in a different direction of rotation, which results in a mixing plane which is essentially formed by a circular plane. The appropriately blended or homogenized material is drawn off via a gap 16 facing the axis of rotation 3 and located between the rotating wall elements, and is removed via an axial conduit 17. In this case, the gaps 15 and 16 which define the feed and draw-off openings for the material to be mixed or homogenized, are located in a common plane extending normally in respect to the axis of rotation 3.
The grinding chamber 5 has a cross section which conically tapers from an area of the draw-off opening 16 near the axis toward an area of the feed opening 15 remote from the axis, so that there is a high concentration of grinding bodies in the area of entry into grinding chamber 5, which is aided by the direction of movement of the grinding bodies in the grinding chamber or annular chamber 5, caused by centrifugal force. At the same time it is possible, based on the illustrated arrangement of the feed and draw-off openings, to omit filters or screens or the like in the area of the draw-off opening 16 for separating the grinding bodies, because the grinding bodies are effectively moved in a direction away from the axis of rotation 3 by centrifugal force, so that, even in the case where the penetrating cross section of the gap or the draw-off opening 16 is greater than the particle size of the grinding bodies, and even with high viscosity of the materials to be mixed, the escape of the grinding bodies is assuredly prevented because of the high rotating speeds and the strains. Throttling devices, not shown in detail, are provided in the axial conduit 17 for regulation or control of the through-flow to achieve a desired result.
In case that two wall elements 2 and 4 have axes of rotation which are different from each other but are parallel to each other, the particular result is an eccentric movement of the one wall element in relation to the other, so that a corresponding narrowing and widening of the gap 12 between the outer surface of the wall element 4 and the inner surface of the rotating part 7 can be achieved.
In the case where the mixtures to be homogenized or dispersed have a greater specific weight than the grinding bodies, it is possible to reverse the functions of the feed and draw-off openings 15 or 16 by means of an appropriate selection of the parameters during blending or homogenizing.
In the embodiment of FIG. 2, again a shell-shaped wall element 2 is driven around an axis of rotation 3 by means of a drive, not shown in detail, to produce a rotating movement. Again, a part 7, extending over the second wall element 4, is connected secure against relative rotation with the wall element 2, in which case only the bearings 10 are sketched in. Differing from the embodiment in accordance with FIG. 1, the second shell-shaped wall element has an axis of rotation 18, which differs from the axis of rotation 3 of the first wall element 2, and encloses an obtuse angle with the axis of rotation 3. Because of the inclined disposition of the second wall element 4 in relation to the first wall element 2, a grinding chamber 5 is created, the cross section of which, again starting at the central area, tapers in the direction toward the areas remote from the axis, which results in different cross-sectional surfaces in different sections because of the inclination of the wall element 4 in respect to the wall element 2. Because of this, if the shell-shaped wall elements 2 and 4 are moved in the same direction and at the same rpm, it is possible to move the entire material to be homogenized, including the schematically indicated grinding balls 19, simultaneously without a noticeable relative movement between the grinding bodies 19 and the disks 2 or 4 occurring. Blending and homogenizing in this device is accomplished by an appropriate kneading effect, which is caused by the different cross-sectional surfaces particularly in the radially outwardly located areas of the grinding chamber 5 because of the inclined position of the wall element 4 in respect to the wall element 2. A kneading effect similar to the one in the grinding chamber 5 is caused in the gap 12 between the outer surface 13 of the wall element 4 and the inner surface of the part 7 extending over the wall element 4 and connected fixed against relative rotation with the first wall element. Thus, appropriate pre-processing also results with this embodiment before the material enters the grinding chamber 5 via a slit or gap 15, similar to the first embodiment of FIG. 1, in the course of which in the embodiment of FIG. 2 the blended material is drawn off directly via the axial conduit 17. Again the small grinding bodies are moved by centrifugal force into areas of the grinding chamber 5 remote from the axes of rotation 3 or 18, wherein, because of the cross-sectional surface which tapers to different degrees, a particularly strong stress by means of the grinding bodies 19 again takes place immediately prior to the entry of the material to be blended or homogenized into the grinding chamber 5.
The result of this embodiment, which employs a kneading effect, is that the mixing and grinding effect is practically exclusively caused by the forward movement of the mixture in the radial direction. The result as a whole is that there is no relative movement between the wall elements 2 or 4 and the material to be mixed, and that the mixture is moved at least once during each revolution of the wall elements in the direction toward the axes of rotation 3 and 18 and away from them.
The angle between the axes of rotation 3 and 18 can be continuously adjustable, starting with a position where they are aligned with each other, up to a maximum value, for adaptability to different materials to be mixed or homogenized.
|
In a process for dispersing, blending or homogenizing of solid/liquid and/or liquid/liquid mixtures, the dispersion or emulsion to be homogenized is introduced into a rotating grinding chamber (5) which is at least partially filled with grinding bodies and is bounded by at least two rotatable wall elements (2, 4), wherein the dispersion or emulsion to be homogenized is guided through the grinding chamber (5) in a direction crosswise to the axis of rotation (3) of the wall elements (2, 4). In a device for executing the process having a grinding chamber (5) in which grinding bodies (19) are disposed, the grinding chamber (5) is bounded by at least two wall elements (2, 4) which are rotatably driveable, and the grinding chamber (5) has at least one feed and/or draw-off opening (15, 16,) on its sides facing towards and facing away from the axis of rotation (3).
| 1
|
TECHNICAL FIELD
This invention relates to nonlinear optical devices such as electrooptic modulators and switches, frequency converters, data processors, optical parametric oscillators and amplifiers, and optically nonlinear materials useful in such devices.
BACKGROUND OF THE INVENTION
Optical transmission systems have come into widespread use primarily because of the ability of optical fibers to transmit much greater quantities of information than other comparable transmission media. Processing of such information normally requires that the information be converted to an electronic form. Thus, it has long been realized that if such functions as modulation, switching, mixing, data processing and the like could be performed directly on lightwaves, optical communications systems could be made to be much more efficient. It is also known that optically nonlinear materials can be used to make electrooptical modulators, switches, optical parametric devices and other devices for operating directly on lightwaves. Lithium niobate is the most commonly used nonlinear medium, although certain organic crystalline materials have also been proposed.
The U.S. Pat. No. 4,859,876, of Dirk et al., granted Aug. 22, 1989, hereby incorporated herein by reference, describes a nonlinear element comprising a glassy polymer containing an optically nonlinear organic moiety. The nonlinearity results from electric poling which aligns permanently dipoles within the polymer. The glassy polymer that was principally described was polymethylmethacrylate (PMMA), while other acrylate based polymers were also mentioned. The Dirk et al. patent represents a significant advance of the state of the art since polymers such as PMMA can be applied as a film to a substrate and their properties controlled much more easily and accurately than crystalline substances. The PMMA films constituting the heart of the various electrooptic devices may range from only about one micron to about two hundred microns in thickness.
A problem with the nonlinear devices of Dirk et al. is that their nonlinear susceptibility tends to deteriorate over time, particularly when subjected to high temperatures on the order of or exceeding 80° C. Such lower susceptibilities generally mean that the devices perform the functions for which they were intended with less efficiency than would otherwise be the case. As a consequence, systems which use these devices may required special cooling apparatus to keep the devices from reaching elevated temperatures and other design precautions may be required to compensate for a deterioration of optical properties with time.
SUMMARY OF THE INVENTION
In accordance with the invention, an optically nonlinear element comprises cross-linked triazine polymer containing a covalently bonded optically nonlinear dye moiety. Cured triazine strongly stabilizes this dye moiety, and such stabilization continues over time and under conditions of high temperature. This stability also characterizes the dipole alignment needed for high nonlinear susceptibility. The triazine offers the advantages of the materials described in the Dirk et al. patent, such as ease of use in a thin film form, and yet is inherently thermally stable. As will be described in detail, triazine polymer can be made with a dicyanovinylazo moiety that is capable of maintaining a large nonlinear susceptability while being transparent over a useful optical wavelength of about 0.8 to about 2.0 microns. A specific cross-linked triazine with this dye moiety may be made by cyclotrimerizing a p-(N,N-bis(4'-cyanatobenzyl)amino)-p'-(2,2dicyanovinyl)azobenzene monomer. During the cyclotrimerization or cure, the element is subjected to a poling voltage which aligns the dipoles of the dye moiety to give a large useful nonlinear susceptibility.
These and other objects, features and advantages of the invention will be better understood from a consideration of the following detailed description taken in conjunction with the accompany drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic perspective view of an electrooptical directional coupler or switch in accordance with an illustrative embodiment of the invention;
FIG. 2 is a schematic perspective view of an integrated solid state laser tuner and frequency stabilizer, within which the invention is used;
FIG. 3 is a diagrammatic representation of a device for generating second harmonic frequencies, within which the invention is used;
FIG. 4 is a diagrammatic representation of an electrooptic phase/intensity modulator within which the invention is used;
FIG. 5 is a perspective schematic view of an electrooptical guided wave intensity modulator within which the invention is used;
FIG. 6 is a diagrammatic illustration of a method for making a synthetic monomer in accordance with one feature of the invention;
FIG. 7 is a diagrammatic illustration of a method for making triazine polymer from the monomer of FIG. 6;
FIG. 8 is a graph comparing the thermal stability of two optically nonlinear materials of the prior art with that of a triazine material made in accordance with the invention; and
FIG. 9 is a diagrammatic illustration of a generalized monomer that can be used for making triazine in accordance with one aspect of the invention.
DETAILED DESCRIPTION
The devices described herein operate directly on light waves and illustrate different device functions. These devices make use of a polymer, specifically, triazine, having within it a constituent that has a finite nonlinear optical susceptibility. This nonlinear optical characteristic is imposed by the known process of electric poling, in which an electric field is applied to the material to align dipoles of constituent molecules permanently in generally the same direction during cure. The devices of FIGS. 1-5 demonstrate various ways in which the nonlinear optical susceptibility of such a nonlinear polymeric element can be exploited. In all of these devices, it is intended that the nonlinear material be substantially transparent at the optical wavelength of operation; that is, its attenuation at such wavelength is sufficiently low so as to allow for a commercially operable and feasible device.
Referring to FIG. 1, there is shown schematically an electrooptic directional coupler or switch 1. The coupler comprises a substrate 2, a pair of spaced channel waveguides 3 and 4 on one surface of the substrate, and a pair of electrodes 5 and 6, one electrode associated with and contiguous to each of the channel waveguides. At a central regions 7 and 8 of the waveguides 3 and 4, respectively, the waveguides are parallel to each other and the spacing between them is small, typically from five to twenty microns. The electrodes 5 and 6 are positioned adjacent the waveguides in this narrowly spaced region so as to maximize the electric field developed across the waveguides upon application of a voltage to the electrodes. Alternatively, as shown by the dotted lines, one may employ top and bottom electrodes on opposite sides of the waveguides to enhance the field for a given applied voltage.
The waveguides 3 and 4 are made of a triazine material exhibiting a nonlinear optical susceptibility in response to an applied electric field. Light, preferably from a laser, is directed into one end of waveguide 3 as designated by S 1 . In the absence of any applied field, the electromagnetic field associated with the light extends beyond the confines of waveguide 3 and penetrates waveguide 4 in region 8 of that waveguide. If the length of the portions 7 and 8 are properly selected, the light will essentially be emitted from waveguide 4 as shown by S 2 . There is thus a complete transfer of the light from one waveguide to the other. By applying an appropriate voltage by means of the electrodes, the nonlinear response of the waveguide material to the electric field can produce a slight change in the transmission characteristic of the waveguide. When properly adjusted, this voltage or electric field will prevent the transfer of light from one waveguide to the other and the light will be transmitted directly through waveguide 3 so as to be emitted as shown by S 3 . The nonlinear optical susceptibility is often designated by χ, whose value is a designation of the efficiency of the element; that is, the higher the value of χ the greater the response to an applied electric field. When an optically nonlinear material responds to a voltage or an electric field in this manner, it is often referred to as electrooptic material.
FIG. 2 shows an integrated laser tuner and frequency stabilizer using the triazine nonlinear or electrooptic medium described herein. A junction or injection laser 20 is devised such as to have a light emitting junction 23 which is contiguous to a thin electrooptic film. The film 22 may be provided with opposing electrodes 24 and 25 as shown on one side of the laser, or by electrodes 24a and 25a as shown on the other side of the laser. Either electrode configuration can be used to excite an optically nonlinear response in the nonlinear film 22. The electrooptical effect of the film under properly applied fields results in a useful tunable filter function, or as a frequency stabilizer of the laser output.
FIG. 3 shows the triazine optically nonlinear medium used in an optical parametric device for second harmonic frequency generation. Here an incident light beam 30 at a frequency f impinges on the optically nonlinear film 31. Due to the nonlinear optical properties, two colinear beams 32 and 33 are emitted, one at the same frequency f and one at twice the original frequency 2f. The emerging colinear beams 32 and 33 may be directed through a prism 34 which spatially separates them into separate beams 32 and 33. The beam of frequency 2f may be used independently of the other beam if for any of various reasons a higher 2f frequency is desirable. This embodiment demonstrates that an applied electric field is not always required for the nonlinear optical element to preform a useful function.
FIG. 4 shows the use of a triazine nonlinear polymer film in an electrooptical phase/intensity modulator. Here, incident light 40 having a polarization P 1 is passed through a nonlinear film 41, which is provided with transparent electrodes 42 and 43 on opposite surfaces. Upon passing through the film, the natural birefringence of the optically nonlinear film causes a change of polarization of the light to P 2 . When a voltage is applied to the film by means of a voltage source 44, the electric field applied to the film changes its optical properties. The nonlinear response causes a change in the film's index of refraction, thereby altering its birefringence and this, in turn, causes the emitted light to have yet a different polarization designated as P 3 . Thus, a polarization modulation between the values P 2 and P 3 can be achieved through periodic applications of the voltage to the film 41. An intensity modulation can optionally be obtained by placing a polarizer 45 at the output path of the beam which is oriented to allow the passage of either P 2 or P 3 , but not both. It should be noted that the nonlinear optical film of both devices of FIGS. 3 and 4 are preferably deposited on a transparent substrate.
FIG. 5 shows a guided wave electrooptic intensity modulator employing a triazine nonlinear optical layer 50. The film 50 is formed on a conductive substrate 51 having an insulative coating 52. The film is formed as an interferometric waveguide structure with an electrode 53 placed on one arm 54 of the interferometer. As voltages are applied to arm 54 by electrode 53, an electric field is produced in arm 54 of the interferometer. This field changes the index of refraction of the material and results in an effective change of the optical path length in arm 54 of the interferometer relative to the other arm. This in turn produces either constructive or destructive interference of light at a recombination point 55. As the voltage is modulated so as to alternate between constructive and destructive conditions, the output intensity varies between maximum and minimum values as well.
The nonlinear optical medium used in all of the devices of FIGS. 1-5 and other electrooptic and optical parametric devices that may be made in accordance with the invention, comprises cross-linked triazine containing a covalently bonded optically nonlinear dye moiety. In accordance with one feature of the invention, the dye moiety may be dicyanovinylazo dye, which is substantially transparent to light having wavelengths between 08. and 2.0 microns and, accordingly, the light with which such devices are used should be of a corresponding wavelength. The dipoles of the triazine molecules are aligned by applying a poling voltage during cure (i.e., during, cross-linking), as will be explained more fully later. A detailed method that I have used in the laboratory for making triazine with a dicyanovinylazo moiety will now be discussed.
FIG. 6 summarizes a method for making a synthetic monomer in accordance with the invention while FIG. 7 shows the method for making triazine oligomers from the synthesized monomer; the final polymer results from curing the oligomers. Referring to FIG. 6, 60 refers to a starting material; 7.0 grams of thionyl chloride (SOCl 2 ) was added drop by drop into a solution of material 60 in sixty milliliters of CH 3 CN. This yielded an intermediate 61 which was separated from a gummy residue by draining from a separatory funnel. The intermediate 61 was added over ten minutes into a well stirred solution at room temperature of 2.36 grams of aniline (PhNH 2 ) in twelve grams of triethylamine (TEA). After filtering off triethylammonium hydrochloride, the solution was concentrated to yield a syrup of the intermediate compound shown in FIG. 6 as 62, which may be designated as bis(4-hydroxybenzyl)aniline. Seven grams of the intermediate 62 was dissolved in fifteen milliliters of acetone and the solution cooled in a xylene liquid nitrogen bath to -15° C. To this was added a solution of cyanogen bromide (CNBr) in acetone (3.0 grams CNBr in seven milliliters of acetone). This was followed by the addition by drops of four grams of triethylamine. The temperature was maintained at about -10° C. for fifteen minutes and then warmed to room temperature in one hour. This yielded the intermediate 63 which may be designated as bis(4-cyanatobenzyl) aniline.
Seven hundred milligrams of intermediate 63 were dissolved in twenty milliliters of acetone. To this was added four drops of acetic acid and a solution of one thousand eighty milligrams of diazonium salt (4-(2,2,-dicyanovinyl)benzene diazonium hexafluorophosphate) in twelve milliliters of acetone. It should be noted that the diazonium salt eventually constitutes the dye moiety of the final polymer. The mixture was stirred in a nitrogen atmosphere for eighteen hours at room temperature and then heated at 44° C. for one hour. The mixture was then mixed with fifty milliliters of equal parts of acetone and water and the precipitate collected and washed with water until neutral. When dried, this yielded 1.15 grams of intermediate 64, a monomer which may be designated as p-(N,N-bis(4'-cyanatobenzyl) amino)-p'-(2,2-dicyanovinyl)azobenzene.
Referring to FIG. 7, the monomer 64 (100 milligrams) was next dissolved in a solvent such as methylethylketone (MEK) or γ-butryrolactone (500 milligrams). The γ-butryrolacetone is preferred. To this solution was added a metal complex catalyst at a concentration of between 0.1 to five percent by weight of the monomer, preferably 08. to 2.0 percent. Typical catalysts are copper benzoylacetonate (CBA), zinc benzoylacetonate, and copper or zinc naththenate, although CBA is preferred. This solution was then heated in a sealed tube at 150° C. for thirty minutes to initiate cyclotrimerization. The resulting oligomer solution is appropriate for coating as by spin-coating on a substrate such as an aluminized wafer. The coating is next polymerized or, more specifically, polycyclotrimerized, by heating at a temperature of between 100° and 170° C., preferably between 130° and 160° C. The temperature is preferably raised quickly to 100° C., and thereafter raised at about two degrees per minute to the final temperature, and is held at the final temperature for about one-half hour.
The oligomer 66 contains a dicyanovinylazo dye moiety 65 which may be poled to impart a nonlinear optical susceptibility. During the cure, an electric field typically of 1×10 6 volts per centimeter or more is applied to the coating so as to pole the dye moiety. The electric field may be applied between parallel electrode plates, or alternatively may be applied by corona poling as is known in the art.
During cure, the solution was polycyclotrimerized to yield a cross-linked triazine polymer which has been poled to be optically nonlinear. As is known, cross-linked triazine extends in three dimensions and therefore differs from polymers such as PMMA which extends in only two dimensions. The geometry resulting from three-dimensional cross-linking is believed to confine the poled dye moieties 65 more strongly than would be the case with two-dimensional polymers. As a consequence, over time and under conditions of relatively high temperature, the dye moieties 65 remain firmly confined within the triazine polymeric structure.
This advantage has been verified experimentally in tests, the results of which are summarized in FIG. 8 FIG. 8 shows the variation of r for three different materials as a function of time in days, where r is the ratio of the electrooptical coefficient of the poled film to the original electrooptic coefficient. Thus, if there is no change with time, r will remain one. The electrooptic coefficient is a function of both the optical susceptibility (in this case, the second order optical susceptibility) and the density of nonlinear moieties. Thus, a decay of r generally indicates a decay in number of effective nonlinear moieties. Curve 67 shows the change of electrooptic coefficient with respect to time of the material discussed in the Dirk et al. patent, namely, disperse red dye 1 dissolved in polymethylmethacrylate (DR1/PMMA). At 25° C., room temperature, the curve 67 shows a reduction of electrooptic coefficient after ten days to a value of less than half the original value. Curve 68 shows that at 80° C. there is a precipitate drop to virtually zero, which indicates that the material could not practically be used at that temperature. Curve 69 is an example of a covalently bonded nonlinear dye molecule in a glassy polymer host as described in general in the Dirk et al. patent, the material being dicyanovinylazobenzene-methylmethacrylate (DCV-MMA). Curve 69 shows that there is some deterioration with time at 25° C. Curve 70 again shows a precipitate drop in electrooptic coefficient at 80° C. and thereafter a continued deterioration with time.
Curve 71 shows the change of electrooptical coefficient of triazine at 85° C. one can see that even at this high temperature, there is only a modest deterioration and that, after ten days, the second order optical susceptibility is about eight-tenths of its original value. The original measured value of the second order optical susceptibility χ.sup.(2) was equal to about 75×10 -9 esu (electrostatic units). This demonstrates that triazine is practical for use as a nonlinear element in the various devices of FIGS. 1-5, in environments that may consistently be heated to temperatures as high as 85° C., and that such reliability has an extended lifetime.
The triazine oligomer solution that we have described can be coated on any of various substrates using any of various techniques well known in the art. After coating, the solvent is removed during the heat and cure process. Multiple coatings can be made, but it is believed that most useful device coatings will be in the thickness range of one micron to two hundred microns. Any of various substrates can be used and a poling conductor may be provided on one surface of the substrate.
The monomer 64 of FIGS. 6 and 7 from which the triazine molecule is made should be considered as only one example of a suitable triazine precursor. FIG. 9 shows a generalized formula for triazine precursors that could be used. In FIG. 9, R1 and R2 may be (CH 2 )n or ##STR1## which may also be designated as 2-(4'-methylenephenylene)propylidenyl, where n is an integer from zero to ten. R3 and R4 may be hydrogen, alkyl, alkenyl, alkoxy, or aryloxy. R5 may be hydrogen, alkyl or alkoxy. R6 may be p-(2,2-dicyanovinyl)phenyl, p-(1,2, 2-tricyanovinyl)phenyl, 5-(2,2-dicyanovinyl)thiazolyl, 5-(1,2,2-tricyanovinyl)thiazolyl, 4-chloro-5-(2,2-dicyanovinyl)thiazolyl, 4-chloro-5-(1,2,2-tricyanovinyl)thiazolyl, or 5-nitrothiazolyl.
The foregoing has shown in detail how cross-linked triazine containing an optically nonlinear dye moiety can be made and used in any of various useful devices. The second order susceptibility is competitive to that of materials described in the prior art, even at elevated temperatures, but it may have useful susceptibilities at the third or higher orders as well. Various other methods for making triazine with such dye moiety may be made by those skilled in the art without departing from the general teachings hereof. Devices other than those explicitly described for making use of triazine as the optically nonlinear element may likewise be made by those skilled in the art. Various other embodiments and modifications of the invention may be made without departing from the spirit and scope of the invention.
|
Optically nonlinear device elements such as directional couplers, switches, frequency stabilizers, optical parameters devices and modulators use as an optically nonlinear element a cross-linked triazine polymer containing a covalently bonded optically nonlinear dye moiety. A specific cross-linked triazine with this dye moiety may be made by cyclotrimerizing a p-(N,N-bis(4'-cyanatobenzyl)amino-p'-(2,2-dicyanovinyl)azobenzene monomer. During polycyclotrimerization or cure, the element is subjected to a poling voltage which aligns the dipoles of the dye moiety to give a large useful nonlinear susceptibility.
| 2
|
CROSS REFERENCE TO RELATED CO-PENDING APPLICATIONS
[0001] This application claims the benefit of U.S. provisional application Ser. No. 61/041,629 filed Apr. 2, 2008 and entitled “APPARATUS AND METHOD FOR SEMICONDUCTOR WAFER ALIGNMENT”, the contents of which are expressly incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an apparatus and a method for semiconductor alignment, and more particularly to an interwafer wafer-to-wafer alignment that provides nanometer range alignment accuracy.
BACKGROUND OF THE INVENTION
[0003] Alignment of semiconductor wafers is usually achieved by utilizing mechanical or optical fiducial marks, such as notches at the edges of wafers, pins, e-beam etchings, or holographic images, among others. Mechanical alignment marks provide millimeter range alignment accuracy, while optical marks provide micron to submicron alignment accuracy.
[0004] In several semiconductor processes, such as 3-D integration, bonding and mask alignment, among others, submicron to nanometer alignment accuracy is desirable.
SUMMARY OF THE INVENTION
[0005] A wafer-to-wafer alignment apparatus and method according to this invention utilize microscopes that are inserted between two wafers to be aligned parallel to each other. This “interwafer” alignment method can be used for any type of wafer material, transparent or not transparent, uses visible light and does not require fiducial marks at the back of the wafers. The alignment accuracy is of the order of a few hundred nanometers. In general, in one aspect, the invention features an apparatus for aligning semiconductor wafers including equipment for positioning a first surface of a first semiconductor wafer directly opposite to a first surface of a second semiconductor wafer and equipment for aligning a first structure on the first semiconductor wafer with a second structure on the first surface of the second semiconductor wafer. The aligning equipment comprises at least one movable alignment device configured to be moved during alignment and to be inserted between the first surface of the first semiconductor wafer and the first surface of the second semiconductor wafer.
[0006] Implementations of this aspect of the invention may include one or more of the following features. The positioning equipment are vibrationally and mechanically isolated from the alignment equipment. The apparatus may further include an inverted U-shaped frame and a vibration isolated base. The inverted U-shaped frame is supported on a top surface of the base. The inverted U-shaped frame includes left and right vertical columns and a horizontal beam comprising left and right ends. Each of the column tops comprises two parallel vertical slots extending from the column top surface toward the column center and the two vertical slots are separated by a center block. The center block extends from the bottom of the slots toward the column top and has a height less than the height of the vertical slots thereby forming a gap between the two vertical slots near the column top surface. The left and right ends of the horizontal beam are supported upon the center blocks of the left and right vertical columns, respectively. The apparatus may further include an XYZ stage supporting the movable alignment device and the XYZ stage is configured to slide along the horizontal beam and be supported by the horizontal beam. The movable alignment device includes an optical microscope assembly including an elongated tube and first and second optical microscopes arranged coaxially within the elongated tube along a first axis. The first and second optical microscopes are configured to obtain first and second images of the first and second structures, respectively. The first and second images of the first and second structures are used to determine coordinates of the first and second structures relative to fixed top and bottom reference marks and to guide the positioning equipment for aligning the first surfaces of the first and second semiconductor wafers parallel to each other. The apparatus further includes a microscope calibration reference unit including fixed top and bottom reference marks. The calibration reference unit may be attached to one of the vertical columns. The optical microscope assembly may further include a mirror plane arranged so that the first axis is parallel to the mirror plane. The apparatus may further include pattern recognition software used to analyze the first and second images of the first and second structures, respectively, and to determine their coordinates relative to the fixed top and bottom reference marks. The positioning equipment includes a lower support block and an upper supporting block. The lower supporting block includes a lower wafer plate supporting the first semiconductor wafer and the upper supporting block includes an upper wafer plate supporting the second semiconductor wafer and a plate leveling system for leveling the upper wafer plate. The plate leveling system includes a spherical wedge error compensation mechanism that rotates and/or tilts the upper wafer plate around a center point corresponding to the center of the second semiconductor wafer without translation. The lower support block includes a coarse X-Y-T stage, an air bearing Z-stage carried by the coarse X-Y-T stage and a fine X-Y-T stage carried on top of the Z-stage, and wherein the X-Y-T fine stage carries the lower wafer plate. The X-Y-T coarse stage further includes one or more position sensors for measuring the X-Y-T distance between the coarse X-Y-T stage and the fine X-Y-T stage. The position sensors may be capacitance gauges. The upper and lower wafer plates comprise materials having a CTE matching the semiconductor wafer CTE. The apparatus may further include a fixture for transporting the first and second semiconductor wafers. The fixture includes an outer ring supporting a lower wafer carrier chuck and three or more clamp/spacer assemblies arranged at the periphery of the outer ring. Each of the clamp/spacer assemblies includes a clamp and a spacer. The clamp and the spacer are configured to be moved independent from each other and from the motion of clamps or spacers of the other assemblies and the motion is precise and repeatable both at room and high temperatures. The fixture further may further include a center pin for pinning together the centers of the first and second semiconductor wafers. The first semiconductor wafer is placed upon the lower wafer carrier chuck, the spacers are inserted on top of the edge of the first semiconductor wafer surface and then the second semiconductor wafer is placed on top of the spacers and then the first and second semiconductor wafers are clamped together via the clamps.
[0007] In general, in another aspect, the invention features an apparatus for aligning semiconductor wafers including equipment for positioning a first surface of a first semiconductor wafer directly opposite to a first surface of a second semiconductor wafer and equipment for aligning a first structure on the first semiconductor wafer with a second structure on the first surface of the second semiconductor wafer. The aligning equipment includes at least one movable alignment device configured to be moved during alignment. The positioning equipment are vibrationally and mechanically isolated from the alignment device motion.
[0008] In general, in another aspect, the invention features a method for aligning semiconductor wafers including positioning a first surface of a first semiconductor wafer directly opposite to a first surface of a second semiconductor wafer, providing alignment equipment comprising at least one movable alignment device and then aligning a first structure on the first semiconductor wafer with a second structure on the first surface of the second semiconductor wafer by inserting the movable alignment device between the first surface of the first semiconductor wafer and the first surface of the second semiconductor wafer.
[0009] Implementations of this aspect of the invention may include one or more of the following features. The positioning step is vibrationally and mechanically isolated from the inserting of the movable alignment device between the first surface of the first semiconductor wafer and the first surface of the second semiconductor wafer. The movable alignment device includes an optical microscope assembly including an elongated tube and first and second optical microscopes arranged coaxially within the elongated tube along a first axis. The first and second optical microscopes are configured to obtain first and second images of the first and second structures, respectively. The first and second images of the first and second structures are used to determine coordinates of the first and second structures relative to fixed top and bottom reference marks and to guide the positioning equipment for aligning the first surfaces of the first and second semiconductor wafers parallel to each other. The apparatus further includes a microscope calibration reference unit including fixed top and bottom reference marks. The calibration reference unit may be attached to one of the vertical columns. The optical microscope assembly may further include a mirror plane arranged so that the first axis is parallel to the mirror plane. The method may further include providing pattern recognition software for analyzing the first and second images of the first and second structures, respectively, and determining their coordinates relative to the fixed top and bottom reference marks. The positioning step may include providing a lower support block comprising a lower wafer plate and placing the first semiconductor wafer upon the lower wafer plate and then providing an upper supporting block comprising an upper wafer plate for supporting the second semiconductor wafer and a plate leveling system for leveling the upper wafer plate. The plate leveling system may include a spherical wedge error compensation mechanism that rotates and/or tilts the upper wafer plate around a center point corresponding to the center of the second semiconductor wafer without translation. The lower support block includes a coarse X-Y-T stage, an air bearing Z-stage carried by the coarse X-Y-T stage and a fine X-Y-T stage carried on top of the Z-stage, and wherein the X-Y-T fine stage carries the lower wafer plate. The X-Y-T coarse stage further includes one or more position sensors for measuring the X-Y-T distance between the coarse X-Y-T stage and the fine X-Y-T stage. The apparatus may further include a fixture for transporting the first and second semiconductor wafers. The fixture includes an outer ring supporting a lower wafer carrier chuck and three or more clamp/spacer assemblies arranged at the periphery of the outer ring. Each of the clamp/spacer assemblies includes a clamp and a spacer. The clamp and the spacer are configured to be moved independent from each other and from the motion of clamps or spacers of the other assemblies and the motion is precise and repeatable both at room and high temperatures. The fixture further may further include a center pin for pinning together the centers of the first and second semiconductor wafers. The aligning of the first structure with the second structure includes the following steps. First, placing the first semiconductor wafer upon the lower support block with its first surface facing up. Next, supporting the second semiconductor wafer by the upper wafer plate with its first surface facing down. Next, inserting the optical microscope assembly into the fixed reference unit and focusing the first and second optical microscopes onto the fixed bottom and top reference marks, respectively. Next, using the pattern recognition software to determine position and distance of the fixed top and bottom reference marks and the mirror plane angular position. Next, inserting the optical microscope assembly between the first surfaces of the first and second semiconductor wafers, and focusing the second optical microscope onto the second structure of the second semiconductor wafer and then locking the optical microscope assembly position. Next, moving the coarse X-Y-T stage and Z-stage to focus the first microscope onto the first structure of the first semiconductor wafer and locking coarse X-Y-T and Z stages. Next, using the pattern recognition software to determine position coordinates of the first and second structures and determine their offsets. Finally, moving fine X-Y-T stage by the amount of the determined offsets and an amount determined by a global calibration method, thereby bringing the first and second structures in alignment with each other. The alignment of the first and second structures may further include the following. Moving the optical microscope assembly out from in between the first surfaces of the first and second semiconductor wafers and then moving the Z-stage up while maintaining the fine X-Y-T stage alignment with feedback from the position sensors. Next, bringing the first surface of the first semiconductor wafer in contact with the first surface of the second semiconductor wafer, then clamping the first and second semiconductor wafers together and then unloading the aligned first and second semiconductor wafers. After supporting the second semiconductor wafer by the upper wafer plate the method may further include moving the Z-stage up to bring the spacers on top of the first semiconductor wafer first surface in contact with the second semiconductor first surface. Next, performing wedge error compensation of the second semiconductor wafer under force feedback control and locking the wedge position and then moving the first semiconductor wafer down and removing the spacers.
[0010] The details of one or more embodiments of the invention are set forth in the accompanying drawings and description below. Other features, objects and advantages of the invention will be apparent from the following description of the preferred embodiments, the drawings and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Referring to the figures, wherein like numerals represent like parts throughout the several views:
[0012] FIG. 1 is a schematic diagram of an aligner system according to this invention;
[0013] FIG. 2 is a detailed side view of area P of FIG.1 ;
[0014] FIG. 3 is a schematic side view of the aligner system of FIG. 1 ;
[0015] FIG. 4 is a schematic diagram of the microscope system of FIG. 1 ;
[0016] FIG. 5 is a perspective view of the aligner apparatus according tot his invention;
[0017] FIG. 6 is a perspective side view of the aligner apparatus of FIG. 3 ;
[0018] FIG. 7 is a front cross-sectional view of the aligner apparatus of FIG. 3 ;
[0019] FIG. 8 is a perspective top view of the microscope system of FIG. 3 ;
[0020] FIG. 9 is a perspective side view of the microscope system of FIG. 8 ;
[0021] FIG. 10 is a cross-sectional side view of the microscope system of FIG. 8 ;
[0022] FIG. 11 is detailed view of the two microscope systems within the aligner of FIG. 8 ;
[0023] FIG. 12 is a top view of the wafer fixture tool;
[0024] FIG. 13 is a top view of the wafer fixture tool loaded with the top and lower plates;
[0025] FIG. 14 is a schematic cross-sectional view of the wafer fixture tool loaded with the top and lower plates and wafers in the clamped position;
[0026] FIG. 15 is a top view of the lower plate of the global calibration device;
[0027] FIG. 16 is a side view of the top and lower plates of the global calibration device;
[0028] FIG. 17 is a side view of the top and lower plates and transparent wafer of the global calibration device
[0029] FIG. 18A-FIG . 18 B is a flow diagram of the alignment process;
[0030] FIG. 19A is a schematic diagram of step 610 of the alignment process of FIG. 18B ;
[0031] FIG. 19B is a schematic diagram of step 611 of the alignment process of FIG. 18B ;
[0032] FIG. 19C is a schematic diagram of step 613 of the alignment process of FIG. 18B ;
[0033] FIG. 20A is a schematic diagram of steps, 608 and 611 of the alignment process of FIG. 18A-FIG . 18 B;
[0034] FIG. 20B is a schematic diagram of steps, 608 and 612 of the alignment process of FIG. 18A-FIG . 18 B; and
[0035] FIG. 20C is a schematic diagram of steps, 608 and 613 of the alignment process of FIG. 18A-FIG . 18 B.
DETAILED DESCRIPTION OF THE INVENTION
[0036] Referring to FIG. 1-FIG . 5 a wafer alignment apparatus 100 , includes a base 102 supporting an inverted U-shaped frame 104 , first and second microscope sets 210 a, 210 b, a lower wafer support block 150 supporting a lower wafer 80 and an upper wafer support block 180 holding an upper wafer 90 . Base 102 is made of a solid material and is supported on a table 106 via four vibration isolating legs 108 a, 108 b, 108 c, 108 d. In one example, base 102 is a rectangular shaped block made of granite material. In other examples, base 102 may be made of metal or ceramic material and may have a honeycomb structure. The inverted U-shaped frame 104 includes left and right vertical legs 101 , 103 respectively, and a beam 105 supported on the tops 113 , 114 of the left and right legs 101 , 103 , respectively. Each of the leg tops 113 , 114 includes two vertical slots 111 , 112 extending from the top surface 119 of the leg toward the center of the leg, as shown in FIG. 2 . Vertical slots 111 , 112 divide the top of each leg 101 , 103 , respectively, into three separate block extensions 121 , 122 , 123 , also shown in FIG. 2 . The ends 105 a, 105 b of beam 105 are fixedly attached to the outer two block extensions 121 , 123 of each leg 101 , 103 , respectively. Vertical slots 111 , 112 are spaced apart by a distance 115 a and a gap 115 is formed between them, as shown in FIG. 2 . Gap 115 extends from the top surface 119 of the leg, has a height 116 less than the height 117 of the slots 111 and 112 and the same width as the distance 115 a between the slots 111 and 112 . Gap 115 is dimensioned to receive a support bar 120 extending from the top 113 of left leg 101 to the top 114 of right leg 103 , as shown in FIG. 7 . Left and right ends 120 a, 120 b of support bar 120 are placed within the gaps 115 of the left and right legs 101 , 103 , respectively, and are fixedly attached to the inner blocks 122 , as shown in FIG. 6 and FIG. 2 . In this type of arrangement there is no contact between the ends 105 a, 105 b of the frame beam 105 and the ends 120 a, 120 b, of support bar 120 . Frame beam 105 supports two separate sets of microscope X-Y-Z stages 201 a, 201 b controlling the motion of the two microscope sets 210 a, 210 b, respectively. The upper wafer support block 180 is fixedly attached to support bar 120 . The lack of contact between the ends 105 a, 105 b of the frame beam 105 and the ends 120 a, 120 b, of support bar 120 isolates the frame beam 105 from the support bar 120 and prevents the transfer of vibrations due to the microscope stage motion to the upper wafer support block 180 and therefore to the upper wafer 90 .
[0037] Referring to FIGS. 3 and 4 , each microscope set 210 a, 210 b, includes two coaxially arranged microscopes 224 a, 224 b and 225 a, 225 b, placed within elongated tubes 202 a, 202 b, respectively. Each microscope 224 a, 224 b includes a light source 211 a, 211 b, a high performance objective lens 212 a, 212 b and a CCD camera 213 a, 213 b. A double-sided mirror 215 arranged at 45 degrees angle relative to the optical axis 217 is also included. Light 214 a emitted from light source 211 a is focused via the objective lens 212 a and directed via the mirror 215 toward the lower wafer surface 81 . Light 216 a reflected by the lower wafer surface 81 is then directed by the mirror 215 and focused onto the CCD camera 213 a. Similarly, light 214 b emitted from light source 211 b is focused via the objective lens 212 b and directed via the mirror 215 toward the upper wafer surface 91 . Light 216 b reflected by the upper wafer surface 91 is then directed by the mirror 215 and focused onto the CCD camera 213 b. The surface images of the lower and upper wafer surfaces 81 , 91 collected by the CCD cameras 213 a, 213 b are then used to align the wafer surfaces 81 , 91 parallel to each other. In one example, light sources 211 a, 211 b are yellow Light Emitting Diodes (LED). In other examples, other visible or infrared light sources are used.
[0038] Elongated tubes 202 a, 202 b are connected to inverted U-shape structures 204 a, 204 b that are carried by the microscope XYZ stages 201 a, 201 b, respectively, around the frame beam 105 . Microscope stages 201 a, 201 b move the axes 217 a, 217 b of the microscopes in X, Y, Z directions. In some embodiments stages 201 a, 201 b are X-Y-Z-T stages and may also rotate the microscope axes around an axis perpendicular to them by an angle theta (T). The legs of the U-shape structures 204 a, 204 b are fixedly connected to plates 232 a, 232 b, 234 a, 234 b and plates 232 a, 232 b, 234 a, 234 b are connected to the ends of the elongated tubes 202 a, 202 b, via three kinematic couplings 233 a, 233 b, 233 c, as shown in FIG. 8 . Mirrors 235 a, 235 b, are also connected to plates 232 a, 232 b, respectively, separately from the elongated tubes, and are arranged below the elongated tubes 202 a, 202 b, so that the microscope axes 217 a, 217 b are parallel to the mirror planes 236 a, 236 b, respectively, shown in FIG. 11 . Furthermore, the apparatus includes left and right microscope calibration reference units 140 a, 140 b attached on the left and right frame legs 101 , 103 , respectively, shown in FIG. 1 and FIG. 7 . Each reference unit 140 a, 140 b, includes fixed top and bottom reference marks K, K′, L, L′ located on fixed top and bottom plates 141 a, 141 b, 142 a, 142 b, respectively. The X-Y-Z and T coordinates of the two microscope optical axes 217 a, 217 b, and the angular position of the mirror planes 236 a, 236 b, shown in FIG. 11 , are determined in reference to these fixed marks and are used as references for the wafer alignment process, as will be described below.
[0039] Referring to FIG. 7 , upper wafer 90 is held via vacuum suction onto upper wafer block 180 , so that surface 91 to be aligned parallel to the lower wafer surface 81 is facing down. Upper wafer block 180 includes an upper wafer plate 182 supporting the wafer 90 and a plate leveling system 184 for leveling upper wafer plate 182 . The plate leveling system includes a spherical Wedge Error Compensating (WEC) mechanism that rotates and/or tilts the upper wafer plate 182 around a center point corresponding to the center of the wafer 90 without translation. Lower wafer 80 is held via vacuum suction onto lower wafer block 150 , so that its surface 81 to be aligned parallel to the upper wafer surface 91 is facing up. Lower wafer block 150 includes a coarse X-Y-T air-bearing table 152 carrying an air bearing Z-stage 154 , and a fine X-Y-T stage 155 is carried on top of the Z-stage. Fine X-Y-T stage 155 carries the lower wafer plate 156 upon which a fixture 300 carrying wafer 80 is positioned. In one example, coarse X-Y-T table 152 has a position range of ±3 millimeters and ±3 degrees, while fine X-Y-T stage has a position range of ±100 micrometers and ±1 millidegree and the Z-axis range is 60 millimeters. Connected to the coarse X-Y-T stage 152 are three position sensors 157 that measure the X-Y-T-distance between the coarse stage 152 and fine stage 155 and provide feedback for the fine X-Y-T manipulation of the lower wafer surface plane 81 . In one example, the position sensors 157 are capacitance gauges and are used for making high precision non-contact measurements of linear displacements. Upper and lower wafer plates 182 , 156 , are made of materials with CTE matching the CTE of the wafers. In one example, wafers 80 , 90 are made of silicon and plates 182 , 156 are made of silicon carbide. In other embodiments, separate sets of position sensors are placed on both the lower wafer plate and the upper wafer plate.
[0040] Referring to FIG. 12 , a fixture 300 is used to transport the upper and lower wafers 90 , 80 in and out of the alignment apparatus and to maintain the alignment of the two wafers for further processing, such as bonding of the wafers or further deposition steps. Fixture 300 includes an outer ring 310 supporting a lower wafer carrier chuck 315 and three clamp/spacer assemblies 320 a, 320 b, 320 c, arranged at the periphery of ring 310 . Each clamp/spacer assembly 320 a includes a spacer 321 a and a clamp 322 a. The motion of clamp/spacer assemblies is very precise and repeatable both at room temperatures and at the high temperatures where the further wafer processing takes place. Wafer 80 is placed on top of lower wafer carrier chuck 315 , the spacers 321 a, 321 b, 321 c are inserted on top of the edges of the wafer surface 81 , then the upper wafer 90 is placed on top of the spacers 321 a, 321 b, 321 c, and then the upper wafer carrier chuck 316 is placed on top of the upper wafer 90 and the clamps 322 a, 322 b, 322 c engage the upper wafer carrier chuck to clamp the two wafers together onto the fixture. The spacers 321 a, 321 b, 321 c, may be moved independent from each other from the clamping motion to bring the wafer surfaces 91 , 81 in contact or to set a gap between them. The two clamped wafers may also be pinned together via a center pin 325 , as shown in FIG. 14 . In one example ring 310 is made of titanium and wafer carrier chucks 315 , 316 are made of silicon carbide.
[0041] Referring to FIG. 18A-FIG . 20 C, the alignment process includes the following steps. First, microscope sets 210 a, 210 b are positioned in the reference units 140 a, 140 b and microscopes 224 a, 224 b and 225 a, 225 b are focused onto the fixed top and bottom reference marks K, K′, L, L′ located on the top and bottom plates 141 a, 141 b, 142 a, 142 b, respectively. Next, a pattern recognition software is used to determine the X-Y coordinates of the fixed reference marks K, K′, L, L′ and their separation distance, as well as the angular positions theta (T) of the mirror planes 236 a, 236 b (reflecting the positions of microscope axes 217 a, 217 b ) relative to the reference marks. Reference marks K, L and axis 217 a define a reference plane 290 a (shown in FIG. 20A ) for microscopes 224 a, 224 b and marks K′, L′ and axis 217 b define a reference plane 290 b (not shown) for microscopes 225 a, 225 b. Next, the microscope sets 210 a, 210 b are inserted between the lower wafer 80 and upper wafer 90 and the X-Y-Z microscope stages 201 a, 201 b, are moved so that the images A′, B′ of the fiducial marks A, B, on the upper wafer surface 91 are brought into the field of view (FOV) 280 of the microscopes 224 b, 225 b looking up and the microscopes 224 b, 225 b are focused onto them, respectively, as shown in FIG. 19A . The microscope stages 201 a, 201 b are locked and then the lower wafer 80 is moved in the X-Y-T- and Z directions to bring the images C′, D′ of the lower wafer fiducial marks C, D, into the field of view 282 of the microscopes 224 a, 224 b looking down and to focus the microscopes 224 a, 225 a onto them, respectively, as shown in FIG. 19B . Next, the positions of the fiducial marks A, B, C, D are determined by analyzing their images A′, B′, C′, D′ within the corresponding fields of view 280 , 282 of microscopes 224 b, 225 b, 224 a, 225 a with the pattern recognition software Patmax® program available from Cognex Co, Natick Mass., and by taking into consideration the positions of the microscopes 224 b, 225 b, 224 a, 225 a relative to the reference planes 290 a, 290 b. In addition to the microscope positions any change in the mirror angles ( and the upon them reflected optical axes 217 a, 217 b ) is taken into consideration and the X-Y-T offsets Δx, Δy, Δθ, shown in FIG. 20B , between the upper fiducial marks A, B and lower fiducial marks C, D are determined. Next, the lower wafer 80 (and carrier) is moved in the X-Y-T directions by the determined amount of the X-Y-T offsets Δx, Δy, Δθ, to position the fiducial marks C, D of the lower wafer 80 in alignment with the fiducial marks A, B of the upper wafer 90 , shown in FIG. 19C and FIG. 20C . This results with the lower wafer 80 being in alignment with the upper wafer 90 while they are separated by a distance 294 . Next, the lower wafer 80 is moved up in the Z-direction while the X-Y-T position of wafer stage 155 is maintained by measuring its distance from the coarse stage 152 with the three co-planar position sensor 157 that are fixed on it and adjusting the position of wafer stage 155 so that the aligned lower wafer 80 position is maintained. The lower wafer 80 is moved up in the Z-direction until surface 81 contacts the surface 91 of the upper wafer 90 . The aligned stack of wafers 80 , 90 is clamped with clamps 322 a, 322 b, 322 c onto the fixture 300 and is removed from the aligner for further processing, such as bonding of the two wafers. In other embodiments, wafer 80 is moved up in the Z-direction until surface 81 contacts spacers 321 a, 321 b, 321 c inserted between the two wafers. In this configuration wafers 80 and 90 are clamped together while separated by a distance corresponding to the spacer thickness. The complete alignment sequence 600 is depicted in FIG. 18A-FIG . 18 B and includes the following steps. Starting out, the microscopes are out of the space between the upper and lower blocks 180 , 150 and the Z-axis of the X-Y-T-Z wafer stage 152 is down ( 601 ). Next, the fixture 300 with the upper and lower wafer chucks is loaded in the aligner and placed on the X-Y-T-Z wafer stage 152 ( 602 ). X-Y-T-Z wafer stage 152 is then moved up in the Z-direction and the upper chuck is handed over to the upper block 180 . X-Y-T-Z wafer stage 152 with the lower wafer chuck is then moved down ( 603 ). Next, the upper wafer 90 is loaded in the aligner and transferred to the upper wafer chuck ( 604 ). The lower wafer is then loaded into the aligner and transferred onto the lower wafer chuck and the spacers are placed on top of the lower wafer surface ( 605 ). The z-axis of the lower wafer stage 152 is then moved up to bring the spacers in contact with the upper wafer 90 and to perform the Wedge Error Correction (WEC) on the upper wafer plate under force feedback control ( 606 ). The upper wafer plate position is locked and the z-axis is moved down and the spacers are removed ( 607 ). Next the microscopes are inserted in the fixed reference units and the upper microscopes are focused onto the fixed top marks and the lower microscopes are focused onto the fixed bottom marks ( 608 ). The fixed mark images are analyzed with an image pattern recognition software and their position, the distance from each other and the mirror angular positions (i.e., axes of the microscopes) are determined ( 609 ). These measurements define the reference point (i.e., center of coordinate system) for the further measurements. Next, the microscopes are inserted between the upper and lower wafer and the upper directed microscopes are focused onto the upper wafer marks. The microscope positions are then locked ( 610 ). The lower X-Y-T-Z wafer stage 152 is then moved to focus the lower directed microscopes onto the lower wafer marks and the stage position is locked ( 611 ). The images of the upper and lower marks are analyzed with the image pattern recognition software and their position relative to the fixed mark positions and the X-Y-T offsets between them are determined and the mirror angular positions (i.e., axes of the microscopes) are also measured ( 612 ). The lower wafer fine stage is then moved by the X-Y-T offset amount and by the amount determined by the global calibration, as is described below ( 613 ). Next, the microscopes are moved out of the space between the upper and lower wafer ( 614 ) and the lower wafer stage is moved up in the z-direction while the X-Y-T alignment of the fine wafer stage is maintained with the help of the position sensors ( 615 ). The lower wafer 80 is brought into contact with the upper wafer 90 and the stack is clamped together ( 616 ) in the fixture 300 . Finally, the aligned wafer set and fixture are removed from the aligner and placed into another process chamber ( 617 ) for further processing such as bonding or deposition.
[0042] The aligner system 100 is calibrated with a global calibration device 400 shown in FIG. 14-FIG . 17 . Global calibration device 400 includes a lower plate 415 , an upper plate 425 and a clear transparent wafer 430 (shown in FIG. 17 ) arranged between them. Lower plate 415 includes concentric vacuum grooves 418 and fiducial marks 416 a, 416 b. Upper plate 425 includes vacuum grooves 419 and transparent wafer 430 includes fiducial marks 432 a, 432 b. Lower plate 415 , transparent wafer 430 and upper plate 425 are placed in fixture 300 and are placed in the aligner apparatus 100 . The above described alignment process 600 is performed to bring the fiducial marks 432 a, 432 b of the transparent wafer 430 in alignment with the fiducial marks 416 a, 416 b of the lower plate 415 . Next, the transparent wafer 430 is placed in contact with the lower plate and the overlap of the transparent wafer marks 432 a, 432 b with the lower plate marks 416 a, 416 b is observed with the down focusing microscopes 225 a, 224 a. Any X-Y-T offsets between these marks are measured, as well as the mirror angular positions and are used for the global calibration correction.
[0043] In some embodiments, the entire aligner 100 may be enclosed in a controlled atmosphere, temperature and pressure chamber 70 , as shown in FIG. 1 . The microscope stages 201 a, 201 b may be X-Y-Z-T stages.
[0044] Several embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications is made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.
|
An apparatus for aligning semiconductor wafers includes equipment for positioning a first surface of a first semiconductor wafer directly opposite to a first surface of a second semiconductor wafer and equipment for aligning a first structure on the first semiconductor wafer with a second structure on the first surface of the second semiconductor wafer. The aligning equipment comprises at least one movable alignment device configured to be moved during alignment and to be inserted between the first surface of the first semiconductor wafer and the first surface of the second semiconductor wafer. The positioning equipment are vibrationally and mechanically isolated from the alignment device motion.
| 7
|
FIELD OF THE INVENTION
The present invention relates generally to magnetic materials, and more particularly, to high frequency magnetic materials used in power electronics applications.
BACKGROUND OF THE INVENTION
High operating frequencies are desirable for power conditioning equipment (such as power supplies, power amplifies and lamp ballasts) in order to reduce the size of magnetic components. Unfortunately, however, it has been heretofore impossible to substantially reduce the size of magnetic components because the operating flux density has to be reduced too much to enable proper operation and still have acceptable losses at high frequencies. In particular, while at low frequencies (e.g. 100 kHz), the operating flux density can be in the 1000-3000 Gauss range using semi-conducting ferromagnetic materials (typically ferrites), the operating flux density to achieve acceptable losses in the megahertz range is from 20 to 300 Gauss, which is too low to give any significant size advantage.
In addition, there is considerable drive to push the operating frequencies of power conditioning equipment to frequencies even higher than 5.0 MHz. However, the losses of the current high frequency materials rise very sharply with increasing frequency in 1 to 10 MHz range, making these material unsuitable for use at such high frequencies. In particular, the losses of these high frequency materials increase as the 4 th power of the frequency above one megahertz.
A variety of publications describe the state of the art in this field. These publications include a book by A. Goldman: Modern Ferrite Technology (Van Nostrand Reinhold, N. Y., 1990, p. 185-211). Detailed properties of soft ferrites are also described in a book by E. C. Snelling: Soft Ferries: Properties and Applications, 2 nd edition (Butterworths, London, 1988) and 1 st edition (Iliffe, London, 1969, chapters 2, 3).
The following are the four major reasons for the two problems described hereinabove and for making the current state-of-the-art materials unsuitable for use in high frequency and high flux density operation.
First, the people involved in the development of high frequency magnetic materials for use in power electronics have only tried to reduce eddy current losses. Unfortunately, the methods used to control eddy current losses (these methods include reducing the grain size to increase the grain boundary surface and increased addition of materials like SiO 2 and CaO) have resulted in increased hysteresis loss. This increased hysteresis loss produces a very high dependence of the net high frequency losses on the flux density because hysteresis loss varies as the cube of the flux density. Thus, making these materials unsuitable for use at high flux densities and high frequencies.
Yet, another problem with the current approach for making low loss high frequency magnetic material is that the eddy current losses are not completely eliminated and they still make substantial contribution to the total loss in the 100 kHz to 1.0 MHz. This is evident from the measured net losses, which increase as the square of the frequency (hysteresis loss increase, generally, linearly with frequency). In addition, the eddy loss dominate the net losses at frequencies higher than 1 MHz. The main reason for this failure to control eddy current losses are very thin, non-uniform grain boundary layer, which is supposed to produce high resistivity. However, at high frequencies this layer begins to yield due to capacitive electrical shorting of boundary layer. The thinner that layer the more noticeable is this effect. The measured resistivity of the current state-of-the-art materials show a continuous decrease in the value of the resistivity in 100 kHz to 10 MHz range. All the previous attempts to reduce this effect have failed.
Yet, another problem with the current high frequency material is that very large electric fields are produced at the grain boundaries, which leads to a dielectric break down of the material at the grain boundaries and to a resistivity, which is a decreasing function of the flux density. This is because the thickness of the grain boundary layer is extremely small (for typical high frequency ferrite the thickness is in 10 −3 to 10 −2 micron range) and the fact that the resistivity of the crystallites is negligible compared to that of grain boundary layer. In particular, even for a very small core, the induced electric field at 1.0 MHz and at 500 Gauss exceeds 10 kV/cm. These values of electric field far exceed the dielectric strength (typically around 2 kV/cm) of the material at the grain boundary. This leads to resistivity, which decreases rapidly with increasing frequency and flux density. The end result is the increased dependence of high frequency loss on flux density, which further limits the flux density at which these materials can be operated.
The fourth major problem relate to the use of these materials for very high frequency applications and for very high power. This is because of large permeability and dielectric constant, which give a small electromagnetic wavelength at high frequencies. Due to this very small wavelength, dimensional resonance can be set up even in small cores and leads to additional losses. In particular, for typical high frequency ferrites, the wavelength is about 1 mm at 10 MHz and thus making these materials unsuitable even for very small cores. As power level of application such as power supply increases, the size of core increases making the problem worst and restricting the use of these materials to very low powers at such high frequencies.
Accordingly, it is desirable to provide high power magnetic material, which can be operated at high flux levels (e.g. greater than 500 Gauss) while maintaining high frequency operation (e.g. 1 to 10 MHz). Furthermore, such material should have a resistivity, which is independent of the frequency and flux density and should allow for independent control and reduction of hysteresis loss and eddy current loss. In addition, such magnetic material should have a structure, which allows for effective size of the core to be substantially smaller than the electromagnetic wavelength at high frequencies.
SUMMARY OF THE INVENTION
A composite, high frequency, low loss material consists of alternate magnetic plates and insulating films. The magnetic plates are designed to have very lax requirements on the resistivity of the magnetic material comprising the magnetic plates, so that the hysteresis loss can be reduced easily. The eddy current loss is controlled by the thin insulating films and by varying the thickness of the magnetic plates. The insulating films are designed to have high integrity (free of pin holes and other defects), high dielectric strength, high resistivity and, preferably, low dielectric constant. The insulating films perform the same functions as that of the grain-boundary layer in current state-of-the-art magnetic material (ferrites) but are able to maintain their functionality up to much high frequency and much higher flux densities resulting in very high resistivity of the composite material. The resistivity of the composite material is independent of the frequency and flux density to high values of frequencies (˜100 MHz). The magnetic plates and the insulating films can be co-fired. One method of co-firing utilizes green tape technology.
Alternatively, the magnetic plates and the insulating films can be manufactured separately and then the composite ferrite be fabricated by using adhesive and/or heat and pressure treatment. Yet another method of fabricating these composite ferrites is by manufacturing the low hysteresis loss ferrite plates, depositing thin or thick films of the insulating material on both sides of the ferrite plates, stacking the ferrite plates and then applying heat and pressure to melt or soften the insulating films and to attach the ferrite plates to each other. A further method of fabricating these composite ferrite plates is by making a stack of low hysteresis loss ferrite plates with spacers, and dipping the stack in a liquid insulating material or pouring the insulating material over the stack.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the present invention will become apparent from the following detailed description of the invention when read with the accompanying drawings in which:
FIG. 1 illustrates the basic structure of the new high frequency, low loss magnetic material comprising alternate layers of low Hysteresis loss magnetic material and thin films of electrically insulating material.
FIG. 2 graphically illustrates the independence of the resistivity of the new high frequency, low loss magnetic material up to very high frequencies. Also shown is the resistivity of conventional high frequency magnetic materials as function of frequency.
FIG. 3 illustrates another embodiment of the new high frequency, low loss magnetic material comprising alternate layers of low hysteresis magnetic material, thin insulating films and adhesive layers. Shown is a cross-sectional view.
FIG. 4 illustrates yet another embodiment of the current invention comprising curved shaped low Hysteresis loss magnetic material and insulating films.
FIG. 5 illustrates another embodiment of the present invention comprising pie-piece shaped cross-section of low Hysteresis loss magnetic material plates and insulating films.
FIG. 6 shows a stack arrangement of low Hysteresis loss magnetic plates with spacers. This arrangement is used in one of the methods of making new high frequency, low loss composite material in which the stack is dipped in a molten or liquid insulating material. Alternately, a molten or insulating material is poured on the stack so that a thin film of the insulating material is formed between the adjacent magnetic plates.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a simple embodiment of the high frequency, low loss composite magnetic material comprising alternate layers of magnetic plates 10 and insulating films 20 . Magnetic plates 20 comprise low hysteresis loss magnetic material, such as MnZn ferrites with hysteresis loss densities of 0.01 to 0.10 joules/cycle/cc. The thickness of magnetic plates 10 would be chosen such that the eddy currents flowing within a given magnetic plate 10 are not significant. For operation in the frequency range of 1-10 MHz, a typical thickness of magnetic plates 10 is on the order of 0.010-0.100 inch. Insulating films 20 comprise a material such as Kapton polyamide film (manufactured by E. I. duPont de Nemours and Company), silicone dioxide (SiO 2 ), aluminum oxide, calcium oxide, magnesium oxide, aluminum nitride or beryllium oxide. A typical thickness for insulating films 20 is on the order of 10 to 30 microns. Insulating films 20 have high resistivity, high dielectric strength and, preferably, low dielectric constant. Insulating films 20 perform the same function in controlling the bulk eddy currents as that of insulating grain boundary layer in a typical state-of-the-art, high frequency magnetic materials, such as a ferrite, but are able to maintain their functionality to much higher frequencies. Typical range of operation of the present invention is 1-10 MHz, although, advantageously, these materials can also be used in lower frequency ranges (e.g. 100 kHz to 1 MHz) to reduce the size of magnetic components because they can be driven at much higher flux levels.
Advantageously, the relative thickness of insulating films 20 relative to magnetic plates 10 is very large, when compared to the thickness of magnetic grains of the grain boundary layer in a typical conventional high frequency magnetic material. A typical relative thickness of insulating films 20 of the present invention is of the order of 0.1, while the relative thickness of a conventional insulating grain boundary layer is in the range 10 −4 -10 −3 . This very large relative thickness of insulating films 20 results in a very large reduction in the overall capacitance and therefore, the material is able to retain high resistivity up to very high frequencies. FIG. 2 is a graphical comparison of the resistivity of the material made according to the present invention with that of a typical state-of-the-art high frequency material. As shown in the graph of FIG. 2, a typical material made according to present invention is able to maintain high resistivity up to 100 MHz. In contrast, the resistivity of the current state-of-the-art high frequency materials (such as a high frequency ferrite) begins to drop at 10-100 kHz range and continues to decrease with increasing frequencies in 100 kHz to 10 MHz range. The high resistivity of the new materials eliminates bulk eddy current loss even at very high frequencies, thus allowing the new material to be used at high frequencies.
Advantageously, the problem of dielectric break down does not occur in the material made according to the present invention. This is because the thickness (˜10 microns) of the insulating films 20 is many orders of magnitude larger than the thickness of the grain boundary layer in a typical high frequency magnetic material (10 −3 -10 −2 microns) for a ratio of ˜1000:1. This relatively large thickness means that the electric fields induced by the rapidly changing magnetic fields would be orders of magnitude smaller than those seen at the grain boundary in a conventional high frequency magnetic material. Thus, the problem of dielectric breakdown does not occur in the materials made according to the present invention and the materials are able to maintain high resistivity up to very high flux levels and high frequencies. This allows the new materials to be operated at high flux levels and at high frequencies. Additionally, modern insulating materials, which have extremely high resistivities, can be used, resulting in much higher resistivities of the composite high frequency material of the present invention. This is shown in FIG. 4, which shows the resistivity of the new composite material to be orders of magnitude higher than those of conventional high frequency magnetic materials.
The choice of insulating materials used at the grain boundary of the conventional high frequency magnetic material is very limited. Typically only SiO 2 or CaO can be used in conventional material. These insulating materials have relatively low dielectric strength (˜2 kV/cm). Materials made according to present invention enable the use of modern insulating materials for making insulating films 20 . Modern materials, such as the polyamide Kapton films made by E. I. duPont de Nemours and Company, have extremely high dielectric strength (˜100 kV/cm). The use of such materials further eliminates the problem of dielectric breakdown at high flux levels and, advantageously, allows the material to be driven to high flux levels at high frequencies.
Advantageously, the structure of the composite, high frequency material of the present invention enables independent and simultaneous control and reduction of the high frequency eddy current loss and the hysteresis loss. It is very difficult to obtain such control in other high frequency materials. In particular, the resistivity of the magnetic material of magnetic plates 10 can be chosen to be relatively low. A typical high frequency resistivity of the magnetic material of the magnetic plates 10 is on the order of 0.01 to 0.1 ohm-m. This is because the eddy current loss in the present invention is controlled independently by the insulating films 20 and by the thickness of the magnetic plates 10 and a high resistivity of the magnetic material of plates 10 is not needed. The very lax requirements on the resistivity of the magnetic materials of plates 10 allows the grains of the magnetic material to be made relatively large, thereby reducing the surface area of the grain boundaries and making it possible to achieve very low hysteresis losses. Additionally, the lax requirements on the resistivity of the material of magnetic plates 10 makes it possible to use a larger ratio of Fe +3 to Fe +2 , which leads to further reduction in the hysteresis loss.
Advantageously, the thickness of magnetic plates 10 is typically an order of magnitude smaller than the size of a typical high frequency core of a magnetic component and, therefore, the problem of dimensional resonance is avoided up to much higher frequencies. In particular, the magnetic components made with the composite high frequency, low loss material of the present invention is able to function properly in the 1-10 MHz range. This also allows the material made according to present invention to be used in very high power cores.
FIG. 3 illustrates another embodiment of the present invention, comprising alternate layers of low hysteresis loss magnetic plates 10 , thin insulating films 20 , and very thin adhesive films 30 , shown in cross-section. Such an embodiment is suitable, for organic insulating films 20 , such as Kapton polyamide manufactured by E. I. duPont de Nemours and Company. Suitable materials for the adhesive films comprise various hyprocarbon resins such as TEFLON, which s also manufactured by duPont.
FIG. 4 illustrates another embodiment of the present invention, comprising alternate layers of curved magnetic plates 10 and curved insulating films 20 . This embodiment is suitable for the manufacture of rounded core pieces, such as the center post and the outer walls of a pot core, RM core or PQ core.
FIG. 5 shows yet another embodiment of the present invention, comprising alternate magnetic plates 10 , each having a substantially pie-piece shaped cross-section, and insulating films 20 with triangular cross-section. Such an embodiment is suitable for making the center post of a pot core or a RM core or PQ core.
There are many methods of making the composite, high frequency material of the present invention. One method involves separately preparing the magnetic plates 10 by either pressing a low hysteresis loss material in plate shapes prior to firing, or by machining the magnetic plates 10 from a pre-fired block of low hysteresis loss magnetic material. After making the magnetic plates, an adhesive 30 is applied to the both sides of the insulating films 20 or the magnetic plates 10 , or to both, and a stack is built of alternating magnetic plates 10 and insulating films 20 . Finally mechanical pressure or heat or both are applied to the stack to bond the magnetic plates 10 and the insulating plates 20 . Such a method is suitable for use when the insulating film 10 is made of a polymer or polyamide such as Kapton films made by E. I. duPont de Nemours and Company.
A further method of making the composite, high frequency magnetic material of the present invention comprises separately making magnetic plates 10 by either (a) pressing a low Hysteresis loss material in plate shapes prior to firing and then firing, or (b) by machining the magnetic plates 20 from a block of pre-fired low Hysteresis loss material, disposing a small amount of an insulating material on at least one side of the magnetic plates 10 , stacking the plates on top of each other, applying heat and pressure to melt or soften the insulating material, and cooling the stack so that thin insulating films 20 are formed, and provide bonding, between adjacent magnetic plates 10 . The insulating material can be disposed in powder form or through thick or thin film processes. This method is suitable when the insulating material is a glass (silicon dioxide) or a low melting temperature glass.
Yet another method of making the composite, high frequency magnetic material of the present invention comprise co-firing magnetic plates 10 and the insulating films 20 . This method is suitable when the insulating material comprises a ceramic such as aluminum oxide, aluminum nitride or beryllium oxide. Such materials have firing conditions similar to those of high frequency magnetic materials and can be fired along with the high frequency magnetic plates 10 . This method comprises green tape technology. In this method, green tapes of low hysteresis loss magnetic material and of an insulating material are prepared separately. Typical thickness of these green tapes is in 0.001″ to 0.005″ range. The tapes are cut into suitable sizes and small stacks are made of a small number of green tapes of the low hysteresis loss magnetic material. A big stack is made by alternating small stacks of magnetic material green tapes with the insulating green tapes. The big stack is laminated under mechanical pressure. The laminated big stack is heated to 400-600° C. to burn off the binder in the tapes and, finally, the big stack is sintered at 1000-1400° C. and cooled. The sintering and cooling, in some cases, is done under controlled atmosphere in which the amount of oxygen and other gases is prescribed according to a predetermined formula.
A yet further method of making the composite, high frequency magnetic material of the present invention is illustrated in FIG. 6, which shows a stack of magnetic plates 10 with spacers 40 during a process of making the composite high frequency material. The stack is dipped in a molten insulating material so as to form thin insulating films 20 between adjacent magnetic plates after cooling. Alternately, the molten insulating material is poured on the stack so as to fill the gaps between the adjacent magnetic plates 10 . This method is suitable when the insulating material is glass (silicon dioxide) or an organic material. Preferably, the insulating material has a low melting temperature.
While the preferred embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the scope of invention herein. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims:
|
A high frequency, low loss, power, composite magnetic material includes alternating magnetic plates of low hysteresis loss material and electrically insulating films. The multi-layer structure allows for independently and simultaneously controlling and reducing hysteresis loss and eddy current loss, and maintaining a high resistivity, while operating at high frequencies and at high flux density levels, resulting in extremely low net loss density for the composite material. Methods of making this material include co-firing of the magnetic plates and thin insulating films, making the magnetic plates (of low hysteresis material, such as a ferrite) and insulating films separately, and using heat and/or pressure and/or adhesive or making a stack of magnetic plates with spacers in between them and dipping in a molten or liquid insulating material.
| 8
|
RELATED APPLICATION
[0001] The present application claims the benefit of U.S. Provisional Application Ser. No. 60/917,853, filed May 14, 2007, the entire contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Automated quantitative analysis of biomarker expression in tissue sections or tissue microarrays presents several challenges, including heterogeneity of tissue sections, sub-cellular localization of staining and the presence of background signal. For example, depending on the type of tumor or tissue section being analyzed, the area of interest may represent nearly the entire sample or only a small percentage. For instance, a pancreatic carcinoma or lobular carcinoma of the breast with substantial desmoplastic response may show stromal tissue representing a large percentage of the total area. If the goal of the assay is to determine epithelial cell expression of a given marker, a protocol must be used that evaluates only that region. The protocol must not only be able to select the region of interest but also normalize it, so that the expression level read from any given area can be compared with that of other areas. Sub-cellular localization presents similar challenges. Automated systems and methods for rapidly analyzing tissue sections, including tissue microarrays, which permit the identification and localization of identified biomarkers within sub-cellular compartments in tissues and other cell containing samples, are needed.
[0003] Certain methods (including confocal and convolution/deconvolution microscopy) have been used to quantify expression of proteins at the cellular (or sub-cellular) level within a single high power field. These methods, however, are computationally intensive and laborious techniques that operate on multiple serial images. As a result, the current standard for analysis of immunohistology, is conventional pathologist-based analysis and grading of the sample according to scale.
[0004] Automated systems for histological analysis of tissue sections often include methods that either have 1) an operator examining an image of a field of view of a stained tissue and adjusting parameters for optimal analysis conditions or 2) consistent settings that treat an entire data set in the same manner, but an operator is still required to make judgment calls in setting the initial parameters i.e. thresholds. Both of these methods suffer at least the disadvantage that the data is not being treated by a single uniform method that is completely objective. These decisions can influence the output of the system and affect data quality. They also add an extra layer of system complexity in that analysis methods can be adjusted to individual experiments or individual specimens and no universal method is used.
SUMMARY OF THE INVENTION
[0005] The present invention relates generally to methods of detecting and quantifying protein expression and identifying marker-defined biological compartments. It is an object of the present invention to provide methods of defining compartments within which biomarker expression is localized and quantified in tissues and cell containing samples, which requires minimal user intervention and provides optimal compartment, including sub-cellular compartment resolution.
[0006] In one embodiment, the present invention is directed to a method for defining a first marker defined biological compartment relative to a second marker defined biological compartment present in a biological sample of interest, comprising comparing the intensity in each of the pixel locations in a first high resolution image of the first marker defined biological compartment with the intensity in each of the corresponding pixel locations of a second high resolution image of the second marker defined biological compartment, wherein the first high resolution image was prepared using a first imaging agent that is specific for the first marker defined biological compartment, and wherein the second high resolution image was prepared using a second imaging agent that is specific for the second marker defined biological compartment, wherein differences in pixel intensity define the first marker defined biological compartment relative to the second marker defined biological compartment. In a particular embodiment, the method is automated, e.g., wherein the method is implemented by a computer. In a particular embodiment, the pixels of the two high resolution images are plotted, wherein the axes of the plot comprise the intensity of the first imaging agent and the intensity of the second imaging agent. In particular embodiments, the methods of the present invention optionally comprise i) assigning pixels to a cluster characterized by high first imaging agent intensity and low second imaging agent intensity to the first compartment; ii) assigning pixels to a cluster characterized by high second imaging agent intensity and low first imaging agent intensity to the second compartment; and iii) assigning pixels to a cluster characterized by low first imaging agent intensity and low second imaging agent intensity to background and removing such pixels from further analysis. In a particular embodiment, any of the assigning steps are performed using a clustering algorithm, e.g., a k-means clustering method to determine a cluster membership for each pixel. In a particular embodiment, the methods of the invention optionally comprise assigning remaining pixels with first imaging agent intensity and second imaging agent intensity to either the first compartment or the second compartment based on probability. In a particular embodiment, the methods of the invention optionally comprise assigning those remaining pixels with first imaging agent intensity and second imaging agent intensity to neither the first compartment nor the second compartment. In a particular embodiment, the biological compartment is selected from the group consisting of: a cell type, sub-cellular compartment, a tissue compartment, and a localized cellular or tissue compartment. In a particular embodiment, the biological compartment is a sub-cellular compartment selected from the group consisting of: cell nucleus, cytoplasm, nuclear membrane, cellular membrane, mitochondria, endoplasmic reticulum, peroxisome and lysosome. In a particular embodiment, the biological compartment is a tissue compartment selected from the group consisting of: epithelium, stroma, mesothelia. In a particular embodiment, the sample is a tissue sample, cell preparation or sub cellular fraction. In a particular embodiment, the methods of the invention optionally comprise defining a mask defined by the pixel intensity of the first and/or second imaging agent and defining compartment assignment for only those pixels within the mask. In a particular embodiment, the methods of the invention optionally comprise incubating the sample with a first imaging agent that specifically labels the first marker defined biological compartment, a second imaging agent that specifically labels a second marker defined biological compartment
[0007] In one embodiment, the present invention is directed to a computer implemented method for defining a first marker defined biological compartment relative to a second marker defined biological compartment present in a biological sample comprising: a) incubating the sample with a first imaging agent that specifically labels the first marker defined compartment, and a second imaging agent that specifically labels the second marker defined compartment; b) obtaining a first high resolution image of the first imaging agent labeled sample, and a second high resolution image of the second imaging agent labeled sample; c) determining a first and a second imaging agent intensity in each corresponding pixel location in the first and the second image; d) performing a clustering analysis on each pixel based on the first and the second imaging agent intensity of each pixel in each of the pixel to calculate clusters; e) assigning those pixels in the cluster characterized by high first imaging agent pixel intensity and low second imaging agent pixel intensity to the first compartment; f) assigning those pixels in the cluster characterized by high second imaging agent pixel intensity and low first imaging agent pixel intensity to the second compartment; and g) assigning those pixels in the cluster characterized by low first imaging agent pixel intensity and low second imaging agent pixel intensity to background and removing such pixels from further analysis, thereby defining a first marker defined sub-cellular compartment relative to a second marker defined sub-cellular compartment.
[0008] In one embodiment, the present invention is directed to a computer implemented method for localizing and quantitating a particular biomarker within a first marker defined biological compartment relative to a second marker defined biological compartment present in a biological sample comprising: a) incubating the tissue sample with a first imaging agent that specifically labels the first marker defined compartment, a second imaging agent that specifically labels a second marker defined sub-cellular compartment, and a third imaging agent that specifically labels the biomarker; b) obtaining a first high resolution image of the first imaging agent labeled sample, a second high resolution image of the second imaging agent labeled sample, and a third high resolution image of the third imaging agent labeled sample; c) determining the first and second imaging agent pixel intensity in each of the pixel locations in the first and the second image; d) performing a clustering analysis on the pixels to assign pixels to the first marker defined compartment or the second marker defined compartment; and e) analyzing in the third image the pixel locations assigned to the compartments so as to identify those pixel locations with an intensity value indicative of the third imaging agent, and determining the total intensity value of the third imaging at the pixel locations assigned to each of the first and second compartments, so as to thereby localize and quantitate the biomarker in the first compartment relative to the second compartment. In a particular embodiment, the high resolution images are obtained using an upright or inverted optical microscope. In a particular embodiment, the cluster analysis is performed using reiterative k-means clustering on the first and the second pixel intensity in each of the pixel locations to calculate three centroids using Euclidean or log-likelihood distances. In a particular embodiment, the methods of the present invention optionally comprise i) plotting the pixel locations and the calculated centroids where the axes of the plot comprise the intensity of the first imaging agent and the intensity of the second imaging agent at pixel locations for the first compartment and the second compartment; ii) connecting the centroids to define a triangle; iii) assigning those pixel locations having an intensity not within the area of the triangle: (1) to the first compartment if the pixel intensity is substantially indicative of the first imaging agent; (2) to the second compartment if the pixel intensity is substantially indicative of the second imaging agent, or (3) to neither compartment if the pixel intensity is substantially indicative of background; and iv) assigning those pixel locations within the area of the triangle the first compartment or the second compartment based upon a value corresponding to the probability that the pixel originates from the first or the second compartment. In a particular embodiment, the biomarker is selected from the group consisting of: a protein, a peptide, a nucleic acid, a lipid and a carbohydrate. In a particular embodiment, each of the first, the second and the third imaging agents comprise a fluorophore. In a particular embodiment, the quantitation of the biomarker present within the first or the second compartment comprises summing the intensity values of the third imaging agent at the pixel locations within the compartment and dividing the sum by the number of pixels in the compartment. In a particular embodiment, a pixel location not assigned to the first or the second compartment is assigned to a third compartment. In a particular embodiment, the sample is a tissue sample with a thickness of about five microns. In a particular embodiment, the first compartment is a cellular membrane and the second compartment is a cell nucleus. In a particular embodiment, the biological sample is a fixed tissue section. In a particular embodiment, the first or the second imaging agent reacts with a marker that is selected from the group consisting of: cytokeratin, beta catenin, alpha catenin and vimentin. In a particular embodiment, at least one of the first, the second or the third imaging agents comprises a fluorophore selected from the group consisting of: 4′,6-diamidino-2-phenylindole (DAPI), Cy3, Cy-5-tyramide and Alexa fluor dyes. In a particular embodiment, the biomarker is selected from the group consisting of: Her-2/neu, estrogen receptor, progesterone receptor, epidermal growth factor receptor, phosphatase and tensin homolog (PTEN), and excision repair cross complementation group 1 (ERCC1). In a particular embodiment, a mask is applied to the first, the second and the third high resolution images, and only pixels within the mask are analyzed.
[0009] In one embodiment, the present invention is directed to a computer readable medium comprising the computer readable instructions stored thereon for execution by a processor to perform a method for determining an optimal dilution of a reagent for use in a quantitative immunoassay comprising the steps of: receiving a plurality of dilution sets, each dilution set having a different respective dilution value and comprising a respective plurality of immunoassay staining intensity values; determining for each of the plurality of dilution sets a respective dynamic range metric related to the respective plurality of immunoassay staining intensity values; and identifying the dilution set having the numerically greatest dynamic range metric, the dilution value of the identified dilution set being representative of an optimal dilution level of the reagent for use in the quantitative immunoassay.
[0010] In one embodiment, the present invention is directed to an electromagnetic signal carrying computer-readable instructions for determining an optimal dilution of a reagent for use in a quantitative immunoassay comprising the steps of: receiving a plurality of dilution sets, each dilution set having a different respective dilution value and comprising a respective plurality of immunoassay staining intensity values; determining for each of the plurality of dilution sets a respective dynamic range metric related to the respective plurality of immunoassay staining intensity values; and identifying the dilution set having the numerically greatest dynamic range metric, the dilution value of the identified dilution set being representative of an optimal dilution level of the reagent for use in the quantitative immunoassay.
[0011] In one embodiment, the present invention is directed to a computer implemented method for defining a first marker defined sub-cellular compartment relative to a second marker defined sub-cellular compartment present in individual cells of interest contained in a tissue sample comprising: a) incubating the tissue sample with a first stain that specifically labels the first marker defined sub-cellular compartment, a second stain that specifically labels a second marker defined sub-cellular compartment, b) obtaining a high resolution image of each of the first and the second stain in the tissue sample using a microscope so as to obtain: i) a first image of the first marker defined sub-cellular compartment; ii) a second image of the second marker defined sub-cellular compartment; and c) determining the first and second stain intensity in each of the pixel locations in the first and the second image; d) plotting the pixels, where the axes of the plot comprise the intensity of the first stain and the intensity of the second stain; e) performing reiterative k-means clustering on the first and the second stain intensity in each of the pixel locations to calculate three clusters; f) assigning those pixels in the cluster characterized by high first stain intensity and low second stain intensity to the first compartment; g) assigning those pixels in the cluster characterized by high second stain intensity and low first stain intensity to the second compartment; h) assigning those pixels in the cluster characterized by low first stain intensity and low second stain intensity to background and removing such pixels from further analysis; i) assigning those pixels with first stain intensity and second stain intensity to either the first compartment or the second compartment based upon based on probability thereby defining a first marker defined sub-cellular compartment relative to a second marker defined sub-cellular compartment.
[0012] In one embodiment, the present invention is directed to a computer implemented method for defining a first marker defined sub-cellular compartment relative to a second marker defined sub-cellular compartment present in individual cells of interest contained in a tissue sample comprising: a) incubating the tissue sample with a first stain that specifically labels the first marker defined sub-cellular compartment, a second stain that specifically labels a second marker defined sub-cellular compartment, b) obtaining a high resolution image of each of the first and the second stain in the tissue sample using a microscope so as to obtain: i) a first image of the first marker defined sub-cellular compartment; ii) a second image of the second marker defined sub-cellular compartment; and c) determining the first and second stain intensity in each of the pixel locations in the first and the second image; d) plotting the pixels, where the axes of the plot comprise the intensity of the first stain and the intensity of the second stain; e) performing reiterative k-means clustering on the first and the second stain intensity in each of the pixel locations to calculate three clusters; f) assigning those pixels in the cluster characterized by high first stain intensity and low second stain intensity to the first compartment; g) assigning those pixels in the cluster characterized by high second stain intensity and low first stain intensity to the second compartment; h) assigning those pixels in the cluster characterized by low first stain intensity and low second stain intensity to background and removing such pixels from further analysis; i) assigning those pixels with first stain intensity and second stain intensity to neither the first compartment or the second compartment; thereby defining a first marker defined sub-cellular compartment relative to a second marker defined sub-cellular compartment.
[0013] In one embodiment, the present invention is directed to a computer implemented method for localizing and quantitating a particular biomarker within a first marker defined sub-cellular compartment relative to a second marker defined sub-cellular compartment present in individual cells of interest contained in a tissue sample comprising: a) incubating the tissue sample with a first stain that specifically labels the first marker defined sub-cellular compartment, a second stain that specifically labels a second marker defined sub-cellular compartment, and a third stain that specifically labels the biomarker; b) obtaining a high resolution image of each of the first, the second, and the third stain in the tissue sample using an upright or inverted optical microscope so as to obtain: i) a first image of the first marker defined sub-cellular compartment; ii) a second image of the second marker defined sub-cellular compartment; and iii) a third image of the biomarker, c) determining the first and second stain intensity in each of the pixel locations in the first and the second image; d) performing reiterative k-means clustering on the first and the second stain intensity in each of the pixel locations to assign pixels to the first marker defined sub-cellular compartment of the second marker defined sub-cellular compartment; e) analyzing in the third image the pixel locations assigned to the first sub-cellular compartment, the second sub-cellular compartment, or both compartments in step (f) and step (g) so as to identify those pixel locations having an intensity value indicative of the third stain, and determining the total intensity value of the third stain at the pixel locations assigned to each of the first and second sub-cellular compartment; so as to thereby localize and quantitate the biomarker in the first sub-cellular compartment relative to the second sub-cellular compartment
[0014] In one embodiment, the present invention is directed to a computer implemented method for localizing and quantitating a particular biomarker within a first marker defined sub-cellular compartment relative to a second marker defined sub-cellular compartment present in individual cells of interest contained in a tissue sample comprising: a) incubating the tissue sample with a first stain that specifically labels the first marker defined sub-cellular compartment, a second stain that specifically labels a second marker defined sub-cellular compartment, and a third stain that specifically labels the biomarker; b) obtaining a high resolution image of each of the first, the second, and the third stain in the tissue sample using an upright or inverted optical microscope so as to obtain: i) a first image of the first marker defined sub-cellular compartment; ii) a second image of the second marker defined sub-cellular compartment; and iii) a third image of the biomarker, c) determining the first and second stain intensity in each of the pixel locations in the first and the second image; d) performing reiterative k-means clustering on the first and the second stain intensity in each of the pixel locations to calculate three centroids using Euclidean or log-likelihood distances; e) plotting the pixel locations and the calculated centroids where the axes of the plot comprise the intensity of the first stain and the intensity of the second stain pixel locations for the first compartment and the second compartment. f) connecting the centroids to define a triangle, g) assigning those pixel locations having an intensity not within the area of the triangle: (1) to the first compartment if the pixel intensity is substantially indicative of the first stain; (2) to the second compartment if the pixel intensity is substantially indicative of the second stain, or (3) to neither compartment if the pixel intensity is substantially indicative of background; h) assigning those pixel locations within the area of the triangle the first compartment or the second compartment based upon a value corresponding to the probability that the pixel originates from the first or the second compartment; i) analyzing in the third image the pixel locations assigned to the first sub-cellular compartment, the second sub-cellular compartment, so as to identify those pixel locations having an intensity value indicative of the third stain, and determining the total intensity value of the third stain at the pixel locations assigned to each of the first and second sub-cellular compartment; so as to thereby localize and quantitate the biomarker in the first sub-cellular compartment relative to the second sub-cellular compartment.
[0015] Other features, objects, and advantages of the invention will be apparent from the following figures, detailed description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The patent or application file contains multiple figures executed in color. Copies of this patent or patent application publication with color figures will be provided by the Office upon request and with payment of the necessary fee.
[0017] FIG. 1 is a schematic of the clustering used to determine three centroids in the data.
[0018] FIG. 2 shows a cell line stained with DAPI (nuclei), anti-Cytokeratin (Cy3), and anti-integrin alpha-V (Cy5).
[0019] FIG. 3 is a scatter plot showing DAPI (norm) vs. Cy3 (norm).
[0020] FIG. 4 presents data showing clustering using Log-Likelihood Distance (Auto).
[0021] FIG. 5 presents data showing clustering of DAPI Percentage: Log Likelihood Distance (Force 3). Both produced equivalent clustering, use Cy3 percentage, taking the top cluster as Cy3-predominant positive pixels and the bottom cluster as DAPI-predominant positive pixels.
[0022] FIG. 6 shows “Signaling Cluster” Cy3 Percentage (based on normalized values) Log-Likelihood (Standardized)-Force 3.
[0023] FIG. 7 shows staining of cell type Her2 Spot 17.
[0024] FIG. 8 shows staining of cell type p53 Spot 2.
[0025] FIGS. 9A through 9C is are plots showing clustering analysis. FIG. 9A ) Model description of C-AQUA method showing specific pixel assignment: background (box between points A and C), 100% cytoplasm/Cy3 (box between the left border and C; Y-axis; 0% nuclear/DAPI), 0-100% cytoplasm/Cy3 (triangle ABC; 0% nuclear/DAPI), 0-100% nuclear/DAPI (triangle ABD, 0% cytoplasm/Cy3), and 100% nuclear/DAPI (bottom box; X-axis; 0% cytoplasm/Cy3). FIG. 9B ) 2×2 scatter-plot showing Cy3 (Y) and Dapi (X) pixel intensities graphed against one another with indicated centroids (B, Background; C, Cytoplasm; N, Nuclear). This image passed validation in that both compartment centroids were greater than 1 standard deviation away from the background centroid. FIG. 9C ) 2×2 scatter-plot of a different tissue spot showing indicated pixel intensities and centroids. This image failed validation due to insufficient distance (<1 standard deviation) between the cytoplasmic centroid (C) and background centroid (B).
[0026] FIGS. 10A and 10B are plots showing comparisons between AQUA® and C-AQUA analysis. FIG. 10A ) Regression analysis with indicated Pearson R and Spearman's Rho values between AQUA® scores generated by two highly trained operators using traditional AQUA® analysis algorithms. FIG. 10B ) Regression analysis with indicated Pearson R and Spearman's Rho values between AQUA® scores generated by two highly trained operators using C-AQUA algorithms on the same data set as in A.
[0027] FIGS. 11A and 11B are plots showing comparisons between AQUA® and C-AQUA analysis. FIG. 11A ) Linear regression analysis for nuclear compartment size between AQUA® analysis (Y-axis) and C-AQUA analysis (X-axis) with indicated Pearson's R and Spearman's Rho values. FIG. 11B ) Linear regression analysis for cytoplasmic compartment size between AQUA® analysis (Y-axis) and C-AQUA analysis (X-axis) with indicated Pearson's R and Spearman's Rho values.
[0028] FIGS. 12A through 12C are plots showing comparisons between AQUA® and C-AQUA analysis. FIG. 12A ) Linear regression analysis for ER AQUA® scores between AQUA® analysis (Y-axis) and C-AQUA analysis (X-axis) with indicated Pearson's R and Spearman's Rho values. FIG. 12B ) Linear regression analysis for PR AQUA® scores between AQUA® analysis (Y-axis) and C-AQUA analysis (X-axis) with indicated Pearson's R and Spearman's Rho values. FIG. 12C ) Linear regression analysis for Her2 AQUA® scores between AQUA® analysis (Y-axis) and C-AQUA analysis (X-axis) with indicated Pearson's R and Spearman's Rho values.
[0029] FIGS. 13A through 13C are plots showing comparisons between AQUA® and C-AQUA analysis. Survival outcome comparisons for FIG. 13A ) ER, FIG. 13B ) PR, and FIG. 13C ) Her2 expression for AQUA® analysis (left) and C-AQUA analysis (right) showing similar survival outcomes based on cutpoint assignment as determined by unsupervised log-likelihood distance clustering [ FIG. 13A ) traditional AQUA®: 11.4% reduction in overall survival (log-rank p=0.018) from 80.9% (ER High) to 69.5% (ER Low); C-AQUA: 13.8% reduction in overall survival (log-rank p=0.005) from 81.6% (ER High) to 67.8% (ER Low); FIG. 13B ) traditional AQUA®: 12.4% reduction in overall survival (log-rank p=0.021) from 84.2% (PR High) to 71.8% (PR Low); C-AQUA: 14.5% reduction in overall survival (log-rank p=0.001) from 83.3% (PR High) to 68.8% (PR Low); and FIG. 13C ) traditional AQUA®: 18.5% total reduction in overall survival (log-rank p=0.022) from 77.1% (Her2 Low) to 73.8% (Her2 Mid) to 58.6% (Her2 High); C-AQUA: 24.2% total reduction in overall survival (log-rank p=0.002) from 77.8% (Her2 Low) to 73.8% (Her2 Mid) to 53.6% (Her2 High)].
[0030] FIGS. 14A and 14B show PTEN expression AQUA® score comparison (linear regression) as determined by AQUA® and C-AQUA analysis. FIG. 14A ) Linear regression analysis for nuclear PTEN expression as determined by AQUA® analysis (Y-axis) and C-AQUA analysis (X-axis) with indicated Pearson's R. FIG. 14B ) Linear regression analysis for cytoplasmic PTEN expression as determined by AQUA® analysis (Y-axis) and C-AQUA analysis (X-axis) with indicated Pearson's R values.
[0031] FIG. 15 PTEN cytoplasmic expression AQUA® scores.
[0032] FIG. 16 shows the correlation of PTEN AQUA® scores derived by both methods to patient outcome is shown in Kaplan Meier curves. PTEN AQUA® scores were significantly correlated with patient survival. Low PTEN expression was associated with poor outcome compared to high PTEN expression.
[0033] FIGS. 17A and 17B show ERCC1 expression AQUA® score comparison (linear regression) as determined by AQUA® and C-AQUA analysis. FIG. 14A ) Linear regression analysis for nuclear ERCC1 expression as determined by AQUA® analysis (Y-axis) and C-AQUA analysis (X-axis) with indicated Pearson's R. FIG. 14B ) Linear regression analysis for cytoplasmic ERCC1 expression as determined by AQUA® analysis (Y-axis) and C-AQUA analysis (X-axis) with indicated Pearson's R values.
[0034] FIG. 18 ERCC1 cytoplasmic expression AQUA® scores.
[0035] FIG. 19 shows the correlation of ERCC1 AQUA® scores derived by both methods to patient outcome is shown in Kaplan Meier curves. ERCC1 AQUA® scores were significantly correlated with patient survival. Low ERCC1 expression was associated with poor outcome compared to high ERCC1 expression.
DETAILED DESCRIPTION
[0036] It is to be appreciated that certain aspects, modes, embodiments, variations and features of the invention are described below in various levels of detail to provide a substantial understanding of the present invention.
[0037] Unless defined otherwise, all technical and scientific terms used herein generally have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. As used in this specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents unless the content clearly dictates otherwise. For example, reference to “a cell” includes a combination of two or more cells, and the like. Generally, the nomenclature used herein and the laboratory procedures in cell biology, immunohistochemistry, and imaging (e.g., cells and tissue) described below are those well known and commonly employed in the art. Standard techniques, or modifications thereof, are used for immunohistochemical analyses. All references cited herein are incorporated herein by reference in their entireties and for all purposes to the same extent as if each individual publication, patent, or patent application was specifically and individually incorporated by reference in its entirety for all purposes.
[0038] Tissue microarray technology offers the opportunity for high throughput analysis of tissue samples (Konen, J. et al., Nat. Med. 4:844-7 (1998); Kallioniemi, O. P. et al., Hum. Mol. Genet. 10:657-62 (2001); Rimm, D. L. et al., Cancer J. 7:24-31 (2001)). For example, the ability to rapidly perform large scale studies using tissue microarrays can provide critical information for identifying and validating drug targets/prognostic markers (e.g. estrogen receptor (ER) and HER2/neu) and candidate therapeutics.
[0039] Most biomarkers exhibit a parametric (normal, “bell-shaped”) distribution, and consequently are best analyzed by a continuous scale (e.g., 0 to 1000). Unfortunately, manual observation tends to be nominal (e.g. 1+, 2+, 3+), primarily because the human eye in unable to reliably distinguish subtle differences in staining intensity. Several methods have been developed to translate nominal manual observations into a continuous scale. Foremost among these is the H-score where the percent of positively stained cells (0 to 100) is multiplied by the staining intensity (e.g. 0 to 3) to make a theoretically continuous scale (0 to 300). However, the inability to detect subtle differences in staining intensity, particularly at the low and high ends of the scale, as well as the tendency to round scores (e.g. 50% at 3+ for a score of 150, versus 47% at 3+ for a score of 141), limits the effectiveness of the H-score.
[0040] In some aspects, the present invention provides improved methods to quantify and localize a particular target in defined cellular components. The present inventors have discovered a method to accomplish this that has the advantage of being completely objective and minimizes operator intervention or decision making. The method performs a clustering on the intensity data for each cellular compartment acquired. This clustering allows for removal of background, assignment of specific pixels to a given compartment and probabilistic assignment of pixels to each compartment where there may be overlapping signals. Once pixels are assigned to each compartment (or discarded in the case of noise) the associated target signals can be measured, for example summed and a score calculated.
[0041] The invention provides methods for objective pixel assignment to specific compartments. The assignment is preferentially determined on an image-to-image basis, rather than setting universal criteria. Furthermore, pixel assignment (e.g., Cy3/Cytokeratin pixels to cytoplasm) is also a function of other compartment images such that consideration is given to the status of pixels in other compartment images. In one embodiment one image is of a first stain that specifically labels a first compartment (e.g., a Cy3/cytokeratin image, representing the cytoplasmic compartment) and a second image is of a second stain that specifically labels a second compartment (e.g., DAPI image, representing the nuclear compartment) and pixel assignments are based on four criteria:
[0042] 1.) Low intensity in both first and second image (e.g., DAPI and Cy3):BACKGROUND: REMOVE
[0043] 2.) High second stain (e.g., DAPI) intensity relative to first stain (Cy3) intensity: SECOND COMPARTMENT (e.g., NUCLEAR)
[0044] 3.) High first stain (e.g., Cy3) intensity relative to second stain (e.g., DAPI) intensity: FIRST COMPARTMENT (e.g., CYTOPLASMIC)
[0045] 4.) High second stain and first stain (e.g., DAPI and Cy3) intensity: INDETERMINANT: REMOVE
[0046] Clustering is a mathematical algorithmic function whereby centroids within data sets are defined by relative distances of each data point to one another, as determined, for example, by Euclidean or log-likelihood distance. While not wishing to be bound by theory, it is believed that clustering pixel intensities from at least two images (i.e. DAPI and Cy3), could result in centroids that define pixels as described, at least, by the above criteria. Because clustering is objective and can be performed individually on each image, clustering was discovered to provide reliable assignment of pixels to compartments, independent of operator intervention.
[0047] In another embodiment, pixels containing signal indicative of both the first and second stain are assigned to compartments by the following method. Every pixel in acquired images has three attributes—intensity contribution from compartment marker A, intensity contribution from compartment marker B and an intensity contribution from the target or biomarker of interest. These intensities are measured in their respective fluorescence channels per the experimental configuration. To avoid experimental bias, the target intensity is not manipulated in this current method. Thus, the data for the two compartment attributes can be illustrated in a two-dimensional plot schematically shown in FIG. 1 . The typical spread of the data is represented by the dashed right triangle.
[0048] Pixels with a strong bias towards either of the axes can be assigned to that compartment (e.g., pixels in regions A and B could be absolutely assigned to compartments A and B respectively). Pixels near the origin represent low intensities for both channels and can be discarded as background along with outlier pixels that have high intensity but similar values, shown in region D. Pixels that remain in the region labeled A/B can then be assigned to each compartment based on probability. This assignment allows target signal in those pixels to be distributed across both compartments based on the probability characterization.
[0049] To define the regions described above, for example, for every image, clustering is used to determine three centroids in the data (shown as C1, C2 and C3). This method is fully automated and does not require any operator decisions to proceed. The analysis is accomplished by performing k-means clustering on three centroids using Euclidean distances. Once these points are determined, the regions illustrated in the FIG. 1 are generated using these points. The data are then analyzed as follows: (i) Background and outlier pixels are discarded from further calculation. A pixel is defined as background if its distance to the origin is less than twice that of the background centroid (C2) distance to the origin. A pixel is define as an outlier if its intensity exceeds the value defines by the line or plane defined by the outermost centroids (e.g., C1 and C3 in FIG. 1 ; region D); (ii) Pixels in regions A and B are assigned exclusively to those two compartments; (iii) Pixels in the triangular region A/B are then assigned a probability value that allows them to essentially be distributed in multiple compartments. This probability value can be calculated based on distance from the two regions A and B, or, using a shape function that will also assign a probability of each pixel having a contribution from the background region by examining each pixel's distance from the three vertices given by the centroids; (iv) With all pixels assigned, the associated target scores can be summed up for each compartment and a score calculated using standard methods:
[0000]
∑
i
#
pixels
Int
i
*
P
i
∑
i
#
pixels
P
i
[0000] where Int is the intensity of the pixel, P is the probability of the pixel being assigned to a particular compartment (ranging from 0 to 1).
General Methods
[0050] In general, described herein are a collection of techniques that can be used for rapid, automated analysis of cell containing samples, including tissues and tissue microarrays. While these techniques build on one another and are described as a cohesive process, each technique has wide applicability and may be used individually or in combinations other than those described below.
[0051] In a particular embodiment, the methods of the invention are preferentially used with AQUA® analysis, the features of which are described in U.S. Pat. No. 7,219,016, which is incorporated by reference in its entirety.
[0052] In a typical AQUA® experimental setup, tissue samples are stained with markers that define, for example, the sub-cellular compartments of interest and the specific target (or targets) being studied. Pixel-based local assignment for compartmentalization of expression (PLACE) is the key algorithm that functions to effectively segment image pixels for the purpose of expression compartmentalization. A critical step in this algorithm is the setting of intensity thresholds that are used to delineate background or non-specific pixels from signal-specific pixels. Images that have been “masked” in this way are subsequently combined in a mutually-exclusive fashion such that pixels above the thresholds are assigned to specific sub-cellular compartments. Once pixels have been assigned to each compartment, the signal for the target biomarker can then be averaged over all of the pixels assigned to a given compartment, which is the AQUA® score for that sample.
[0053] For example, in an epithelial tumor specimen, two stains can be used to differentiate the tumor region and incorporated sub-cellular compartments: DAPI (4′-6-Diamidino-2-phenylindole; a nuclear/dsDNA specific staining marker) and cytokeratin (an epithelial specific biomarker tagged for fluorescent readout). These images are individually thresholded to remove non-specific signal then combined to produce an image that represents pixels that are not only epithelial specific but also represent cytoplasm and nuclear-specific pixels. Pixel intensities from a specific target that has been labeled for readout in a third fluorescent channel can subsequently be quantified within this “PLACEd” image.
[0054] It would be advantageous, specifically for clinical operation, to enhance the AQUA® analysis scoring algorithm such that image segmentation is completely automated, thus removing the user-defined threshold step. This would improve the system in several ways: First, due to operator time associated with defining an optimized threshold setting, efficiency of the system would greatly increase. Second, due to the subjective nature of setting thresholds, even by experienced operators, operator-to-operator variability could be removed. Third, for purposes of clinical and/or research lab efficiency and quality control, a uniform method of setting thresholds must be applied for all channel-specific images acquired across a TMA cohort or whole tissue section. Development of an automated PLACE-like method would allow for image segmentation to be optimized on an image-by-image basis. And finally, the method described here involves examination of compartment images simultaneously, so thresholds are set in the context of pixel data for all compartment markers.
[0055] The present invention may be used to localize and quantitate a biomarker within any imageable, cell-containing sample, including, but not limited to, tissue biopsies and cell containing fluid samples, such as, for example, blood, urine, spinal fluid, saliva, lymph, pleural fluid, peritoneal fluid and pericardial fluid and for the analysis of tissue microarrays.
[0056] Any optical or non-optical imaging device can be used, such as, for example, upright or inverted optical microscopes, scanning confocal microscopes, cameras, scanning or tunneling electron microscopes, scanning probe microscopes, and imaging infrared detectors etc.
[0057] In the embodiments described above, the computer can include hardware, software, or a combination of both to control the other components of the system and to analyze the images. The analysis described above is implemented in computer programs using standard programming techniques. Such programs are designed to execute on programmable computers each comprising a processor, a data storage system (including memory and/or storage elements), at least one input device, at least one output device, such as a display or printer. The program code is applied to input data (e.g., stitched together images or image stacks) to perform the functions described herein and generate information (e.g., localization of signal), which is applied to one or more output devices. Each computer program can be implemented in a high-level procedural or object-oriented programming language, or an assembly or machine language. Each such computer program can be stored on a computer readable storage medium (e.g., CD ROM or magnetic diskette) that, when read by a computer, can cause the processor in the computer to perform the analysis described herein.
[0058] The following provides a detailed description of a specific embodiment of the preparation and analysis of tissue microarrays according to methods described herein, although similar steps could be performed with respect to any cell containing sample. A tissue microarray includes multiple samples of histospots prepared from histocores embedded typically in a thin block of paraffin at regular intervals, forming a series of rows and columns. Histospots (thin sections of histocores) may be substantially disk-like in shape and will typically a thickness of about five microns and a diameter of about 0.6 millimeters. Typically the centers of the histospots are spaced about a few tenths of a millimeter apart in paraffin blocks. Sections of the histospots may be mounted on a microscope slide. A tissue microarray may include any number of histospots, typically on the order of several hundred to a few thousand.
[0059] An optical microscopy station can be used to obtain an appropriate image of the tissue. A microscopy station includes an optical microscope for imaging the tissue, and a computer for analyzing the images. An optical microscope includes a mount, housing a light source, a sample stage, an objective lens and a CCD camera. A frame grabber software is used to acquire the images through CCD camera.
[0060] An optical microscope also includes several light filters to provide the appropriate illumination spectra for standard or fluorescent microscopy. For example, for fluorescent microscopy the filters may be in filter wheels and a housing, which house a series of dichroic filters. The filters in the wheel allow selection of the appropriate illumination spectra. The filters in wheel alter (filter) the transmitted light for isolation of spectral signatures in fluorescent microscopy. A sample stage supports and appropriately positions the microscope slide containing the tissue sample or tissue microarray. A sample stage can be linearly translated in the x, y, and z directions (axes are shown). A sample stage includes motors to enable automated translation. A computer controls the sample stage translation by servo control of the motors.
[0061] A tissue microarray can be imaged as follows: a user places the microarray on a sample stage. The user adjusts the sample stage so that the first (e.g., top-left) histospot is at the center of the field of view and focused on by the CCD camera. The objective lens should be adjusted to the appropriate resolution, for example, a 0.6 millimeter histospot can be viewed at 10× magnification. The histospots generally correspond to areas of higher light intensity than the surrounding paraffin, as assessed through various means including signals derived from the visible light scattering of stained tissues, tissue autofluorescence or from a fluorescent tag. A computer can acquire a low-resolution image (e.g. 64 pixel×64 pixel with 16 bit resolution) using computer software (Softworx 2.5, Applied Precision, Issaquah, Wash.) and an imaging platform (e.g., Deltavision). A computer automatically translates sample stage by an amount approximately equal to a field of view. The computer then acquires a second low-resolution image. This process is repeated until the computer has acquired images of the entire tissue sample or microarray. Using commercially available software, the computer then generates a composite image of the entire tissue microarray by stitching together the sequence of images like patchwork.
[0062] Biological markers, which may be detected in accordance with the present invention include, but are not limited to any nucleic acids, proteins, peptides, lipids, carbohydrates or other components of a cell. Certain markers are characteristic of particular cells, while other markers have been identified as being associated with a particular disease or condition. Examples of known prognostic markers include enzymatic markers such as, for example, galactosyl transferase II, neuron specific enolase, proton ATPase-2, and acid phosphatase. Hormone or hormone receptor markers include human chorionic gonadotropin (HCG), adrenocorticotropic hormone, carcinoembryonic antigen (CEA), prostate-specific antigen (PSA), estrogen receptor, progesterone receptor, androgen receptor, gC1q-R/p33 complement receptor, IL-2 receptor, p75 neurotrophin receptor, PTH receptor, thyroid hormone receptor, and insulin receptor.
[0063] Lymphoid markers include alpha-1-antichymotrypsin, alpha-1-antitrypsin, B cell marker, bc1-2, bc1-6, B lymphocyte antigen 36 kD, BM1 (myeloid marker), BM2 (myeloid marker), galectin-3, granzyme B, HLA class I Antigen, HLA class II (DP) antigen, HLA class II (DQ) antigen, HLA class II (DR) antigen, human neutrophil defensins, immunoglobulin A, immunoglobulin D, immunoglobulin G, immunoglobulin M, kappa light chain, kappa light chain, lambda light chain, lymphocyte/histocyte antigen, macrophage marker, muramidase (lysozyme), p80 anaplastic lymphoma kinase, plasma cell marker, secretory leukocyte protease inhibitor, T cell antigen receptor (JOVI 1), T cell antigen receptor (JOVI 3), terminal deoxynucleotidyl transferase, unclustered B cell marker.
[0064] Tumor markers include alpha fetoprotein, apolipoprotein D, BAG-1 (RAP46 protein), CA19-9 (sialyl lewisa), CA50 (carcinoma associated mucin antigen), CA125 (ovarian cancer antigen), CA242 (tumour associated mucin antigen), chromogranin A, clusterin (apolipoprotein J), epithelial membrane antigen, epithelial-related antigen, epithelial specific antigen, epidermal growth factor receptor, estrogen receptor, gross cystic disease fluid protein-15, hepatocyte specific antigen, HER2, heregulin, human gastric mucin, human milk fat globule, MAGE-1, matrix metalloproteinases, melan A, melanoma marker (HMB45), mesothelin, metallothionein, microphthalmia transcription factor (MITF), Muc-1 core glycoprotein. Muc-1 glycoprotein, Muc-2 glycoprotein, Muc-5AC glycoprotein, Muc-6 glycoprotein, myeloperoxidase, Myf-3 (Rhabdomyosarcoma marker), Myf-4 (Rhabdomyosarcoma marker), MyoD1 (Rhabdomyosarcoma marker), myoglobin, nm23 protein, placental alkaline phosphatase, prealbumin, progesterone receptor, prostate specific antigen, prostatic acid phosphatase, prostatic inhibin peptide, PTEN, renal cell carcinoma marker, small intestinal mucinous antigen, tetranectin, thyroid transcription factor-1, tissue inhibitor of matrix metalloproteinase 1, tissue inhibitor of matrix metalloproteinase 2, tyrosinase, tyrosinase-related protein-1, villin, von Willebrand factor, CD34, CD34, Class II, CD51 Ab-1, CD63, CD69, Chk1, Chk2, claspin C-met, COX6C, CREB, Cyclin D1, Cytokeratin, Cytokeratin 8, DAPI, Desmin, DHP (1-6 Dipheynyl-1,3,5-Hexatriene), E-Cadherin, EEA1, EGFR, EGFRvIII, EMA (Epithelial Membrane Antigen), ER, ERB3, ERCC1, ERK, E-Selectin, FAK, Fibronectin, FOXP3, Gamma-H2AX, GB3, GFAP, Giantin, GM130, Golgin 97, GRB2, GRP78BiP, GSK3 Beta, HER-2, Histone 3, Histone 3_K14-Ace [Anti-acetyl-Histone H3 (Lys 14)], Histone 3_K18-Ace [Histone H3-Acetyl Lys 18), Histone 3_K27-TriMe, [Histone H3 (trimethyl K27)], Histone 3_K4-diMe [Anti-dimethyl-Histone H3 (Lys 4)], Histone 3_K9-Ace [Acetyl-Histone H3 (Lys 9)], Histone 3_K9-triMe [Histone 3-trimethyl Lys 9], Histone 3_S10-Phos [Anti-Phospho Histone H3 (Ser 10), Mitosis Marker], Histone 4, Histone H2A.X_S139-Phos [Phospho Histone H2A.X (Ser139)antibody], Histone H2B, Histone H3_DiMethyl K4, Histone H4_TriMethyl K20-Chip grad, HSP70, Urokinase, VEGF R1, ICAM-1, IGF-1, IGF-1R, IGF-1 Receptor Beta, IGF-II, IGF-IIR, IKB-Alpha IKKE, IL6, IL8, Integrin alpha V beta 3, Integrin alpha V beta6, Integrin Alpha V/CD51, integrin B5, integrin B6, Integrin B8, Integrin Beta 1(CD 29), Integrin beta 3, Integrin beta 5 integrinB6, IRS-1, Jagged 1, Anti-protein kinase C Beta2, LAMP-1, Light Chain Ab-4 (Cocktail), Lambda Light Chain, kappa light chain, M6P, Mach 2, MAPKAPK-2, MEK 1, MEK 1/2 (Ps222), MEK 2, MEK1/2 (47E6), MEK1/2 Blocking Peptide, MET/HGFR, MGMT, Mitochondrial Antigen, Mitotracker Green FM, MMP-2, MMP9, E-cadherin, mTOR, ATPase, N-Cadherin, Nephrin, NFKB, NFKB p105/p50, NF-KB P65, Notch 1, Notch 2, Notch 3, OxPhos Complex IV, p130Cas, p38 MAPK, p44/42 MAPK antibody, P504S, P53, P70, P70 S6K, Pan Cadherin, Paxillin, P-Cadherin, PDI, pEGFR, Phospho AKT, Phospho CREB, phospho EGF Receptor, Phospho GSK3 Beta, Phospho H3, Phospho HSP-70, Phospho MAPKAPK-2, Phospho MEK1/2, phospho p38 MAP Kinase, Phospho p44/42 MAPK, Phospho p53, Phospho PKC, Phospho S6 Ribosomal Protein, Phospho Src, phospho-Akt, Phospho-Bad, Phospho-IKB-a, phospho-mTOR, Phospho-NF-kappaB p65, Phospho-p38, Phospho-p44/42 MAPK, Phospho-p70 S6 Kinase, Phospho-Rb, phospho-Smad2, PIM1, PIM2, PKC 13, Podocalyxin, PR, PTEN, R1, Rb 4H1, R-Cadherin, ribonucleotide Reductase, RRM1, RRM11, SLC7A5, NDRG, HTF9C, HTF9C, CEACAM, p33, S6 Ribosomal Protein, Src, Survivin, Synapopodin, Syndecan 4, Talin, Tensin, Thymidylate Synthase, Tuberlin, VCAM-1, VEGF, Vimentin, Agglutinin, YES, ZAP-70 and ZEB.
[0065] Cell cycle associated markers include apoptosis protease activating factor-1, bcl-w, bcl-x, bromodeoxyuridine, CAK (cdk-activating kinase), cellular apoptosis susceptibility protein (CAS), caspase 2, caspase 8, CPP32 (caspase-3), CPP32 (caspase-3), cyclin dependent kinases, cyclin A, cyclin B1, cyclin D1, cyclin D2, cyclin D3, cyclin E, cyclin G, DNA fragmentation factor (N-terminus), Fas (CD95), Fas-associated death domain protein, Fas ligand, Fen-1, IPO-38, Mc1-1, minichromosome maintenance proteins, mismatch repair protein (MSH2), poly (ADP-Ribose) polymerase, proliferating cell nuclear antigen, p16 protein, p27 protein, p34cdc2, p57 protein (Kip2), p105 protein, Stat 1 alpha, topoisomerase I, topoisomerase II alpha, topoisomerase III alpha, topoisomerase II beta.
[0066] Neural tissue and tumour markers include alpha B crystallin, alpha-internexin, alpha synuclein, amyloid precursor protein, beta amyloid, calbindin, choline acetyltransferase, excitatory amino acid transporter 1, GAP43, glial fibrillary acidic protein, glutamate receptor 2, myelin basic protein, nerve growth factor receptor (gp75), neuroblastoma marker, neurofilament 68 kD, neurofilament 160 kD, neurofilament 200 kD, neuron specific enolase, nicotinic acetylcholine receptor alpha4, nicotinic acetylcholine receptor beta2, peripherin, protein gene product 9, S-100 protein, serotonin, SNAP-25, synapsin I, synaptophysin, tau, tryptophan hydroxylase, tyrosine hydroxylase, ubiquitin.
[0067] Cluster differentiation markers include CD1a, CD1b, CD1c, CD1d, CD1e, CD2, CD3delta, CD3epsilon, CD3gamma, CD4, CD5, CD6, CD7, CD8alpha, CD8beta, CD9, CD10, CD11a, CD11b, CD11c, CDw12, CD13, CD14, CD15, CD15s, CD16a, CD16b, CDw17, CD18, CD19, CD20, CD21, CD22, CD23, CD24, CD25, CD26, CD27, CD28, CD29, CD30, CD31, CD32, CD33, CD34, CD35, CD36, CD37, CD38, CD39, CD40, CD41, CD42a, CD42b, CD42c, CD42d, CD43, CD44, CD44R, CD45, CD46, CD47, CD48, CD49a, CD49b, CD49c, CD49d, CD49e, CD49f, CD50, CD51, CD52, CD53, CD54, CD55, CD56, CD57, CD58, CD59, CDw60, CD61, CD62E, CD62L, CD62P, CD63, CD64, CD65, CD65s, CD66a, CD66b, CD66c, CD66d, CD66e, CD66f, CD68, CD69, CD70, CD71, CD72, CD73, CD74, CDw75, CDw76, CD77, CD79a, CD79b, CD80, CD81, CD82, CD83, CD84, CD85, CD86, CD87, CD88, CD89, CD90, CD91, CDw92, CDw93, CD94, CD95, CD96, CD97, CD98, CD99, CD100, CD101, CD102, CD103, CD104, CD105, CD106, CD107a, CD107b, CDw108, CD109, CD114, CD115, CD116, CD117, CDw119, CD120a, CD120b, CD121a, CDw121b, CD122, CD123, CD124, CDw125, CD126, CD127, CDw128a, CDw128b, CD130, CDw131, CD132, CD134, CD135, CDw136, CDw137, CD138, CD139, CD140a, CD140b, CD141, CD142, CD143, CD144, CDw145, CD146, CD147, CD148, CDw149, CDw150, CD151, CD152, CD153, CD154, CD155, CD156, CD157, CD158a, CD158b, CD161, CD162, CD163, CD164, CD165, CD166, and TCR-zeta.
[0068] Other cellular markers include centromere protein-F (CENP-F), giantin, involucrin, lamin A&C [XB 10], LAP-70, mucin, nuclear pore complex proteins, p180 lamellar body protein, ran, r, cathepsin D, Ps2 protein, Her2-neu, P53, S100, epithelial marker antigen (EMA), TdT, MB2, MB3, PCNA, and Ki67.
[0069] Cell containing samples may be stained using dyes or stains, histochemicals, or immunohistochemicals that directly react with the specific biomarkers or with various types of cells or sub-cellular compartments. Not all stains are compatible. Therefore the type of stains employed and their sequence of application should be well considered, but can be readily determined by one of skill in the art. Such histochemicals may be chromophores detectable by transmittance microscopy or fluorophores detectable by fluorescence microscopy. In general, cell containing samples may be incubated with a solution comprising at least one histochemical, which will directly react with or bind to chemical groups of the target. Some histochemicals must be co-incubated with a mordant or metal to allow staining A cell containing sample may be incubated with a mixture of at least one histochemical that stains a component of interest and another histochemical that acts as a counterstain and binds a region outside the component of interest. Alternatively, mixtures of multiple probes may be used in the staining, and provide a way to identify the positions of specific probes.
[0070] The following, non-limiting list provides exemplary chromophores that may be used as histological imaging agents (stains or counterstains) and their target cells, sub-cellular compartments, or cellular components: Eosin (alkaline cellular components, cytoplasm), Hematoxylin (nucleic acids), Orange G (red blood, pancreas, and pituitary cells), Light Green SF (collagen), Romanowsky-Giemsa (overall cell morphology), May-Grunwald (blood cells), Blue Counterstain (Trevigen), Ethyl Green (CAS) (amyloid), Feulgen-Naphthol Yellow S (DNA), Giemsa (differentially stains various cellular compartments), Methyl Green (amyloid), pyronin (nucleic acids), Naphthol-Yellow (red blood cells), Neutral Red (nuclei), Papanicolaou stain (which typically includes a mixture of Hematoxylin, Eosin Y, Orange G and Bismarck Brown mixture (overall cell morphology), Red Counterstain B (Trevigen), Red Counterstain C (Trevigen), Sirius Red (amyloid), Feulgen reagent (pararosanilin) (DNA), Gallocyanin chrom-alum (DNA), Gallocyanin chrom-alum and Naphthol Yellow S (DNA), Methyl Green-Pyronin Y (DNA), Thionin-Feulgen reagent (DNA), Acridine Orange (DNA), Methylene Blue (RNA and DNA), Toluidine Blue (RNA and DNA), Alcian blue (carbohydrates), Ruthenium Red (carbohydrates), Sudan Black (lipids), Sudan IV (lipids), Oil Red-O (lipids), Van Gieson's trichrome stain (acid fuchsin and picric acid mixture) (muscle cells), Masson trichrome stain (hematoxylin, acid fuchsin, and Light Green mixture) (stains collagen, cytoplasm, nucleioli differently), Aldehyde Fuchsin (elastin fibers), and Weigert stain (differentiates reticular and collagenous fibers). A comprehensive list of such stains, their description, and general use is given in R. D. Lillie, “Conn's Biological Stains”, 8th ed., Williams and Wilkins Company, Baltimore, Md. (1969). Suitable mordants and compositions of the preceding are well-known to one of skill in the art.
[0071] The following, non-limiting list provides exemplary fluorescent histological stains and their target cells, sub-cellular compartments, or cellular components if applicable: 4′,6-diamidino-2-phenylindole (DAPI) (nucleic acids), Eosin (alkaline cellular components, cytoplasm), Hoechst 33258 and Hoechst 33342 (two bisbenzimides) (nucleic acids), Propidium Iodide (nucleic acids), Spectrum Orange (nucleic acids), Spectrum Green (nucleic acids), Quinacrine (nucleic acids), Fluorescein-phalloidin (actin fibers), Chromomycin A 3 (nucleic acids), Acriflavine-Feulgen reaction (nucleic acid), Auramine O-Feulgen reaction (nucleic acids), Ethidium Bromide (nucleic acids). Nissl stains (neurons), high affinity DNA fluorophores such as POPO, BOBO, YOYO and TOTO and others, and Green Fluorescent Protein fused to DNA binding protein, such as histones, ACMA, Quinacrine and Acridine Orange.
[0072] A wide variety of proprietary fluorescent organelle-specific probes are commercially available, and include mitochondria-specific probes (MitoFluor and MitoTracker dyes), endoplasmic reticulum (ER) and Golgi probes (ER-Tracker and various ceramide conjugates), and lysosomal probes (LysoTracker dyes). These probes, as well as many nonproprietary fluorescent histochemicals, are available from and extensively described in the Handbook of Fluorescent Probes and Research Products 8.sup.th Ed. (2001), available from Molecular Probes, Eugene, Oreg.
[0073] Each cell containing sample may be co-incubated with appropriate substrates for an enzyme that is a cellular component of interest and appropriate reagents that yield colored precipitates at the sites of enzyme activity. Such enzyme histochemical stains are specific for the particular target enzyme. Staining with enzyme histochemical stains may be used to define a sub-cellular component or a particular type of cell. Alternatively, enzyme histochemical stains may be used diagnostically to quantitate the amount of enzyme activity in cells. A wide variety of enzymatic substrates and detection assays are known and described in the art.
[0074] Acid phosphatases may be detected through several methods. In the Gomori method for acid phophatase, a cell preparation is incubated with glycerophosphate and lead nitrate. The enzyme liberates phosphate, which combines with lead to produce lead phosphate, a colorless precipitate. The tissue is then immersed in a solution of ammonium sulfide, which reacts with lead phosphate to form lead sulfide, a black precipitate. Alternatively, cells may be incubated with a solution comprising pararosanilin-HCl, sodium nitrite, napthol ASB1 phosphate (substrate), and veronal acetate buffer. This method produces a red precipitate in the areas of acid phosphatase activity. Owing to their characteristic content of acid phosphatase, lysosomes can be distinguished from other cytoplasmic granules and organelles through the use of this assay.
[0075] Dehydrogenases may be localized by incubating cells with an appropriate substrate for the species of dehydrogenase and tetrazole. The enzyme transfers hydrogen ions from the substrate to tetrazole, reducing tetrazole to formazan, a dark precipitate. For example, NADH dehydrogenase is a component of complex I of the respiratory chain and is localized predominantly to the mitochondria.
[0076] Other enzymes for which well-known staining techniques have been developed, and their primary cellular locations or activities, include but are not limited to the following: ATPases (muscle fibers), succinate dehydrogenases (mitochondria), cytochrome c oxidases (mitochondria), phosphorylases (mitochondria), phosphofructokinases (mitochondria), acetyl cholinesterases (nerve cells), lactases (small intestine), leucine aminopeptidases (liver cells), myodenylate deaminases (muscle cells), NADH diaphorases (erythrocytes), and sucrases (small intestine).
[0077] Immunohistochemistry is among the most sensitive and specific histochemical techniques. Each histospot may be combined with a labeled binding composition comprising a specifically binding probe. Various labels may be employed, such as fluorophores, or enzymes that produce a product that absorbs light or fluoresces. A wide variety of labels are known that provide for strong signals in relation to a single binding event. Multiple probes used in the staining may be labeled with more than one distinguishable fluorescent label. These color differences provide a way to identify the positions of specific probes. The method of preparing conjugates of fluorophores and proteins, such as antibodies, is extensively described in the literature and does not require exemplification here.
[0078] Although there are at least 120,000 commercially available antibodies, exemplary primary antibodies, which are known to specifically bind cellular components and are presently employed as components in immunohistochemical stains used for research and, in limited cases, for diagnosis of various diseases, include, for example, anti-estrogen receptor antibody (breast cancer), anti-progesterone receptor antibody (breast cancer), anti-p53 antibody (multiple cancers), anti-Her-2/neu antibody (multiple cancers), anti-EGFR antibody (epidermal growth factor, multiple cancers), anti-cathepsin D antibody (breast and other cancers), anti-Bc1-2 antibody (apoptotic cells), anti-E-cadherin antibody, anti-CA125 antibody (ovarian and other cancers), anti-CA15-3 antibody (breast cancer), anti-CA19-9 antibody (colon cancer), anti-c-erbB-2 antibody, anti-P-glycoprotein antibody (MDR, multi-drug resistance), anti-CEA antibody (carcinoembryonic antigen), anti-retinoblastoma protein (Rb) antibody, anti-ras oneoprotein (p21) antibody, anti-Lewis X (also called CD15) antibody, anti-Ki-67 antibody (cellular proliferation), anti-PCNA (multiple cancers) antibody, anti-CD3 antibody (T-cells), anti-CD4 antibody (helper T cells), anti-CD5 antibody (T cells), anti-CD7 antibody (thymocytes, immature T cells, NK killer cells), anti-CD 8 antibody (suppressor T cells), anti-CD9/p24 antibody (ALL), anti-CD10 (also called CALLA) antibody (common acute lymphoblasic leukemia), anti-CD11c antibody (Monocytes, granulocytes, AML), anti-CD13 antibody (myelomonocytic cells, AML), anti-CD 14 antibody (mature monocytes, granulocytes), anti-CD15 antibody (Hodgkin's disease), anti-CD19 antibody (B cells), anti-CD20 antibody (B cells), anti-CD22 antibody (B cells), anti-CD23 antibody (activated B cells, CLL), anti-CD30 antibody (activated T and B cells, Hodgkin's disease), anti-CD31 antibody (angiogenesis marker), anti-CD33 antibody (myeloid cells, AML), anti-CD34 antibody (endothelial stem cells, stromal tumors), anti-CD35 antibody (dendritic cells), anti-CD38 antibody (plasma cells, activated T, B, and myeloid cells), anti-CD41 antibody (platelets, megakaryocytes), anti-LCA/CD45 antibody (leukocyte common antigen), anti-CD45RO antibody (helper, inducer T cells), anti-CD 45RA antibody (B cells), anti-CD39, CD100 antibody, anti-CD95/Fas antibody (apoptosis), anti-CD99 antibody (Ewings Sarcoma marker, MIC2 gene product), anti-CD 106 antibody (VCAM-1; activated endothelial cells), anti-ubiquitin antibody (Alzheimer's disease), anti-CD71 (transferrin receptor) antibody, anti-c-myc (oncoprotein and a hapten) antibody, anti-cytokeratins (transferrin receptor) antibody, anti-vimentins (endothelial cells) antibody (B and T cells), anti-HPV proteins (human papillomavirus) antibody, anti-kappa light chains antibody (B cell), anti-lambda light chains antibody (B cell), anti-melanosomes (HMB45) antibody (melanoma), anti-prostate specific antigen (PSA) antibody (prostate cancer), anti-S-100 antibody (melanoma, salvary, glial cells), anti-tau antigen antibody (Alzheimer's disease), anti-fibrin antibody (epithelial cells), anti-keratins antibody, anti-cytokeratin antibody (tumor), anti-alpha-catenin (cell membrane), anti-Tn-antigen antibody (colon carcinoma, adenocarcinomas, and pancreatic cancer); anti-1,8-ANS (1-Anilino Naphthalene-8-Sulphonic Acid) antibody; anti-C4 antibody; anti-2C4 CASP Grade antibody; anti-2C4 CASP a antibody; anti-HER-2 antibody; anti-Alpha B Crystallin antibody; anti-Alpha Galactosidase A antibody; anti-alpha-Catenin antibody; anti-human VEGF R1 (Flt-1) antibody; anti-integrin B5 antibody; anti-integrin beta 6 antibody; anti-phospho-SRC antibody; anti-Bak antibody; anti-BCL-2 antibody; anti-BCL-6 antibody; anti-Beta Catanin antibody; anti-Beta Catenin antibody; anti-Integrin alpha V beta 3 antibody; anti-c ErbB-2 Ab-12 antibody; anti-Calnexin antibody; anti-Calreticulin antibody; anti-Calreticulin antibody; anti-CAM5.2 (Anti-Cytokeratin Low mol. Wt.) antibody; anti-Cardiotin (R2G) antibody; anti-Cathepsin D antibody; Chicken polyclonal antibody to Galactosidase alpha; anti-c-Met antibody; anti-CREB antibody; anti-COX6C antibody; anti-Cyclin D1 Ab-4 antibody; anti-Cytokeratin antibody; anti-Desmin antibody; anti-DHP (1-6 Dipheynyl-1,3,5-Hexatriene) antibody; DSB-X Biotin Goat Anti Chicken antibody; anti-E-Cadherin antibody; anti-EEA1 antibody; anti-EGFR antibody; anti-EMA (Epithelial Membrane Antigen) antibody; anti-ER (Estrogen Receptor) antibody; anti-ERB3 antibody; anti-ERCC1 ERK (Pan ERK) antibody; anti-E-Selectin antibody; anti-FAK antibody; anti-Fibronectin antibody; FITC-Goat Anti Mouse IgM antibody; anti-FOXP3 antibody; anti-GB 3 antibody; anti-GFAP (Glial Fibrillary Acidic Protein) antibody; anti-Giantin antibody; anti-GM130 antibody; anti-Goat a h Met antibody; anti-Golgin 97 antibody; anti-GRB2 antibody; anti-GRP78BiP antibody; anti-GSK-3Beta antibody; anti-Hepatocyte antibody; anti-HER-2 antibody; anti-HER-3 antibody; anti-Histone 3 antibody; anti-Histone 4 antibody; anti-Histone H2A X antibody; anti-Histone H2B antibody; anti-HSP70 antibody; anti-ICAM-1 antibody; anti-IGF-1 antibody; anti-IGF-1 Receptor antibody; anti-IGF-1 Receptor Beta antibody; anti-IGF-II antibody; anti-IKB-Alpha antibody; anti-IL6 antibody; anti-IL8 antibody; anti-Integrin beta 3 antibody; anti-Integrin beta 5 antibody; anti-Integrin b8 antibody; anti-Jagged 1 antibody; anti-protein kinase C Beta2 antibody; anti-LAMP-1 antibody; anti-M6P (Mannose 6-Phosphate Receptor) antibody; anti-MAPKAPK-2 antibody; anti-MEK 1 antibody; anti-MEK 2 antibody; anti-Mitochondrial Antigen antibody; anti-Mitochondrial Marker antibody; anti-Mitotracker Green FM antibody; anti-MMP-2 antibody; anti-MMP9 antibody; anti-Na+/K ATPase antibody; anti-Na+/K ATPase Alpha 1 antibody; anti-Na + /K ATPase Alpha 3 antibody; anti-N-Cadherin antibody; anti-Nephrin antibody; anti-NF-KB p50 antibody; anti-NF-KB P65 antibody; anti-Notch 1 antibody; anti-OxPhos Complex IV—Alexa488 Conjugate antibody; anti-p130Cas antibody; anti-P38 MAPK antibody; anti-p44/42 MAPK antibody; anti-P504S Clone 13H4 antibody; anti-P53 antibody; anti-P70 S6K antibody; anti-P70 phospho kinase blocking peptide antibody; anti-Pan Cadherin antibody; anti-Paxillin antibody; anti-P-Cadherin antibody; anti-PDI antibody; anti-Phospho AKT antibody; anti-Phospho CREB antibody; anti-Phospho GSK-3-beta antibody; anti-Phospho GSK-3 Beta antibody; anti-Phospho H3 antibody; anti-Phospho MAPKAPK-2 antibody; anti-Phospho MEK antibody; anti-Phospho p44/42 MAPK antibody; anti-Phospho p53 antibody; anti-Phospho-NF-KB p65 antibody; anti-Phospho-p70 S6 Kinase antibody; anti-Phospho PKC (Pan) antibody; anti-Phospho S6 Ribosomal Protein antibody; anti-Phospho Src antibody; anti-Phospho-Bad antibody; anti-Phospho-HSP27 antibody; anti-Phospho-IKB-a antibody; anti-Phospho-p44/42 MAPK antibody; anti-Phospho-p70 S6 Kinase antibody; anti-Phospho-Rb (Ser807/811) (Retinoblastoma) antibody; anti-Phsopho HSP-7 antibody; anti-Phsopho-p38 antibody; anti-Pim-1 antibody; anti-Pim-2 antibody; anti-PKC β antibody; anti-PKC β11 antibody; anti-Podocalyxin antibody; anti-PR antibody; anti-PTEN antibody; anti-R1 antibody; anti-Rb 4H1 (Retinoblastoma) antibody; anti-R-Cadherin antibody; anti-RRM1 antibody; anti-S6 Ribosomal Protein antibody; anti-S-100 antibody; anti-Synaptopodin antibody; anti-Synaptopodin antibody; anti-Syndecan 4 antibody; anti-Talin antibody; anti-Tensin antibody; anti-Tuberlin antibody; anti-Urokinase antibody; anti-VCAM-1 antibody; anti-VEGF antibody; anti-Vimentin antibody; anti-ZAP-70 antibody; and anti-ZEB.
[0079] Fluorophores that may be conjugated to a primary antibody include but are not limited to Fluorescein, Rhodamine, Texas Red, Cy2, Cy3, Cy5, VECTOR Red, ELF™ (Enzyme-Labeled Fluorescence), Cy0, Cy0.5, Cy1, Cy1.5, Cy3, Cy3.5, Cy5, Cy7, Fluor X, Calcein, Calcein-AM, CRYPTOFLUOR™'S, Orange (42 kDa), Tangerine (35 kDa), Gold (31 kDa), Red (42 kDa), Crimson (40 kDa), BHMP, BHDMAP, Br—Oregon, Lucifer Yellow, Alexa dye family, N-[6-(7-nitrobenz-2-oxa-1,3-diazol-4-yl)amino]caproyl] (NBD), BODIPY™, boron dipyrromethene difluoride, Oregon Green, MITOTRACKER™ Red, DiOC.sub.7 (3), DiIC.sub.18, Phycoerythrin, Phycobiliproteins BPE (240 kDa) RPE (240 kDa) CPC (264 kDa) APC (104 kDa), Spectrum Blue, Spectrum Aqua, Spectrum Green, Spectrum Gold, Spectrum Orange, Spectrum Red, NADH, NADPH, FAD, Infra-Red (IR) Dyes, Cyclic GDP-Ribose (cGDPR), Calcofluor White, Lissamine, Umbelliferone, Tyrosine and Tryptophan. A wide variety of other fluorescent probes are available from and/or extensively described in the Handbook of Fluorescent Probes and Research Products 8.sup.th Ed. (2001), available from Molecular Probes, Eugene, Oreg., as well as many other manufacturers.
[0080] Further amplification of the signal can be achieved by using combinations of specific binding members, such as antibodies and anti-antibodies, where the anti-antibodies bind to a conserved region of the target antibody probe, particularly where the antibodies are from different species. Alternatively specific binding ligand-receptor pairs, such as biotin-streptavidin, may be used, where the primary antibody is conjugated to one member of the pair and the other member is labeled with a detectable probe. Thus, one effectively builds a sandwich of binding members, where the first binding member binds to the cellular component and serves to provide for secondary binding, where the secondary binding member may or may not include a label, which may further provide for tertiary binding where the tertiary binding member will provide a label.
[0081] The secondary antibody, avidin, strepavidin or biotin are each independently labeled with a detectable moiety, which can be an enzyme directing a colorimetric reaction of a substrate having a substantially non-soluble color reaction product, a fluorescent dye (stain), a luminescent dye or a non-fluorescent dye. Examples concerning each of these options are listed below.
[0082] In principle, any enzyme that (i) can be conjugated to or bind indirectly to (e.g., via conjugated avidin, strepavidin, biotin, secondary antibody) a primary antibody, and (ii) uses a soluble substrate to provide an insoluble product (precipitate) could be used.
[0083] The enzyme employed can be, for example, alkaline phosphatase, horseradish peroxidase, beta-galactosidase and/or glucose oxidase; and the substrate can respectively be an alkaline phosphatase, horseradish peroxidase, beta.-galactosidase or glucose oxidase substrate.
[0084] Alkaline phosphatase (AP) substrates include, but are not limited to, AP-Blue substrate (blue precipitate, Zymed catalog p. 61); AP-Orange substrate (orange, precipitate, Zymed), AP-Red substrate (red, red precipitate, Zymed), 5-bromo, 4-chloro, 3-indolyphosphate (BCIP substrate, turquoise precipitate), 5-bromo, 4-chloro, 3-indolyl phosphate/nitroblue tetrazolium/iodonitrotetrazolium (BCIP/INT substrate, yellow-brown precipitate, Biomeda), 5-bromo, 4-chloro, 3-indolyphosphate/nitroblue tetrazolium (BCIP/NBT substrate, blue/purple), 5-bromo, 4-chloro, 3-indolyl phosphate/nitroblue tetrazolium/iodonitrotetrazolium (BCIP/NBT/INT, brown precipitate, DAKO, Fast Red (Red), Magenta-phos (magenta), Naphthol AS-BI-phosphate (NABP)/Fast Red TR (Red), Naphthol AS-BI-phosphate (NABP)/New Fuchsin (Red), Naphthol AS-MX-phosphate (NAMP)/New Fuchsin (Red), New Fuchsin AP substrate (red), p-Nitrophenyl phosphate (PNPP, Yellow, water soluble), VECTOR™ Black (black), VECTOR™ Blue (blue), VECTOR™ Red (red), Vega Red (raspberry red color).
[0085] Horseradish Peroxidase (HRP, sometimes abbreviated PO) substrates include, but are not limited to, 2,2′ Azino-di-3-ethylbenz-thiazoline sulfonate (ABTS, green, water soluble), aminoethyl carbazole, 3-amino, 9-ethylcarbazole AEC (3A9EC, red). Alpha-naphthol pyronin (red), 4-chloro-1-naphthol (4C1N, blue, blue-black), 3,3′-diaminobenzidine tetrahydrochloride (DAB, brown), ortho-dianisidine (green), o-phenylene diamine (OPD, brown, water soluble), TACS Blue (blue), TACS Red (red), 3,3′,5,5′Tetramethylbenzidine (TMB, green or green/blue), TRUE BLUE™ (blue), VECTOR™ VIP (purple), VECTOR™ SG (smoky blue-gray), and Zymed Blue HRP substrate (vivid blue).
[0086] Glucose oxidase (GO) substrates, include, but are not limited to, nitroblue tetrazolium (NBT, purple precipitate), tetranitroblue tetrazolium (TNBT, black precipitate), 2-(4-iodophenyl)-5-(4-nitorphenyl)-3-phenyltetrazolium chloride (INT, red or orange precipitate), Tetrazolium blue (blue), Nitrotetrazolium violet (violet), and 3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyltetrazolium bromide (MTT, purple). All tetrazolium substrates require glucose as a co-substrate. The glucose gets oxidized and the tetrazolium salt gets reduced and forms an insoluble formazan that forms the color precipitate.
[0087] Beta-galactosidase substrates, include, but are not limited to, 5-bromo-4-chloro-3-indoyl beta-D-galactopyranoside (X-gal, blue precipitate). The precipitates associated with each of the substrates listed have unique detectable spectral signatures (components).
[0088] The enzyme can also be directed at catalyzing a luminescence reaction of a substrate, such as, but not limited to, luciferase and aequorin, having a substantially non-soluble reaction product capable of luminescencing or of directing a second reaction of a second substrate, such as but not limited to, luciferine and ATP or coelenterazine and Ca. 2+ , having a luminescencing product.
[0089] The following references, which are incorporated herein in their entireties, provide additional examples: J. M Elias (1990) Immunohistopathology: A practical approach to diagnosis. ASCP Press (American Society of Clinical Pathologists), Chicago; J. F. McGinty, F. E. Bloom (1983) Double immunostaining reveals distinctions among opioidpeptidergic neurons in the medial basal hypothalamus. Brain Res. 278: 145-153; and T. Jowett (1997) Tissue In situ Hybridization: Methods in Animal Development. John Wiley & Sons, Inc., New York; J Histochem Cytochem 1997 December 45(12):1629-1641.
[0090] Cellular preparations may be subjected to in-situ hybridization (ISH). In general, a nucleic acid sequence probe is synthesized and labeled with either a fluorescent probe or one member of a ligand:receptor pair, such as biotin/avidin, labeled with a detectable moiety. Exemplary probes and moieties are described in the preceding section. The sequence probe is complementary to a target nucleotide sequence in the cell. Each cell or cellular compartment containing the target nucleotide sequence may bind the labeled probe. Probes used in the analysis may be either DNA or RNA oligonucleotides or polynucleotides and may contain not only naturally occurring nucleotides but their analogs such as dioxygenin dCTP, biotin dcTP 7-azaguanosine, azidothymidine, inosine, or uridine. Other useful probes include peptide probes and analogues thereof, branched gene DNA, peptidomimetics, peptide nucleic acids, and/or antibodies. Probes should have sufficient complementarity to the target nucleic acid sequence of interest so that stable and specific binding occurs between the target nucleic acid sequence and the probe. The degree of homology required for stable hybridization varies with the stringency of the hybridization. Conventional methodologies for ISH, hybridization and probe selection are described in Leitch, et al. In Situ Hybridization: a practical guide, Oxford BIOS Scientific Publishers, Microscopy Handbooks v. 27 (1994); and Sambrook, J., Fritsch, E. F., Maniatis, T., Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Press (1989).
[0091] The present invention is further illustrated by the following examples, which should not be construed as limiting in any way. The contents of all cited references are hereby expressly incorporated by reference.
EXEMPLIFICATION
Example 1
Methodology—Using Publicly Available Tools
[0092] To begin to address the feasibility of performing clustering algorithms on image data, SPSS (SPSS, Inc., Chicago, Ill.) statistical software package was applied in studies with data files representing pixel intensities for each pixel (DAPI, Cy3, and Cy5) from a selected high resolution image (e.g., 2048×2048 pixels). FIG. 2 shows the images that were used in the first analysis, depicting a cell line control stained with DAPI (nuclei), anti-Cytokeratin (Cy3), and anti-integrin alpha-V (Cy5). For these images, every 64th pixel was outputted to the data file. FIG. 3 shows a scatter plot of normalized pixel intensities for DAPI and Cy3 (normalized on a 0-1 scale by dividing by max pixel intensity). Clustering normalized pixel values [using two-step cluster algorithm: log-likelihood distance; cluster limit=15] resulted in two clusters (Table 1).
[0000]
TABLE 1
Cluster Distribution
N
% of Combined
% of Total
Cluster 1
58719
89.6
89.6
Cluster 2
6816
10.4
10.4
Combined
65535
100.0
100.0
Total
65535
100.0
[0093] Cluster 1 was the lowest value cluster and contained ˜90% of the pixels for both Cy3 and DAPI. Visualization of the cluster assignments ( FIG. 4 ) reveals Cluster 1 are pixels that represent low values in both DAPI and Cy3 with Cluster 2 representing pixels having value in both images. Cluster 1 thus defines pixels that fit criteria 1 from above. These are background pixels that have value in neither Cy3 nor DAPI. Therefore, this cluster can be removed from analysis.
[0094] To differentiate the subsequent three criteria, a metric termed, “Cy3 Percentage” was developed/defined whereby:
[0000]
Cy
3
Pixel
Intensity
(
Normalized
)
(
Cy
3
Pixel
Intensity
(
NORM
)
+
DAPI
Pixel
Intensity
(
NORM
)
)
[0095] This yields a metric for the relative pixel intensity between Cy3 and DAPI. This could also be performed using DAPI as the numerator, wherein the approach yielded equivalent results ( FIG. 5 ). Clustering on this method will indicate:
[0096] High DAPI intensity relative to Cy3 intensity: LOW Cy3 Percentage Cluster
[0097] High Cy3 intensity relative to DAPI intensity: HIGH Cy3 Percentage Cluster
[0098] High DAPI AND Cy3 intensity: MIDDLE Cy3 Percentage Cluster
[0099] Performing this clustering [using two-step cluster algorithm: log-likelihood distance; cluster limit=3], 3 clusters (Table 2 and FIG. 6 ) were observed representing, based on axes relationships, the above three criteria.
[0000]
TABLE 2
Cluster Distribution
N
% of Combined
% of Total
Cluster 1
1689
25.1
25.1
Cluster 2
1645
24.5
24.5
Cluster 3
3388
50.4
50.4
Combined
6722
100.0
100.0
Total
6722
100.0
[0100] Treating the “DAPI Cluster” (Cluster 1) and “Cy3 Cluster” (Cluster 3) separately to calculate a target AQUA® score [sum Cy5 pixel intensities in each cluster, divide by the total number of pixels in the cluster, multiply by a constant, 100,000] yielded AQUA® scores that fit with the expected biology of the target in that Cy3 expression was observed as greater than DAPI expression (Integrin is predominantly associated with the membrane/cytoplasm) as shown in Table 3. As additional proof of concept, high DAPI signal in DAPI pixels versus Cy3 pixels (Table 4) and higher Cy3 signal in Cy3 pixels versus DAPI pixels (Table 5) were observed by these methods. Similar results were observed when Euclidean distance algorithms were used rather than log-likelihood (Tables 6-8).
[0000]
TABLE 3
Resulting AQUA ® Scores, Log Likelihood Clustering
Cy3 Pixels
DAPI Pixels
Relevant Ratio
AltP
3102
976
3.18
Cy3%-LL
3630
1983
1.83
**Summed Cy5 power in each cluster (DAPI cluster (bottom cluster); Cy3 cluster (top cluster)); divided by total number of pixels * 100000.
[0000]
TABLE 4
Resulting AQUA ® Scores, Log Likelihood Clustering
Cy3
DAPI
Relevant Ratio
AltP
NA
NA
NA
Cy3%-LL
115
291
2.6
**Summed DAPI power in each cluster (DAPI cluster (bottom cluster); Cy3 cluster (top cluster)); divided by total number of pixels * 100000.
[0000]
TABLE 5
Resulting AQUA ® Scores, Log Likelihood Clustering
Cy3
DAPI
Relevant Ratio
AltP
NA
NA
NA
Cy3%-LL
4014
767
5.28
**Summed Cy3 power in each cluster (DAPI cluster (bottom cluster); Cy3 cluster (top cluster)); divided by total number of pixels * 100000
[0000]
TABLE 6
Resulting AQUA ® Scores, Euclidean Distance Clustering
Cy3 Pixels
DAPI Pixels
Relevant Ratio
AltP
3102
976
3.18
Cy3%-LL
3560
2396
1.49
**Summed Cy5 power in each cluster (DAPI cluster (bottom cluster); Cy3 cluster (top cluster)); divided by total number of pixels * 100000.
[0000]
TABLE 7
Resulting AQUA ® Scores, Euclidean Distance Clustering
Cy3
DAPI
Relevant Ratio
AltP
NA
NA
NA
Cy3%-LL
321
535
1.6
**Summed DAPI power in each cluster (DAPI cluster (bottom cluster); Cy3 cluster (top cluster)); divided by total number of pixels * 100000
[0000]
TABLE 8
Resulting AQUA ® Scores, Euclidean Distance Clustering
Cy3
DAPI
Relevant Ratio
AltP
NA
NA
NA
Cy3%-LL
7551
1163
6.5
**Summed Cy3 power in each cluster (DAPI cluster (bottom cluster); Cy3 cluster (top cluster)); divided by total number of pixels * 100000.
Example 2
[0101] Data for every pixel image was obtained and analyzed for the images presented in FIG. 7 (Her2 stained breast cancer epithelium). First pass clustering was performed as before to remove background pixels (Table 9) followed by clustering the Cy3 percentage metric (Table 10).
[0000]
TABLE 9
Cluster Distribution
N
% of Combined
% of Total
Cluster 1
3145854
75.0
75.0
Cluster 2
1048450
25.0
25.0
Combined
4194304
100.0
100.0
Total
4193404
100.0
[0000]
TABLE 10
Cluster Distribution
N
% of Combined
% of Total
Cluster 1
236673
22.6
22.6
Cluster 2
296558
28.3
28.3
Cluster 3
515219
49.1
49.1
Combined
1048450
100.0
100.0
Total
1048450
100.0
[0102] The resultant AQUA scores fit expectation in that increased Her2 expression in Cy3 relative to DAPI, increased DAPI in DAPI relative to Cy3, and increased Cy3 in Cy3 relative to DAPI (Tables 11-13). Furthermore, the clustering method exceeded the performance of the current AQUA® method as a high Cy3/DAPI ratio for Her2 was observed (see FIG. 7 ). Her2 is a predominantly cytoplasmic/membraneous protein.
[0000]
TABLE 11
Resulting Cy5 AQUA ® Scores
Cy3 Pixels
DAPI Pixels
Relevant Ratio
AltP
617
346
1.78
Pixel #
304138
292536
Cy3%-LL
1133
290
3.9
515219
236673
**Summed Cy5 power in each cluster (DAPI cluster (bottom cluster); Cy3 cluster (top cluster)); divided by total number of pixels * 100000.
[0000]
TABLE 12
Resulting DAPI AQUA ® Scores
Cy3
DAPI
Relevant Ratio
AltP
NA
NA
NA
Cy3%-LL
309
547
1.8
**Summed DAPI power in each cluster (DAPI cluster (bottom cluster); Cy3 cluster (top cluster)); divided by total number of pixels * 100000
[0000]
TABLE 13
Resulting Cy3 AQUA ® Scores
Cy3
DAPI
Relevant Ratio
AltP
NA
NA
NA
Cy3%-LL
7551
1163
6.5
**Summed Cy3 power in each cluster (DAPI cluster (bottom cluster); Cy3 cluster (top cluster)); divided by total number of pixels * 100000.
Example 3
[0103] Data for every pixel image was obtained and analyzed for the images presented in FIG. 8 (p53 stained cervical cancer epithelium). First pass clustering was performed as before to remove background pixels followed by clustering the Cy3 percentage metric (Table 14).
[0000]
TABLE 14
Cluster Distribution
N
% of Combined
% of Total
Cluster 1
1926335
45.9
45.9
Cluster 2
776690
18.5
18.5
Cluster 3
1491279
35.6
35.6
Combined
4194304
100.0
100.0
Total
4194304
100.0
[0104] Note first pass clustering resulted in 3 clusters. However, the background cluster (Cluster 1) is equivalent to the background cluster obtained when two clusters were “forced” (Table 15).
[0000]
TABLE 15
Cluster Distribution
N
% of Combined
% of Total
Cluster 1
1932895
46.1
46.1
Cluster 2
2261409
53.9
53.9
Combined
4194304
100.0
100.0
Total
4194304
100.0
[0105] The resultant AQUA® scores fit expectation in that increased p53 expression in DAPI relative to Cy3, increased DAPI in DAPI relative to Cy3, and increased Cy3 in Cy3 relative to DAPI (Tables 16-18).
[0000]
TABLE 16
Resulting Cy5 AQUA ® Scores
Cy3 Pixels
DAPI Pixels
Relevant Ratio
AltP
92
440
4.7
Pixel Count:
985051
455948
Cy3%-LL
190
735
3.9
Pixels
1484438
277449
**Summed Cy5 power in each cluster (DAPI cluster (bottom cluster); Cy3 cluster (top cluster)); divided by total number of pixels * 100000.
[0000]
TABLE 17
Resulting Cy3 AQUA ® Scores
Cy3
DAPI
Relevant Ratio
AltP
NA
NA
NA
Cy3%-LL
1753
477
3.7
**Summed DAPI power in each cluster (DAPI cluster (bottom cluster); Cy3 cluster (top cluster)); divided by total number of pixels * 100000.
[0000]
TABLE 18
Resulting DAPI AQUA ® Scores
Cy3
DAPI
Relevant Ratio
AltP
NA
NA
NA
Cy3%-LL
376
1793
4.8
**Summed Cy3 power in each cluster (DAPI cluster (bottom cluster); Cy3 cluster (top cluster)); divided by total number of pixels * 100000.
[0106] Background pixels within the target image may also be an issue. In order to address this issue, clustering [using two-step cluster algorithm: log-likelihood distance; cluster limit=15] was performed on Cy5 pixel values to remove background (Table 19).
[0000]
TABLE 19
Cluster Distribution
N
% of Combined
% of Total
Cluster 1
1879937
82.9
82.9
Cluster 2
313604
13.8
13.8
Cluster 3
74428
3.3
3.3
Combined
2267969
100.0
100.0
Total
2267969
100.0
[0107] Dropping the bottom cluster as background improves area ratio metrics (Cytoplasm:Nucleus for Her2; and Nucleus:Cytoplasm for p53) as shown in Tables 20 and 21 (compare rows 2 and 3).
[0000]
TABLE 20
P53: COMPARTMENT: Resulting Cy5 AQUA ® Scores
Cy3 Pixels
DAPI Pixels
Relevant Ratio
AltP
53
440
4.7
Pixel Count:
985051
455948
Cy3%-LL-All
190
735
3.9
Target Pixels
1484438
277449
Cy3%-LL-Top
34
612
18
Target_Comp Pixels
Cy3%-LL-Top
797
1405
1.76
Target_Comp Pixels
(only Target)
**Summed Cy5 power in each cluster (DAPI cluster (bottom cluster); Cy3 cluster (top cluster)); divided by total number of pixels * 100000.
[0000]
TABLE 21
Her2: Resulting Cy5 AQUA ® Scores
Cy3 Pixels
DAPI Pixels
Relevant Ratio
AltP
617
346
1.78
Pixel#
304138
292536
Cy3%-LL
1133
290
3.9
515219
236673
Cy3%-LL-Top
612
145
4.2
Target_Comp Pixels
Cy3%-LL-Top
2379
2171
1.10
Target_Comp Pixels
(only Target)
**Summed Cy5 power in each cluster (DAPI cluster (bottom cluster); Cy3 cluster (top cluster)); divided by total number of pixels * 100000.
Example 4
Construction of Tissue Microarrays and Immunohistochemical Staining Methods for Estrogen Receptor (ER) and HER2/neu and for Analysis of Nuclear Associated Beta-Catenin
[0108] Tissue microarray design: Paraffin-embedded formalin-fixed specimens from 345 cases of node-positive invasive breast carcinoma were identified. Areas of invasive carcinoma, away from in situ lesions and normal epithelium, were identified and three 0.6 cm punch “biopsy” cores were taken from separate areas. Each core was arrayed into a separate recipient block, and five-micron thick sections were cut and processed as previously described (Konenen, J. et al., Nat. Med., 4:844-7, 1987). Similarly, 310 cases of colon carcinoma were obtained and arrayed, as previously described (Chung, G. et al., Clin. Cancer Res . (In Press)). Immunohistochemistry: Pre-cut paraffin-coated tissue microarray slides were deparaffinized and antigen-retrieved by pressure-cooking (Katoh, A. K. et al., Biotech. Histochem ., F2:291-8, 1997). Slides were stained with antibodies to one of three target antigens: monoclonal anti-E.R. (mouse, Dako Corporation, Carpinteria, Calif.), polyclonal anti-HER2/neu (rabbit, Dako Corp.), monoclonal (mouse clone 14, BD Transduction Labs, San Diego, Calif.) anti-beta-catenin, or polyclonal rabbit anti-betacatenin. Primaries were incubated overnight at 4° C. A corresponding goat antimouse or anti-rabbit secondary antibody conjugated to a horseradish peroxidase decorated dextran-polymer backbone was then applied for 1 hr (Envision, DAKO Corp.). Target antigens were either visualized with a visible light chromagen (Diaminobenzidine, DAKO) for visual analysis, or a fluorescent chromagen (Cy-5-tyramide, NEN Life Science Products, Boston, Mass.). Slides designated for automated analysis were counterstained with DAPI for visualization of nuclei, and either polyclonal rabbit anticytokeratin (Zymed, So. San Francisco, Calif.) or rabbit anti-alpha-catenin to distinguish between tumor cells and stroma as well as to visualize the cell membrane. In many cases, exponentially subtracted images of histospots stained with anti-cytokeratin provided an acceptable marker for the cell membrane due to the sub-membranous coalescence of cytokeratin in tumor cells. These antibodies were visualized using either Cy3- or Alexa 488-conjugated goat anti-mouse or anti-rabbit secondary antibodies (Amersham, Piscataway, N.J. and Molecular Probes, Eugene, Oreg.). Slides designated for visual inspection were counterstained with ammonium hydroxide acidified hematoxylin. Manual examination of microarrays for E.R., HER2/neu, and beta-catenin levels has been previously described (Snead, D. R. et al., Histopathology, 23:233-8, 1993).
Example 5
Clustering AQUA® Analysis
[0109] The Automated QUantitative Analysis platform (AQUA® platform) is an automated fluorescence-based image analysis platform used for the objective and reproducible quantification of protein expression in specific cellular and sub-cellular compartments using the Pixel-based Locale Assignment for Compartmentalization of Expression (PLACE) algorithm Inherent to PLACE is a user-defined step whereby specific pixel intensity thresholds must be set manually to differentiate background from signal-specific pixels within multiple compartment images. To reduce operator time, remove operator-to-operator variability, and to obtain objective and optimal pixel separation for each image, a dichotomous, unsupervised pixel-based clustering algorithm (K-means clustering-based mathematics) allowing for the objective and automated differentiation of signal from background as well as differentiation of compartment-specific pixels (e.g., DAPI v. Cy3) on an image-by-image basis, is herein described. This new algorithm was tested by quantifying compartment-specific estrogen receptor (ER), progesterone receptor (PR), Her2 expression on large cohort (n=682) of breast cancer patients with a high degree of correlation (R=0.992, 0.987 and 0.990 respectively) with conventional AQUA® analysis using manual threshold settings as determined by an experienced operator. Expression scores obtained by clustering AQUA (c-AQUA) maintained equivalent quantitative relationships as shown by comparable data clustering and associated survival outcomes. Although either system is suitable for the methods of the invention, this new clustering algorithm enhances the efficiency and objectivity of the current AQUA® platform.
Methods
[0110] Cohort: A large breast cancer cohort in tissue microarray (TMA) format was employed in these studies to test C-AQUA algorithms. This cohort from the Yale Tissue Microarray Facility (YTMA49) has been described in detail previously (Dolled-Filhart, M. et al., Clin. Cancer Res., 12:6459-68, 2006). Briefly, the breast cohort (n=652) of invasive ductal carcinoma serially collected from the Yale University Department of Pathology from 1961 to 1983. Also on the array are a selection of normal tissue and cell line controls. The mean follow-up time is 12.8 years with a mean age of diagnosis of 58.1 years. This cohort contains approximately half node-positive and half node-negative specimens.
[0111] Immunofluoresence staining. YTMA49 was staining using an indirect immunofluorescence protocoll. In brief, pre-cut paraffin-coated tissue microarray slides were de-paraffinized and antigen-retrieved by heat-induced epitope retrieval in 10 mM Tris (pH 9.0). Using an auto-stainer (LabVision, Fremont, Calif.), slides were pre-incubated with Background Sniper (BioCare Medical, Concord, Calif.). Slides were then incubated with primary antibodies against ER (Dako, Carpinteria, Calif.), clone 1D5, 1:200 dilution), PR (Dako (Carpinteria, Calif.), mouse monoclonal clone PgR636, 1:1000 dilution), or Her2 (Dako (Carpinteria, Calif.), rabbit polyclonal, 1:8000 dilution) and pan-cytokeratin (rabbit polyclonal, 1:200 dilution, DAKO, Carpinteria, Calif.) diluted in DaVinci Green (BioCare Medical, Concord, Calif.) for 1 hour at RT. Slides were washed 3×5 min with 1×TBS containing 0.05% Tween-20. Corresponding secondary antibodies were diluted in Da Vinci Green and incubated for 30 minutes at room temperature. These included either antibodies directly conjugated to a fluorophore for anti-cytokeratin (Alexa 555-conjugated goat anti-rabbit; 1:100, Molecular Probes, Eugene, Oreg.), and/or conjugated to a horseradish peroxidase (HRP) for ER, PR, and Her2 (Dako, Carpinteria, Calif.), anti-mouse or -rabbit Envision (Dako, Carpinteria, Calif.)). Slides were again washed 3×5 min with TBS containing 0.05% Tween-20. Slides were incubated with a fluorescent chromagen (Cy-5-tyramide, NEN Life Science Products, Boston, Mass.), which, like DAB, is activated by HRP and results in the deposition of numerous covalently associated Cy-5 dyes immediately adjacent to the HRP-conjugated secondary antibody. Cy-5 (red) was used because its emission peak is well outside the green-orange spectrum of tissue auto-fluorescence. Slides for automated analysis were cover slipped with an anti-fade DAPI-containing mounting medium (ProLong Gold, Molecular Probes, Eugene, Oreg.).
[0112] Image Acquisition: Automated image capture was performed by the HistoRx PM-2000TH, which has previously been described in detail (Camp, R. et al., Nat. Med., 8:1323-1327, 2002; Giltnane, J. & Rimm, D., Nat. Clin. Pract. Oncol., 1:104-11, 2004; Cregger, M. et al., Arch. Pathol. Lab. Med., 130:1026-30, 2006). High-resolution, 8 bit (resulting in 256 discrete intensity values per pixel of an acquired image) digital images of the cytokeratin staining visualized with Cy3, DAPI, and target staining with Cy5 were captured and saved for every histospot on the array. Pixels were written to image files as a function of power (Power (P)=((Pixel Intensity/256)/exposure time) to help compensate for experimental variations in staining intensity. In and out-of-focus images were taken for each channel for future use with the traditional AQUA® script and validation program.
[0113] Traditional AQUA® analysis: AQUA® analysis was performed. In brief, a tumor-specific mask is generated by manually thresholding the image of a marker (cytokeratin) that differentiates tumor from surrounding stroma and/or leukocytes. This creates a binary mask (each pixel is either ‘on’ or ‘off’). Thresholding levels were verified, and adjusted if necessary, by spot-checking a small sample of images and then remaining images are automatically masked using the single determined threshold value. All subsequent image manipulations involve only image information from the masked area. Next, two images (one in-focus, one out of focus, taken 6 μm deeper into the sample) are taken of the compartment-specific tags and the target marker. A percentage of the out-of-focus image is subtracted from the in-focus image, based on a pixel-by-pixel analysis of the two images using an algorithm called RESA (Rapid Exponential Subtraction Algorithm). The RESA algorithm enhances the interface between areas of higher intensity staining and adjacent areas of lower intensity staining, allowing easier assignment of pixels to background and adjacent compartments. Finally, the PLACE algorithm assigns each pixel in the image to a specific sub-cellular compartment. Pixels that cannot be accurately assigned to a compartment within a user-defined degree of confidence (100% in this case) are discarded. For example, pixels where the nuclear and cytoplasmic pixel intensities are too similar to be accurately assigned are negated (usually comprising <8% of the total pixels). Once each pixel is assigned to a sub-cellular compartment (or excluded as described above), the signal in each location is summed. These data are saved and can subsequently be expressed either as a percentage of total signal or as the average signal intensity per compartment area. Images were validated according to the following: 1)>2% tumor area covered, 2) Images in bottom 10% of DAPI and/or Cy3 total intensity removed, 3) DAPI AQUA® score ratio (DAPI measured in nucleus/DAPI measured in cytoplasm)>1.5.
[0114] Clustering AQUA® Algorithm (C-AQUA): Tumor masks were applied to the images to exclude any regions of non-tissue or non-tumor and consider only tumor tissue for analysis (as in the traditional experiment described above, however, a fixed set of parameters is used for all experiments). This also improves the sensitivity and computational efficiency of the method by removing a large number of non-contributing pixels (for example, in a high resolution image of a 0.6 mm histospot, taken at 20× objective power, <50% of the pixels will represent tissue). Generating the tumor mask is accomplished as described above and using values that have been defined by examination of a number of different samples.
[0115] Image segmentation by clustering was accomplished using k-means clustering based on Euclidean distances (Jain, A. et al., ACM Computing Surveys, 31:264-323, 1999). First, all pixels were assigned characteristics based on power (see image acquisition) reported for compartment images, and can be represented as coordinates (PDAPI, Pcy3). As a result of this, pixels could be presented in a 2-D scatter-plot of compartment intensities ( FIGS. 9A-C ). The model used to perform the image segmentation asserts that pixels will fall into two classifications: 1) Those that have low signal in all compartments tested (i.e., background), and 2) Pixels with the property that one compartment marker shows higher staining than the others (e.g., higher Cy3 intensity than DAPI). For the data presented here, for two sub-cellular compartments, this would result in the need to identify three data centroids. The selection of initial value positions is important because it can impact how long the k-means algorithm will take to converge on a solution and prevent ‘swapping’ of centers, which would result in incorrect assignment. For the model described here, the background cluster is initialized to the origin while the cytokeratin and nuclear centers are initialized to their respective maximum values and zero (e.g., for the DAPI marker, the initial value is (PDAPI(max), 0). Pixels are then assigned to each cluster based on Euclidean distance. Cluster centroid values are then calculated and cluster pixel membership is re-assessed. The method runs iteratively and terminates after there is convergence (no membership changes) or 30 iterations.
[0116] Once cluster centroids have been defined, error checking occurs to detect conditions that may result in erroneous results. The first condition is if there is not enough signal in either one of the compartments, which will result in a segregation of the compartment based upon background noise. To detect this, a method is implemented that will compare each compartment center to the background cluster center. If a compartment center is within one standard of the foreground membership to the background cluster, the data point will be flagged and excluded from analysis. The second error check derives from the fact that the algorithm also detects the amount of area that is producing a viable signal. Should this area be too small to get a good sample size, the spot should be flagged and omitted from analysis since it is underrepresented. For the present system, which is equipped with a 2048×2048 CCD chip for acquiring images, the number of pixels reported must be greater than 210,000 pixels (5%). FIG. 9B shows an image that passes all quality control specifications whereas FIG. 9C shows an image that fails due to cluster distance failure in the Cy3 channel.
[0117] From examination of the scatter plots in FIGS. 9B and 9C , it can be seen that there will generally be pixels that have intensities higher than background, but have similar intensity contribution for each channel. Thus, once convergence is reached, a geometric method is then used to further define the certainty of a pixel as being a member of either cluster. Each pixel is characterized based upon its location in the cluster and proximity to other clusters. If both the Cy3 and DAPI pixels value are less than B, then there is zero certainty in both compartments and the pixel value is set to zero in both compartments ( FIG. 9A ). This represents background in the image. If Cy3 is greater than B and DAPI is less than B, then there is 100% probability for cytoplasm and 0% probability for nuclear ( FIG. 9A ). Conversely, if DAPI is greater than B and Cy3 is less than B, then there is 100% probability for nuclear and 0% probability for cytoplasm ( FIG. 9A ). For values in the center region of the scatter-plot that are not definitively assigned to either compartment, a probability function region is defined by the triangles ABC and ABD. In these regions, pixels are assigned to either Cy3 (triangle ABC) or DAPI (triangle ABD) exclusively. However, their contribution to the overall calculation is modified by their location within the triangles. Pixels in triangle ABC are assigned a probability based on their proximity to the vertices. Probabilities for pixels within the triangular regions are calculated via a well defined and continuous function that ranges from 0 to 1 (100% probability). As a pixel approaches C, the value approaches 100%, as a pixel approaches the vertices A or B (or the line segment connected A and B) the value approaches zero. Triangle ABD follows the same logic, with values approaching 100% as pixels approach the vertex D.
Results
[0118] Comparison of PLACE algorithms for compartment assignment: AQUA® analysis and C-AQUA analysis was performed on the same set of acquired and validated images (n=388 out of a total possible of 652). Although the results are similar, an operator was required to determine setup and threshold levels to generate images, whereas the associated images generated with C-AQUA were generated automatically, in an unsupervised fashion.
[0119] Two operators set up a traditional AQUA® and C-AQUA experiment on the same data set. Setup for a the traditional AQUA® experiment took an average of 20 minutes, whereas average set up time for C-AQUA was less than 2 minutes and did not require subjective operator intervention. Regression analysis between two operators for the two methods is shown in FIG. 10 . Although highly correlative ( FIG. 10A ; Pearson R=0.992, p<0.001; Spearman's R=0.989, p<0.001), resultant AQUA® scores from AQUA® analysis was nonetheless different between operators, whereas AQUA® scores generated with C-AQUA were identical ( FIG. 10B ; Pearson R=1.000, p=0; Spearman's R=1.000, p=0).
[0120] Linear regression analysis was performed to examine overall comparisons for all images. Comparison of nuclear compartment size showed a highly significant correlation between conventional AQUA® analysis and C-AQUA ( FIG. 10A ; Pearson's R=0.779 (p<0.001); Spearman's R=0.793 (p<0.001)). Cytoplasmic compartment size was also significantly correlated ( FIG. 10B ; Pearson's R=0.923; Spearman's R=0.914 (p<0.001)). These data not only demonstrate the ability of C-AQUA to establish cellular compartments comparable to that of conventional AQUA®/PLACE algorithms, but also demonstrate that C-AQUA compartmentalization is not absolutely equivalent. This is due to the fact that compartmentalization is optimized for each image, rather than thresholding being universally applied across all images as with the conventional AQUA® analysis/PLACE algorithms.
[0121] Comparison of PLACE algorithms for expression score calculations: To confirm that C-AQUA produces equivalent AQUA® scores, conventional AQUA® analysis and C-AQUA analysis were performed for three common biomarkers of breast cancer; estrogen receptor (ER), progesterone receptor (PR), and Her2. Testing was performed on a large breast cancer cohort (n=607) of breast cancer patient samples in TMA format. AQUA® scores for both conventional AQUA® analysis and C-AQUA analysis in relevant cellular compartments produced highly correlative results in both value and rank-order analysis [ FIG. 11A (ER, nucleus): Pearson's R=0.992 (p<0.001) and Spearman's R=0.993 (p<0.001); FIG. 11B (PR, nucleus): Pearson's R=0.987 (p<0.001) and Spearman's R=0.962 (p<0.001); FIG. 11C (Her2, cytoplasm/membrane): Pearson's R=0.990 (p<0.001) and Spearman's R=0.976 (p<0.001)].
[0122] Comparison of PLACE algorithms for survival outcomes: Although highly significant correlation between AQUA® scores obtained through conventional AQUA® analysis and C-AQUA was observed, it is important to demonstrate that equivalent data relationships are maintained such that comparable cut-points with respect to outcome (e.g., survival) can be obtained. To test this unsupervised log-likelihood distance clustering was performed for each set of AQUA® scores. For ER, two clusters were identified for both conventional AQUA® and C-AQUA scores with 95% overall agreement. ER expression in breast cancer is predictive of better survival. Kaplan-Meier survival analysis demonstrated AQUA® score clusters obtained for both traditional AQUA® analysis and C-AQUA analysis produced equivalent survival outcome results in that high ER expression significantly predicts an increase in five-year disease specific survival [ FIG. 12A ; traditional AQUA® analysis: 11.4% reduction in overall survival (log-rank p=0.018) from 80.9% (ER High) to 69.5% (ER Low); C-AQUA: 13.8% reduction in overall survival (log-rank p=0.005) from 81.6% (ER High) to 67.8% (ER Low)].
[0123] For PR, two clusters were identified for both conventional AQUA® analysis and C-AQUA scores with 83% overall agreement. PR expression in breast cancer is also predictive of better survival. Kaplan-Meier survival analysis demonstrated AQUA® score clusters obtained for both traditional AQUA® analysis and C-AQUA analysis produced equivalent survival outcome results in that high PR expression significantly predicts an increase in five-year disease specific survival [ FIG. 12B ; traditional AQUA®: 12.4% reduction in overall survival (log-rank p=0.021) from 84.2% (PR High) to 71.8% (PR Low); C-AQUA: 14.5% reduction in overall survival (log-rank p=0.001) from 83.3% (PR High) to 68.8% (PR Low)].
[0124] For Her2, three clusters were identified for both conventional AQUA® analysis and C-AQUA scores with 94% overall agreement. Her2 expression in breast cancer is predictive of decreased survival. Kaplan-Meier survival analysis demonstrated AQUA® score clusters obtained for both traditional AQUA® and C-AQUA analysis produced equivalent survival outcome results in that high Her2 expression significantly predicts decreased five-year disease specific survival [ FIG. 12C ; traditional AQUA®: 18.5% total reduction in overall survival (log-rank p=0.022) from 77.1% (Her2 Low) to 73.8% (Her2 Mid) to 58.6% (Her2 High); C-AQUA: 24.2% total reduction in overall survival (log-rank p=0.002) from 77.8% (Her2 Low) to 73.8% (Her2 Mid) to 53.6% (Her2 High)].
Discussion
[0125] The use of advanced image analysis is rapidly being adopted to facilitate analysis of samples in pathology laboratories. The associated automation, quantification and more objective analytical methods are providing pathologists access to improved and greater amounts of information. The AQUA® system is a robust and quantitative immunohistochemistry (IHC) platform is now a research system for biomarker characterization and discovery (Berger, A. et al., Cancer Res., 64:8767-8772, 2004; Camp, R. et al., Cancer Res., 63:1445-1448, 2003; Dolled-Filhart, M. et al., Clin. Cancer Res., 9:594-600, 2003; McCabe, A. et al., J. Natl. Cancer Inst., 97:1808-15, 2005). Unlike traditional IHC, the AQUA® system is objective and produces strictly quantitative in situ protein expression data on a continuous scale rather than subjective, categorical data. The AQUA® system takes advantage of the multiplexing power of fluorescence by using multiple markers to molecularly differentiate cellular and sub-cellular compartments within which simultaneous quantification of biomarkers-of-interest in specific cell types and sub-cellular compartments can be performed.
[0126] Clustering is a mathematical method whereby data is segregated based on the relationships of various properties inherent to each measurement (Miller, D. et al., Front. Biosci., 13:677-90, 2008), in this instance, the intensities of fluorescent measurements for pixels within an image. Clustering can be applied to multiple images of a single field of view using pixel intensities to ascribe centroids specific to background and signal or even different signaling levels. Application of these types of clustering algorithms to individual fluorescent images (e.g., DAPI or Cy3) allow for automated segmentation of background from specific signal for individual cellular compartments, just as user-defined thresholds accomplish.
[0127] A specific segmentation algorithm that results in clusters as described above is herein described, thus allowing for an automated PLACE-like algorithm that removes operator-to-operator variability and optimizes compartmentalization of expression on an image-by-image basis. C-AQUA shows a high degree of correlation with traditional AQUA® analysis as performed by an experienced operator.
[0128] Image segmentation such that protein expression can be quantified in specific cellular and sub-cellular compartments is an advance over other manual image quantification methods where these expression levels must be identified manually and the expression scored categorically by eye. It is also an advance over PLACE which does requires operator input, facilitated by image enhancement (RESA), to define specific pixel intensity thresholds to separate non-specific signal and background from specific signal in each compartment image.
[0129] Although other platforms exist for digitally performing pathological analysis, the quantitative AQUA® system provides advantages. The endpoint, however, in AQUA® analysis, which is image segmentation of not only specific signal from background but also two or more independent signals from independent images, presented a unique challenge. It was hypothesized that pixel intensities from two or more images could be clustered in parallel, thereby not only removing common background signal from all queried images but differentiating, with a high degree of confidence, specific signals from multiple images allowing for strict compartmentalization of expression for target-specific pixels. The beneficial characteristics of the PLACE algorithm's ability to segment images and compartmentalize expression is therefore maintained, but it is enhanced via in an automated method for compartmentalization and generating an AQUA® score.
[0130] There are several key advantages to compartmentalization by the C-AQUA method. First, the operator input time is significantly reduced. With C-AQUA, the need to optimize thresholds is eliminated, thus reducing the setup time to 1-2 minutes. Second, an operator is not always capable of accurately analyzing an image using manual visual methods. Although trained operators typically determine approximately equivalent thresholds, changes in thresholds settings lead to differences in compartmentalization, which can potentially lead to difference in AQUA® scores ( FIG. 10 ; comparisons are shown in FIG. 13 ). Given that accuracy and precision are of utmost importance, especially in a clinical setting, the enhancement of an already robust and reproducible system to a level of complete automation, and thus eliminating all sources of variability, is paramount. Third, user-defined thresholds must be equally applied across all images within a set being analyzed, whereas C-AQUA affords the opportunity to optimize compartmentalization on an image-by image basis.
[0131] It is possible to apply C-AQUA to more than two images allowing for the automated and optimal compartmentalization of three or more molecularly-defined compartments. For example, pixel assignment for nuclear (DAPI), cytoplasm (cytokeratin) and also membrane (pan-cadherin) could be achieved with the same level of accuracy and efficiency.
Example 6
Clustering AQUA® Analysis of PTEN Expression
[0132] A glioblastoma (GBM) TMA (110 GBM patients samples at 2× redundancy; median follow-up time: 13.2 months) was stained for detection of PTEN (Clone 138G6 mouse monoclonal, CST #9559) along with nuclear and non-nuclear compartments generally as described above, except S100 was used as the non-nuclear compartment marker. Images acquired as described above were analyzed using traditional AQUA® analysis and clustering AQUA® analysis. PTEN AQUA® score comparison (linear regression) between AQUA® and C-AQUA analysis is shown in FIG. 14 . FIG. 14A ) Linear regression analysis for nuclear PTEN expression as determined by AQUA® analysis (Y-axis) and C-AQUA analysis (X-axis) with indicated Pearson's R. FIG. 14B ) Linear regression analysis for cytoplasmic PTEN expression as determined by AQUA® analysis (Y-axis) and C-AQUA analysis (X-axis) with indicated Pearson's R values.
[0133] PTEN cytoplasmic expression AQUA® scores are further described in FIG. 15 . The correlation of PTEN AQUA® scores derived by both methods to patient outcome is shown in Kaplan Meier curves in FIG. 16 . PTEN AQUA® scores were significantly correlated with patient survival. Low PTEN expression was associated with poor outcome compared to high PTEN expression.
Example 7
Clustering AQUA® Analysis of ERCC1 Expression
[0134] A lung cancer TMA [INSERT TMA DETAILS] was stained for detection of ERCC1 along with nuclear and non-nuclear compartments as described above. Images acquired as described above were analyzed using traditional AQUA® analysis and clustering AQUA® analysis.
[0135] ERCC1 AQUA® score comparison (linear regression) between AQUA® and C-AQUA analysis is shown in FIG. 17 . FIG. 17A ) Linear regression analysis for nuclear ERCC1 expression as determined by AQUA® analysis (Y-axis) and C-AQUA analysis (X-axis) with indicated Pearson's R. FIG. 14B ) Linear regression analysis for cytoplasmic ERCC1 expression as determined by AQUA® analysis (Y-axis) and C-AQUA analysis (X-axis) with indicated Pearson's R values.
[0136] ERCC1 cytoplasmic expression AQUA® scores are further described in FIG. 18 . The correlation of ERCC1 AQUA® scores derived by both methods to patient outcome is shown in Kaplan Meier curves in FIG. 19 . ERCC1 AQUA® scores were significantly correlated with patient survival. Low ERCC1 expression was associated with relatively poor outcome compared to high ERCC1 expression.
EQUIVALENTS
[0137] The present invention is not to be limited in terms of the particular embodiments described in this application, which are intended as single illustrations of individual aspects of the invention. Many modifications and variations of this invention can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and apparatuses within the scope of the invention, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. The present invention is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this invention is not limited to particular methods, reagents, compounds compositions or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.
|
The present invention relates generally to improved methods of defining areas or compartments within which biomarker expression is detected and quantified. In particular, the present invention relates to automated methods for delineating marker-defined compartments objectively with minimal operator intervention or decision making. The method provides for precise definition of tissue, cellular or subcellular compartments particularly in histological tissue sections in which to quantitatively analyzing protein expression.
| 6
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the detection of small magnetized particles (beads) by a GMR sensor, particularly when such particles or beads are attached to molecules whose presence or absence is to be determined in a chemical or biological assay.
[0003] 2. Description of the Related Art
[0004] GMR (giant magnetoresistive) devices have been proposed as effective sensors to detect the presence of specific chemical and biological molecules (the “target molecules”) when, for example, such target molecules are a part of a fluid mixture that includes other molecules whose detection is not necessarily of interest. The basic method underlying such magnetic detection of molecules first requires the attachment of small magnetic (or magnetizable) particles (also denoted “beads”) to all the molecules in the mixture that contains the target molecules. The magnetic beads are made to attach to the molecules by coating the beads with a chemical or biological species that binds to the molecules in the mixture. Then, a surface (i.e., a solid substrate) is provided on which there has been affixed receptor sites (specific molecules) to which only the target molecules will bond. After the mixture has been in contact with the surface so that the target molecules have bonded, the surface can be flushed in some manner to remove all unbonded molecules. Because the bonded target molecules (as well as others that have been flushed away) are equipped with the attached magnetic beads, it is only necessary to detect the magnetic beads to be able, at the same time, to assess the number of captured target molecules. Thus, the magnetic beads are simply “flags,” which can be easily detected (and counted) once the target molecules have been captured by chemical bonding to the receptor sites on the surface. The issue, then, is to provide an effective method of detecting the small magnetic beads, since the detection of the beads is tantamount to detection of the target molecules.
[0005] One prior art method of detecting small magnetic beads affixed to molecules bonded to receptor sites is to position a GMR device beneath them; for example, to position it beneath the substrate surface on which the receptor sites have been placed.
[0006] FIG. 1 is a highly schematic diagram (typical of the prior art methodology) showing a magnetic bead ( 10 ) covered with receptor sites ( 20 ) that are specific to bonding with a target molecule ( 30 ) (shown shaded) which has already bonded to one of the sites. A substrate ( 40 ) is covered with receptor sites ( 50 ) that are also specific to target molecule ( 30 ) and those sites may, in general, be different from the sites that bond the magnetic particle to the molecule. The target molecule ( 30 ) is shown bonded to one of the receptor sites ( 50 ) on the surface.
[0007] A prior art GMR sensor ( 60 ), shown without any detail, is positioned beneath the receptor site. As shown schematically in the cross-sectional view of FIG. 2a , the prior art GMR sensor (( 60 ) in FIG. 1 ) ( 60 ), is preferably in the form of a laminated thin film stripe that includes a magnetically free layer ( 610 ) and a magnetically pinned layer ( 620 ) separated by a thin, non-magnetic but electrically conducting layer ( 530 ). Typically, the sensor will also include a capping layer or overlayer ( 550 ). The GMR properties of such a film stripe causes it to act essentially as a resistor whose resistance depends on the relative orientation of the magnetic moments of the free and pinned layers (shown here as arrows ( 640 ), ( 650 ) both directed out of the figure plane). FIG. 2 b shows, schematically, an overhead view of the sensor of FIG. 2 a , showing more clearly the direction of the magnetic moments ( 640 ) and ( 650 ), shown dashed, as it is below ( 640 ). Also shown are two lobes outlining a region of equal strength of an external magnetic field B ( 800 ). The field strength is shown directionally as arrows ( 160 ) that would be produced by a magnetized particle (not shown here) that is positioned above the sensor, as shown in FIG. 1 . This will also be shown more clearly in FIG. 3 , below. The field of the lobes will deflect ( 640 ) (deflection not shown), but leave ( 650 ) unchanged.
[0008] FIG. 3 shows, schematically, a magnetic particle ( 10 ) situated (by binding) over a surface layer ( 45 ) formed on a substrate ( 40 ) in a typical prior art configuration. The surface layer is required to support the bonding sites and can be a layer of Si 3 N 4 and the substrate can be a Si substrate on or within which the required circuitry can be formed. For simplicity, a target molecule is not shown. A GMR sensor ( 60 ), as illustrated in any of the previous figures, is positioned between the surface layer and the substrate ( 40 ). An electromagnet ( 100 ) is positioned beneath the substrate and creates a magnetic field H ( 120 ) directed vertically through the substrate, the GMR sensor, and the magnetic bead. The external field, H, is directed perpendicularly to the magnetic moments of the GMR sensor ( 640 ), ( 650 ) so as not to change their relative orientations. Because of the magnetic properties of the bead, the external field H ( 120 ), induces a magnetic moment M ( 150 ), shown as an arrow in the bead which, in turn, produces a magnetic field B ( 160 ) that extends beyond the boundary of the bead as shown by the dashed lobes. The magnetic field B ( 160 ), in turn, penetrates the plane of the sensor and its component in that plane (shown as the lobes ( 800 ) in FIG. 2 b ) can change the orientation of the magnetic moment of the sensor free layer as is shown schematically in FIGS. 4 a and 4 b.
[0009] The magnetization of the free layer ( 640 ), is now changed in direction relative to the magnetization of the pinned layer ( 650 ), because of the presence of the magnetic field of the magnetized bead ( 160 ) that is directed within the plane of the free layer. Because the presence of the magnetized bead affects the magnetic moment of the free layer, it thereby, changes the resistance of the GMR sensor strip. By detecting the changes in resistance, the presence or absence of a magnetized bead is made known and, consequently, the binding of a target molecule is detected. Ultimately, an array of sensors can be formed beneath a substrate of large area that is covered by a large number of binding sites. The variation of the resistance of the sensor array is then a good indication of the number of target molecules that has been captured at sites and that number, in turn, can be related to the density of such target molecules in the mixture being assayed.
[0010] As is well known by those skilled in the field, although the magnetization of the free layer moves in response to external magnetic stimuli during operation of the sensor, the magnetization of the free layer is preferably fixed when the sensor is in a quiescent mode and not acted on by external fields. The fixing of the free layer magnetization under these conditions is called “biasing” the free layer and the position of the magnetic moment of the free layer in this position is called its bias point.. It is also known to those skilled in the art that the bias position of the free layer is subject to the effects of hysteresis, which means that the bias position is not maintained after the magnetization of the free layer is made to cycle through positive and negative directions by external magnetic stimuli and a quiescent state is once again achieved. This hysteresis has a negative impact on the reproducibility of sensor readings, particularly when the external stimuli moving the free layer magnetization are small to begin with. One of the objects of the present invention will be to eliminate the adverse effects of hysteresis. Given the increasing interest in the identification of biological molecules it is to be expected that there is a significant amount of prior art directed at the use of GMR sensors (and other magnetic sensors) to provide this identification. A detailed research paper that presents an overview of several different approaches as well as the use of GMR sensors is: “Design and performance of GMR sensors for the detection of magnetic microbeads in biosensors” J. C. Rife et al., Sensors and Actuators A 107 (2003) 209-218. An early disclosure of the use of magnetic labels to detect target molecules is to be found in Baselt (U.S. Pat. No. 5,981,297). Baselt describes a system for binding target molecules to recognition agents that are themselves covalently bound to the surface of a magnetic field sensor. The target molecules, as well as non-target molecules, are covalently bound to magnetizable particles. The magnetizable particles are preferably superparamagnetic iron-oxide impregnated polymer beads and the sensor is a magnetoresistive material. The detector can indicate the presence or absence of a target molecule while molecules that do not bind to the recognition agents (non-target molecules) are removed from the system by the application of a magnetic field.
[0011] A particularly detailed discussion of the detection scheme of the method is provided by Tondra (U.S. Pat. No. 6,875,621). Tondra teaches a ferromagnetic thin-film based GMR magnetic field sensor for detecting the presence of selected molecular species. Tondra also teaches methods for enhancing the sensitivity of GMR sensor arrays that include the use of bridge circuits and series connections of multiple sensor stripes. Tondra teaches the use of paramagnetic beads that have very little intrinsic magnetic field and are magnetized by an external source after the target molecules have been captured.
[0012] Coehoorn et al. (US Pub. Pat. Appl. 2005/0087000) teaches a system that is similar to that of Tondra (above), in which magnetic nanoparticles are bound to target molecules and wherein the width and length dimensions of the magnetic sensor elements are a factor of 100 or more larger than the magnetic nanoparticles.
[0013] Prinz et al. (U.S. Pat. No. 6,844,202) teaches the use of a magnetic sensing element in which a planar layer of electrically conducting ferromagnetic material has an initial state in which the material has a circular magnetic moment. In other respects, the sensor of Prinz fulfills the basic steps of binding at its surface with target molecules that are part of a fluid test medium. Unlike the GMR devices disclosed by Tondra and Coehoorn above, the sensor of Prinz changes its magnetic moment from circular to radial under the influence of the fringing fields produced by the magnetized particles on the bound target molecules.
[0014] Gambino et al. (U.S. Pat. No. 6,775,109) teaches a magnetic field sensor that incorporates a plurality of magnetic stripes spaced apart on the surface of a substrate in a configuration wherein the stray magnetic fields at the ends of the stripes are magnetostatically coupled and the stripes are magnetized in alternating directions.
[0015] Simmonds et al. (U.S. Pat. No. 6,437,563) teaches a method of detecting magnetic particles by causing the magnetic fields of the particles to oscillate and then detecting the presence of the oscillating fields by inductively coupling them to coils. Thus, the sensor is not a GMR sensor as described above, but, nevertheless, is able to detect the presence of small magnetic particles.
[0016] Finally, Sager et al. (U.S. Pat. No. 6,518,747) teaches the detection of magnetized particles by using Hall effect sensors.
[0017] The methods cited above that rely on the use of a GMR sensor, rather than methods such as inductive sensing or Hall effect sensing, will all be adversely affected by the failure of the GMR sensor to maintain a reproducible bias direction for its free layer magnetization. This lack of reproducibility is a result of magnetic hysteresis that occurs whenever the external magnetic fields being detected cause the magnetic moment of the sensor free layer to cycle about its bias direction. In the present use of the GMR sensor to detect the presence of extremely small magnetized particles, the external fields are small. Because of this, methods to fix the bias point of the sensor free layer cannot fix it too strongly as this would limit the ability of the free layer magnetic moment to respond to the very stimuli it is attempting to measure. It is, therefore, necessary to find a way of fixing the free layer bias point while still allowing the magnetic moment sufficient freedom of motion to detect even very small external magnetic fields.
SUMMARY OF THE INVENTION
[0018] A first object of this invention is to provide a method of determining the presence or absence of small magnetized particles.
[0019] A second object of this invention is to provide such a method that detects the aforementioned magnetized particles when they are bonded to chemical or biological molecules.
[0020] A third object of the present invention is to provide such a method that uses the magnetoresistive properties of a GMR sensor to detect the presence of a small magnetized particle.
[0021] A fourth object of the present invention is to provide a GMR sensor to be used in detecting the presence of small magnetized particles wherein the response of the sensor to external magnetic fields is not adversely affected by a non-reproducibility of its free layer bias point due to magnetic hysteresis.
[0022] A fifth object of the present invention is to provide a GMR sensor having a high sensitivity and a free layer bias point that is reproducible.
[0023] The objects of the present invention will be achieved by a GMR sensor design having the following characteristics, all of which are schematically illustrated in FIG. 4 a and 4 b and will be discussed below in greater detail.
[0024] 1. The sensor consists of multiple long stripes (only three being shown here) of GMR films ( 1 , 2 , 3 ), electrically connected ( 500 , 600 ) in series.
[0025] 2. The free and pinned layers of each sensor stripe are magnetically biased, the biased magnetic moments being shown as single arrows, ( 11 , 22 , 33 ), in the lengthwise direction.
[0026] 3. The sensor stripes are arranged in a serpentine configuration so that adjacent stripes are substantially parallel to each other and have the bias positions of their magnetic moments oriented in parallel directions.
[0027] 4. The spacing ( 44 ) between neighboring sensor stripes is much smaller than the dimensions of the magnetic particles that they will be detecting.
[0028] 5. The width of each stripe ( 800 ) is comparable to the dimensions of the magnetic particles being detected.
[0029] 6. The structure of each individual stripe is a capped lamination (see FIG. 4b ) comprising a free layer ( 99 ) and a pinned layer ( 77 ) separated by a metallic spacer layer ( 88 ), wherein the pinned layer can be a synthetic layer for enhanced pinning strength. The stripes are surrounded by insulating layers ( 45 ).
[0030] 7. The magnetic anisotropy of each stripe is reduced by minimizing its free layer thickness and providing a minimal interlayer coupling between the free and pinned layers.
[0031] 8. The free layer thickness is minimized, while not degrading the stripe's dR/R.
[0032] 9. The interlayer coupling is minimized by adjusting the thickness of the metallic layer separating the free and pinned layers.
[0033] 10. The film magnetostriction can be adjusted, in conjunction with an overcoat stress, to produce a net stress-induced anisotropy. With proper combination of these two stress factors, the easy axis of the stress-induced anisotropy can be oriented perpendicular to the longitudinal direction of the stripe, so as to cancel out the free layer shape anisotropy.
[0034] The characteristics enumerated above will produce a sensor having a reproducible bias point while still retaining a free layer magnetization that is responsive to the effects of small external magnetic fields. In particular, by orienting the bias direction along the lengthwise direction of the sensor stripe, the adverse hysteresis effects on a stable bias point will be offset by the shape anisotropy produced by a stripe shape that is longer than it is wide. By a combination of magnetostriction and stress-induced anisotropy that is perpendicular to the shape anisotropy, however, the overall magnetization remains responsive and the sensor is sensitive to small external fields. In addition, by forming a narrow space (less than bead diameter) between adjacent stripes in an array, making the width of the stripes comparable to the dimensions of the bead and by orienting adjacent sensor stripes parallel to each other, the position of a magnetic particle is likely to overlap two adjacent stripes, thereby, having its detectability enhanced by the series response of two stripes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] The objects, features, and advantages of the present invention are understood within the context of the Description of the Preferred Embodiment as set forth below. The Description of the Preferred Embodiment is understood within the context of the accompanying figures, wherein:
[0036] FIG. 1 (prior art) is a schematic representation of a magnetic bead bonded to a target molecule and the target molecule bonded to a receptor site.
[0037] FIG. 2 a (prior art) is a schematic cross-sectional representation of a GMR sensor such as is positioned beneath the substrate of FIG. 1 .
[0038] FIG. 2 b (prior art) is a schematic illustration of an overhead view of the sensor of FIG. 2 a , showing also the presence of an external field produced by a magnetized particle.
[0039] FIG. 3 (prior art) is a schematic perspective representation of a typical biased GMR sensor stripe over which a magnetized particle is positioned.
[0040] FIG. 4 a is a schematic overhead view of a sensor array formed of the sensor stripes of the present invention.
[0041] FIG. 4 b is a cross-sectional schematic view of one sensor stripe of the array.
[0042] FIG. 5 is a schematic overhead view of two interconnected sensor stripes of the present invention showing the effects of a magnetized bead.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] The preferred embodiments of the present invention are a GMR sensor stripe and an array of such GMR sensor stripes, capable of detecting the presence of magnetic particles or beads, typically bonded to chemical molecules. The GMR stripe and the array of stripes, by virtue of their formation, are not adversely affected by instability of a free layer bias point due to hysteresis. We use the term “stripe” to characterize a GMR sensor element and to emphasize the fact that it is deposited in the shape of a long, approximately rectangular strip or stripe. When used to detect magnetic particles bonded to target molecules (eg. in a bio-chemical assay) the array is formed beneath a surface on which are affixed bonding sites for target molecules. To perform the detection process, the target molecules whose presence is to be detected, as well as others that are not targets, are first magnetically tagged, by being bonded to small magnetic particles or beads that are subsequently magnetized by an external magnetic field.
[0044] The advantages of the present invention reside in the fact that the bias point of the free and pinned layer magnetizations of each GMR sensor stripe in the array is oriented along the lengthwise direction of the stripe. The fact that the stripes are thin and longer then they are wide, provides a shape anisotropy that maintains a bias point in the lengthwise direction that is stable with respect to hysteresis effects produced by the cyclic motion of the free layer magnetic moment during its use in detection processes. In order to ensure that the shape anisotropy does not adversely affect the sensitivity of the sensor to small external fields that move the magnetization away from the longitudinal bias direction, a compensating anisotropy is produced by combining a stress induced anisotropy due to magnetostriction of the sensor magnetic layers with the stresses in the magnetic layers produced by tension or compression of the various surrounding sensor overlayers that encapsulate the sensor. This combination of magnetostriction and compressional or tensile overlayer stress can be adjusted to reduce the overall magnetic anisotropy. Finally, the sensor free layer is made as thin as possible while not sacrificing the GMR ratio, dR/R, and the interlayer coupling between the free and pinned layers is adjusted to be smaller than the magnetic anisotropies.
[0045] The sensor stripes produced by the methods of this invention are then connected in electrical series in a serpentine fashion that places individual stripes side-by-side in a parallel configuration, with a narrow space between adjacent stripes and with the bias directions of their magnetizations (i.e., their magnetic moments) parallel. To achieve this configuration, the individual stripes are placed side-by-side as desired and then electrically connected between the aligned top and bottom edges of adjacent stripes with a conducting element to create a continuous electrical circuit. Because the stripes are very narrowly spaced (less than a bead diameter) and are very narrow themselves (approximately a bead diameter) there is a great likelihood that individual beads located above the stripes will straddle two adjacent stripes, thereby, enhancing the response of the array.
[0046] Because the methods of forming the binding surface, the nature and formation method of the binding sites and the means of attaching the magnetic beads to the target molecules are all well known in the art (see the above cited journal article and the prior art patents), the detailed description of the invention that now follows will be restricted to the construction of the sensor stripes and the array configuration.
[0047] Referring now to FIG. 4 a , there is shown a schematic overhead view of a small array of GMR stripes or, equivalently, what could be a segment of a larger array, in which there are three electrically connected GMR sensor stripes of the present invention, denoted for reference purposes as stripes 1 , 2 and 3 . These stripes are of generally rectangular shape, having parallel lateral edges ( 101 ), ( 202 ), ( 303 ) of length between approximately 10 microns and 200 microns and parallel transverse edges ( 111 ), ( 222 ), ( 333 ) of width between approximately 1 micron and 5 microns. The stripes are connected in electrical series in an electrically conductive continuous serpentine configuration that aligns successive stripes adjacent to each other with their magnetic moments, when in a quiescent state, oriented in parallel (arrows ( 11 ), ( 22 ), ( 33 )). The separation ( 44 ) between adjacent stripes (filled by the surrounding layers of insulation ( 45 )) is less than the diameter of the magnetic particles to be detected, which are typically between approximately 0.2 microns and 1 micron. As can be seen in the figure, the co-linear upper transverse edges ( 111 ), ( 222 ) of stripes 1 and 2 , are electrically connected with a conducting element ( 500 ), as are the lower transverse edges ( 222 ), ( 333 ) of stripes 2 and 3 ( 600 ). The free lower edge of stripe I ( 111 ) and the free upper edge of stripe 3 ( 333 ) are each conductively connected to terminal connectors ( 550 ) for the purpose of engaging the array within an external circuit (not shown). If the three stripes are part of a larger array, the terminal connectors would be absent and connections to other GMR stripes would be made. As can be envisioned, if the array consisted of M stripes, the connections would proceed, pairwise, in like fashion, with end stripes 1 and M being connected to terminals. It is understood that the array of FIG. 4a will be encapsulated within surrounding layers of insulation ( 45 ).
[0048] The dimensional difference between the length and width of each sensor stripe gives the stripe a shape asymmetry that produces a magnetic anisotropy along the lengthwise dimension. This anisotropy assists in maintaining the bias point (the magnetic moment under quiescent conditions) of the free layer when that bias point is also in the lengthwise direction as shown in FIG. 4 a . However, the magnetic anisotropy cannot be too great or it will impede the variations in magnetic moment of the free layer under the action of external magnetic fields. Thus, some degree of additional magnetic anisotropy must be incorporated into the sensor stripe in order to produce the required sensor sensitivity. This will now be discussed with reference to FIG. 4 b.
[0049] Referring to FIG. 4b there is shown a cross-sectional view of a single GMR stripe, such as either of the three stripes in FIG. 4 a , illustrating, schematically, the preferred sequence of layers that form the GMR sensor stripe. Looking from the bottom up, there is shown a substrate ( 55 ), which can be a layer of oxide, a pinning layer ( 66 ), which can be a single layer of antiferromagnetic material, a pinned layer ( 77 ) which can be either a single layer of ferromagnetic material, such as CoFe or NiFe, formed to a thickness between approximately 10 and 100 angstroms or a laminated synthetic antiferromagnetic layer formed of two such ferromagnetic layers coupled by a non-magnetic coupling layer, a spacer layer ( 88 ) of a non-magnetic, electrically conducting material such as Cu, formed to a thickness between approximately 10 and 20 angstroms, a free layer ( 99 ) formed of a ferromagnetic material such as CoFe or NiFe, to a thickness between approximately 10 and 100 angstroms, and an overlayer ( 100 ) or capping layer to protect the sensor structure. The overlayer can be a portion of the surrounding insulating layers, which are formed of oxides or nitrides of Si or it can be a portion of the layer that supports the bonding sites for the magnetically tagged particles, the supporting layers being typically formed of similar insulating materials. After the sensor stripe is fabricated, the pinned and free layers are annealed to set their magnetic moment directions (i.e, their magnetizations) along the lengthwise dimension of the stripe as shown here as ( 777 ) and ( 999 ) also in FIG. 4a (as ( 11 ), ( 22 ) and ( 33 )) so that the bias point (direction of the magnetic moment when the stripe is quiescent, i.e. is not acted on by external fields) is along the lengthwise direction of the stripe. It is further noted that the stripe is surrounded by layers of insulation ( 45 ), such as alumina or oxides or nitrides of silicon formed to thicknesses between approximately 1000 angstroms and 2 microns, to isolate it electrically from neighboring circuit elements (not shown) and that such insulating material will contribute to stresses exerted on the stripe.
[0050] By adjusting the spacer layer ( 88 ) the interlayer coupling between the free ( 99 ) and pinned ( 77 ) layers can be reduced so that the variation of the free layer magnetization in response to small external fields produces the required response of the sensor. Further, the free layer itself must be made as thin as possible, without sacrificing the dRJR of the sensor (the measure of its sensitivity), so that the free layer is responsive to small external fields. In addition, as is known in the art, the ferromagnetic layers exhibit the phenomenon of magnetostriction, which is typically defined in terms of a coefficient of magnetostriction. For example, NiFe alloy has a coefficient of magnetostriction that approaches zero at a composition of about 19% Fe. The coefficient becomes negative with less Fe and positive with more Fe. A thin layer (such as is formed herein) of positive coefficient of magnetostriction will exhibit a magnetic anisotropy in a direction of tensile stress on the layer. Likewise, a film having a negative coefficient of magnetostriction will exhibit a magnetic anisotropy in a direction of compressive stress on the layer. As the GMR sensor is a metallic stripe (as shown in FIG. 4b ) encapsulated in surrounding insulation layers from above and below (and possibly including the substrate itself), it will generally be under anisotropic compressive or tensile stress that is substantially within the plane of the sensor layers. The magnitude of this stress will depend on the material forming the surrounding insulation layers and specific processes involved in their fabrication. The magnetostriction coefficient of the GMR sensor can be adjusted by its composition to give a magnetostriction coefficient that, when combined with the anisotropic stress of the surroundings, will result in a stress induced magnetic anisotropy that is perpendicular to the lengthwise direction of the stripe. For example, if the anisotropic stress of the GMR sensor is tensile in the lengthwise direction, the magnetically free layer magnetostriction coefficient is adjusted to be slightly negative, so that the stress induced magnetic anisotropy will be perpendicular to the lengthwise direction of the stripe while the magnitude is small enough so that the net anisotropy is still in the lengthwise direction.
[0051] Referring now to FIG. 5 , there is shown, schematically, just stripes 1 and 2 of the array in FIG. 4 a . A magnetized bead (not shown) is located above the separation between the stripes and produces two lobes ( 1001 ) and ( 2002 ) defining equal-strength field lines of its magnetic field. The field vectors are directed as shown by the enclosed arrows, within the plane of the stripes. It can be seen that the parallel configuration of the adjacent stripes 1 and 2 and the new orientation of their magnetic moments ( 11 ) and ( 22 ) caused by the field of the magnetized bead, combined with the narrow separation between stripes, the narrowness of each stripe and the series connection of the stripes, produces a significant enhancement of the sensor's response. The maximum response of the sensor array to the presence of a magnetized particle occurs when the particle is over the separation between adjacent stripes, as shown in this figure. In that position, each of the two lobes causes a strong deflection of the magnetic moments of the respective stripes. Because of the series connection of the two stripes, the dR/R of each stripe effectively add to produce a doubling of the voltage drop across the array. If the magnetic bead is not precisely over the separation between stripes, the narrow width of each stripe still ensures that the magnetic field of the bead impinges on more than one stripe and enhances the response of the array.
[0052] As is finally understood by a person skilled in the art, the preferred embodiments of the present invention are illustrative of the present invention rather than limiting of the present invention. Revisions and modifications may be made to methods, materials, structures and dimensions employed in forming and providing a GMR sensor stripe array with a stable free layer bias point, while still forming and providing such an array and its method of formation in accord with the spirit and scope of the present invention as defined by the appended claims.
|
A sensor array comprising a series connection of parallel GMR sensor stripes provides a sensitive mechanism for detecting the presence of magnetized particles bonded to biological molecules that are affixed to a substrate. The adverse effect of hysteresis on the maintenance of a stable bias point for the magnetic moment of the sensor free layer is eliminated by a combination of biasing the sensor along its longitudinal direction rather than the usual transverse direction and by using the overcoat stress and magnetostriction of magnetic layers to create a compensatory transverse magnetic anisotropy. By making the spaces between the stripes narrower than the dimension of the magnetized particle and by making the width of the stripes equal to the dimension of the particle, the sensitivity of the sensor array is enhanced.
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention relates to high performance thermosetting resin systems. More particularly, the subject invention relates to heat-curable resin systems containing cyanate ester-functional oxazolinylpolysiloxanes.
2. Description of the Related Art
High performance thermosetting resins based upon cyanate esters find application in many areas where high strength and heat resistance are important. Such resins, which contain monomers having two or more cyanate ester (cyanate) groups, polymerize to form highly cross-linked triazine structures. Unfortunately, the high strength and heat resistance which results from the polymer structure also causes the polymer to be brittle, and subject to impact induced damage.
Modification of these resin systems to improve their flexibility and reduce susceptibility to impact induced damage has been but partially successful. Copolymerization with epoxy resins, bismaleimide resins, and modification with cyanate-reactive acrylonitrile-butadiene elastomers have imparted greater toughness to cyanate resin systems, but generally with considerable loss of heat resistance.
SUMMARY OF THE INVENTION
It has now been discovered that cyanate resins and other resin systems may be successfully modified through incorporation of a cyanate-functional oxazolinylpolysiloxane into the resin system. The resulting toughened resin systems show a considerable increase in flexibility without a concomitant decrease in heat resistance.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The cyanate-functional oxazolinylpolysiloxanes of the subject invention are readily prepared by the catalyzed or uncatalyzed reaction of at least a molar equivalent of a di- or polycyanate functional monomer with an epoxy-functional polysiloxane.
In the claims, the term "polycyanate" shall include dicyanates as well as cyanate-functional monomers containing more than two cyanate groups.
The cyanate-functional monomers are well known to those skilled in the art. These monomers are generally prepared by reacting a cyanogen halide with a di- or polyhydric phenol or similar compound. Examples of phenols which are commonly used to prepare the cyanate resins include mononuclear phenols such as hydroquinone and resorcinol; the various bisphenols, i.e. bisphenol A, bisphenol F and bisphenol S; and the various phenol and cresol based novolac resins. Examples of the method of preparation and of specific cyanate functional monomers may be found in U.S. Pat. Nos. 3,448,079, 3,553,244 and 4,663,398. Particularly preferred are the cyanates of hydroquinone, bisphenol A, bisphenol F, 2,2',6,6'-tetramethylbisphenol F, bisphenol S, and the phenolic novolac resins, and the di- and polyphenols which are derived from the reaction products of phenol and dicyclopentadiene in the presence of Friedel-Crafts catalysts as disclosed in U.S. Pat. No. 3,536,734, hereinafter referred to as phenolated dicyclopentadiene. The cyanate functional resins are generally used in an amount at least equivalent to the number of moles of epoxy groups in the epoxy-functional siloxane and preferably in excess. For example, to one mole of a linear siloxane or polysiloxane terminated at both ends with epoxy functionality will be added two moles or more of a dicyanate. The amount of excess cyanate may be adjusted depending upon the particular application or the degree of toughness required.
The epoxy-terminated siloxanes may be prepared by methods well known to those skilled in the art. See, for example, J. Riffle, et. al., Epoxy Resin Chemistry II, ACS Symposium Series No. 221, American Chemical Society, pp. 24-25. Generally speaking, the epoxy functional polysiloxanes are prepared by the equilibrium polymerization of the readily available bis (3-glycidoxypropyl)tetramethyldisiloxane with a cyclic siloxane oligomer, preferably octamethylcyclotetrasiloxane or octaphenylcyclotetrasiloxane.
The equilibrium polymerization generally proceeds in the presence of a catalyst such a tetramethylammonium or tetrabutylammonium hydroxide or the corresponding siloxanolates. Particularly preferred is tetramethylammonium siloxanolate. The reaction proceeds readily at temperatures from about 50° C. to about 200° C., preferably from about 80° C. to about 150° C.
Reaction of the cyanate-functional monomer with the epoxy-functional siloxane occurs at elevated temperatures, e.g. from about 80° C. to about 250° C., preferably from about 130° C. to about 210° C. to yield a cyanate-functional oxazolinylpolysiloxane. The reaction sequence may be illustrated as follows: ##STR1## wherein each R may be, for example, a C 1 -C 6 lower alkyl, C 1 -C 6 lower alkoxy, C 1 -C 6 haloalkyl, vinyl, allyl, allyloxy, propenyl, propenyloxy, acetoxy, C 5 -C 10 cycloalkyl, or aryl radical.
Catalysts are not necessary for the reaction between the cyanate monomer and the epoxy-functional polysiloxane. However, if desirable, metal catalysts such as tin octoate, dibutyltindilaurate, dibutyltindiacetate, or compounds of lead or zinc which catalyze triazine formation from cyanates may be used. Other catalysts which may be useful include metal acetylacetonates, metal alkyls such as butyl titanate and propyl aluminum, metal chlorides such as tin(IV) chloride; imidazoles, particularly 2-substituted and 2,4-disubstituted imidazoles, and tertiary amines such as N,N-dimethylbenzylamine, triethylenediamine, N-methylmorpholine and the like. The catalysts, when utilized, are generally present to the extent of from about 1.0×10 -6 to about 2.0 wt. percent, preferably from about 1.0×10 -3 to about 0.5 weight percent, and most preferably from about 1.0×10 -2 to about 0.5 weight percent.
The examples which follow illustrate the practice of the subject invention. These examples are by way of illustration only, and should not be interpreted as limiting the scope of the invention in any way.
EXAMPLE 1
Preparation of Tetramethylammonium Siloxanolate
Into a 250 ml three neck round bottom flask equipped with a mechanical stirrer and reflux condenser are placed 118.6 g (0.4 mol) octamethylcyclotetrasiloxane and 18.6 g (0.1 mol) tetramethylammonium hydroxide pentahydrate. The mixture is stripped of water over a period of 48 hours by means of a flow of nitrogen while stirring at 70° C. The resulting viscous syrup is used as a polymerization catalyst without further purification.
EXAMPLE 2
Preparation of Epoxy-Functional Polysiloxane Copolymer
To a 2 liter three neck round bottom flask equipped with a mechanical stirrer and reflux condenser are charged 534.4 g octamethylcyclotetrasiloxane, 534.4 g octaphenylcyclotetrasiloxane, 90.7 g bis[3-glycidoxypropyl]tetramethyldisiloxane, and 12.0 g tetramethylammonium siloxanolate from Example I. The resulting mixture is stirred at 80° C. for 48 hours under nitrogen. During this period, the viscosity is observed to increase and then reach a stable value. The catalyst is then destroyed by heating to 150° C. for 4 hours. After cooling to room temperature, the filtered reaction mixture is extracted twice with methanol (300 ml×2) to remove unreacted cyclic oligomers. The product is then dried in vacuo at 1 torr and 150° C. The product is a viscous oil (1100 g) having an epoxy equivalent weight (EEW) of 1210.
Example 3
Preparation of Epoxy-Functional Polydimethylsiloxane
Using the procedure of Example 2, a reactor is charged with 18.3 g bis[3-glycidoxypropyl]tetramethyldisiloxane, 182.0 g octamethylcycloetrasiloxane, and 1.4 g tetramethylammonium siloxanolate. The product is a colorless, viscous oil (180 g, EEW =2200).
Example 4
Heat-Curable Resin Adhesive
A heat-curable resin adhesive composition is prepared by mixing 20.0 g of the epoxy-functional polysiloxane from Example 2 with 180.0 g 2,2',6,6'-tetramethylbisphenol F dicyanate in a 500 ml glass reactor. The mixture is heated, with vigorous stirring, to 190° C. and maintained at that temperature for 5 hours under nitrogen. After cooling to 70° C., 5.25 g of fumed silica (CAB-O-SIL® M-5, a product of the Cabot Corporation), 0.6 g copper acetylacetonate and 8.0 g of a novolac epoxy resin (DEN® 31, a product of the Dow Chemical Company) are added. The homogenous mixture is coated on a 112 fiberglass carrier.
Comparison Example A
Heat-Curable Resin Adhesive
A resin composition similar to that of example 4, but without the cyanate-functional oxazolinylpolysiloxane modifier, is prepared by admixing 180 g 2,2',6,6'-tetramethylbisphenol F dicyanate, 5.25 g CAB-O-SIL® M-5, 0.6 g copper acetylacetonate, and 8.0 g DEN® 431.
The adhesives prepared in Example 4 and Comparison Example A are used to bond aluminum sheets. The resins are cured by heating for 4 hours at 177° C., 2 hours at 220° C. and 1 hour at 250° C. Single lap shear strengths are measured by ASTM method D-1002. Results are presented in Table I below.
TABLE I______________________________________ Single Lap Sheer Strength (psi)Adhesive Formulation 20° C. 177° C.______________________________________Example 4 3100 3300Comparison Example A 2000 2510______________________________________
Example 5
Heat-Curable Modified Bismaleimide Resin Adhesive
A heat-curable bismaleimide adhesive composition is prepared by first admixing 10.0 g of the epoxy-functional polysiloxane of Example 2 with 70.0 g 2,2',6,6'-tetramethylbisphenyl F dicyanate in a 500 ml reactor. After heating at 190° C. for 5 hours with vigorous stirring, the mixture is cooled to 150° C. and 10.0 g of the bismaleimide of 4,4'-diaminodiphenylmethane is added. After stirring for 30 minutes, the mixture is allowed to cool to 70° C. and 3.2 g CAB-O-SIL® M-5, 0.43 g zinc naphthenate, and 2.0 g benzylalcohol are added. After coating onto a 112 glass fabric, the adhesive is used to bond aluminum. The cure cycle is identical to that used previously for Example 4 and Comparison Example A. Single lap shear strength (ASTM 1002) are as follows:
TABLE II______________________________________Temp Shear Strength (psi)______________________________________ 20° C. 2890177° C. 3060205° C. 3270______________________________________
Example 6
Heat-Curable Resin Formulation
A heat-curable cyanate resin formulation is prepared by stirring together 6 g of bisphenol A dicyanate and 16.0 g of the epoxy functional silicone of Example 3 at 150° C. under nitrogen for 5 hours. To the resulting homogenous but opaque mixture is added 0.079 g zinc octoate. The resulting mixture is cured at 177° C. for 4 hours, then 205° C. for an additional 4 hours. The resin showed good adhesion to both aluminum and glass. Thermogravimetric Analysis (TGA) of the cured elastomer and of cured bisphenol A dicyanate are presented in Table III which indicates that despite large quantities of modifier, the finished elastomer has virtually the same heat resistance as the polymerized cyanate resin itself.
TABLE III______________________________________ TGA (°C.) in AirResin 5% Wt. Loss 10% Wt. Loss______________________________________Modified Cyanate of Example 6 430 440Bisphenol A dicyanate 440 445______________________________________
The cyanate-functional oxazolinylpolysiloxane modifiers of the subject invention may be used to toughen a number of high performance resin systems. Due to the variety of reactions in which the cyanate radical may take part, these modifiers may be used, for example, in epoxy resin systems, cyanate resin systems, and bismaleimide resin systems, to name a few. Such resin systems are well known to those skilled in the art.
The toughened resin systems find use as laminating resins, as matrix resins in high performance, fiber reinforced prepregs, as potting and encapsulating resins, and as structural adhesives. When used in prepregs, traditional fiber reinforcement such as carbon/graphite, fiberglass, boron, and other fibers may be used in woven or non-woven form, as a mat, or as collimated fiber tows. Rovings and yarns may also be used. The use of such fiber reinforcement is commonplace in the aerospace and transportation industries.
|
Cyanate-functional oxazolinylpolysiloxanes are useful for toughening high performance resin systems such as cyanates, epoxies, and bismaleimides without substantial loss of heat resistance.
| 2
|
CROSS REFERENCE TO RELATED PATENTS
Anderson et al. U.S. Pat. No. 3,731,649 issued May 8, 1973 entitled "Ribbon Inking Machine;" Anderson et al. U.S. Pat. No. 3,733,211 issued May 15, 1973 entitled "Ribbon Inking Method."
BACKGROUND OF THE INVENTION
The invention set forth in this specification is primarily directed to improvements which are primarily intended to be utilized in combination in ribbon inking machines.
For many years it has been customary to throw out and replace inked ribbons as are commonly utilized in connection with various types of computing, calculating, addressing and related machines after the ink within such ribbons has been consumed or exhausted as the result of prolonged use of such ribbons. To a large extent it is considered that economy can be achieved by re-inking such ribbons after they have been used.
Preferably such ribbons have been re-inked utilizing a method in which ink is applied to such ribbons and in which such ribbons are then heated to a moderate extent sufficient to lower the viscosity of the ink applied so as to tend to cause such ink to permeate such ribbons and to a sufficient extent so that any thermoplastic material within such ribbons which has been stretched from an initial shape as a result of prolonged use tends to assume its initial configuration. In order to achieve the last result it has been considered necessary to hold a ribbon under tension as it is heated.
Unquestionably prior machines for re-inking ribbons as indicated in the preceding have been highly utilitarian and serviceable. Unfortunately, however, these machines have tended to be somewhat limited in their utilization because of several different factors. One of these is that such machines have normally been constructed so that the speed at which a ribbon passes over a heating structure will vary depending upon the diameter of a roll of ribbon being inked. This is considered disadvantageous since it results in a portion of a ribbon which is being re-inked being subjected to either a greater or lesser amount of heat than other portions of the same ribbon. This will cause unequal permeation of the ink applied to such a ribbon into the interstices of a ribbon. It will also tend to result in uneven shrinking of a stretched ribbon along the length of a ribbon back to or towards its initial configuration. Such prior machines have also been somewhat limited in their suitability for use with ribbons of various different thicknesses.
SUMMARY OF THE INVENTION
From the foregoing it will be apparent that there is need for improvement in the field of re-inking ribbons such as are used in various types of business machines. A broad objective of the present invention is to fulfill this need. More specifically the invention is directed towards supplying new and improved ribbon inking machines.
The invention is intended to provide ribbon inking machines which will uniformly ink and heat an elongated ribbon at all points along the length of such a ribbon. The invention is also intended to provide ribbon inking machines which will accommodate ribbons of different thicknesses automatically without adjustment. Further objectives of the invention are to provide ribbon inking machines which can be constructed at a comparatively nominal cost using many stock parts and which are capable of performing reliably for a prolonged period with little or no maintenance.
The invention is also concerned with new and improved means for holding a movable element relative to guides permitting the element to be moved in a linear path. The invention is also concerned with a structure which can be utilized in order to mechanically move such an element along such guides. In accordance with this invention such means and such a mechanical structure are preferably included within a ribbon inking machine as indicated in the preceding discussion.
Certain of the above noted objectives of the invention are achieved by providing in a ribbon inking machine having a frame, a drum mounted on said frame, a carriage movably mounted on said frame so as to be capable of being moved toward and away from the drum, a ribbon feeding means mounted on the carriage, a ribbon inking means mounted on the carriage, and a ribbon takeup means mounted on the frame, the improvement which comprises: guide rod means located adjacent to the drum, a pressing element mounted on the guide rod means so as to be capable of being moved on the guide rod means toward and away from the drum, flexible band means located on the pressing element so as to extend around the guide rod means, tightening means for tightening the band means relative to the guide rod means so as to position the pressing element in a desired position with respect to the guide rod means and mechanical means for moving the pressing element with respect to the drum and guide rod means, the mechanical means being capable of being used to space the pressing element away from the drum.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is best more fully discussed by referring to the accompanying drawings in which:
FIG. 1 is a side elevational view of a presently preferred embodiment of a ribbon inking machine in accordance with this invention;
FIG. 2 is a cross-sectional view taken of line 2--2 of FIG. 1;
FIG. 3 is an enlarged partial cross-sectional view taken at line 3--3 of FIG. 2;
FIG. 4 is a partial cross-sectional view taken at line 4--4 of FIG. 3, and
FIG. 5 is a partial cross-sectional view showing the construction of a detent latch employed in conjunction with the machine illustrated in the preceding figures.
The concepts of the invention which are considered to be entitled to protection are set forth and defined in the appended claims forming a partof the disclosure of this specification. It will be realized that these concepts can be easily embodied in a variety of differently appearing structures through the use or exercise of routine engineering skill.
DETAILED DESCRIPTION
In the drawings there is shown a ribbon inking machine 10 in accordance with the concepts of this invention. In many respects the construction of this machine is related to the construction of the machine illustrated in the Anderson et al. U.S. Pat. Nos. 3,731,649 and 3,733,211. In the interest of brevity the entire disclosures of both of these U.S. patents are incorporated herein by reference for the purpose of indicating prior structures and prior known practice in connection with the re-inking of business machine ribbons.
The machine 10 includes a frame 12 having sides 14 spaced from one another.These sides 14 have upwardly extending extensions 16 which carry a rotatable drum 18 in a conventional manner so that this drum 18 is supported by bearings 20 located on the extension 16. This drum 18 is adapted to be driven by a small motor 22 connected to the drum 18 by a conventional power transmission mechanism 24. This motor 22 is also adapted to rotate a takeup roller 26 through the use of another conventional drive mechanism 28. This roller 26 is preferably mounted on slip clutches 30.
An appropriate conventional control box 32 is provided on one of the extensions. Through the adjustment of a control knob 34 on this box 32 thedrum 18 may be rotated at various different speeds as desired. An on/off switch 36 on the box 32 is used to turn the motor 22 on or off. The box 32is connected to the motor 22 in a conventional manner (not shown).
The sides 14 also support a water cooled chilling roller 38 in such a manner that the axis of this roller 38 is parallel to the axis of the drum18 and the roller 26. The sides 14 also support parallel ways 40. These ways 40 in turn support a movable carriage 42 in such a manner that this carriage 42 can be moved back and forth relative to the drum 18 between the position shown in solid lines in FIG. 1 and the position shown in phantom in FIG. 1. It will be noted that at all times the carriage 42 is parallel to the axis of the drum 18.
This is to permit a ribbon pay off roller 44 and an ink applicator roller 46 on the carriage 42 to remain parallel to the axis of the drum 18 at alltimes. This carriage 42 also transfers a roller 48 which is contacted by the applicator roller 46 so as to meter on to the applicator roller 46 a uniform film of ink. The carriage 42 also supports two pivotally mounted arms 40 which carry an idler roller 52 as shown in FIG. 1 of the drawings.The carriage 42 also supports another idler roller 54.
The various rollers 44, 46, 48, 52 and 54 are all constructed in a known orconventional manner. None of these rollers on this carriage 42 are directlyconnected to any mechanical source of power. In the machine 10 they are caused to turn as a length of ribbon 56 is pulled through the machine as the result of frictional contact with the drum 18. This ribbon 56 comes off the ribbon pay off roller 44 and passes beneath the idler roller 52 and then around a part of the applicator roller 46 and then beneath the idler roller 54. From this idler roller 54 the ribbon 56 passes upwardly around the drum 18 and then beneath the water cooled, chilling roller 38 to the takeup roller 26.
The idler roller 52 is used merely to assure a desired contact between the ribbon 56 and the applicator roller 46 so that there will be adequate timefor ink to transfer to the ribbon 56 from the applicator roller 46 and so that there will be adequate frictional contact to turn the applicator roller 46 in such a manner that the frictional contact between it and the transfer roller 48 will cause rotation of the transfer roller 48; such rotation actuates this transfer roller 48 to dispense and transfer ink to the applicator roller 46.
As the machine 10 is being set up for use the carriage 42 will normally be in a position as shown in phantom at the left of FIG. 1. When the carriage42 is in this position there is adequate access to it to permit servicing and to permit a full ribbon pay off roller 44 containing a ribbon 56 to beinked to be located upon it. After such a roller 44 has been located in place the carriage 42 will be moved toward the position as shown in full lines in FIG. 1.
When the carriage 42 reaches this position a small, elongated retainer pin 58 mounted on the carriage 42 will move into a small hole 60 in a block 62mounted on the frame 12. When the pin 58 is in this position a ball 64 willbe biased by a spring 66 so as to fit against a groove 68 in the pin 58 in such a manner as to detachably latch or hold the carriage 42 in an operative position. This structure involving the pin 58 and the ball 64 can be regarded or termed a detent mechanism for holding the carriage 42 in an operative position relative to the frame 12.
When the carriage 42 is manipulated in the manner described a pressing element 70 will normally be in a position in which it is spaced from the drum 18. This pressing element 70 is mounted upon an elongated plate 72 bymeans of conventional fasteners 74 at both ends of the plate 72 in such a manner that it can "rock" back and forth a limited amount relative to the plate 72. This facilitates alignment of the element 70 when it is moved relative to the drum 18 so that it is congruent to the drum 18.
The plate 72 includes terminal holes 76 and cylindrical bushings 78 mountedon the plate 72 beneath the holes 76. These holes 76 and these bushings 78 are employed to slidably mount the plate 72 and the pressing element 70 upon guide rods 80 which depend from supports 82 mounted on the sides 14. These guide rods 80 carry enlarged washers 84 and nuts 86. Normally this plate 72 will be biased upwardly by small coil springs 88 around the rods 80 engaging the washers 84 and the bushings 78. Conventional adjustable stops 129 carried by the plate 72 serve to limit downward movement of the plate 72 by hitting against the washers 84.
The position of the plate 72 can be manually manipulated through the use ofa handle 90 secured to a rocker shaft 92 which is rotatably mounted on the supports 82. Each end of the shaft 92 carries a small crank arm 94 which is connected to an end of the plate 72 by a link 96. With this structure when the handle 90 is rotated counter-clockwise from its position as indicated in FIG. 1 the arms 94 will be correspondingly rotated and this in turn will move the links 96 upwardly in such a manner as to cause upward movement of the plate 72. As such rotation of the handle 90 is continued the links 96 will pass through an "over center" position relative to the crank arms 94. In such an over center position the arms 94and the links 96 will be parallel. After these arms 94 and links 96 pass through this position the normal action of gravity will tend to pull the plate 72, the arms 94 and the links 96 downwardly to a point where notches98 on the arms 94 will be engaged by pins 100 on the supports 82. Such engagement will then hold the plate 72 against downward movement in a position in which the pressing element 70 is spaced from the drum 18.
Such spacing will allow the ribbon 56 from the carriage 42 to be passed around the drum 18 and under the chilling roller 38 to the takeup roller 26. This ribbon 56 will of course normally be attached to this takeup roller 26 at this point so that it can be wound around it as the machine 10 operates. Before the machine 10 is operated, however, the handle 90 will be rotated back to its original position and released.
This of course will lower the pressing element 70 so that this element willmove toward the drum 18, tending to push the ribbon 56 into contact with the drum 18. Only enough pressure to collapse springs 88 will be used to move the plate 72 and the pressing element 70 against the ribbon 56 and the drum 18. Because the guide rods 80 have smooth exteriors this action will serve to position the pressing element 70 in a desired operative manner with respect to a ribbon 56 of any commonly utilized thickness. This is important since it avoids having to utilize special means to gaugethe thickness of a ribbon 56 and to adjust the machine 10 to accommodate any change in the thickness of one ribbon over another.
When the pressing element 70 is so positioned normally a control switch 102mounted upon a control box 104 on one of the sides 14 will be actuated so as to actuate two solenoids 106 mounted on the ends of the plate 72 and drive motor 22. This switch 102 is preferably connected in a conventional manner (not shown) to these solenoids 106 and to another switch 108 on theframe 12 in such a position as to be engaged and closed by the carriage 42 when the carriage 42 is in a position as shown in FIG. 1. This switch 108 serves in a conventional manner to "block" the operation of the switch 102to actuate the solenoids 106 unless the carriage 42 is in an operative position as shown.
When the switch 102 is actuated so as to actuate the solenoids 106 the armatures 110 on these solenoids 106 move inwardly relative to these solenoids 106. This brings coil springs 112 on these armatures into contact with rocker arms 114 mounted on the plate 72 by means of pivots 116. These arms 114 have cylindrical ends 118. A flexible band 120 extendsin essentially an S-shaped path around each of the ends 118 and around an adjacent guide rod 80. These bands 120 are attached by fasteners 122 to the arms 114 and to blocks 124 on the plate 72.
When the solenoids 106 are actuated in this manner these bands 120 are tightened with respect to the rods 80 so as to hold the plate 72 and the pressing element 70 in the positions allowed by stops 129 as a result of movement of the handle 90. Hence, these bands 120 and the various parts associated with them are a locking or holding means for locking or holdingthe pressing element 70 in the desired operative position. This, of course,avoids having to adjust the locking structure employed each time a ribbon 56 of a different thickness is processed.
During such processing conventional heater elements 126 on the pressing element 70 will be actuated through the actuation of an electrical control128 on the box 104 so as to supply a desired amount of heat to the pressingelement 70 and to the ribbon 56 as this ribbon 56 passes between the pressing element 70 and the drum 18. These elements 126 and 128 are connected in a conventional manner; as the ribbon 56 passes from the drum 18 it will be cooled back to room temperature or below by passing under the chilling roller 38. Because of the method of operation involved here in heating the ribbon 56 and in winding it there will be absolutely no tendency to stretch the ribbon 56 so that it necks down or reduces its width, and the constant drum 18 speed will reink evenly regardless of ribbon length.
After the ribbon 56 processed in the manner noted is completely wound upon the takeup roller 26 the tension on this ribbon 56 will gradually increasebetween rollers 18 and 54. This will apply rearward force to the idler roller 54 used on the carriage 42 for the purpose of controlling the anglethat the ribbon 56 travels as it is being processed. Such force on the roller 54 will cause the carriage 42 to be moved away from the drum 18 andwill spring the pin 58 loose from the block 62. As this occurs the switch 108 will be disengaged and will open. This will have the effect of stopping the current supplied to the solenoids 106 and the driving motor 22. When this occurs the armatures 110 of the solenoids 106 will move so as to loosen the bands 120 and driving motion stops. The springs 88 will then move the element 70 upwardly. At this point an operator will normallytake over so that the machine 10 will be used in inking or re-inking another ribbon.
|
The subject matter of this specification pertains to improvements intended to be utilized in a ribbon inking machine having a frame, a drum mounted on the frame, a carriage movably mounted on the frame so as to be capable of being used with respect to the drum, a ribbon feed roller mounted on the carriage, a ribbon inking structure mounted on the carriage, and a ribbon takeup roller mounted on the frame. Such a machine is preferably constructed to include a pressing element mounted on guide rods so as to be capable of being moved towards and away from the drum. Solenoids are used to control the tension on bands mounted on the pressing element and passing around the guide rods. When they are tightened they hold the pressing element relative to the guide rods. A mechanical mechanism provided for raising and lowering the pressing element is located on the guide rods. Although this mechanism and these bands are intended for use in a ribbon inking machine as described it is considered that other uses will be found for them.
| 1
|
This invention relates to apparatus and processes for permanently sealing abandoned well bores. More particularly, the invention relates to such apparatus and procedures used to seal abandoned water wells.
BACKGROUND OF THE INVENTION
Refilling or sealing up of abandoned water well bores is generally mandated by governmental statutes and regulations. Usually the various state Departments of Natural Resources also regulate and specify the types of material which must be introduced into the abandoned well in order to properly seal the same as well as procedures which are acceptable for such purposes. Such sealing of well bores is necessary in order to prevent surface water from entering underground aquifers from which drinking water is drawn and also due to safety concerns.
The typical regulations involved require that a material, usually a clay such as bentonite, be used to reseal the well bores. However, such materials generally must be first screened in order to avoid introduction into the aquifer of very fine materials which could interrupt or contaminate underground waterflow channels.
No suitable apparatus has been available, commercially, to fill the need for such apparatus. The procedures utilized heretofore have been painstaking, involving tedious manual operations using various hand tools. Thus, a substantial need has existed for improved procedures and apparatus which would facilitate sealing of abandoned well bores.
SUMMARY OF THE INVENTION
An important object of the invention is to provide improved apparatus for efficiently sealing abandoned well bores, especially those resulting from abandonment of water wells. A related object is to provide improved procedures, utilizing the apparatus, for sealing of such unused or abandoned well bores. As used herein, “well bore”, is intended to include the open shaft of a well whether or not a casing is contained therein.
In accordance with one aspect of the invention, the process involves the introduction of comminuted bentonite into a hopper out of which the flow of material is regulated by means of a suitable flow control mechanism. In accordance with another related aspect, the material flows from the hopper down an inclined screening surface which removes undesired fine materials prior to feeding the mixture, such as bentonite, into the well bore.
In accordance with a further aspect of the invention, a vibrating mechanism, usually employing an eccentric vibration causing means, is used to vibrate the inclined screen in order to efficiently cause separation of the fine materials from the blend which is used. Another advantage of the invention is that the vibrating mechanism also helps to efficiently cause flow of the materials out of the hopper onto the screening surface.
In accordance with still a further aspect of the invention, a collecting and distributing chute is provided at the bottom of the inclined screening surface to collect, and divert into the well bore, the screened clay materials which are used to reseal the well bore, and to efficiently direct the same into the well bore.
In accordance with further aspects of the invention, the apparatus is compact and transportable. The apparatus includes adjustable and collapsible supporting legs which can be folded against the main body of the apparatus for easy transportation thereof.
Further objects and advantages of the invention will be apparent from the following claims and detailed description of the preferred embodiment, and by the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the preferred apparatus of the invention; and,
FIG. 2 is a perspective view of the apparatus shown in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
The apparatus of this invention is generally indicated by numeral 10 . As seen, the apparatus includes flow directing apparatus in the form of a generally funnel shaped collecting/flow directing receptacle 11 . The collecting portion of the funnel-shaped flow director 11 , as best seen in FIG. 2, is preferably of a rectangular configuration, and narrows to a lower portion 12 adapted to direct the flow of particles of a well bore resealing material, such as bentonite 14 . As seen, the bentonite is directed, as indicated by arrows, into the well bore 16 .
Also, referring to the drawings, it is seen that the main body of the apparatus 10 is supported by a pair of side frame beams 18 connected by a plurality of supporting cross-members 19 . As shown, the side beams or rails 18 are formed of a C-shaped configuration, but it should be understood that other configurations may be substituted. Also, while the funnel-shaped flow director 11 , 12 is shown to be rectangular in configuration, it will be apparent to those skilled in the art that these components can be of other configurations, for example, circular.
The side frame members 18 are supported by adjustable front legs 20 and rear legs 22 , which are pivotally connected to side frame members 18 and which are preferably formed of a telescoping configuration so that the length thereof can be adjusted to adapt to various slopes and irregularities of the terrain surrounding the well.
As best seen in FIG. 1, each of the legs 22 has a telescoping end 23 and the legs 20 have telescoping end sections 21 suitable for the purpose adjusting the apparatus 10 to the slope of the terrain on which it is used.
Each of the legs 20 and 22 is connected by a bolt 25 , or similar fastener, to the side frame member 18 , so that it is pivotable thereagainst. Thus, the legs 20 and 22 can each be folded toward each other for transportation and extended downwardly, as illustrated, for use. Preferably, each of the legs is provided with a cord or cable 24 which limits the pivoting of the legs 20 and 22 , thereby stabilizing the structure of apparatus 10 during use.
Also as seen in the drawings, the apparatus 10 is provided with a material-feeding hopper 30 supported on the side rails 18 by suitable brackets 31 . Hopper 30 into which the bentonite 14 or similar material is fed is of a size convenient to receive batches of the bentonite as required for filling the well bore 16 .
At the bottom of the hopper 30 , there is provided a slidable plate 36 , which can be extended or retracted in order to control the size of the opening between the hoppers 30 and a screen 40 supported by side rails 18 and cross members 19 so that the rate of flow of the bentonite material 14 can be controlled, or discontinued entirely, when required.
Placed along the length of the space between side rails 18 is a screen 40 . Screen 40 has openings of a size such as required to remove the fines 48 from the bentonite material 14 . Generally these openings may be about ¼ inch, which has been found to comply with the most stringent code requirements which generally require a 3 minute screening period for a 50 lb. batch of bentonite. Usually, the fines are simply allowed to fall on and become blended into the surface soil adjacent to the well bore 16 . However, if desired, the fines could be removed by collection thereof on a canvass or other collecting surface.
In order to ensure efficient separation through screen 40 of fines 48 and directing of the remainder of the bentonite 14 into the collecting funnel structure 11 , there is provided a vibrating device 42 . Vibrator 42 is preferably based on the use of a rotatable mechanism which is eccentric which thus causes vibration during rotation thereof together with the entire structure of device 10 . Vibrator 42 is supported on a crossbar 44 , which is, in turn, supported on two cross rails 18 by means of suitable mounting brackets 46 .
In practice, the legs 20 and 22 are folded against the frame 18 , and held in place either by Velcro® straps 27 or rubber cords, commonly referred to as “bungee cords”, or other fastening means. Then, the apparatus 10 is erected over the abandoned well bore 16 as indicated. The side frame rails 18 are placed at a downwardly extending angle toward the chute 11 due to the differing lengths of the shorter forward legs 20 and the longer rear legs 22 . These legs are adjusted to account for irregularities in the terrain surrounding the well bore 16 . After the apparatus has thus been set-up in place, a suitable amount of bentonite 14 is placed in the upper hopper 32 and the vibrator motor 42 started. Generally, such a motor may be either gasoline powered or electrically powered, using a portable generator or power source available at the site. Then, the sliding flow control plate 36 is opened to commence the flow of the bentonite onto the inclined screening surface 40 . The bentonite 14 , with the fines 48 removed, continues its flow into the collecting chute 11 , and are dropped into the well shaft 16 . The procedure is continued until the well shaft is suitably packed with the bentonite. It will be apparent that, reversing the set-up steps after completion of the well sealing procedure, the apparatus 10 is readily retracted into a transport position for removal, either to storage, or another job site.
While preferred embodiments of the invention have been shown and described for purposes of illustration, it will be apparent to those skilled in the art that various other modifications may be made without departing from the spirit of the invention.
|
Apparatus and process for sealing of abandoned water well bores includes a hopper for dispensing comminuted well bore packing material such as a bentonite clay onto an inclined screening surface which removes undesired fine materials. A chute for collecting material flowing off of the screening surface and directing the same into the well bore is generally funnel shaped. The apparatus includes an eccentric vibrating mechanism for vibrating the inclined screening surface to remove the undesired fine materials.
| 4
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the art of hand-held labelers.
1. Brief Description of the Prior Art
The following U.S. patents are made of record: U.S. Pat. No. 3,330,207 to DeMan granted Jul. 11, 1967 and U.S. Pat. No. 4,116,747 to Hamisch, Jr. granted Sep. 26, 1978.
SUMMARY OF THE INVENTION
This invention relates to an improved hand-held labeler capable of feeding a relatively long label.
In accordance with one embodiment of the invention, there is provided a hand held labeler for printing and applying pressure sensitive labels. The labeler has a housing which mounts a platen and a cooperable print head. The print head moves toward and away from the platen to effect printing. A manually operable actuator is disposed at a handle of the housing. When the actuator is moved in one direction, the print head is moved toward the platen and a feed wheel is advanced to advance a label carrying web. When the actuator moves in the opposite direction, the print head moves away from the platen and the feed wheel is advanced further to further advance the label carrying web. The advance of the web is caused by a first pawl and ratchet mechanism coupled to the feed wheel and the further advance is caused by a second pawl and ratchet mechanism. As the print head nears printing cooperation with the platen, the first pawl and ratchet mechanism is rendered ineffective. This causes the advance of the feed wheel to be interrupted to avoid the possibility of smearing the printing when the print head cooperates with the platen to print on an intervening label.
In another embodiment there is provided a one-way clutch for driving the feed wheel as the print head is moving toward the platen.
In both disclosed embodiments, the gearing is tailored to the desired length of advance of label carrying web during each cycle of operation. It is preferred that the print head be mounted for straight line movement and that the actuator oscillate in one direction and in a direction opposite to the one direction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a hand-held labeler of the invention equipped with a roll of labels;
FIG. 2 is an exploded perspective view of the labeler shown in FIG. 1;
FIG. 3 is a fragmentary perspective view showing a portion of the labeler and the label roll; FIG. 4 is a fragmentary, exploded, perspective view of some of the components shown in FIG. 3; FIG. 5 is a perspective view of a ratchet wheel shown in FIGS. 3 and 4;
FIG. 6 is a perspective view of a compound gear shown in FIGS. 2, 3 and 4;
FIG. 7 is a side elevational view of gearing also shown in FIGS. 3 and 4;
FIG. 8 is a sectional view taken along 8--8 of FIG. 7;
FIG. 9 is a perspective view of an applicator assembly at a front end portion of the labeler;
FIG. 10 is an exploded perspective view of the applicator assembly also shown in FIGS. 1, 2 and 9;
FIG. 11 is a sectional view showing the applicator assembly mounted at the front end portion of the labeler;
FIG. 12 is a fragmentary, exploded, perspective view of an alternative embodiment of the labeler; and
FIG. 13 is a perspective view of one of the gears shown in FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present application relates to improvements over a hand held labeler depicted in U.S. Pat. No. 4,116,747 of Paul H. Hamisch, Jr. assigned to Monarch Marking Systems, Inc. While retaining the essential structure, function and arrangement of parts of the labeler depicted in U.S. Pat. No. 4,116,747, but adding the improvements shown and described in the present application, applicants have been able to print and apply labels of substantially greater length. Accordingly, U.S. Pat. No. 4,116,747 is incorporated herein by reference and this patent may be referred to for further details. In instances which components of the present invention are the same or essentially the same as components in U.S. Pat. No. 4,116,747, the same reference characters are used.
With reference to FIG. 1 of the present application, there is shown a labeler 300 having a housing or frame 31. The housing 31 supports a roll R of a composite label web C of pressure sensitive labels L. The labels L are releasably adhered to the supporting material or carrier web S. The housing 31 is shown to have a handle 111 at which an actuator 113 in the form of a lever 114 is pivotally mounted. An applicator assembly or applicator head 307 which includes an applicator 306 in the form of a pair of rolls 306' is disposed at the front end portion of the housing 31 of the labeler 300. If desired, the applicator 306 can be made of a one-piece roll which is twice as wide as one of the rolls 306', and as such would be easier to assemble onto the applicator head 307.
With reference to FIG. 2, there is shown the labeler 300 with its housing 31 which includes frame or housing sections 32 and 33. The housing section 33 has a post 303 connected to the housing section 32 by a screw 39. The housing 31 mounts a subframe 40 comprised of substantially mirror image subframe sections 41 and 42. The subframe sections 41 and 42 have ball tracks 45 and 46. A print head 301 has a pair of opposed ball tracks 131 and 132. A ball bearing strip 47 is received between tracks 45 and 131 and a ball bearing strip 48 is received between tracks 46 and 132 to guide the print head 301 for straight line movement on the subframe 40. Straight line movement of the print head 301 is preferred as it produces the best printing, as compared, for example, with pivotal movement of the print head. The print head 301 has a set of printing members 301' which are selectively movable by a selector 302'.
There is a feed wheel assembly 57 which includes a feed wheel 69 having teeth 68 to which a ratchet wheel 133 is coupled. The teeth 68 are arranged in a staggered pattern and engage staggered feed slits or holes in the carrier web S. The ratchet wheel 133 cooperates with a pawl 164 to provide a pawl and ratchet mechanism 349'. The pawl 164 is pivotally mounted on a second gear 119. A first gear 118 meshes with a first gear section 116 and a first rack 121. The gear 119 meshes with a second gear section 117 and a second rack 122. The gear I 19 rotates on a tubular portion 149 and the gear 118 rotates on a collar 41' formed integrally with subframe section 41. The lever 114 is pivoted at its lower end portion to the lower end portion of the handle 110. A resilient device 123 urges the actuator 113 counterclockwise as shown in FIG. 2.
The label roll R is mounted in the hub members 304 and 305 which are mounted to respective subframe sections 41 and 42 by means of retainers 179. The composite label web C passes from the roll R over and through a resilient device 305 secured to the subframe sections 41 and 42. From there the web C passes partly around a roller 54 and over the platen 85. The composite web C passes beneath a hold down and guide member 92. The carrier web S makes a sharp bend about the delaminator 86 and the label L (shown in phantom lines in FIG. 11) passes into underlying relationship to an applicator head 307. From there the carrier web S passes about the roller 53 and passes between die roller 66 and the feed wheel 69. As shown, the die roller 66 is rotatably mounted by a holder 59. A stripper 308 secured to the subframe 40 strips the advancing carrier web S from the feed wheel 69.
Movable housing section or cover 191 is pivotally mounted on the post 34. The cover 191 has shoulders 206 which latch with the latch 76. A guide plate 70 is adjacent the feed wheel 69 and the stripper 308.
The cover 191 carries an inking mechanism 309 comprised of a pivotal member 310 and an ink roller 227.
Turning to the improvement which enables the labeler 300 to feed long labels L, there is shown in FIG. 2 an integrated molded compound gear generally indicated at 311 which includes a small gear 312 and a larger gear 313. A gear 314 meshes with the gear 118 and gear 312. The gear 313 meshes with a gear 315. The gear 315 pivotally mounts a pawl 316 which cooperates with a ratchet in the form of a ratchet wheel 317. The ratchet wheel 317 is coupled to the feed wheel 69.
As shown in FIGS. 2, 3 and 4, the gears 311 and 314 are rotatably mounted on respective tubular members 318 and 319 of a bracket 320. The tubular members 318 and 319 receive respective studs 318' and 319' on the subframe section 41. Screws 321 threadably received by the studs 318' and 319' hold the bracket 320 in position. The ratchet wheel 317 has an integral tubular sleeve 323. The gears 118 and 315 are rotatably mounted on the collar 41'. As shown in FIG. 5, there is an integrally formed cross-shaped member 324 coaxially of the ratchet wheel 317 and the sleeve 323. The member 324 is received in a cross-shaped hole 325, and thus the ratchet wheel 317 and the feed wheel assembly 57 are coupled. One arm 326 of the member 324 is large and three arms 327 are small. Likewise, one pocket or recess 328 is large and three pockets or recesses 329 are small. The arm 326 is received in the pocket 328 and the arms 327 are received in the pockets 329. Thus, the ratchet wheel 317 is keyed to the feed wheel assembly in one and only one angular position, so that the feed wheel assembly 57 and the ratchet wheel 317 are always in their proper orientation with respect to each other.
The pawl 316 is pivotally mounted to the gear 315 as best shown in FIGS. 4 and 8. The pawl 316 has a split projection 330 and a head 331. Once the head 331 is snapped into a hole 331' in the gear 315, the pawl 316 is captive but can pivot in the hole 331'.
As shown in FIG. 7, the pawl 316 has a tooth 332 cooperable with one of the four teeth 333 of the ratchet wheel 317. The pawl 316 has an integrally formed leaf spring 334 which normally urges a side of surface 335 of the tooth 332 against the outer surface 336 of the ratchet wheel 317. As the gear 315 rotates counterclockwise as seen in FIG. 7, the pawl 316 which the gear 315 carries also moves counterclockwise until its tooth 332 engages the tooth 333 on the ratchet wheel 317. Continued counterclockwise rotation of the gear 315 and the pawl 316 causes the ratchet wheel 317 to be driven counterclockwise. The pawl 316 has an integrally formed cam follower 337 which cooperates with a cam surface 338 on the bracket 320 when the pawl 316 has driven the ratchet wheel 317 through a predetermined angle so that the tooth 332 on the pawl 316 moves radially outwardly and out of driving contact with the tooth 333 on the ratchet wheel 317. When this drive connection between the pawl 316 and the ratchet wheel 317 ceases to exist, the ratchet wheel 317 ceases to rotate even though the counterclockwise rotation of the gear 315 and the pawl 316 continues. It should be noted that when the user operates the actuator 11 3, the gear sections 11 6 and 117 drive the gears 118 and 119 which in turn drive the racks 121 and 122 with which the print head 301 is connected. Thus, the actuator 113 moves upon complete actuation of the actuator 113 until the print head 301 is in printing cooperation with the platen 85. The cam follower 337 and the cam surface 338 are constructed so that the tooth 332 loses its drive connection with the tooth 333 as the print head 301 is nearing and continues to move to the printing cooperation with the platen 85 and the intervening label L, but before such printing cooperation occurs. This prevents smearing of the printing which may occur if advance of the feed wheel 69 continues up to such printing cooperation. As the actuator 113 is operated in one direction, referred to herein as a first direction, to move the print head 301 in a first direction toward the platen 85, the gear 119 brings the pawl 164 pivotally mounted on the gear 119 into a ready position. When the user releases the actuator 113, the resilient device 123 acts on the actuator 113 to move the actuator 113 in the opposite direction, which can be referred to as a second direction. This causes the gears 118 and 119 to rotate to move the print head 301 in a second or return direction. During such return movement of the actuator 113 and the print head 301, the gear 119 causes the pawl 164 to cooperate with the ratchet wheel 133 to resume advance of the feed wheel 69 and to further advance the carrier web S. During the return movement, the gears 118, 312, 313, 314 and 315 return to their initial positions, and the pawl 316 returns to its initial position ready to engage the next tooth 333 on the ratchet wheel during the next cycle.
With reference to FIGS. 9, 10 and 11, the applicator head 307 is shown to include a molded body 340 having a pair of spaced arms 341 with aligned holes 342. The body 340 is preferably composed of a material which is somewhat flexible and resilient to withstand impact when the labels are being applied to merchandise, and when the labeler 300 is dropped. A suitable material is a urethane. A pin 343 press fitted into the holes 342 extends through holes 344 in the applicator rolls 306' of the applicator 306. The arms 341 thus straddle the applicator rolls 306'. The pin 343 rotatably mounts the applicator rolls 306'. The body 340 also have a pair of spaced arms 345 which receive the post 303. The body 340 also has U-shaped aligned grooves 346 which capture a tongue 347 on the inker spring 302. The inker spring 302 has a forked end 302" which captures a tongue 347' on the housing 31. As shown, the applicator head 307 is cantilevered to the frame 31. This assures that the applicator 306 is sufficiently far from the peel roller 86 to be able to apply a long label L.
With reference to FIGS. 12 and 13, there is disclosed an alternative embodiment which is identical to the embodiment of FIG. 1 through 11 except as described below. Like reference characters are used for parts that has the same construction, function and relative locations as parts in the embodiment of FIGS. 1 through 11. In the embodiment of FIGS. 12 and 13, gear 314' and gears 312' and 313' of a compound gear 311' are identical to the respective gears 314, 312 and 313 except that the gear 314' and the compound gear 313' have stepped inside diameters and are mounted on stepped posts 318" and 319" and bushings 311a and 314a. The housing section 32 is close enough to the gears 311' and 314' so that the gears 311' and 314' do not shift axially on the posts 318" and 319". The gear 314' meshes with the gear 118 and with the gear 312'. The gear 313' meshes with the gear 315'. The gear 315' has an integral shaft 350 received by a one-way clutch 351. The gear 315' can rotate in one direction (clockwise as viewed in FIG. 12) without imparting any motion to the feed wheel assembly 57, but the clutch 351 clutches to the shaft 350 when the gear 315 rotates counterclockwise to drive the feed wheel assembly 57 to advance the web C. The one-way clutch 351 is received in a tubular end portion 352 of the feed wheel assembly 57. The gears 118 and 315' rotate on the collar 41'. When the actuator 113 is released, the pawl 164 and the ratchet 133 further advance the carrier web S as explained with respect to the embodiment of FIGS. 1 through 11, and also the gears 314', 312', 313' and 315' return to their initial positions as permitted by the one-way clutch 351.
The gears 311, 3 14 and 315 in the one embodiment and the gears 311', 314' and 315' in the other embodiment are considered to constitute gearing. The pawl 316 and the ratchet wheel 317 are considered to be the pawl and ratchet mechanism 349. The gear section 116, the gear 118, the set of gears 312, 313, 314 and 315, the pawl 316 and the ratchet 317 is considered to be a drive connection. The gear section 117, the gear 119, the pawl 164 and the ratchet 153 is considered to be a drive connection.
Although the invention is disclosed in connection with a labeler that both prints and applies labels, it can be used in connection with a labeler or applicator which only applies, but does not print, labels.
The expression "label" as used in this application is intended to include tape.
Other embodiments or modifications of the invention will suggest themselves to those skilled in the art, and all such of these as come within the spirit of this invention are included within its scope as best defined by the appended claims.
|
There is disclosed a hand-held labeler which can feed and apply a relatively long label or tape to merchandise or packaging. In one embodiment the feeding of the label web is accomplished by using a feed wheel that is driven both during the feeding stroke of a manual actuator and during its return stroke. The print head is driven toward and away from a platen during each cycle and the advance of the feed wheel is interrupted as the print head nears printing cooperation with the platen and the intervening label. In another embodiment some of the advance of the feed wheel is through a one way clutch.
| 1
|
FIELD OF THE INVENTION
This invention relates to an improved method and apparatus for controlling slurry pressure in a filter press in which slurry material is supplied under pressure to a plurality of filter plates by a feed pump and, more particularly, to a method and apparatus in which the slurry pressure is detected by a sensor and adaptively controlled throughout the filtration cycle in a manner which decreases the filtration cycle time while increasing its efficiency.
BACKGROUND OF THE INVENTION
Referring to the general type of filter press mentioned above, if the slurry is initially pumped into the filter press too quickly under too much pressure, this results in the phenomenon known as "blinding" wherein the particulate in the slurry is driven with excessive force into the filter cloth of the filter plates, which disadvantageously clogs the filter cloth. It is therefore desirable to feed the slurry more gradually into the filter press so that the particulate gradually accumulates on the filter cloth to create a particulate bed on the filter cloth. This gradually-accumulated particulate bed filters the remaining slurry upstream thereof.
The aforementioned gradually-accumulated particulate bed is conventionally produced by stepwise increasing the feed pump pressure over time until the slurry pressure eventually reaches a desired end pressure value. However, in order to ensure effective filtering, the magnitude and timing of the stepwise pressure increments are typically determined based on a laboratory analysis of the slurry and the characteristics of the press filter being used. The filter press is typically provided with control devices such as relays, switches and timers which are then configured to produce the desired pressure increments at the desired times.
Thus, the aforementioned stepwise pressure increment approach requires calculation of the magnitude and timing of the pressure increments for each different slurry to be filtered. Moreover, the aforementioned relays, switches and timers introduce undesirable mechanical complexity and require a relatively large amount of space. In addition, the stepwise pressure increment approach requires a preset filtration cycle time (based on the calculated timing parameters) which cannot be adaptively adjusted during the cycle. Further, this approach does not take into account, or adjust for, operational or environmental changes which occur from cycle to cycle.
Hence, although the conventional stepwise pressure increment approach is effective to avoid the "blinding" phenomenon, the benefits of this approach are nevertheless offset to some extent by the disadvantageous factors mentioned above.
One conventional system uses a programmable logic controller (PLC) to control the stepwise pressure increments. This system eliminates some of the difficulties associated with electromechanical control devices, but does not address the other disadvantages mentioned above. A special programming unit is required to program the predetermined cycle parameters into the PLC. Whenever new cycle parameters are required for a new slurry, the programming unit must be temporarily connected to the PLC to program the new cycle parameters into the PLC.
In some conventional systems, a pressure switch is provided in the air supply to the feed pump. Each time the feed pump executes a stepwise pressure increment, the air pressure drops temporarily and causes the pressure switch to activate a timer. However, using this approach, the range of acceptable pressure increments is limited by the sensitivity of the pressure switch. That is, the pressure switch will not trigger the timer unless the pressure increment is sufficient to cause an air pressure drop at least as large as the sensitivity of the pressure switch. Also, the pump pressure is subject to pressure head losses and the like, and consequently the pressure switch can be erroneously actuated.
One known system has attempted to avoid the aforementioned step-wise pressure increment method, and instead has utilized sensors and controls which attempt to regulate the air supply pressure to the pump in response to the slurry pressure leaving the pump so that the pump and slurry pressure are maintained in closer relationship to one another throughout the filter press cycle. This known arrangement, however, is believed to experience operational difficulties caused by the fact that the pump air pressure always attempts to respond to the slurry pressure. In this respect, the Assignee has discovered that in some cycles during filling of the filter press the slurry pressure will suddenly significantly drop prior to again resuming a gradual increase, possibly due to sudden dislodgement of clogs within the press. When these sudden slurry pressure drops occur, it has been observed that if the pump air pressure is allowed to drop due to its responding to the slurry pressure in an attempt to maintain a uniform pressure differential therebetween, then often times can cause a stall condition in the pump and hence seriously disrupt proper operation of the filter press. Further, in this known arrangement, the cycle terminates by activating a timer when a predetermined maximum slurry pressure is reached, which timer permits the press to continue to operate for a preset period of time, such as about two hours, before shutting down the system. This can, in some instances, cause premature shut down of the press prior to complete filling thereof, such as occurs when a premature pressure spike occurs so as to activate the maximum pressure sensor.
Considering the aforementioned approaches to slurry pressure control during the filtration cycle, none of them is capable of adjusting slurry pressure near the end of the cycle, that is, the slurry end pressure. However, Applicants have recognized that adjustment of slurry end pressure facilitates an increase in the filtration cycle efficiency so as to permit shut down of the press only when the press is full.
It is therefore an object of this invention to provide an improved filter press control apparatus, and a method of control, which overcomes many of the advantages associated with prior control methods and apparatus for filter presses.
It is therefore one object of the present invention to provide a slurry press control method and apparatus which can suitably adjust end pressure, and in fact respond to pressure changes after the maximum end pressure has been sensed, to permit continued operation of the filter press and resetting of the end pressure if certain operational conditions are met so as to ensure that the end pressure, when sensed, will permit shut down only when the press is substantially full.
It is another object of the present invention to provide a slurry pressure control method and apparatus, as aforesaid, which is able to sense and respond to, and hence adjust the preset end pressure, such as when the air line pressure decreases, so that the end pressure will still be sufficiently less than the line pressure to permit shut down of the press upon completion of the cycle.
It is a further object of the present invention to provide a slurry pressure control method and apparatus, as aforesaid, which avoids the "blinding" phenomena while also avoiding the disadvantages associated with the prior art approach of stepwise pressure increments.
It is still a further object of the invention to provide a slurry pressure control method and apparatus which is capable of maintaining a substantially uniform pressure differential between the pump and slurry pressures throughout the filling cycle to optimize the filling of the press, with the control method and apparatus being such as to maintain the pump pressure constant when the slurry pressure decreases during the cycle so as to prevent control problems such as pump stall.
It is another object of the present invention to provide a slurry pressure control method and apparatus, as aforesaid, which enables the filter press cycle to automatically proceed substantially unattended between press start up and shut down so that a complete cycle can be carried out without requiring substantial or constant operator control and/or observation.
It is still another object of the invention to provide an improved slurry control method and apparatus, as aforesaid, wherein the press has a visual display and controller provided directly thereon which permits easy inputting of various cycle parameters such as initial start pump pressure, slurry cycle end pressure and the like, and which provides during the operating cycle a visual display of all critical and desirable operating conditions, with the visual display permitting the various conditions to be sequentially visually displayed on the control panel, with such display being automatically or manually scrolled to provide the operator with important information as to the current status of the cycle without requiring continuous monitoring or attendance by the operator.
A method for controlling the filling of a filter press with slurry according to a preferred embodiment of the present invention includes the sequentially executed steps of: gradually increasing the pressure of the slurry supplied to thee press until the slurry pressure reaches an upper pressure limit; recording a trigger point in time at which the slurry pressure reaches the upper pressure limit; and determining whether the slurry pressure subsequently falls below a lower pressure limit within a predetermined period of time commencing at the trigger point. If the slurry pressure does fall below the lower pressure limit within the predetermined period of time, then the above-listed sequence of steps is repeated until the slurry pressure fails to fall below the lower pressure limit within the predetermined period of time, thereby indicating that the press is full and terminating the process.
The aforementioned method is preferably carried out by providing the press of the invention with a control panel thereon which contains suitable control means, such as a suitable microprocessor, capable of responding to a signal which is indicative of the slurry pressure leaving the pump so as to adjust the air pressure supplied to the pump to maintain a substantially constant differential therebetween, except for the air pump pressure being maintained substantially constant when the slurry pressure decreases, with the pump pressure remaining constant until the slurry pressure again builds up so as to permit resumption of the predetermined differential between the pressures. The controller also preferably includes a visual display panel directly on the press for permitting operator-setting of cycle parameters, and for also permitting display of actual cycle parameters and conditions throughout the rather lengthy press filling cycle so as to permit the operator to readily and promptly obtain necessary information without requiring constant attendance or supervision by the operator.
Other objects and purposes of the invention will be apparent to persons familiar with systems of this general type upon reading the following specification and inspecting the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment of the invention is described in detail below with reference to the drawings, in which:
FIG. 1 is a side elevational view of a filter press which embodies the present invention;
FIG. 2 is an exploded view of a portion of the filter press of FIG. 1;
FIG. 3 is a diagrammatic view which illustrates the manner in which the present invention filters slurry material and controls slurry pressure;
FIG. 4 is a graph which illustrates pump pressure and slurry pressure during a filtration (i.e. press filling) cycle according to the present invention;
FIG. 4A corresponds to the graph of FIG. 4 but illustrates the control of the pump pressure during the filling cycle when the slurry pressure decreases;
FIG. 5 is an enlargement of a portion of FIG. 4;
FIG. 6 is a flow chart illustrating the process by which the present invention controls slurry pressure during filling of the press;
FIG. 7 illustrates a variation for incorporation into the control process of the present invention, which variation is illustrated for incorporation into the flow chart of FIG. 6;
FIG. 8 illustrates the control panel and visual display as associated with the filter press;
FIG. 9 is a flow chart illustrating, in steplike sequence, the visual displays and prompts which appear on the display panel when setting (i.e., programming) the operational parameters of the press cycle; and
FIG. 10 is a flow chart similar to FIG. 9 which illustrates some of the displays which are sequentially provided on the display panel of the press to initiate and during the cycle of filter press operation.
Certain terminology will be used in the following description for convenience in reference only, and will not be limiting. For example, the words "upwardly", "downwardly", "rightwardly" and "leftwardly" will refer to directions in the drawings to which reference is made. The words "inwardly" and "outwardly" will refer to directions toward and away from, respectively, the geometric center of the press and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof, and words of similar import.
DETAILED DESCRIPTION
FIGS. 1-3 illustrate a filter press 10 embodying the present invention. The filter press 10 includes a frame 11 having a pair of upright supports 13 and a pair of generally parallel, horizontal slide rails 15 supported on the supports 13 and extending generally horizontally therebetween.
A movable head or follower 21 is supported for sliding movement longitudinally along the slide rails 15. A fluid pressure cylinder 17 is mounted on one of the supports 13. A cylinder rod 19 is extendable from and retractable into the pressure cylinder 17. The cylinder rod 19 extends generally parallel to the slide rails 15 and has one end connected to the movable head 21, whereby the pressure cylinder 17 effects reciprocal sliding movement of the movable head 21 along the slide rails 15.
A stationary head 23 is fixedly mounted on the other support 13, and a plurality of filter plates 25 are interposed between the movable head 21 and the stationary head 23. The filter plates 25 are supported on the slide rails 15 and are freely reciprocally slidable thereon between the upright supports 13.
Each of the filter plates 25 has a pair of parallel enlarged faces, each of which is provided with a filter cloth 27. The filter cloths 27 lie in substantially vertical planes which are perpendicular to the slide rails 15. A central opening 33 extends completely through each of the filter plates 25 at the center of the filter cloths 27.
When the pressure cylinder 17 is actuated so as to slide the movable head 21 rightwardly in FIG. 1, the filter plates 25 are pressed together between the heads 21 and 23 in snugly adjacent, sealed relationship relative to one another. The sealed relationship between adjacent filter plates 25 may be effected by, for example, a suitable O-ring or gasket as is well known in the art.
Each filter plate 25 is a generally hollow, rectangular body having an interior space or chamber 26 defined there-inside and separated from the exterior thereof by the filter cloths 27. The filter plates 25 are provided with return passages 31 which communicate with the interiors 26 of the filter plates 25 for permitting clear filtrate to be returned from the filter plates. As shown in FIG. 3, when the filter plates 25 are disposed in adjacent sealed relationship, the return passages 31 define return conduits 31' which carry clear filtrate out of the filter press 10.
Pressurized slurry material is supplied to the filter press 10 from a feed pump 35 via a supply inlet 37. The feed pump 35 is conventionally a double-diaphragm air-activated pump connected by an air line 36 to a source of pressurized air 38, such as a central pressurized air supply within a building. The slurry supply inlet 37 communicates through the head 23 with the aligned central openings 33 of the filter plates 25. Slurry chambers 29 are defined between opposing filter cloths 27 of adjacent filter plates 25. The slurry material passes from the supply inlet 37 through the aligned central openings 33 and into the slurry chambers 29 as illustrated by the arrows in FIG. 3. When the slurry is sufficiently pressurized, particulate accumulates on the filter cloths 27 while clear filtrate passes through the filter cloths 27 into the interiors 26 of the respective filter plates 25 and ultimately into the return conduits 31'. The particulate accumulates in the slurry chambers 29, forming filter cakes C as shown in FIG. 2. The filter plates 25 are thereafter slidably separated, and the filter cakes C are removed.
The description of the structure and operation of the filter press as described above is well known, and further detailed description of the press is believed unnecessary. The following description will hence be directed to the control apparatus and method associated with the filter press for optimizing start up and filling of the press with filtrate throughout a cycle, optimizing shut down of the press when filled so as to complete the cycle, and controlling of the press in response to changing external or internal operating conditions and parameters so as to optimize the filling efficiency of the cycle.
A pressure sensor 39 is provided to monitor the slurry pressure supplied to the press. In the disclosed embodiment, the pressure sensor is disposed at the supply inlet 37 between the feed pump 35 and the filter press 10, normally adjacent the pump discharge. Because the pressure sensor 37 interacts with the slurry material, it is necessary to use a sensor which will not be clogged by the slurry material. A conventional diaphragm sensor accurately detects the slurry pressure without being clogged by the slurry material.
The feed pump 35, as noted above, is preferably an air-activated diaphragm type pump. The slurry pressure is characterized by a sequence of pressure pulses. These pressure pulses are detected by the sensor 37, and the output of the sensor 37 is filtered by a smoothing filter 41 which eliminates short spikes associated with the pulsing slurry pressure. Thus, the output of filter 41 essentially represents an average value of the pulsing slurry pressure. This average slurry pressure is provided to a control unit 43 which controls the feed pump 35 in response to the slurry pressure. More specifically, the control unit 43 controls the pressure regulator R so that the pressure supplied through line 36 from the air source 38, the latter being typically a rather high and fairly uniform pressure, is reduced so that the actual air pressure supplied to the pump 35 (i.e. the pump pressure) is only a small amount greater than the actual slurry pressure, as explained in detail below. The control unit 43 preferably includes a conventional microprocessor circuit, as will be evident from the following description.
FIG. 4 illustrates pump pressure and slurry pressure during a filtration (i.e. press filling) cycle according to the method of the present invention. The air pressure P a to the feed pump 35 (shown by solid line in FIG. 4) is set to an initial value P 0 (about 25 PSI in a typical cycle) and, when the slurry pressure P w (shown by broken line in FIG. 4) rises to within a predetermined range of the air pressure, the air pressure P a is then increased so as to normally continuously maintain a predetermined pressure difference δP between the pump pressure and the slurry pressure P w . This difference δP between pump pressure and slurry pressure is referred to as lead pressure, and the lead pressure is preferably approximately 5 PSI in the disclosed embodiment.
When the air pressure P a to the feed pump reaches an upper pressure limit P 1 , it is maintained at that upper pressure limit. Thereafter, the slurry pressure P w eventually reaches the upper pressure limit P 1 . After the slurry pressure initially reaches the upper pressure limit, it will often subsequently drop substantially to a pressure level below a lower pressure limit P 2 , the latter typically being about 10 PSI less than P 1 . This may indicate that the press is not yet filled, and hence the utility of the filtration cycle is not necessarily exhausted just because the slurry pressure has reached the upper pressure limit P 1 .
Referring to FIG. 5, when the slurry pressure initially reaches the upper pressure limit P 1 , a timer in the control unit 43, which timer has a preset timer value T v programmed therein, is initialized and started. The filtration cycle is not considered finished unless and until the slurry pressure remains above the lower pressure limit P 2 for the entire duration of the timer. Thus, if the slurry pressure falls below the lower pressure limit P 2 before the timer times out or expires (δt 1 <TIMER VALUE), then the timer is deactivated and is reset and restarted only when the slurry pressure again reaches the upper pressure limit P 1 . This procedure is continued until the slurry pressure fails to fall below the lower pressure limit P 2 before the timer value T v expires. When the slurry pressure fails to fall below the lower pressure limit before the timer expires (δt 2 ≧TIMER VALUE), then the press is full, the filtration cycle is over, the feed pump is shut down, and the filter plates are thereafter sequentially separated to dump the filter cakes.
Referring now to FIG. 4A, wherein there is again illustrated the relationship between the pump and slurry pressures during the press filling cycle, it sometimes occurs that the slurry pressure P w may undergo a substantial decrease over a significant time period during the filling cycle. While the reason for such decrease in slurry pressure is not always known, nevertheless sometimes partial clogs of filtrate within the press become dislodged and repositioned to reduce resistance to further supply of slurry and hence cause such pressure decreases. When such decrease occurs, the pump air pressure P a according to the present invention is maintained constant by the control unit 43, rather than being decreased so as to maintain the differential δP constant. By maintaining the pump air pressure P a constant during the slurry pressure decrease, proper control of the system is maintained and pump stall is prevented. Thereafter the slurry pressure P w will again build up to the point whereby the desired differential δP again exists between the pump and slurry pressures, at which time further increases in slurry pressure will again be sensed by the sensor and signals sent to the controller 43 so as to again permit the pump air pressure to be increased to maintain the desired pressure different δP therebetween.
In a typical embodiment, the upper pressure limit P 1 is approximately 100 PSI, the lower pressure limit P 2 is approximately 95 PSI, and the timer value is approximately 10 minutes (TIMER VALUE=10 minutes). Since the building line air pressure at 38 is typically between about 100 and 120 PSI, the upper limit P 1 is hence selected to be somewhat less than line air pressure. However, parameters such as upper limit pressure P 1 , initial pump pressure P 0 and timer value T v , can be easily changed and programmed into the control unit 43 via the control panel 45 provided on the press, as explained below. Hence, the pertinent operating parameters are easily changed using the control panel 45.
FIG. 6 is a flowchart illustrating the method of controlling slurry pressure P w according to the present invention to achieve the operation illustrated in FIGS. 4 and 5. Initially, the desired operating parameters such as the upper pressure limit P 1 , initial pump pressure P 0 and timer value T v are selected at 51, as explained in detail hereinafter. The lower pressure limit P 2 (as a function of P 1 ) and the pressure differential δP are typically preprogrammed, but could also be selected if desired. Thereafter, at 52, the feed pump is started at the selected initial pressure P 0 .
After starting the feed pump at 52, the sequence of steps at 53-58 is repeatedly executed until the pump pressure reaches the upper pressure limit P 1 . More specifically, the pressure sensor 37 is used to determine slurry pressure at 53, and the actual pump lead pressure δP is determined at 54 by the detected slurry pressure from the pump pressure. At 56, if the actual pump lead pressure is greater than or equal to the desired pump lead pressure δP, then the pump pressure temporarily remains constant and execution returns to 53. Otherwise, if the actual pump lead pressure δP is less than the desired pump lead pressure programmed into the control unit 43, then execution proceeds to 57 where the slurry pressure P w is compared to the upper pressure limit P 1 .
At 57, if the slurry pressure is less than the upper pressure limit P 1 , then the pump pressure is increased at 58 by the control unit 43 controlling the pressure regulator R, and thereafter execution returns to 53. If the slurry pressure has reached the upper pressure limit P 1 at 57, then execution of the sequence of steps 53-58 ends, and another sequence of steps 59-62 begins.
When the slurry pressure P w reaches the upper pressure limit P 1 at 57, the timer of control unit 43 is initialized and started at 59. After the timer is started at 59, then the slurry pressure is continuously updated and compared to the lower pressure limit P 2 until either the slurry pressure reaches the lower pressure limit at 62 or the timer expires at 60. If the slurry pressure reaches the lower pressure limit at 62 before the timer expires at 60, then the sequence 53-62 begins again. On the other hand, if the timer expires at 60 before the slurry pressure reaches the lower pressure limit at 62, then the filtration cycle is completed and the pump is shut down.
It should be evident from FIG. 6 that, once the operating parameters are selected at 51 and the feed pump is started at 52, the remainder of the control method is executed automatically by the arrangement illustrated in FIG. 3. Furthermore, the operation illustrated in FIGS. 4 and 5 reflects the current operating conditions in the filter press and therefore permits adaptive control and efficient use of the filtration cycle time. More specifically, the filtration cycle time reflects the actual conditions in the filter press and is not fixed at a preset time value as is required when predetermined stepwise incremental pressure increases are used. Thus, whenever conditions in the filter press are such as to permit decreasing the filtration cycle time, then the method of the present invention will automatically decrease the filtration cycle time. In addition, the present invention's treatment of the end slurry pressure permits an increase in the filtration cycle efficiency because the current filtration cycle does not end until the filter press capacity and hence its utility has been sufficiently exhausted.
Since the source or line pressure P s in the centralized building supply has been observed to undergo significant fluctuations which cause it to be substantially less than the typical expected value, such as during cycles when a facility is under heavy use, it has been observed that the line pressure P s , instead of typically being at or in excess of 100 PSI, may drop significantly below 100 PSI, and in fact may drop below the predetermined upper pressure limit P 1 . In such instance, since the maximum pump air pressure will always be equal to and more typically slightly below maximum line pressure P s due to head losses and the like, the press would be unable to develop a slurry pressure equal to the upper pressure limit P 1 , and the cycle would not terminate and shut down the press. The microprocessor control of the present invention preferably incorporates therein additional controlling limitations which are depicted by the control steps of FIG. 7.
As indicated by FIG. 7, the control preferably includes the additional steps of determining the pressure P s of the air source at 63, such being through a further pressure detector S2 for feeding a pressure signal to the control unit 43. The preprogrammed or preset upper pressure limit P 1 is then compared to the detected actual pressure of the air source at 64 and, if the air source pressure is greater than the upper pressure limit P 1 , then the control sequences to the next step 53.
However, if the upper pressure limit P 1 at step 64 is not less than the air source pressure P s by at least a minimal predetermined pressure differential, such as about 5 PSI, then the control will reduce the value of the upper pressure limit P 1 at 65 to a value which will be a small predetermined differential below the air source pressure P s and then returned to step 63 to again permit repeating of steps 63 and 64 and thence onto step 63 when applicable. In this fashion, the upper pressure limit P 1 will be continuously adjusted and reduced throughout the filtration cycle, if necessary, to ensure that it is sufficiently less than the source pressure P s to permit termination of the cycle and shut down of the press.
Referring now to FIG. 8, there is illustrated the control panel 45 which, in the preferred embodiment of the invention, is mounted directly on the filter press for providing control of the press, including the inputting of operating parameters into the microprocessor control, and the observing of control and operational conditions. This panel 45 includes a first keypad 71, preferably a membrane-type keypad, for enabling the operator to readily input operating parameters, control the operation of the press, and observe the operating conditions and parameters during an automated operating cycle. For this purpose, the keypad 75 includes three MODE keys, namely "display", "set-up" and "manual" keys; four FUNCTION keys, namely "select", "set", "on" and "off" keys; two VALUE keys, namely "plus" and "minus" keys; which keys permit inputting of operating parameters and selection of the various operating modes and functions. The second keypad 72, also of the membrane type, includes "on" and "off" POWER keys; "open", "closed" and "stop" PRESS keys for respectively controlling the opening and closing movement of the press or stopping such movement; "on" and "off" HYDRAULIC keys for controlling the hydraulic system which pressurizes the press in the closed condition; and "on" and "off" CYCLE keys which control the operational cycle of the press. The keys defining the keypad 72 are primarily for operation of the press, namely the initiation and control of an operational cycle.
Control panel 45 also contains thereon a visual display 73, preferably a LED display, which provides the operator with warnings, programming instructions, set-up and operating instructions, and operating conditions which can be either manually or automatically scrolled across the visual display, as explained below.
Referring now to FIG. 9, there is presented a flow chart which illustrates the visual displays which, in a typical embodiment, will sequentially appear in the display 73 of the control panel 45 (FIG. 8) during initial programming of the microprocessor control by the press operator. These are briefly summarized as follows:
Steps 101-106
The operator pushes the POWER "ON" key and the display 101 appears in window 73. To program the operating parameters of the press, the operator pushes the MODE "SET-UP" key, and the displays 102-106 will sequentially appear in the window 73. To review the functions preprogrammed into the control, including selecting the desired functions and changing or inputting control parameters, the operator will then press the FUNCTION "SELECT" key. The first function or option preprogrammed into the controller by the factory will now be displayed in window 73.
Steps 107-111
Precoat is a process used to precoat the filter press cloths with a release agent to improve filter cake release and filtrate quality. The precoat option, when provided in the controller, fills the filter press uniformly by closing the lower discharge manifold ports of the press for a period of time. After the filter press fills with liquid, the lower ports are reopened resulting in a more uniform press loading. Precoating is a known operating condition in filter presses. If the press is provided with this precoat option, then after the operator presses the "SELECT" key in step 102 above, then the display 107 will appear in window 73. If precoat is not desired, the operator can press the FUNCTION "OFF" key, followed by pressing the FUNCTION "SET" key, in which case the control automatically skips down to step 115.
However, if precoat is desired, and the operator presses the FUNCTION "ON" key, this causes the display 108 to appear and then the operator can press the VALUE "plus" or "minus" keys to set the desired precoat time, which time will appear in the display, with the selected time being locked in by the operator pushing the FUNCTION "SET" key. Next the operator sets the air supply pressure to the precoat pump using the VALUE plus or minus keys, and then locks in the pressure by pushing the FUNCTION "SET" key. The precoat setting is now complete and the next option programmed into the control will be automatically displayed in window 73. If there are no other options, then the display 115 will appear.
Steps 112-114
Evenfill is a process for filling the filter press uniformly by closing the lower discharge manifold ports for a period of time. After the filter press fills with liquid, the lower ports are reopened resulting in a more uniform press loading. Evenfill is an option which can be provided on the press, although a press can be provided with either precoat or evenfill, but not both. If the press is provided with evenfill, then when the operator pushes the "SELECT" key at step 102, then the display 112 will automatically appear. To skip evenfill, the operator sequentially pushes the FUNCTION "OFF" and FUNCTION "SET" keys, and then the program automatically skips to the next option or display, such as display 115. However, if evenfill is desired, then the operator pushes the FUNCTION "ON" key causing the display 113 to appear, and then the operator pushes the VALUE plus or minus keys to set the desired time, and then locks in this time as appearing in display 114 by pushing the FUNCTION "SET" key. The evenfill setting is now complete, and the control will now automatically display in the window 73 the next option which is preprogrammed into the control, such as the display 115.
Alternately, if the press is not provided with either precoat or evenfill, then depression of the SELECT key is step 102 can automatically result in the display 115 appearing in the window.
Steps 115-117
The slurry feed start pressure of display 115 is the initial air pressure supplied to the feed pump for feeding slurry to the press, namely the pressure P 0 . The operator sets the desired start pressure by depressing the VALUE plus or minus keys until the display reads the desired pressure, and then the operator locks in the pressure by depressing the FUNCTION "SET" key. The display 116 then automatically appears, which "end pressure" is the high pressure limit P 1 . Again, the operator depresses the VALUE plus or minus keys to set the maximum slurry end pressure P 1 as appearing in the display 116, and then locks in this value by depressing the FUNCTION "SET" key. Display 117 thereafter appears, with "stall time" being the time value T v . The operator again sets the time by use of the VALUE keys, which time is normally set so as to correspond to or be slightly less than the length of time between pump strokes when the press is filled, which time value will appear in the display 117. This selected time value is then locked in by the operator depressing the FUNCTION "SET" key. The next option preprogrammed into the control will now be displayed in the window 73, which next option will typically be the display 118.
Steps 118-124
After filtration, when the filter press chambers are filled with cake and the press is still closed, air or water pressure can be exerted behind the diaphragms of the filter press plates. This pressure causes the diaphragms to flex outwardly to squeeze out additional liquid found in the filter cakes. This is known as "membrane squeeze". The display 118 allows the operator to either turn on or turn off the membrane squeeze function by depressing either the FUNCTION "OFF" or "ON" keys, followed by depression of "SET" key. If turned "ON", then the membrane squeeze operation will automatically take place during the cycle following filling of the press.
After filtration, when the filter press chambers are filled with cake and the press is still closed, liquid still remains behind the filter plate cloths and in the four-corner discharge plumbing of the press. An air blow down manifold on the filter press allows air to be blown through the plumbing for a period of time to remove the liquids found in the filter plates and discharge plumbing. The operator at display 119 can select to either turn on or off the air blow down and, if turned on, can select at display 121 the period of time for blow down. If the blow down is turned "OFF", then the display automatically indexes to the next display 123, whereas if it is turned "ON", then it indexes first to the display 121 so that the operator can set the desired blow down time as shown at display 122.
Core blow is a process of blowing air through the filter plates to push unfiltered slurry out of the filter plates feed section from the tail plate forward to the head plate and the inlet feed pipe. Again, if at display 123 the operator turns off the "core blow", then the next display, such as whatever option follows next, such as a display 125, will appear. If the operator turns on the core blow, then the operator sets the length of time as indicated at display 124 and locks in the time, whereupon the next display will automatically be indexed into the window.
Other options provided by the press program control, such as options for controlling an automatic plate shifter, controlling bombay doors for dumping the press, or the like, can also be provided. Such additional functions vary from press to press, and are only diagrammatically illustrated by the displays 125 and 126.
Step 127
After all of the options have been selectively displayed in the window 73 and the operator has made the desired choices, then the display 127 will automatically appear in the window 73. To store into memory all of the selections that the operator has previously made, as described above, the operator then sequentially depresses the FUNCTION "ON" and "SET" keys. If the operator pushes the "OFF" key, then he can go back and review the selections, prior to storing them in memory.
Step 128
After performing either of the selections commanded by display 127 above, then the display 128 automatically appears. If the operator depresses the "SELECT" key, then the control automatically returns to the first display that the operator previously programmed, for example display 107. At that time the operator may change the selections as previously programmed, and each time the operator pushes the "SET" key, it will automatically display in window 73 the next screen previously programmed. When the operator has completed his review of all prior selections and made any necessary revisions, then all selections are stored in memory by depressing the "ON" and "SET" keys when reaching display 127. Thereafter, at display 128, the operator then can push the MODE "SET-UP" key to exit from the set-up programming mode of the control. This will now cause the display 129 to automatically appear in the window 73.
The set-up programming is now complete and the control is ready for the operator to initiate a cycle of press operation.
The operation of the filter press according to the present invention will now be described with reference to FIG. 10 wherein some of the displays and specifically the operational instructions which appear in the window 73 are illustrated in step-wise sequence. These are described as follows:
Step 141
The POWER "ON" display appears when the machine is initially turned on by the operator, or after completion of the programming as described above, which programming can be inserted just prior to operation of a cycle, or could have been inserted prior to a previously cycle since such programming will be maintained until changed. If the operator presses "CLOSE" to initiate a cycle, then the display 142 appears and the press is closed. After the press is fully closed, then the display 143 appears, and the operator will press the "ON" key to activate the hydraulic system which clamps the press closed.
Steps 144-145
Pursuant to the prompt of display 143, either display 144 or 145 will appear if the press is equipped with either precoat or evenfill. These operations will automatically be initiated and will time out, which timing out will appear on the display. Thereafter the display 146 will automatically appear.
Step 146
When this display appears, the operator can View the process control cycle by pushing the MODE "DISPLAY" key, and display 147 will appear. If the operator then pushes the "SELECT" key, then the display 148 will appear. If the operator wants to have the control, during the cycle, automatically scroll through the provided parameters and conditions, then the operator will press the FUNCTION "ON" key, and thereafter the displays 149-156 will automatically appear in sequence at timed intervals of rather short duration.
Steps 149-156
The display 149 initially appears and will display the incoming air pressure P s , namely the line pressure; the display 151 will provide the air pressure P a at the feed pump; the display 152 will display the slurry pressure P w ; the display 153 displays the hydraulic pressure which is holding the press in the closed position; the display 154 displays the "cycle time" in hours, with the left side FIGURE being the cycle time which has elapsed from the beginning of the cycle in process, and the right side time being the total time required to complete the prior cycle; the display 155 displays total hours that the press has been running since initial set up; and the display 156 displays the average number of cycles (for example 3.3) during the last 24 hour period prior to initiation of the current cycle in process. The microprocessor controller automatically recomputes this average each time a cycle is completed. The information in display 156 provides the operator with visual indication as to how many cycles can be completed within 24 hours and provides an arcuate number based on the last 24-hour interval, and the display 154 provides the operator with an indication as to how much longer the current cycle will take to complete since it provides not only the elapsed time of the cycle in process, but also the total time required to complete the prior cycle. The displays 149-156 will sequentially appear, and then repeat, so long as the press is filling, prior to shut down.
If the operator at display 148 elects to press the FUNCTION "OFF" and thereafter presses the FUNCTION "SELECT" key, the displays 149-156 can then be manually scrolled.
Steps 159-162
When the filter press is full, the control cycle will end and the display 157 will automatically appear, and the membrane squeeze will automatically occur until it times out. Thereafter display 158 will automatically appear and time out during the air blowing step, followed by appearance of the display 159 which will time out during the core blow step. This then results in the display 161 which indicates that the cycle is complete. At this time the control then waits for the operator to formally end the cycle by pressing the cycle "OFF" key.
Thereafter additional instructional prompts and controls will appear in the display window 73, such as for controlling release of hydraulic pressure and press opening, although description of these latter functions is believed unnecessary.
Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention.
|
A method for controlling the filling of a filter press with slurry according to a preferred embodiment of the present invention includes the sequentially executed steps of: gradually increasing the pressure of the slurry supplied to thee press until the slurry pressure reaches an upper pressure limit; recording a trigger point in time at which the slurry pressure reaches the upper pressure limit; and determining whether the slurry pressure subsequently falls below a lower pressure limit within a predetermined period of time commencing at the trigger point. If the slurry pressure does fall below the lower pressure limit within the predetermined period of time, then the above-listed sequence of steps is repeated until the slurry pressure fails to fall below the lower pressure limit within the predetermined period of time, thereby indicating that the press is full and terminating the process.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to electronically energized light emitters and particularly to control circuits for generating trigger pulses for application to gaseous discharge tube devices. More specifically, this invention is directed to enhancement of the noticeability of warning devices such as, for example, those which employ repetitively energized flash tubes. Accordingly, the general objects of the present invention are to provide novel and improved apparatus and methods of such character.
2. Description of the Prior Art
While not limited thereto in its utility, the present invention has been found to be particularly well suited for use with and/or as a warning device. Warning devices employing Xenon flash tubes are well known in the art and find application on emergency vehicles, aircraft and in other installations where it is considered necessary or desirable to attract attention by means of the generation of intermittent bursts of energy in the visible range of the frequency spectrum. It is generally accepted that electronic flash tubes, such as the aforementioned Xenon tubes, are more readily visible than previous mechanically energized oscillating and rotating beacon type devices. Nevertheless, for some time it has been desired to enhance the attention gathering properties of warning lights employing flash tubes.
For a disclosure of a typical prior art technique for the periodic energization of devices such as gaseous discharge tubes employed as light generators, reference may be had to U.S. Pat. No. 3,515,973 which is assigned to the assignee of the present invention. Power supplies of the type exemplified by U.S. Pat. No. 3,515,973 generate, from a low voltage source, a high voltage which is applied to a capacitive discharge circuit across which the flash tube is connected. The power supply circuits further generate trigger pulses which control the discharge of energy from such capacitive discharge circuits through the flash tube when it is desired to produce a light pulse. The discharge time; i.e., the length of the light pulse produced; is comparatively short and thus the visibility thereof is somewhat limited in spite of the fact that the intensity of the light generated is extremely high. Additionally, with prior art power supplies for flash tubes, the duty cycle is very low. That is, the dwell time between generation of successive trigger pulses constitutes the major portion of the operational cycle.
It has been long recognized, for example as observed in U.S. Pat. No. 3,430,102, that the visibility of a warning light could be enhanced by causing a lamp to "flash" twice in rapid succession. If a pair of flashes in rapid succession were to be produced, the lamp could appear, as a consequence of the retention characteristics of the human eye, to provide a single flash of long duration. Such a "lengthened" output pulse would, of course, have enhanced visibility in comparison to a single light flash of shorter duration.
It is also well known that a discernable double flash enhances visibility. This is particularly true in the case of moving objects where tests have shown that an observer may fix the position of such objects much more readily when two flashes occur in rapid succession than with a single flash followed by the customary delay until a succeeding flash is produced.
If a warning light is to be a commercially viable product, it is necessary that it be characterized by control circuitry which is designed to operate reliably in a rather harsh environment while simultaneously being economical to produce. There has not previously been available an economic and reliable circuit for producing trigger pulse pairs with adjustable timing for use in the firing of gaseous discharge tubes, and particularly Xenon flash tubes, to thereby permit generation of either an apparent long duration flash, a pair of discernable flashes closely spaced in time or a pattern of "double" flashes.
In addition to enhancement of the visibility of warning lights, it is in many instances considered desirable to further augment the attention gathering capability of warning light devices by some auxiliary means. Thus, by way of example, the requirements of the Occupational Safety and Health Act of 1970 have required that devices such as electric trucks for use in factory areas be provided with both visible warning beacons and some form of noise maker which is energized when the vehicle is placed in reverse gear. At the present time separate power supply circuits are employed for energization of the warning beacon and the sound generator. Such use of separate power supplies, of course, increases cost and reduces the reliability of the apparatus. It would thus be desirable to employ the same power supply used to intermittently energize a flash tube type warning light to simultaneously intermittently energize a suitable noise maker to thereby produce pulses of light and sound.
SUMMARY OF THE INVENTION
The present invention overcomes the above briefly discussed and other deficiencies and disadvantages of the prior art by providing a novel and improved method and apparatus for controlling warning devices including flash tube type light sources.
In accordance with a first embodiment of the invention a novel high voltage switching circuit including timing logic permits the generation of pairs of trigger pulses for energizing a flash tube. By means of varying the dwell time between output pulses provided by a timer, trigger pulse spacing may be controlled to produce the effect of a light flash of increased duration or a pair of closely spaced but individually discernable flashes may be generated. Each of the trigger pulses is generated by establishing a discharge path for a capacitor connected in a series resonant circuit.
Pursuant to a second embodiment, a plurality of flash tubes may be energized by multiple trigger pulse pairs generated by logic circuitry.
Also in accordance with the invention, an audible warning device may be operated off of the same power supply employed to generate the high voltage utilized to energize the flash tube or tubes. The audible warning includes an electro-mechanical noise maker which is supplied with current at the frequency of conversion of the low voltage source into the requisite high voltage for the flash tube or tubes.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawing wherein like reference numerals refer to like elements in the figures and in which:
FIG. 1 is a schematic diagram of a preferred embodiment of a power supply and control circuit in accordance with the present invention; and
FIG. 2 is a partial schematic diagram of a second embodiment of the invention, the circuit of FIG. 2 being designed for energization of a plurality of flash tubes.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, power for operating the control circuit is supplied by a direct current source, not shown, connected across a transient protector 10 which will typically be a xenon spark gap. A positive terminal of the DC source is coupled, by a pair of series connected choke coils 12 and 14, to the first end of a primary winding 16 of a non-saturating transformer T1. Transformer T1 also includes a center tapped secondary winding 18 and a feedback winding 20. Transformer T1, in combination with a blocking oscillator including parallel connected transistors Q1 and Q2, forms a "ringing choke" or "fly-back" static inverter. The inductors 12 and 14 cooperate with a pair of capacitors C1 and C2 to define a line filter. The purpose of this line filter is to keep the inverter from modulating the low voltage supply at the frequency of conversion and to simultaneously isolate the inverter from line transients.
Static inverters employing blocking oscillators are well known in the art and thus the operation of the parallel connected transistor switches Q1 and Q2 will be described only briefly herein. The positive potential of the DC source will be applied to the collectors of transistors Q1 and Q2 via primary winding 16 of transformer T1. Continuing with a discussion only of the operation of the circuit including transistor Q1, a voltage divider consisting of resistors R1 and R2 will provide a starting bias which is applied to the base of transistor Q1. At this point it is to be noted that resistor R2 is connected to a negative terminal of the DC source through feedback winding 20 of transformer T1. Upon application of the positive supply potential to its collector and the starting bias to its base, transistor Q1 will be rendered conductive with current being supplied through primary winding 16 of transformer T1. The current drawn by transistor Q1 will increase linearly with base drive for transistor Q1 being supplied via the voltage divider R1, R2 and also from feedback winding 20 of transformer T1 via diode D1. There is a peak value of current through transistor Q1 which can be supported by the forward bias on the transistor even with the additional base drive supplied through diode D1. When this peak value is reached and the current flow can no longer be sustained, the current will begin to decrease, the forward bias on the transistor will simultaneously decrease and the field about primary winding 16 will collapse. When the field begins to collapse transistor Q1 will be deprived of the additional base drive from feedback winding 20 via diode D1 and the forward bias will rapidly decrease to the point where transistor Q1 is turned off.
Thus, to summarize, transistor Q1 functions as a switching device which permits the current flow through primary winding 16 of transformer T1 to increase linearly to a peak value and, when this peak value is reached, the current flow will rapidly decrease and the field about winding 16 will rapidly collapse. Diode D2 is connected between the base of transistor Q1 and the negative side of the DC power source to protect the base-emitter junction of transistor Q1 from the reverse voltage induced in feedback winding 20 when the field about primary winding 16 collapses. The switching circuit including transistor Q2 is identical to and parallel with the circuit including transistor Q1 and transistors Q1 and Q2 are matched and in parallel so that they will equally divide the primary winding current of transformer T1.
When the field about primary winding 16 of transformer T1 collapses, energy will be transferred to secondary winding 18 and will be stored in capacitors C3 and C4. Capacitors C3 and C4 will be discharged through the load, which is shown as being a xenon flash tube 22, upon the generation of trigger pulses in the manner to be described below. Resistors R3 and R4 are respectively connected in parallel with capacitors C3 and C4 to provide for the bleeding off of the charge on these capacitors when the circuit is not in use; i.e., resistors R3 and R4 are included in the circuit to minimize potential shock hazard to service personnel.
The embodiment of FIG. 1 further comprises a voltage sensitive shut-off circuit including normally non-conductive transistors Q3, Q4 and Q5. Transistors Q3 and Q4 define a Schmitt trigger circuit. The high output voltage developed across series connected capacitors C3 and C4 is applied, via conductor 24, to a voltage divider comprised of series connected resistors R5, R6 and R7; resistor R6 being a variable resistance. The voltage appearing at the wiper arm of variable resistor R6 is applied to the base of transistor Q3. The emitter of transistor Q3 is connected to ground via a Zener diode ZD1; diode ZD1 thus establishing a reference voltage for the turning on of transistor Q3. When the high output voltage applied to conductor 24 exceeds a preselected level, transistor Q3 will be biased into conduction with the base-emitter current initially being supplied from the voltage divider R5, R6 and R7. When transistor Q3 becomes conductive current will be drawn through the base-emitter junction of transistor Q4 thus also turning on transistor Q4. The conduction of transistor Q4 will supply additional base-emitter current for transistor Q3 via a feedback circuit consisting of diode D3 and resistor R8. Thus, in the customary manner of operation of a Schmitt trigger circuit, transistor Q3 will be locked in the conductive condition when its base voltage exceeds a reference established by the setting of variable resistance R6 and by Zener diode ZD1; conduction of Q3 indicating that the voltage across capacitors C3 and C4 has exceeded a preselected level indicative of, for example, a failure of flash tube 22. The conduction of transistor Q4 will drive transistor Q5 into saturation. Conduction of transistor Q5 will shunt off all base drive to switching transistors Q1 and Q2 thus disabling the static inverter.
As the voltage on conductor 24 decreases, the base-emitter drive for transistor Q3 will similarly decrease and ultimately there will be insufficient drive to maintain transistor Q3 in the conductive state; i.e., when the high voltage falls to a sufficiently low level the current feedback from transistor Q4 will be insufficient to hold the Schmitt trigger in the conductive condition. It is to be observed that the turn-off voltage for the Schmitt trigger will be at a level which is substantially below that which initially causes conduction of transistor Q3. This feature will permit continued operation with, for example, the embodiment of FIG. 2 where a plurality of flash tubes are energized from the same power source and only one of such flash tubes fails thus causing the high voltage to periodically rise above the shut-off level. The Zener diode ZD2 connected in parallel with the Schmitt trigger circuit permits the operation of the shut-off circuit to be independent of line voltage.
The circuit for generating trigger pulses which control the discharge of capacitors C3 and C4 through the flash tube load consists of a logic section and a high voltage switching section. The logic section comprises a monolithic timing circuit 26 which may, for example, be a Signetics Corporation type NE555V timer. Timing circuit 26 provides an output square wave with an adjustable duty cycle. A variable bias voltage developed across an RC circuit comprised of resistors R9 and R10 and capacitor C5 controls the "on" and "off" times of the output of timer 26. Thus, when capacitor C5 charges to the threshold voltage level of the timer, the output of the timing circuit will go negative and will stay negative for a portion of the cycle determined by the discharge time of C5; i.e., the duration of the negative portion of each cycle of the square wave will be a function of the time constant of the timing circuit including resistor R10 and capacitor C5. A Zener diode ZD3 is included to provide voltage protection for timing circuit 26.
The square wave output of timing circuit 26 is coupled, via capacitor C6, to the input of the high voltage switching circuit which generates trigger pulses for flash tube 22. A resistor R11 connected across the input to the trigger pulse generation circuitry forms, in cooperation with capacitor C6, a differentiator whereby negative and positive pulses respectively synchronized with the trailing and leading edges of each positive half-cycle of the timing circuit output square wave will be generated.
The negative pulses appearing at the output of the differentiator are coupled, via diode D4, to the cathode of a first silicon controlled rectifier SCR-1. The positive going output pulses from the differentiator are applied, via diode D5, to the gate electrode of a second silicon controlled rectifier SCR-2. Considering the operation of the rectifier device SCR-1, it is to be noted that SCR-1 has a "fixed gate"; i.e., the gate electrode of SCR-1 is connected to ground via a resistor R12. Accordingly, application of a negative going pulse to the cathode of SCR-1 will result in the gate junction of this device effectively assuming a positive potential with respect to ground and, accordingly, SCR-1 will be forward biased and will conduct. A diode D6, connected between the cathode of SCR-1 and ground, becomes forward biased during conduction of SCR-1 and completes the forward conduction path for the rectifier. Diode D6 also prevents the negative pulses applied to the cathode of SCR-1 from being shorted to ground. Resistors R13 and R14; resistor R14 being connected between the anode of SCR-1 and ground; define a voltage divider which provides proper bias voltage for operation of SCR-1.
The voltage appearing at the anode of SCR-1 when the rectifier device is in the non-conductive state charges a capacitor C7; charging current flow being through the primary winding of a trigger transformer T2 which forms part of the flash tube package. Capacitor C7 and the primary winding of trigger transformer T2 form a series resonant circuit which rings negative when SCR-1 is initially gated into the conductive state thus affording capacitor C7 a discharge path to ground. The ringing of this series resonant circuit commutates SCR-1 during the transition from negative to positive potential. SCR-1 is also turned off as a consequence of its being starved for current since, upon discharge of capacitor C7, the high anode voltage will be reduced by the flash tube load thus, in turn, reducing the holding current for SCR-1.
The operation of SCR-2 in response to the application of a positive going pulse to its gate electrode is similar to that described above with respect to SCR-1. SCR-2 will be "fired" a short time after the firing of SCR-1; the delay being determined by the setting of timing circuit 26 and being of appropriate duration to permit the recharging of capacitors C3 and C4 to a level sufficient to provide a trigger pulse magnitude adaquate to ionize the flash tube 22. In this regard it is to be noted that the voltage divider consisting of resistors R13' and R14' associated with SCR-2 will be comprised of resistors having different values when compared to the voltage divider R13-R14 associated with SCR-1. Thus, the voltage divider consisting of resistors R13' and R14' will apply the required trigger voltage to the anode of SCR-2, and thus to capacitor C7', at a time during the operational cycle when the high voltage supply capacitors C3 and C4 are not fully charged. With regard to the charging of capacitors C3 and C4, it is to be observed that the frequency of operation of the power supply blocking oscillator; i.e., the frequency of conversion of the static inverter is substantially greater than the output frequency of timer 26.
The circuit of FIG. 1 may also include means for energizing an audible warning device. This audible warning device is, in the embodiment of FIG. 1, an electro-mechanical noise maker 28 coupled, by means of an isolation capacitor C8 and a switch S-1, to the blocking oscillator side of primary winding 16 of transformer T1. Thus, presuming switch S-1 has been closed, the sound generating device will provide a "chirp" each time the switching transistors Q1 and Q2 are turned off. While the audible warning device obviously draws some power, there is insufficient current flow to ground through the noise maker to have a deleterious effect on the operation of the static inverter and thus the audible warning may be added to the flash lamp control circuit without any deleterious effect on the operation of the static inverter.
Referring now to FIG. 2, a modification of the logic and high voltage switching circuitry for use with the basic power supply of FIG. 1 is depicted. The trigger pulse generation circuitry depicted in FIG. 2 is utilized to generate trigger pulse pairs for application to two pair of flash tubes. It will, however be obvious to those skilled in the art that the circuit of FIG. 2 may be employed, either as shown or with slight modification, to control the operation of from two to four flash tubes and also to apply trigger pulses to such tubes in any desired sequence.
The FIG. 2 embodiment employs the adjustable timer 26; the timing adjustment circuitry and protective devices, including noise filters C7 and C8, for the timer being shown in somewhat more detail in FIG. 2. The unsymmetrical square wave output of timer 26 is delivered to a logic circuit indicated generally at 30 and to a divider circuit 32. Logic circuit 30, in the disclosed embodiment, is a quad NOR gate such as, for example, RCA type CD4001. The divide by two circuit 32 consists of a steering flip-flop and may, for example, comprise an RCA type CD4027AE. The Q 2 and Q 2 outputs from the divider circuit 32 are also applied as inputs to the quad NOR gate 30.
Divider circuit 32 alternatively provides, on the Q 2 and Q 2 outputs, positive pulses synchronized with the leading edge of alternate positive going output pulses of timer 26; i.e., the output signals from divider circuit 32 are positive pulses having a duration equal to a full cycle of the square wave output of timer 26. The Q 2 and Q 2 outputs of divider circuit 32 are applied to RC differentiating circuits consisting respectively of resistor R20 in combination with capacitor C10 and resistor R22 in combination with capacitor C12. The positive going output pulses provided by the differentiator connected to the Q 2 output of timer 32 are coupled, via a diode D10, to the gate electrodes of silicon controlled rectifiers SCR-3 and SCR-4. Similarly the positive voltage spikes provided at the output of the differentiator associated with the Q 2 output of timer 32 are coupled, via diode D12, to the gate electrodes of rectifiers SCR-5 and SCR-6. Diodes D10 and D12 are included in the circuit to prevent noise feedback from the switching circuit to divider 32.
As noted above, logic circuit 30 is a quad NOR gate; i.e., circuit 30 is an integrated circuit which includes NOR gates 34, 36, 38 and 40. These four NOR gates provide a positive output potential when both inputs thereto are at a zero level. As noted above, the square wave output of timer 26 is applied as a first input to each of gates 34, 36, 38 and 40. The Q 2 output of divider circuit 32 is applied as the second input to NOR gates 34 and 36 while the Q output of divider 32 is applied as the second input to NOR gates 38 and 40. Thus, the outputs of gates 34 and 36 will be synchronized with one another but not with the synchronized outputs of gates 38 and 40. The outputs of gates 38 and 40 will go positive in synchronism with the trailing edges of positive portions of every other cycle of the square wave output of timer 26; i.e., the outputs of NOR gates 38 and 40 will be positive when the output of timer 26 is at the zero level between positive pulses and the Q 2 output of divider 32 is also at the zero level. Similarly, the outputs of NOR gates 34 and 36 will go positive in synchronism with the trailing edges of those timer output pulses which do not, because of the state of the divider 32, affect NOR gates 38 and 40. The outputs of NOR gates 34, 36, 38 and 40 are applied, via differentiator circuits and couplng diodes, respectively to the gate electrodes of rectifiers SCR-4, SCR-3, SCR-5 and SCR-6. Thus, a positive pulse commensurate with the output of NOR gate 34 going positive will be generated by the differentiator comprising resistor R24 and capacitor C14 and this pulse will be coupled via diode D14 to the gate electrode of silicon controlled rectifier SCR-4. Similarly and simultaneously, a positive pulse commensurate with the output of NOR gate 36 going positive will be generated by differentiator R26-C16 and coupled by diode D16 to the gate electrode of SCR-3. Positive pulses resulting from the gating of NOR gate 38 will be provided by differentiator R28-C18 and coupled by diode D18 to the gate of SCR-5 while positive pulses commensurate with the enabling of gate 40 will be provided by differentiator R30-C20 and coupled by diode D20 to the gate of SCR-6.
In the manner described above in the discussion of FIG. 1, trigger pulses for the firing of flash tubes are generated by "firing" the SCR's to thereby establish a discharge path for a capacitor connected in a series resonant circuit. Thus, the operation of silicon controlled rectifiers SCR-3, SCR-4, SCR-5 and SCR-6 is identical to that of SCR-2 of FIG. 1. The primary windings of the trigger pulse transformers for each of the four flash tubes are respectively connected at points A, B, C and D and FIG. 2 and capacitors C22, C24, C26 and C28 are in the separate series resonant circuits; these capacitors being charged from the high voltage source comprising series connected capacitors C3 and C4 of the power supply of FIG. 1.
In operation, the flash tubes connected at points A and B will be energized simultaneously and twice in rapid succession and the flash tubes connected at points C and D will thereafter be flashed simultaneously and twice in rapid succession; the delay between the generation of the second pulse of a trigger pulse pair for a first pair of lamps and the generation of the first trigger pulses for the other pair of lamps being commensurate with the time period the output of timer 26 is in the positive state. To be more specific, SCR-5 and SCR-6 will be simultaneously caused to conduct when the outputs of NOR gates 38 and 40 go positive. The SCR's will, in the manner described above in the discussion of FIG. 1, be commutated and will be biased into conduction a second time in response to the differentiated positive going Q 2 output of timer 32. The time delay between successive simultaneous "firings" SCR-5 and SCR-6 will be determined by the "off" time of the timer 26. Thereafter, in the same manner, rectifier devices SCR-3 and SCR-4 will be turned on in response to the outputs of gates 34 and 36 going positive, these rectifier devices will be commutated and SCR-3 and SCR-4 will again be caused to conduct by the pulse commensurate with the Q 2 output of divider 32 going positive.
As noted above, it will be understood that the embodiment of FIG. 2 may be employed to provide any desired sequence of flash lamp energization. Thus, by way of example, the circuit of FIG. 2 could be employed to gate eight silicon controlled rectifiers for use in the generation of trigger pulses for four flash tubes. Alternatively, a pair of NOR gates and four silicon controlled rectifiers may be employed to generate pulse pairs for use in controlling a pair of flash tubes.
While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation.
|
The visibility of warning lights employing flash tubes is enhanced by control circuitry which generates closely spaced trigger pulse pairs for energizing the tubes to thereby produce double flashes. Noticeability of the warning light may be enhanced by addition thereto of a noise maker which operates off the same power supply that provides a high voltage for operating the flash tube or tubes.
| 7
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to systems and methods for retrieving information from databases and more particularly to autoattendant systems and methods for routing incoming calls based on a telephone directory.
2. Description of the Related Technology
Forward searchable telephone directory listings and databases are conventionally ordered and keyed to the names of the listed parties, i.e., an alphabetically arranged listing of names with associated telephone numbers. It is not unusual to have several parties with (i) the same name or (ii) names that might be similarly pronounced by someone requesting a telephone listing or otherwise needing to designate a particular person by name. Upon identifying an ambiguous listing condition, i.e., more than one entry satisfying the spoken name search criteria, conventional automatic voice response units (VRUs) may request further information to resolve the conflict and identify the requested party. In particular, such VRUs may inform the caller that the system has more than one person having the particular name requested, play back the names and respective telephone numbers of the parties, and ask the caller to designate which of the parties is being requested. The caller would then be prompted to select from among the identified parties.
For example, a VRU may be used in voice dialing systems to provide speech activated dialing. Using such a system, a calling party speaks the name of the party to be called and the system attempts to recognize the speech as corresponding to a previously stored speech pattern. Similar systems may also be used to provide automated directory assistance functions, including traditional “411” services, which may include provisions for call completion to the directory number identified.
In contrast to traditional auto-dialers used to initiate outgoing calls, automated attendant (autoattendant) systems are used to automatically answer and handle incoming telephone calls. Traditionally, autoattendants play an announcement to the caller and provide for various selections using a VRU. Thus, the caller may be prompted to dial the extension of the party being called and/or given other options, such as leaving a voice message or accessing a directory of names if the extension of the called party is not known. While early directories required the caller to spell the name of the called party using a telephone DTMF keypad, later systems provided for speech recognition of a spoken name. This improvement has been made possible by the commercial availability of reliable speaker-independent voice recognition. Thus, by incorporating a voice responsive directory assistance fiction, the autoattendant answers an incoming call, asks the caller to speak the name of the party or department being called, uses a speaker-independent voice recognition engine to identify and translate a received speech signal into name data, uses the name data to access a telephone directory, and routes or extends the call to the corresponding telephone number.
These systems, however, fail to provide for the resolution of multiple listings under the same name. Instead, when a name search provides an ambiguous result, such conventional systems inflexibly rely on the caller's ability to distinguish between parties based on telephone numbers, information that the caller may and probably does not have. These systems become even more cumbersome as the number of similar names maintained by the directory increase, such as in those parts of the world where similar names are common and where combinations of multiple pronunciations and nicknames further complicate entry resolution. Conventional systems also fail to provide for parties having multiple telephone numbers, e.g., voice, cellular, fax, etc.
Accordingly, a need exists for a directory search engine and method which can resolve ambiguities resulting from records having similar or identical primary search keys. A further need exists for a directory system and method of providing enhanced disambiguation facilities and user interfaces. A still further need exists for an automated telephone directory system which intelligently interacts with a calling party to identify and select a particular listing from among plural listings satisfying an initial search criterion.
A still further need exists for an automated telephone routing system and method which intelligently and dynamically handles directory searches resulting in the identification of multiple listings to one or more subscribers.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide methods and apparatus which will overcome the disadvantages and meet the needs discussed above.
It is one object of the invention to provide for a database retrieval system which includes disambiguation of entries with the same or similar primary keys.
It is another object of the invention to provide for a user-friendly interface to an automated directory search function which intelligently prompts a user for further information to progressively eliminate non-qualifying listings and refocus the search to identify one or more desired listing(s).
It is a further object of the invention to provide a speaker independent voice recognition and voice response unit which automatically formulates a minimal set of prompts to identify a desired telephone listing when (1) the name of the desired party is not unique or (2) the caller does not initially provide or does not know the full name of the desired party.
The present invention addresses the disadvantages in the prior art by providing an intelligent database search engine which, when finding multiple listings satisfying a primary or initial search request, provides a series of prompts soliciting further information relative to the ambiguous results. The prompts are dynamically composed to quickly minimize the group of qualifying candidate listings until only one listing remains or until no further information distinguishing between or among the candidate listings would be helpful or is available.
A database retrieval system according to the invention includes a searchable database in which the primary key, such a name associated with a telephone directory listing, may be duplicated, i.e., is not unique. To resolve or disambiguate the conflict, the user is prompted to supply additional information determined to be helpful in selecting from among candidate records having the same key. For example, if multiple listings are identified for the telephone listing “John Smith”, the system will examine secondary data fields to identify information unique among the listings, such as the addresses of the listings. The system will then prompt the caller to identify which of the listings is desired, using the address information to distinguish among and select the desired listing(s).
The present adaptive disambiguation system and method dynamically selects additional listing information most useful in resolving the search ambiguity and caller selection process. Using either a fixed or entry specific prioritization, listings with identical or similar name key information are compared to identify distinguishing secondary information (e.g., employee location department, etc.) that might be given to the caller to complete the selection.
By way of example, the following candidate parties might be identified by a corporate automated attendant system in response to a caller asking to be connected to a “Robert Cook”:
Name
Telephone
Last
First
Nickname
Location
Dept.
Number
Cook
Robert
Rob
Arlington, VA
Legal
703-974-1234
Cooke
Robert
Bob
Phila-
Engi-
215-963-1234
delphia, PA
neering
Koch
Robert
Robbie
Silver
Engi-
301-608-5678
Spring, MD
neering
As an initial point, conventional VRUs may not include the capability of matching a spoken name with variations in pronunciation possible for names of a directory listing. For example, the listing “Koch” may be pronounced as “Koch”, “Cook”, “Coke”, etc. The present system accommodates these variations and alternative pronunciations used by both (i) the named party and (ii) the caller by providing generalized and/or listing specific alterative pronunciations and nicknames corresponding to particular names and/or listings. While this feature provides enhanced search capabilities, it also tends to exacerbate the disambiguation problem.
Upon identifying the parties listed in the table above as candidates, the system uses a hierarchical search pattern to identify distinguishing information about the parties for presentation to the caller. As previously mentioned, conventional systems typically provide the caller with the names and telephone numbers of all of the candidate entries. Instead, the present system may first look to the Department field of the candidate entries to determine if they are unique. In this example, two of the candidate parties work in engineering, so that this category of information may not be useful to help select the correct party to be called. The system may next look to the location field and, as in the example above, determine that this information is unique among the candidates. The system would then provide the caller with both the name and location of the identified listings and ask the caller to select among the parties, typically by saying or using a keypad to input the number of the selection, e.g., “Say or push ‘1’ to dial Robert Cook in Arlington, Virginia; ‘2’ for the Robert Cook in Philadelphia, Pennsylvania; and ‘3’ for Mr. Cook in Silver Spring, Maryland.”
In addition to a static presentation of selection alternatives, the system is adaptable to provide an interactive colloquy with the caller in an effort to resolve the ambiguity. For example, the system may attempt to limit the set of candidates by asking a series of questions such as: “We have [specify number found][“multiple”] listings for employees named ‘Robert Cook’, do you know if your Mr. Cook is in Engineering or Legal?” The system would then use any new information to select one or more potential candidates and/or to solicit additional information to resolve or minimize the ambiguity.
To reduce the perception that the system has misinterpreted the name of the party, the system may prompt the caller using the name pronunciation used by the caller. Thus, for example, the system may respond to the name “Robert Cook” with “We have multiple listings for ‘Robert Cook’, including spellings C-O-O-K, C-O-O-K-E, and K-O-C-H. Do you know which spelling is correct?” Alternatively, had the caller requested a listing for a “Robert Koch”, the system would repeat the caller's pronunciation in future prompts during the call, although using standard or party specified pronunciations when providing alternative listings. Thus, the system might respond “We have multiple listings for ‘Robert Koch’, including a ‘Robert Koch’ in Engineering, a ‘Bob Cook’ spelled K-O-C-H in sales, and a ‘Rob Koch’ in Legal. Do you know which department Mr. Koch is in?”
The system may also use a fuzzy logic method in selecting candidates. Criteria may include, for example, the frequency of calls routed to a particular party through the system, party specific nicknames, origin of the caller in comparison to candidate locations, etc. The order of presentation of the candidate names may also be affected by such considerations so that most likely candidates are announced before others.
The system may further consider and eliminate unlikely pronunciations. For example, while the name spelled “K-O-C-H” may be a potential candidate listing for the spoken name “Cook”, the converse is unlikely, i.e., a name pronounced “Koch” would not be spelled “C-O-O-K.” As another feature of the invention, the system may additionally resolve ambiguities based on spelling, providing the spelling of a name to the caller or asking the caller to spell the name of the party being called, the method chosen possibly being dependent on the number of candidate listings identified.
According to one aspect of the invention, an information retrieval system includes a data base including a plurality of records. Each of the records includes (i) a primary key field storing first identification data, (ii) at least one secondary key field storing secondary data, and (iii) a target information field storing requested data. An input processor receives input identification data. A search engine, responsive to the input identification data, accesses the data base, compares the input identification data with the first identification data and identifies matching records. A processor identifies respective secondary data of the matching records, the secondary data distinguishing one or more of the records from the others. An output device is connected to provide a prompt including the secondary data for soliciting an input designating one or more of the selected ones of the records.
According to a feature of the invention, the database may be an ordered directory of subscriber names and respective telephone numbers. According to another feature, the first identification data includes subscriber name information, the secondary data includes location information, and the requested data includes terminal address information. Secondary data may also include name information such as first, middle, nickname, or special pronunciations.
According to another feature of the invention, the system further includes a speech recognition engine receiving a speech signal for providing the input identification data. An interface may be included for providing the speech signal from a telephone network.
According to another feature, the system output device may include a speech playback means in the form of a speech synthesizer for providing a spoken request soliciting the input selecting the one or more of the matching records. Each of the records may include audio data, the speech synthesizer responsive to the audio data for providing the spoken request. The system may further mimic the input speech of the caller by identifying the phonemes of the spoken name and using that information when repeating the name back to the caller.
According to another feature of the invention, the secondary data includes a plurality of information types and each of the secondary key fields stores plural ones of the information types. The information types may include location, department, terminal equipment, alternative names, occupation and specialization information.
According to another feature of the invention, the system includes a telephone dialer for connecting a call in response to a receipt of the input designating one or more of the selected ones of the records.
According to another feature of the invention, each of the records includes audio data and the information retrieval system further comprises a speech synthesizerresponsive to the audio data for providing a speech signal corresponding to a designated one of the selected records. The audio data is formatted as a Windows Wave format (“.WAV”), MPEG Audio Layer 3 (“MP3”), or equivalent “playable” file or may include pronunciation rules for generating speech representing information stored as a part of a corresponding one of the records. Pronunciation rules may also be stored in the form of a pronunciation table of ordered name pronunciation data. A speech generator is responsive to the name pronunciation data for generating a speech signal.
According to another feature of the invention, the system processor is operative in an interactive conversational mode for generating a series of prompts eliciting called party identification information from a caller based on distinguishing characteristics of an initially identified subset of potential called parties.
According to another aspect of the invention, a telephone directory system includes a directory of subscriber records, each of the subscriber records including (i) a primary key field storing subscriber name data, (ii) at least one secondary key field storing secondary data, and (iii) a target information field storing telephone number data. A speech recognition engine is connected for receiving a speech input from a caller and, in response, provides requested party data. A search engine responds to the requested party data for accessing the data base to identify selected ones of the records. The system further includes a processor for identifying respective secondary data of the selected ones of the records, the secondary data distinguishing one or more of the selected ones of the records from the others. An output device is connected to provide a prompt including the secondary data for soliciting an input designating one or more of the selected ones of the records.
According to another aspect of the invention, a method of retrieving data includes the steps of storing a plurality of records, each of the records including a primary key field storing first identification data, at least one secondary key field storing secondary data, and a target information field storing requested data, and receiving input identification data. The identification data is compared with the first identification data and so as to identify selected ones of the records. Respective secondary data of the selected records are used to distinguish one or more of the selected records from the others. A prompt, including the secondary data, is then provided for soliciting an input designating one or more of the selected ones of the records.
Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims, with reference being had to the accompanying drawings forming a part thereof, wherein like numerals refer to like elements throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an interactive, voice responsive autoattendant for answering and forwarding incoming telephone calls.
FIG. 2 is a block diagram of a voice activated dialer function provided by an intelligent peripheral of a public switched telephone network.
FIG. 3 is a block diagram of an autoattendant function provided as part of a private automatic branch exchange (PBX).
FIG. 4 is a logic flow diagram of an interactive directory search method which intelligently uses secondary search criteria to resolve ambiguities resulting from duplicate primary keys.
FIG. 5 is a logic flow diagram of a method of categorizing and prioritizing secondary key information for use in disambiguation of directory search results.
FIG. 6 is a logic flow diagram of a method of identifying candidate listings from a spoken name and using the spoken name to provide prompts mimicking the pronunciation used by the caller.
FIG. 7 is a diagram showing normal and exception processing for identification of listings corresponding to a spoken name.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a block diagram of an autoattendant system for answering and forwarding incoming telephone calls based on a spoken listing request and further showing the organization of a record contained in a database stored by the system. Autoattendant system 10 includes central processing unit (CPU) 12 programmed to coordinate and control system operations according to a program stored in memory (not shown). CPU 12 controls network interface 14 , speech recognition engine 16 , dialer 18 , announcement unit 20 and database management system 22 . Although individual lines are shown for transmission of control and information signals between the elements of autoattendant 10 , typically control and data will be supported by one or more system address and data buses. Network interface 14 is connected to the public switched telephone network (PSTN) for answering incoming telephone calls from the PSTN. This interface may be in the form of single or multiple POTS or ISDN lines or may be a trunk group such as a PBX trunk with associated signaling. Network interface 14 provides an audio output to speech recognition engine 16 which includes a speaker independent recognition capability to convert speech signals in the form of audio to a digital data stream. This digital data stream may be in the form of ASCII text and, preferably, includes the phonetic equivalent of the spoken speech. For example, English language speech may be represented by a set of 39 phonemes, for which the vowels may carry lexical stress, 0 meaning no stress, 1 primary stress, and 2 secondary stress. These phonemes are shown in the following table including examples:
Phoneme
Example
Translation
AA
odd
AA D
AE
at
AE T
AH
hut
HH AH T
AO
ought
AO T
AW
cow
K AW
AY
hide
HH AY D
B
be
B IY
CH
cheese
CH IY Z
D
dee
D IY
DH
thee
DH IY
EH
Ed
EH D
ER
hurt
HH ER T
EY
ate
EY T
F
fee
F IY
G
green
G R IY N
HH
he
HH IY
IH
it
IH T
IY
eat
IY T
JH
gee
JH IY
K
key
K IY
L
lee
L IY
M
me
M IY
N
knee
N IY
NG
ping
P IH NG
OW
oat
OW T
OY
toy
T OY
P
pee
P IY
R
read
R IY D
S
sea
S IY
SH
she
SH IY
T
tea
T IY
TH
theta
TH EY T AH
UH
hood
HH UH D
UW
two
T UW
V
vee
V IY
W
we
W IY
Y
yield
Y IY L D
Z
zee
Z IY
ZH
seizure
S IY ZH ER
The digital phoneme string from speech recognition engine 16 is provided to database management system 22 which, in turn, is connected to telephone directory database 24 . The structure of database 24 is shown in the lower portion of FIG. 1, comprising a plurality of records 30 . Each record 30 includes name information, some of which, depending on the specific input provided by the caller, would constitute first identification or primary key information, typically the last and probably first names 38 a , 38 b , of the party being called. To the extent the caller does not give certain name information, it might be considered secondary information to be used in later disambiguation processing to distinguish between listings, as necessary. Further, some of the name information may be alternate primary key information, i.e., nickname 38 e . Thus, middle name 38 c and suffix or title information 38 d may be either primary or secondary information depending on its use.
In addition to the name field 32 , secondary fields store other information about the listing which may be available to distinguish between and among others of the listings. The secondary information includes fields containing pronunciation rules for speaking the name of the listed party such as the phonetic equivalent for the name as spelled, or, alternatively, the pronunciation preferred by the particular listing as designated by the listing party and at his or her request. Alternatively, field 34 a may include an audio file which may be played by appropriate software, e.g., a WAV or MP 3 format file. Other information which may be used as secondary keys in distinguishing between and among the listings include address/location data field 34 b , business unit/department field 34 c , professional information field 34 d , and terminal type 34 e . While the information contained in the secondary fields would usually be used to distinguish between or among different parties having the same or similar names, the information contained in the terminal type field 34 e would commonly be used to distinguish between multiple listings to the same party to accommodate multiple functions. Thus, a party might have several lines, one for incoming voice calls, another for faxes, and still another for cellular telephone calls. In use, however, this secondary information would be used in a similar manner to the other secondary information. Finally, each of the records includes a telephone number field 36 which is the target information being requested. Of course, although telephone number information is shown, any target information might be included or referenced, such as Internet address, e-mail, medical information, or any other information typically stored in a database or accessible by a directory type listing.
In response to a request from CPU 12 , database management system 22 searches telephone directory database 24 and identifies an initial candidate listing of records satisfying the primary search criteria, i.e., the name information provided by speech recognition engine 16 . The results of the search are then used to select an appropriate announcement to be played to the caller by announcement unit 20 through network interface 14 . For example, if the initial name information provided by the caller resulted in identification of a single entry, the autoattendant 10 would announce to the caller that the call was being forwarded to the named party. The network interface would then provide appropriate signaling to the PSTN to transfer the call to the appropriate telephone number for the named party. For example, using a 3-way calling switch feature, network interface 14 would provide a flash-hook signal to the PSTN by momentarily going “on hook” so that, in response, the corresponding PSTN switch would place the calling party on hold and provide autoattendant 10 with a second dial tone. Upon detecting a second dial tone, network interface 14 would notify CPU 12 , which, in response, would cause dialer 18 to outdial the telephone number corresponding to the party being called, initiate a second “flash-hook” signal to bridge the calls, and, subsequently, go back on hook to drop out of the bridge so that the calling party would be connected directly to the requested listing.
Alternatively, as will be explained in further detail below, if data management system 22 is unable to uniquely identify a listing corresponding to the named party, central processing unit 12 in combination with announcement unit 20 would provide a series of prompts soliciting additional information from the calling party in an attempt to resolve the ambiguity, i.e., disambiguate the listings.
Referring to FIG. 2, autoattendant 10 may be embodied as an intelligent peripheral (IP) within a telephone network. As shown, multiple parties 40 a , 40 b , and 40 c are connected to an originating telephone switch 42 which, in turn, is connected to voice network 46 . Voice network 46 , in turn, connects to destination telephone switch 48 and parties 52 a , 54 b and 52 c as listed in telephone directory database 24 . In addition to the components of the voice network, each switch is interfaced to a switching control network, typically in the form of SS 7 , for providing signaling between and among switches including signal switching points (SSP) 44 and 50 connected to a service transfer point (STP) 54 . STP 54 may be connected directly to IP 58 and/or to an integrated signaling control point (ISCP) 56 providing additional processing and database facilities.
In the network configuration shown in FIG. 2, the autoattendant functionality may be initiated either by and at origination telephone switch 42 in response to a dialed number trigger, or at destination telephone switch 48 in response to a termination trigger. For example, call originating terminal 40 a may dial a telephone number, such as “411” initiating a dialed number trigger at originating telephone switch 42 causing call processing to be suspended by the switch and an appropriate message sent by SSP 44 to STP 54 . STP 54 , alone or via ISCP 56 , would cause IP 58 to initiate processing and provide services to telephone switch 42 , either directly or via an intermediary switch of voice network 46 , including prompts generated by the autoattendant function. Upon identification of an appropriate telephone number, IP 58 would then communicate the telephone number to STP 54 for transmission to SSP 44 and telephone switch 42 whereupon the call would be completed through voice network 46 to telephone switch 48 and the appropriate called party 52 a , 52 b or 52 c . Although herein referenced as an autoattendant function, this functionality when incorporated into a network, particularly using a dedicated, abbreviated 3-digit number such as “411,” would typically be provided as a universal directory assistance service, available network-wide.
An alternative embodiment is shown in FIG. 3, wherein autoattendant 10 is incorporated as customer premises equipment (CPE) as part of or augmenting a local private automatic branch exchange (PBX) 60 . In this configuration, listed parties 62 a - 62 b and 62 c are serviced by autoattendant 10 for connecting incoming calls. In this on-site configuration, calls to a main telephone number are extended to and answered by PBX 60 using autoattendant 10 to provide an appropriate greeting. The calling party or caller is. greeted and prompted to speak the name of the desired person or department so that the call can be completed to that person. Upon identification of the appropriate telephone number or extension, PBX 60 forwards or extends the call to the appropriate party.
FIG. 4 shows the logic flow of the interactive directory search method according to an embodiment of the invention including intelligent secondary search facilities used to resolve ambiguities resulting from duplicate primary keys. Entering the method at step 100 , an initial greeting is played at step 102 . The initial greeting may include a variety of options available to the caller and/or may include a general greeting such as identification of the associated business or facility name. At step 104 , the caller is prompted to say the name of the party being called, the speech signal being received at step 106 and processed at step 108 to extract phoneme information. The phoneme information may then be used to identify spellings of names to be searched for and, as will be described later, to identify specific listings having exceptional pronunciations. The phoneme information may also be used by the system in prompt generation so that the system uses the same name pronunciation as that used by the caller to “parrot back” the requested name.
The database is searched at step 112 to identify all spellings of names and listings corresponding to exceptional pronunciations of names so as to create a candidate list. Processing then continues at step 114 to determine if more than one listing is contained in the candidate list. Step 114 is also the top of a “do while” loop which repeatedly attempts to resolve ambiguities due to multiple listings by using secondary information about each of the listings to disambiguate the search process. Thus, if the candidate list includes a single record, processing continues out the right side of step 114 to provide listing information and any other appropriate processing, e.g., initiate dialing of the corresponding telephone number. Alternatively, if the candidate list includes two or more listings, then processing continues out the left side of step 114 to step 120 where secondary information is searched in an attempt to distinguish the listings from and among each other.
At step 122 , the relevant secondary information is examined to see if it has already been considered in a previous iteration. Thus, if there are still multiple listings in the candidate list and all secondary information useful in distinguishing listings from and among each other have been considered, then processing continues at step 124 where the user is prompted to select a listing by telephone number. If, however, there exists secondary information which has not been considered, processing continues at step 126 which sequentially considers information contained in the secondary information fields. Alternatively, step 126 may prioritize consideration of particularly relevant secondary fields more likely to result in disambiguation of listings or include information more likely to be known by the average caller, e.g., the location or department of a particular party. Another method of categorizing and prioritizing secondary key information will be described below.
Upon identification of a secondary field, processing continues at step 128 where a determination of how many groupings are created by the secondary information is made. This check is performed to avoid enumerating a large number of secondary information categories to a caller when the caller (1) may be able to quickly provide the appropriate secondary information to be matched, or (2) may not know the secondary information to be solicited. For example, if “m” equals 3 , then groupings of four or more would result in processing continuing at step 130 where the caller would be prompted to input the appropriate secondary information, e.g, “We have seventeen listings for a Mr. John Smith at fourteen locations, do you know the location of the Mr. Smith you are looking for?” Alternatively, if a small number of groupings result from the secondary information under consideration, processing continues at step 132 where the caller is prompted to select from among the categories, e.g., “We have listings for a Jane Jones in three of our facilities. Do you want the Jane Jones in Arlington, Silver Spring, or Washington, D.C.?” [pause] “If you like, press or say 1 for Arlington, 2 for Silver Spring, or 3 for Washington, D.C.” Note that in this latter processing, the caller is given the options of saying the name of the desired location, entering the information by DTMF, or saying the number corresponding to the category.
Using either prompting step 130 or 132 , the input is checked at step 134 to determine if valid secondary information has been received. For example, the caller may have been unable to identify the location of the called party so that processing continues back at the top of the while loop represented by step 114 . Alternatively, if a valid secondary information input has been received, processing continues at step 136 where listings of the non-selected categories are eliminated from the candidate list and processing will then continue at decision step 114 . Upon looping back to step 114 , the method determines if there are still multiple entries in the candidate list or if the conflict has been resolved. If multiple entries still exist, the process will loop through, considering other secondary information not previously looked at in an attempt to resolve the ambiguity.
A method of identifying usable secondary information fields, providing prioritization information for use of the fields, and identifying a number of categories into which each of the secondary information fields divides the listings, is implemented by the steps of FIG. 5 . Initially, at step 200 , the processing begins at the top of an outer “FOR” loop which sequentially examines each of the secondary information fields for distinguishing information. Preferably, step 200 considers only those secondary information fields not previously used during the processing described in connection with FIG. 4 . At step 202 , the candidate listing is sorted based on the indexed secondary information field. At step 204 , a variable “count” is set equal to 1 and a variable “secondary data” is set equal to the secondary data contained in the first listing of the sorted list. Processing continues at step 206 , the top of an inner “FOR” loop indexing to the second entry of the list to sequentially examine the secondary data contained therein. At decision step 208 , the secondary data of the two listings are examined to see if they match or if they are different. If there is no match, i.e., the secondary information is useful in distinguishing between the two listings, the variable “count” is incremented at step 210 and then variable “secondary data” is set equal to the secondary data of the listing under consideration. At step 214 , the “listing index” is incremented to point to the next listing and processing loops back to the top step 206 .
Upon completion of the inner “FOR” loop and examination of all current candidate listings based on the current secondary information field, the variable “count” is examined to see if it is equal to the number of listings. If it is, i.e., all listings have unique secondary information, then a boolean flag indicating such is set equal to TRUE at step 218 . Otherwise, the flag would either default to FALSE, or be set to FALSE upon exiting under the “NO” condition of decision box 216 . The number of categories are then stored at step 220 for later reference and, at step 222 , the next secondary information field is indexed for consideration and processing back at step 200 .
A method of identifying an initial list of candidate listings and tailoring prompts to a caller is shown in FIGS. 6 and 7 of the drawings. With particular reference to FIG. 6, an input speech signal is converted to its phonetic equivalent which is then associated with common spellings for that name. Listings containing those spellings are then identified. In addition, listings having exceptional pronunciations of names are identified and added to the previously identified spelling-based listings to create an initial list of candidate listings. In addition, an audio file is created using the phonetic equivalent so as to mimic back to the caller his or her particular pronunciation of the requested name.
An example of creation of a list of candidate listings is shown in connection with FIG. 7 in response to the spoken name “C-O-O-K.” Phonetically, the name “C-O-O-K” is represented as “K UH K” as shown in the upper lefthand portion of FIG. 7 . Using a table lookup, the sequence of phonemes would correspond to the name spelled “C-O-O-K” and “C-O-O-K-E.” Thus, the spellings would be added to the candidate listings. In addition, listings in which the listed party is known to or has requested a particular pronunciation corresponding to the pronunciation spoken by the caller, is identified. In the example of FIG. 7, a Mr. “Robert K-O-C-H” pronounces his name as if spelled “C-O-O-K” as specified in the corresponding listing, as shown. Thus, the listing for “Robert K-O-C-H” has also been included in the candidate listing. The candidate listing is then used to initiate processing corresponding to step 112 of FIG. 4 .
Although unused secondary instruction is sequentially considered in and by the method shown and described with reference to FIG. 5, various criteria may be used to select which category of information will be used as a basis of requesting further information from a caller. For candidate lists having a small number of listings to be resolved and unique secondary information distinguishing the listings, it may be best to solicit the distinguishing information directly. However, where the candidate list is large, it may be more efficient to first request information eliminating a large portion of the listing prior to prompting for distinguishing information. For example, if the candidate list contains more than ten names, it may be more efficient to prompt the caller to provide information not distinguishing individual entries from each other but instead grouping the entries so that a large number may be eliminated from consideration, leaving a manageable list of candidate listings remaining.
The selection of secondary information may also take into consideration the probable availability of such information. For example, if not otherwise supplied, a default first prompt may be to solicit the first name of the called party if not initially supplied.
The system may also take into consideration and use secondary information contained in the initial listing request, such as nicknames used in specifying the desired party, particularly where the nickname is not common to the first names under consideration. For example, while the nickname “Bob” may be commonly used to refer to people names “Robert” and therefore not particularly useful in distinguishing listings, the nickname “Bub” is less common and might result in a search for that nickname in the corresponding field.
Although the embodiment described is in the context of a telephone directory lookup system as implemented by either a call origination or answering system, the invention is applicable to other database search methods, systems and engines to resolve ambiguities between and among entries after an initial primary key search has resulted in the identification of multiple records. For example, in an Internet search situation, wherein a party requests the web site of a particular business name, a search engine may initiate a series of questions to the user requesting further information so as to further limit and, hopefully, identify a specific web address.
While the foregoing has described what are considered to be preferred embodiments of the invention, it is understood that various modifications may be made therein and that the invention may be implemented in various forms and embodiments, and that it may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim all such modifications and variations which fall within the true scope of the invention.
|
A telephone directory search method and system intelligently utilizes secondary information contained in subscriber listings to disambiguate search results and provide telephone number and other data associated with a desired party. Upon identification of more than one listing for a particular requested named party, the system searches through secondary information for each of the parties to identify distinguishing information which is solicited from the calling party. Thus, where there are multiple listings for a particular name, the system attempts to identify distinguishing categories of information such as location, department, terminal type, etc., helpful in refocusing the search and eliminating listings from further consideration. The system considers the size of the candidate list in providing prompts, enumerating secondary data for selection when there are few qualifying entries, while generally soliciting information pertaining to the identified category when there is a wide range of secondary information entries to be considered. To enhance user confidence in system understanding of name information, the system incorporates the name pronunciation used by the calling party in system formulation of prompts and announcements provided back to that caller.
| 8
|
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 09/398,963, filed on Sep. 16, 1999, which claims priority of U.S. Provisional Application No. 60/100,575. The disclosures of U.S. Provisional Application Nos. 60/100,575 and 60/085,401 are incorporated herein by reference as if fully stated here.
FIELD OF THE INVENTION
[0002] The present invention relates generally to television and other viewable programming systems, and more particularly, to an apparatus and method that provides an In-Guide user interface for programmable blocking of viewable programs, such as for parental control of a television receiver.
BACKGROUND OF THE INVENTION
[0003] The V-Chip System
[0004] A system has been proposed in the United States and endorsed by the U.S. Congress commonly known as the V-Chip System. The system involves using the vertical blanking interval (“VBI”) of a standard television signal to include a code which indicates one or more rating factors for the program then being aired. These rating factors can include ratings similar to those promulgated by the Motion Picture Association of America (e.g. G, PG, PG-13, R, NC-17) and numerical ratings of individual categories of program nature such as violence, language, nudity and sexual content. A consumer V-Chip television system would allow a consumer to program his or her television system to exclude programs according to their preferred levels of one or more of these rating criteria or alternatively could be programmed to permit only programs having certain levels of content according to these rating categories.
[0005] A problem with the V-Chip system, as recognized in an article by T. Atherton, entitled “Living With the V-Chip,” The Ottawa Citizen, Entertainment, Section F, pp. F1-F2 (Saturday, Mar. 9, 1996), is that the perceived utility of the V-Chip system to a consumer depends on whether the consumer agrees with the subjective ratings contained in the VBI for most, if not all, programs. The author of this article, who purportedly has been involved in a “Beta-test” of the V-Chip system in Canada, gives two illustrative examples in his article. First, “trash-talk” shows are rated at the lowest possible level for violence and the next lowest level for language and sex categories, even though these shows often contain verbal violence, physical confrontations and graphic verbal sexual discussions. Second, utilizing the overall rating system to exclude this type of program, such as excluding all programs with a rating above PG, results in the blocking out of many programs which the author considers appropriate for viewing and does not wish blocked out, such as the movie Forrest Gump. Although some people may disagree with the author's judgment of the relative harm and worth of particular television programs, the article illustrates, at least, that regardless of how much the ratings providers will be able to adjust and fine tune their ratings system, based upon the majority of consumers' wishes, there will remain a significant portion of the consumer public who will disagree with the rating systems and think that whatever exclusion programming they do will block out desirable programs while not blocking out undesirable programs. Accordingly, improvements on the V-Chip system are needed. One improvement to the V-Chip system is using apparatus and method as described in co-pending U.S. Provisional Patent Application No. 60/076,290, filed Feb. 27, 1998, titled V-Chip Plus: Parental Control Apparatus and Method, the disclosures of which are hereby incorporated by reference as if set forth in full herein.
[0006] Picture-in-Picture Display of Television Programs
[0007] For a number of years, television receivers have been equipped with picture-in-picture (PIP) capability. In PIP format, the moving, real time images of one television channel are displayed on the background of the screen and the moving, real time images of another television channel are displayed in a PIP window overlaid on a small area of the background. Because two channels are simultaneously displayed by the television receiver, two tuners are required. The viewer enters the PIP mode by pressing a PIP key on the viewer's controller. Then, the viewer can change either the channel of the background or the channel of the PIP by resetting the appropriate tuner. To reverse the background and PIP images, the viewer simply presses a SWAP key. To collapse the PIP window, the viewer again presses the PIP key.
[0008] Electronic Television Guides
[0009] Television program guides help television viewers select programs to watch. Such television program guides list the available television programs by day of the week, time of day, channel, and program title (text-based television program guides). For many years, text-based television program guides have been published in hard copy form. More recently, as illustrated by Levine U.S. Pat. No. 4,908,713, text-based television program guides have begun to take an electronic form. In other words, the schedule of program listings is stored in an electronic memory connected to the television receiver. The program listings are recalled from memory by the viewer on command for display on the television screen. Without PIP technology, text-based television program guides overlay the real-time image of the program being received by the television tuner.
[0010] Still Image Picture Augmentation of Text-Based Television Programs
[0011] Despite the prevalence of text-based television program guides, many viewers prefer to make their program selections by switching the television tuner from channel to channel in order to observe on the screen the program being received on the respective channels. This process is sometimes called “grazing.”
[0012] Emanuel U.S. Pat. No. 5,161,019 discloses an automated form of channel grazing. A preselected group of channels are sequentially scanned by switching the tuner of the television receiver from channel to channel. A still image of the program received on each channel is stored in a memory. After all the channels have been scanned, the still images from all of the channels are simultaneously displayed on the television screen. This process gives the viewer more information about the program choices in addition to that obtainable from a textual television program guide, namely, still images of the actual programs are displayed.
[0013] Simultaneous PIP Display of Real-Time Program Images and Electronic Television Program Schedule Guides.
[0014] In one embodiment of the invention described in co-pending PCT Application PCT/US95/11173 for Method and Apparatus for Displaying Television Programs and Related Text, the disclosures of which are hereby incorporated by reference as if set forth in full herein, real-time images of a television program can be displayed in the PIP window. Simultaneously, a television viewer can use a PIP format for display of television program listings from a program schedule data base in the background. The viewer can select a particular program from the displayed current television program listing and cause the corresponding real-time program images to appear in the PIP window. In another embodiment of the invention described in co-pending PCT Application PCT/US95/11173, a television viewer can use a PIP format for display of future television program listings from a program schedule data base in the background and moving images of a video clip of one of the program listings in the background display selected for example by a cursor.
SUMMARY OF THE INVENTION
[0015] The present invention is directed to an apparatus and method that provides for a user interface for programmable blocking, such as for parental control, of viewable programs, such as programs that can be viewed on a television receiver. A memory provides storage of information relating to viewable programming and user defined blocking instructions. A microprocessor generates a blocking command as a function of the information stored in memory. A blocking circuit, such as a blocking circuit which passes a baseband television video signal to a television display, provides blocking of the video signal in response to the blocking command.
DESCRIPTION OF THE DRAWINGS
[0016] 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:
[0017] [0017]FIG. 1 is a schematic showing one embodiment of an apparatus according to the present invention with parental control circuitry embedded in a video cassette recorder;
[0018] [0018]FIG. 2 is a television screen in PIP format displaying password-based options of the V-Chip Plus+In-Guide User Interface Main Blocking Menu to block programs by Ratings/content codes, Time, Channel, Time Allowance, Pay-Per-View dollar Allowance and individual programs as selected from the program schedule grid guide or by inputting compressed codes such as a PlusCode™ which is a compressed code used by Gemstar Development Corporation's VCRPlus+® systems and which presently appear in television calendars and may be used to identify particular programs; FIG. 1 also displays the Global Block/Unblock option which may be used by the Master/Administrator to temporarily override blocking instruction to allow unblocked viewing and to then re-establish blocking instructions;
[0019] [0019]FIG. 3 is a television screen in PIP format displaying a viewer selection from the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “Set Passwords” option;
[0020] [0020]FIG. 4 is a television screen in PIP format displaying the V-Chip Plus+In-Guide User Interface “Set Password” interface screen and sample viewer-defined users;
[0021] [0021]FIG. 5 is a television screen in PIP format displaying the V-Chip Plus+In-Guide User Interface “Set Password” interface screen and a sample viewer-defined password selection;
[0022] [0022]FIG. 6 is a television screen in PIP format displaying a viewer selection from the V-Chip Plus+In-Guide User Interface Main Menu of the “By Ratings” option;
[0023] [0023]FIG. 7 is a television screen in PIP format displaying the V-Chip Plus+In-Guide User Interface “By Ratings” interface screen and sample viewer-defined blocking selections;
[0024] [0024]FIG. 8 is a television screen in PIP format displaying confirmation that Ratings Blocking has been set by RED highlighting on the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Ratings” option;
[0025] [0025]FIG. 9 is a television screen in PIP format displaying a viewer selection from the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Time” option;
[0026] [0026]FIG. 10 is a television screen in PIP format displaying the V-Chip Plus+In-Guide User Interface “By Time” interface screen and sample viewer-defined blocking selections;
[0027] [0027]FIG. 11 is a television screen in PIP format displaying confirmation that Time Blocking has been set by RED highlighting on the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Time” option;
[0028] [0028]FIG. 12 is a television screen in PIP format displaying a viewer selection from the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Channel” option;
[0029] [0029]FIG. 13 is a television screen in PIP format displaying the V-Chip Plus+In-Guide User Interface “By Channel” interface screen and sample viewer-defined blocking selections;
[0030] [0030]FIG. 14 is a television screen in PIP format displaying confirmation that Channel Blocking has been set by RED highlighting on the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Channel” option;
[0031] [0031]FIG. 15 is a television screen in PIP format displaying a viewer selection from the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Time Allowance” option;
[0032] [0032]FIG. 16 is a television screen in PIP format displaying the V-Chip Plus+In-Guide User Interface “By Time Allowance” interface screen and sample viewer-defined blocking selections;
[0033] [0033]FIG. 17 is a television screen in PIP format displaying confirmation that By Time Allowance Blocking has been set by RED highlighting on the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Time Allowance” option;
[0034] [0034]FIG. 18 is a television screen in PIP format displaying a viewer selection from the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the ”By $ Allowance” option;
[0035] [0035]FIG. 19 is a television screen in PIP format displaying the V-Chip Plus+In-Guide User Interface “By $ Allowance” interface screen and sample viewer-defined blocking selections;
[0036] [0036]FIG. 20 is a television screen in PIP format displaying confirmation that By $ Allowance Blocking has been set by RED highlighting on the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By $ Allowance” option;
[0037] [0037]FIG. 21 is a television screen in PIP format displaying a viewer selection from the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “Global Block/Unblock” option;
[0038] [0038]FIG. 22 is a television screen in PIP format displaying the V-Chip Plus+In-Guide User Interface “Global Block/Unblock” interface screen and sample viewer input of user identification and password;
[0039] [0039]FIG. 23 is a television screen in PIP format displaying a sample V-Chip Plus+In-Guide User Interface Main Blocking Menu format that will appear after any Time Allowance or $ Allowance blocking has been set;
[0040] [0040]FIG. 24 a is a television screen in PIP format displaying an alternative embodiment of the V-Chip Plus+In-Guide User Interface “By Ratings” interface screen for TV Ratings Codes and Content Codes in grid format with sample viewer-defined blocking selections;
[0041] [0041]FIG. 24 b is a television screen in PIP format displaying an alternative embodiment of the V-Chip Plus+In-Guide User Interface “By Ratings” interface screen for MPAA Ratings Codes in grid format with sample viewer-defined blocking selections; and
[0042] [0042]FIG. 25 is a television screen in PIP format displaying an alternative embodiment of the V-Chip Plus+In-Guide User Interface “By Time” interface screen and sample viewer-defined blocking selections.
[0043] The accompanying drawings are in color. Color is used in the Detailed Description of the Invention to describe certain features of the invention; the description of color-designated features corresponds to the accompanying drawings. The colored drawings and the color-corresponding description is used as a method of description of a particular embodiment of the present invention. The present invention is not limited by the particular colors used herein to describe the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0044] One embodiment of the present invention uses PIP display formatting to provide a password-protected programmable viewer interface to block or enable television program viewing, such as for parental control of television viewing. A parental control system is described in U.S. Pat. No. 5,382,983, which is hereby incorporated by reference as if set forth in full herein. Such parental control systems include circuitry for providing parental control of the use of a television receiver. As shown in FIG. 1, the circuitry is generally embedded within a VCR 50 connected between a television signal input 52 and a television monitor or display 54 . The parental control circuitry may be controlled by an input or remote controller 56 sending a command signal 58 to the circuitry to permit the user to select either by inclusion or exclusion the particular source and/or programs, channels, dates and times available for television viewing. Co-pending U.S. Provisional Patent Application No. 60/076,290, filed Feb. 27, 1998, titled V-Chip Plus: Parental Control Apparatus and Method, the disclosures of which have been previously incorporated by reference as if set forth in full herein, describes a preferred embodiment of the invention disclosed therein as allowing the viewer consumer to override the operation of the V-Chip system for particular programs contained in consumer programmable enable-override lists and blocking-override lists.
[0045] The present invention is not limited to the PIP television display format environment. The present invention applies equally to all devices that display viewable programming electronically, including but not limited to devices such as television, digital television, PCTV's, and PC's. Furthermore, the present invention applies equally to all viewable electronic programming display formats, including, but not limited to: display formats that provide partial or complete overlay menus; display formats that allow icons to be displayed on the screen to allow for selection of multiple functions, such as program viewing blocking/enablement, to be simultaneously displayed on the television screen; and display formats that allow the viewer to move the location of the viewing window for the program viewing blocking/enablement selection menus.
[0046] Still further, the present invention applies to all viewable programming delivery systems and media, including but not limited to conventional television broadcast, cable television, satellite television, the Internet, the World Wide Web, and all other electronic information networks and electronic viewable programming delivery systems.
[0047] Selection of options, functions, actions, programs, channels, logos and all other selection criteria in this invention applies equally to all methods of selection whether by a television viewer's remote control device, by keyboard, by voice activation, by speech recognition, by motion activation, by motion recognition, by mouse, by trac-ball, by touch pad, and/or by all other cursor-control devices.
[0048] One embodiment of the present invention allows the viewer, while simultaneously viewing real time television programming, to block, or enable, program viewing using password-based category blocking selection criteria including Global blocking/unblocking, and blocking By Ratings, By Time, By Channel, By Time Allowance, and By $ Allowance. “By Grid Guide Selection” blocking allows the viewer to view real time images of simultaneously broadcast programs, and to view video and sound clips of future programs, listed in an electronic program schedule guide and to set blocking/enablement instructions for individual programs, by channel, and/or by time slot.
[0049] After the viewer has selected, as described below, the television program viewing blocking/enablement function (“V-ChipPlus+”), the viewer's screen displays the V-Chip Plus+In-Guide User Interface Main Blocking Menu (the “Main Blocking Menu”). FIG. 2 shows a V-Chip Plus+In-Guide User Interface Main Blocking Menu to block programs by Ratings/content codes, Time, Channel, Time Allowance, Pay-Per-View dollar Allowance and individual programs as selected from the program schedule grid guide or by inputting compressed codes such as a PlusCode™ which is a compressed code used by Gemstar Development Corporation's VCRPlus+® systems and which presently appear in television calendars and may be used to identify particular programs. FIG. 2 also displays the Global Block/Unblock option which may be used by the Master/Administrator to temporarily override blocking instruction to allow unblocked viewing and to then re-establish blocking instructions. The Main Blocking Menu further provides for viewer selection of the Set Passwords option.
[0050] The viewer can enter the Main Blocking Menu in a number of ways. One embodiment is that the viewer, at some point in time after turning on the viewer's television receiver, presses a dedicated key on a remote control device. In another embodiment, the viewer enters the Main Blocking Menu by selecting the Blocking Option from the GuidePlus+Grid Guide option bar, causing the Main Blocking Menu to be displayed in the background window of the PIP display (the “PIP embodiment”). The PIP embodiment is reflected throughout the figures to this patent application. If “By Time Allowance” and/or “By $ Allowance” blocking instructions have been set, the Main Blocking Menu will appear when the viewing device, such as a television, is turned on.
[0051] In other embodiments, the viewer could enter the Main Blocking Menu in other ways, including but not limited to: 1.) The viewer presses a menu key on the viewer's remote control device that would enter a selection menu for various programming features for the viewer's particular viewing device, such as a television. Program view blocking/enablement would be an option on the viewing device's selection general menu. The viewer could then select program view blocking/enablement from the general menu; 2.) The viewer selects a program viewing blocking/enablement icon on the viewer's viewing device screen by, for instance, moving a cursor to the location of the icon and indicating selection of the program viewing blocking/enablement function.
[0052] In another embodiment, the viewer can enter the “Blocking Mode” while in the TV Guide Plus+Grid Guide (the “Grid Guide embodiment”) or similar electronic program viewing scheduling guide (the “Grid Guide”). Co-pending U.S. Provisional Patent Application Serial No. 60/053/330, titled EPG with Advertising Messages, the disclosures of which are hereby incorporated by reference as if set forth in full herein, describes as grid guide 22 such an electronic program viewing scheduling guide. In the Grid Guide embodiment, the viewer enters the “Blocking Mode” by selecting the Blocking Mode function, from for instance, the option bar of the Grid Guide.
[0053] In another embodiment, the viewer would enter PlusCode™ numbers of programs to be blocked.
[0054] From the Main Blocking Menu, the viewer can select from options that allow the viewer to block or enable viewing of programs globally, or to block or enable viewing of programs by Ratings/content codes, Time, Channel, Time Allowance, Pay-Per-View dollar Allowance and By Grid Guide Selection from an electronic television program schedule grid guide. Once the viewer has set blocking instructions, the blocking instruction database is updated and is accessed by a program viewing blocking system, such as is claimed in co-pending U.S. Provisional Patent Application No. 60/076,290, filed Feb. 27, 1998, titled V-Chip Plus: Parental Control Apparatus and Method, the disclosures of which have been previously incorporated by reference as if set forth in full herein. The program viewing blocking system uses the database program viewing blocking instructions to block a particular user from viewing programs as directed by the blocking instructions.
[0055] In one embodiment, the viewer selects a particular option from the Main Blocking Menu by using the arrow keys on the viewer's remote control device to move the highlight bar up or down the Main Blocking Menu selections and by pressing an Enter key, or some other similarly functional key, to select the highlighted option.
[0056] Setting User-level Passwords
[0057] V-Chip Plus+provides password-based options to block programs by Ratings/content codes, Time, Channel, Time Allowance, $ Allowance, and by individual program as selected from a program schedule. FIG. 3 shows a television screen in PIP embodiment format displaying a viewer selection from the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “Set Passwords” option. Turning to FIG. 4, a television screen is shown in PIP format displaying the V-Chip Plus+In-Guide User Interface “Set Password” interface screen and sample viewer-defined users. An alphanumeric password with a plurality of numeric digits may be set up for a plurality of users.
[0058] Viewer names can be input by highlighting a “User” tile in the Set Password interface screen. The “user” tiles in FIG. 3 are shown as blue tiles. The viewer can then input the user name by pressing the Blue “Alpha” button on the Guide Plus+display bar and by then using the up/down arrow keys on the viewer's remote control device to scroll up and down the pull down alphabet menu and selecting the appropriate alphabetic characters. In this manner, the viewer selects the alphabetic characters comprising each viewer's name. To designate another viewer's name, the viewer uses the up/down arrow keys on the viewer's remote control device to highlight another blue “User” tile.
[0059] In the PIP embodiment, the viewer inputs a password for each “User” using the digit keys of the viewer's remote control device and/or the scroll down alphabet menu described above. FIG. 5 shows a television screen in PIP format displaying the V-Chip Plus+In-Guide User Interface “Set Password” interface screen. FIG. 5 shows a sample viewer-defined password selection. A password is not set until the viewer types the password a second time in the Confirm tile for the user specified.
[0060] The viewer with the most restrictive Ratings/content settings is automatically set as the default. The default viewer's settings will be used when the television is turned on after the viewer has input the settings.
[0061] There may be more than one Master viewer. There may be more than one Administrator viewer. One embodiment of the invention would recognize a hierarchy of viewers. The hierarchy would allow a Master viewer to set blocking instructions for all viewers. The hierarch would allow an Administrator viewer to set blocking instructions for all viewers at a hierarchical level below that of the setting Administrator. Only the viewer designated as a Master or Administrator viewer will have the capability to use the Global Block/Unblock function. In one embodiment, only the highest ranking Master viewer would be allowed the capability to use the Global Block/Unblock function.
[0062] Once the viewer completes entering “User” names and passwords, the viewer must press the Blue action “Finished” button on the Guide Plus+screen bar to enter the alpha name into the password database. User names and passwords are not entered into the viewer database until the viewer selects the Blue action “Finished” button. The viewer can select the Blue action “Finished” button after entering each name and after confirming each password. Alternatively, the viewer may enter a plurality of names and passwords before selecting the Blue action “Finished” button. Alternatively, the viewer can press the Green action button to clear the password or alphabetic name inputs so that the viewer can begin inputting the user/password information again. The viewer that is designated as the “Master/Administrator” can turn global settings on or off.
[0063] Once the viewer has completed entering “User” names and passwords, the viewer can return to the Main Blocking Menu by using the up/down arrow keys to highlight V-CHIP+ on the menu bar.
[0064] Blocking from the Grid Guide
[0065] In one embodiment, the viewer enters the Grid Guide to identify particular programs to be blocked at the user level. Once in the Grid Guide, the viewer would enter the Blocking Mode by, for example, using the viewer's remote control device to select a Block[Unblock action button on the Grid Guide. Once in the Grid Guide Blocking Mode, the Master/Administrator would navigate through the schedule of programs as provided by the Grid Guide system, such as using the up/down and left/right arrow keys on the viewer's remote control device.
[0066] Real time images of real time programs highlighted by the viewer in the Grid Guide will be shown in the PIP or other window of the television screen. Co-pending PCT Application PCT/US95/11173 for Method and Apparatus for Displaying Television Programs and Related Text, the disclosures of which have been previously incorporated by reference as if set forth in full herein, describes one embodiment that provides for the display of real-time images of a television program in the PIP window while simultaneously providing that the television viewer can use a PIP format for display of television program listings from a program schedule data base in the background. The viewer can select a particular program from the displayed current television program listing and cause the corresponding real-time program images to appear in the PIP window.
[0067] Video and sound clips of future-scheduled programs highlighted by the viewer in the Grid Guide will be shown in the PIP or other window of the television screen. Co-pending PCT Application PCT/US95/11173, the disclosures of which have been previously incorporated by reference as if set forth in full herein, describes as one embodiment the use by a television viewer of a PIP format for display of future television program listings from a program schedule data base in the background and moving images of a video clip of one of the program listings in the background display selected, for example, by a cursor.
[0068] The viewer selects a particular program, channel logo, or time slot to be blocked by one selection method, for instance, using the viewer's remote control device to point to and select a program, channel or time slot. The viewer's selection would be reflected by color coding or other highlighting method.
[0069] Then, the viewer sets instructions to block the particular program, channel logo, and/or time slot, using, for instance, the viewer's remote control device to select a blocking action button on the Grid Guide. Pressing the Blue action button will block viewing of the highlighted program. When blocking a particular program, the viewer could further select another action to request the following blocking options: 1.) block a particular episode of a program by title for all occurrences of that program on a particular day for all channels and all times (“Daily Blocking”); 2.) block all occurrences of that program by title for the week for all channels and all time slots (“Weekly Blocking”); 3.) block all occurrences of that program by title for all channels and all time slots (“All Blocking”); and/or 4.) block a particular channel at a particular time slot.
[0070] In a Grid Guide embodiment of the present invention, the Grid Guide would show the program title and rating and/or content information.
[0071] Ratings or Content Code Blocking
[0072] The “Master/Administrator” user/viewer can block a selected user's access by ratings or content codes. FIG. 6 shows a television screen in PIP format displaying a viewer selection from the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Ratings” option.
[0073] After entering the “By Ratings” interface screen, the Master/Administrator selects a user from the user pull down menu. The user pull down menu lists all of the users entered in the user database. The Master/Administrator uses the up/down arrow keys on the Master/Administrator's remote control device to scroll up and down the user pull down menu. The Master/Administrator selects a particular user's name. The Master/Administrator must then enter the appropriate password for the Master/Administrator. When the password is accepted, the password tile turns green. Password acceptance is required to allow the Master/Administrator access to the Rating/Content tiles.
[0074] The Master/Administrator then uses the up/down arrow keys to scroll through the various Rating and Content codes. The Rating or Content code tile that can be selected is the tile that is highlighted in blue. The V-Chip Help Text portion of the Guide Plus+screen provides help explanations for the feature currently highlighted by the remote control selection. The V-Chip Help Text provides an explanation of each Rating or Content code as the Rating or Content code tile is highlighted.
[0075] The Master/Administrator presses the Blue action button on the Guide Plus+task bar to select a particular Rating or Content code to be blocked. When the Master/Administrator selects a particular Rating or Content code to be blocked, the tile for that particular code turns red. If the Master/Administrator wants to enable a blocked Rating or Content code, the Master/Administrator selects that particular Rating or Content code and presses the Blue action button on the Guide Plus+task bar, which will return the tile for the particular Rating or Content code to green. FIG. 7 shows a television screen in PIP format displaying the V-Chip Plus+In-Guide User Interface “By Ratings” interface screen and sample viewer-defined blocking selections. FIG. 7 also demonstrates the Help Text explanation for the highlighted Rating code, “NC-17.” Pressing the Green action button on the Guide Plus+Task Bar clears all settings on this screen.
[0076] An alternative embodiment of the “By Ratings” interface is represented in FIGS. 24 a and 24 b . FIG. 24 a demonstrates the use of a “By Ratings” grid for TV ratings codes and content codes. FIG. 24 b demonstrates the use a “By Ratings” interface for MPAA Ratings Codes.
[0077] In FIG. 24 a , all possible TV Ratings Codes (“TV-Y”, “TV-Y7”, etc.) are listed, in this case, on the left side of the grid 110 . Alternatively, MPAA Rating codes, other rating codes or combinations of different rating codes, such as MPAA and TV Ratings Codes may be used in the place of just TV Ratings Codes. Also listed is a grid row for “Unrated” programs 112 . That is, the Master/Administrator can chose to block all programs that are not rated. All possible TV Content Codes, (“S” for Sex, “V” for Violence, “L” for Language, etc.) or a subset thereof are listed, in this case, across the top of the grid 114 . Each grid tile represents a particular combination of a TV Ratings Code and a TV Content Code. The Master/Administrator uses the up/down and left/right arrow keys on the viewer's remote control device to highlight a grid tile. When the appropriate grid tile is highlighted, the Master/Administrator presses the Blue action button on the Guide Plus+task bar to select that particular Rating/Content Code grid tile to be blocked. When the Master/Administrator selects a particular Rating/Content Code grid tile to be blocked, the grid tile for that particular code turns red, or some other color to indicate selection of that tile. In FIG. 24 a , tiles 100 and 102 have been highlighted, selected and turned red (or some other color) to indicate they have been selected. Thereafter, programs that are rated TV-PG and have either L or V content codes will be blocked.
[0078] In addition to selecting individual tiles, entire rows or columns are highlighted for possible selection by moving the highlighted tile with the up/down and left/right arrow keys on the viewer's remote control device to the header row 114 or header (first) column 110 . Thus, entire TV Ratings Codes rows or entire TV Content Codes can be selected with on press of the Blue action button.
[0079] If the Master/Administrator wants to enable a blocked Rating/Content Code grid tile, the Master/Administrator selects that particular Rating or Content Code grid tile and presses the Blue action button on the Guide Plus+task bar, which will return the grid tile for the particular Rating/Content Code tile to green.
[0080] If the uppermost, leftmost tile is highlighted, the entire grid of tiles can be selected by one press of the Blue action button. This selection allows the Master/Administrator to select the tiles that the Master/Administrator wants to allow rather than selecting the tiles that the Master/Administrator want to block.
[0081] Currently, TV Content codes do not apply to MPAA Rating Codes. Accordingly, FIG. 24 b demonstrates that the Master/Administrator can chose any of the MPAA Rating Code grid tiles to select that Rating Code for blocking/enablement. As with FIG. 24 a , FIG. 24 b provides a a grid tile to block/enable unrated programs.
[0082] The Master/Administrator can then select another user name and set Ratings and Content code blocking and/or enablement instructions for each user subsequently selected. Changes are accepted when the Master/Administrator leaves the “By Ratings” interface screen by returning to the Main Blocking Menu.
[0083] Once the viewer has completed entering “By Rating” blocking and/or enablement instructions, the viewer can return to the Main Blocking Menu by using the up/down arrow keys to highlight V-CHIP+ on the menu bar. The “By Ratings” tile on the Main Blocking Menu will be RED, indicating that Ratings Blocking instructions have been set. FIG. 6 shows a television screen in PIP format displaying confirmation that Ratings Blocking instructions have been set by RED highlighting on the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Ratings” option.
[0084] “By Time” Blocking
[0085] The Master/Administrator can set user-level instructions to block program viewing for particular time ranges, for particular days of the week, or for “All Days.” FIG. 8 shows a television screen in PIP format displaying a viewer selection from the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Time” option. By selecting the “By Time” option, the user enters the “By Time” interface screen. FIG. 10 shows a television screen in PIP format displaying the V-Chip Plus+In-Guide User Interface “By Time” interface screen and sample viewer-defined blocking selections.
[0086] In the “By Time” interface screen, the Master/Administrator selects a user from the user pull down menu. The user pull down menu lists all of the users entered in the user database. The Master/Administrator uses the up/down arrow keys on the Master/Administrator's remote control device to scroll up and down the user pull down menu. The Master/Administrator selects a particular user's name. The Master/Administrator must then enter the appropriate password for the Master/Administrator. When the password is accepted, the password tile turns green. Password acceptance is required to allow the Master/Administrator access to the Day of the Week and time range tiles.
[0087] In the “By Time” interface screen, the Master/Administrator uses the up/down arrow keys to scroll through the various days of the week, or to select the “All Days” feature. The Master/Administrator can then enter time range blocking instructions for the particular day of the week, or for “All Days.” The Master/Administrator enters time ranges using the numeric keys on the Master/Administrator's remote control device. The Master/Administrator then selects the am/pm tile and uses the Blue action button on the Guide Plus+task bar to select a.m. or p.m. designation for the identified time range. After the Master/Administrator sets blocking instructions for a time range for a particular day, that day (or the “All Days”) tile turns RED. Pressing the Green action button on the Guide Plus+task bar clears all setting on this screen. The V-Chip Help Text portion of the Guide Plus+screen provides help explanations for the feature currently highlighted by the remote control selection.
[0088] The Master/Administrator can then select another user name and set Time blocking and/or enablement instructions for each user subsequently selected. Changes are accepted when the Master/Administrator leaves the “By Time” interface screen by returning to the Main Blocking Menu.
[0089] Once the viewer has completed entering “By Time” blocking and/or enablement instructions, the viewer can return to the Main Blocking Menu by using the up/down arrow keys to highlight V-CHIP+ on the menu bar. The “By Time” tile on the Main Blocking Menu will be RED, indicating that Time Blocking instructions have been set. FIG. 9 shows a television screen in PIP format displaying confirmation that Time Blocking has been set by RED highlighting on the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Time” option.
[0090] [0090]FIG. 25 is a television screen in PIP format displaying an alternative embodiment of the V-Chip Plus+In-Guide User Interface “By Time” interface screen and sample viewer-defined blocking selections. FIG. 25 provides for the designation by the Master/Administrator of time-sensitive categories such as “School Days,” “Weekdays,” “Weekends” and/or particular days of the week As an example of “School Day” blocking, if the Master/Administrator blocks the time frame from 8 pm to 7 am of a School Day, then the designated time frame is blocked for Sunday through Thursday. On the other hand, if the Master/Administrator blocks the time frame from 3 pm through 6 pm for School Days, then the designated time frame is blocked for Monday through Thursday. As an example of “Weekend” blocking, if the Master/Administrator blocks the time frame from 6 am through 8 am for Weekends, then the designated time frame is blocked for Saturday and Sunday. If the time frame from 6 pm through 7 pm is blocked for Weekends, then the designated time frame for Friday, Saturday and Sunday would be blocked. The Master/Administrator can further designate blocking for Weekdays (Monday through Friday). Further, a “Saturday/Sunday” option may be offered as an alternative the to the “Weekend” time frame where the “Weekend” time frame generally tracks and is the opposite of the “School Days” time periods. Of course, it is possible to have “School Days” and “Weekends” delineated so that they overlap in some areas while neither cover other specific time periods. Further, “School Days” may further be split into “School Days” and “School Nights,” where “School Days” generally refers to Monday-Friday days, while “School Nights” generally refers to Sunday-Thursday nights.
[0091] The use of “School Days” (or “School Days” and “School Nights”) and “Weekdays” also applies equally to the TV allowance embodiment described above in addition to the blocking functions.
[0092] In an alternative embodiment, Holidays, such as national or state holidays, are included in the “Weekend” and “School Days” groupings. Thus, in the United States, the Sunday night before Memorial Day (last Monday in May) would not be part of “School Days” when it otherwise would be. The list of Holidays that would affect the “School Days” and “Weekend” groupings is included into the system by any known data delivery method, including, but not limited to, being included in a factory installed memory, being downloaded over the VBI, a radio signal or other transmission, being downloaded from the Internet or other computer network and being keyed in by the Master/Administrator.
[0093] In another alternative embodiment, the School Days/Weekend, or any other generic time periods are combined with other search criteria to search an electronic program guide (EPG) of the type disclosed in PCT Application PCT/US95/11173. Thus, a theme search for “Educational shows” might be restricted to “School Days” where a theme search for “Cartoons” may be restricted to “Weekends.”
[0094] In another alternative embodiment, the Master/Administrator can choose to block according to Weekend, Weekdays, or specific days of the week. In this embodiment, the Weekend category is defined to be Saturday and Sunday; Weekdays are defined to be Monday through Friday. In this alternative embodiment, neither the Weekend nor the Weekday categories are time-sensitive.
[0095] “By Channel” Blocking
[0096] The Master/Administrator can set user-level instructions to block program viewing for particular channels, for a group of channels by category, or for a group of shows by “Theme.” FIG. 11 shows a television screen in PIP format displaying a viewer selection from the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Channel” option.
[0097] By selecting the “By Channel” option, the user enters the “By Channel” interface screen. FIG. 13 shows a television screen in PIP format displaying the V-Chip Plus+In-Guide User Interface “By Channel” interface screen and sample viewer-defined blocking selections.
[0098] In the “By Channel” interface screen, the Master/Administrator selects a user from the user pull down menu. The user pull down menu lists all of the users entered in the user database. The Master/Administrator uses the up/down arrow keys on the Master/Administrator's remote control device to scroll up and down the user pull down menu. The Master/Administrator selects a particular user's name. The Master/Administrator must then enter the appropriate password for the Master/Administrator. When the password is accepted, the password tile turns green. Password acceptance is required to allow the Master/Administrator access to the Channel and Theme tiles.
[0099] In the “By Channel” interface screen, the Master/Administrator uses the up/down and left/right arrow keys to scroll through the various channels and “Themes.” The Master/Administrator uses the Blue action button on the Guide Plus+task bar to select each channel or Theme to be blocked, or enabled. The tile for a blocked channel or Theme turns RED. The tile for an enabled channel or Theme turns Green. Pressing the Green action button on the Guide Plus+task bar clears all settings on this screen. Data for blocked channels will be stored in memory so it may be viewed if a channel is unblocked. The V-Chip Help Text portion of the Guide Plus+screen provides help explanations for the feature currently highlighted by the remote control selection.
[0100] The Master/Administrator can then select another user name and set Channel or Theme blocking and/or enablement instructions for each user subsequently selected. Changes are accepted when the Master/Administrator leaves the “By Channel” interface screen by returning to the Main Blocking Menu.
[0101] Once the viewer has completed entering “By Channel” blocking and/or enablement instructions, the viewer can return to the Main Blocking Menu by using the up/down arrow keys to highlight V-CHIP+ on the menu bar. The “By Channel” tile on the Main Blocking Menu will be RED, indicating that Channel and/or Theme Blocking instructions have been set. Turning to FIG. 12, a television screen is shown in PIP format displaying confirmation that Channel Blocking has been set by RED highlighting on the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Channel” option.
[0102] “By Time Allowances” Blocking
[0103] The Master/Administrator can set user-level viewing time allowances for each user by day of the week or for an entire week. Television viewing will be blocked if the daily viewing time by the viewing user exceeds the time allowance for the particular day of the week for that user. Television viewing will be blocked if the summation of the daily viewing time by the viewing user exceeds the weekly time allowance for that user. FIG. 14 shows a television screen in PIP format displaying a viewer selection from the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Time Allowance” option.
[0104] By selecting the “By Time Allowance” option, the user enters the “By Time Allowance” interface screen. FIG. 16 shows a television screen in PIP format displaying the V-Chip Plus+In-Guide User Interface “By Time Allowance” interface screen and sample viewer-defined blocking selections.
[0105] In the “By Time Allowance” interface screen, the Master/Administrator selects a user from the user pull down menu. The user pull down menu lists all of the users entered in the user database. The Master/Administrator uses the up/down arrow keys on the Master/Administrator's remote control device to scroll up and down the user pull down menu. The Master/Administrator selects a particular user's name. The Master/Administrator must then enter the appropriate password for the Master/Administrator. When the password is accepted, the password tile turns green. Password acceptance is required to allow the Master/Administrator access to the Time Allowance tiles.
[0106] In the “By Time Allowance” interface screen, the Master/Administrator uses the up/down and left/right arrow keys to scroll through the various days of the week and to set time allowances for the particular days and for the entire week. The Master/Administrator uses the Blue action button on the Guide Plus+task bar to select each day of the week, or the entire week, for which a time allowance is to be set. The Master/Administrator presses the Blue action button on the Guide Plus+task bar to allow input of time allowance. Time allowance is then entered using the numeric keys of the Master/Administrator's remote control device. The Master/Administrator can press the Blue action button on the Guide Plus+task bar to add ½ hour increments, with each subsequent press of the Blue action button. The tile for a day or for the week with a time allowance turns RED. Pressing the Green action button on the Guide Plus+task bar clears all settings on this screen. The daily allowances can sum to a higher number than the total weekly allowance. Once the weekly allowance is reached by the viewing user, television viewing will be blocked for that user for the rest of the week even if the daily allowance for a particular day has not been exceeded. The V-Chip Help Text portion of the Guide Plus+screen provides help explanations for the feature currently highlighted by the remote control selection.
[0107] The Master/Administrator can then select another user name and set time allowances for each user subsequently selected. Changes are accepted when the Master/Administrator leaves the “By Time Allowance” interface screen by returning to the Main Blocking Menu.
[0108] Once the viewer has completed entering user-level “Time Allowances,” the viewer can return to the Main Blocking Menu by using the up/down arrow keys to highlight V-CHIP+ on the menu bar. The “By Time Allowance” tile on the Main Blocking Menu will be RED, indicating that Time Allowances have been set. FIG. 15 shows a television screen in PIP format displaying confirmation that Time Allowances have been set by RED highlighting on the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By Time Allowance” option.
[0109] “By $ Allowance” Blocking
[0110] The Master/Administrator can set user-level Pay-Per-View viewing dollar (“$”) allowances for each user by day of the week or for an entire week. Television viewing will be blocked if the daily viewing dollar amount by the viewing user meets or exceeds the dollar allowance for the particular day of the week for that user. Television viewing will be blocked if the summation of the daily viewing dollar allowance by the viewing user meets or exceeds the weekly dollar allowance for that user. FIG. 17 shows a television screen in PIP format displaying a viewer selection from the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By $ Allowance” option.
[0111] By selecting the “By $ Allowance” option, the user enters the “By $ Allowance” interface screen. FIG. 19 shows a television screen in PIP format displaying the V-Chip Plus+In-Guide User Interface “By $ Allowance” interface screen and sample viewer-defined blocking selections.
[0112] In the “By $ Allowance” interface screen, the Master/Administrator selects a user from the user pull down menu. The user pull down menu lists all of the users entered in the user database. The Master/Administrator uses the up/down arrow keys on the Master/Administrator's remote control device to scroll up and down the user pull down menu. The Master/Administrator selects a particular user's name. The Master/Administrator must then enter the appropriate password for the Master/Administrator. When the password is accepted, the password tile turns green. Password acceptance is required to allow the Master/Administrator access to the $ Allowance tiles.
[0113] In the “By $ Allowance” interface screen, the Master/Administrator uses the up/down and left/right arrow keys to scroll through the various days of the week and to set $ allowances for the particular days and for the entire week. The Master/Administrator uses the Blue action button on the Guide Plus+task bar to select each day of the week, or the entire week, for which a $ allowance is to be set. The Master/Administrator presses the Blue action button on the Guide Plus+task bar to allow input of $ allowance limitations. Dollar allowance is then entered using the numeric keys of the Master/Administrator's remote control device. The Master/Administrator can press the Blue action button on the Guide Plus+task bar to add 50 cent increments, with each subsequent press of the Blue action button. The tile for a day or for the week with a $ allowance turns RED. Pressing the Green action button on the Guide Plus+task bar clears all settings on this screen. The daily allowances can sum to a higher amount than the total weekly allowance. Once the weekly $ allowance is reached by the viewing user, Paid-Per-View television viewing will be blocked for that user for the rest of the week even if the daily $ allowance for a particular day has not been met or exceeded. The V-Chip Help Text portion of the Guide Plus+screen provides help explanations for the feature currently highlighted by the remote control selection.
[0114] The Master/Administrator can then select another user name and set $ allowances for each user subsequently selected. Changes are accepted when the Master/Administrator leaves the “By $ Allowance” interface screen by returning to the Main Blocking Menu.
[0115] Once the viewer has completed entering user-level “$ Allowances,” the viewer can return to the Main Blocking Menu by using the up/down arrow keys to highlight V-CHIP+ on the menu bar. The “By $ Allowance” tile on the Main Blocking Menu will be RED, indicating that $ Allowances have been set. FIG. 18 shows a television screen in PIP format displaying confirmation that $ Allowances have been set by RED highlighting on the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “By $ Allowance” option.
[0116] Global Block/Unblock
[0117] The Master/Administrator, and only the Master/Administrator, can use the Global Block/Unblock instruction. FIGS. 20 and 21 show a television screen in PIP format displaying a viewer selection from the V-Chip Plus+In-Guide User Interface Main Blocking Menu of the “Global Block/Unblock” option. Turning to FIG. 22, a television screen is shown in PIP format displaying the V-Chip Plus+In-Guide User Interface “Global Block/Unblock” interface screen and sample viewer input of user identification and password. In the “Global Block[Unblock” interface screen, the Master/Administrator is prompted for the Master/Administrator's password. Acceptance of the password allows the Master/Administrator to use the Global Block/Unblock instruction. Global Block/Unblock is a toggle switch override command that allows the Master/Administrator to temporarily override all blocking instructions. Using the Global Block/Unblock command does not destroy all of the blocking instructions. The blocking instructions remain in memory. The Master/Administrator can globally unblock all previously set instructions to view programming without any blocking. The Master/Administrator can then globally reset all blocking instructions.
[0118] Time and $ Allowance Accumulation and Blocking
[0119] Turning to FIG. 23, a television screen is shown in PIP format displaying a sample V-Chip Plus+In-Guide User Interface Main Blocking Menu format that will appear after any Time Allowance or $ Allowance blocking has been set. This screen will automatically appear each time that the television is turned on. The screen prompts the viewer for the viewer's “User” identification and for that “User's” password.
[0120] The time that the television is viewed by that user is then accumulated. Accumulated viewing times are compared at periodic time intervals to the time allowances set for that user. If the user's accumulated viewing time meets or exceeds the time allowance for that day, or for the week, the V-Chip Plus+In-Guide User Interface system sends blocking instructions to a program viewing blocking system, such as is claimed in co-pending U.S. Provisional Patent Application Attorney Docket No. 32068/CAG/G207 titled V-Chip Plus: Parental Control Apparatus and Method, the disclosures of which have been previously incorporated by reference as if set forth in full herein, to block that user from further viewing.
[0121] Pay-Per-View dollar amounts agreed to by that user are accumulated. Accumulated Pay-Per-View dollar amounts agreed to by that user are then compared to that user's $ Allowances, by day, and for the week. The $ amount comparison is made each time that the user attempts to select a Pay-Per-View program. If the user's $ Allowance has been met or exceeded, the V-Chip Plus+In-Guide User Interface system sends blocking instructions to a program viewing blocking system, such as is claimed in co-pending U.S. Provisional Patent Application Attorney Docket No. 32068/CAG/G207 titled V-Chip Plus: Parental Control Apparatus and Method, the disclosures of which have been previously incorporated by reference as if set forth in full herein, to block that user from further viewing.
ILLUSTRATIVE EMBODIMENTS
[0122] The embodiments of the invention described herein are only considered to be preferred and/or illustrative of the inventive concept; the scope of the invention is not to be restricted to such embodiments. Various and numerous other arrangements may be devised by one skilled in the art without departing from the spirit and scope of this invention. For example, a variety of different on screen display color schemes can be used to communicate various selections and options to the viewer/user.
|
A system for restricting access to television programs comprising an input for accepting cursor movement and selection commands. In one embodiment, the system displays a list of television viewers to be selected to limit their television program viewing based on a selecting blocking criterion. The system further includes means for blocking or allowing viewing of television programs based on time or dollar allowance when a selection command is entered into the input.
| 7
|
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims benefit of U.S. Provisional Patent Application No. 61/427,578, filed Dec. 28, 2010, entitled Heat Treating and Brazing of an Object, which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to heat processing of objects, and more particularly, to heat treating and/or brazing objects.
BACKGROUND
The manufacture of objects, such as gas turbine engine components, by heat treating and/or brazing, remains an area of interest. Some existing systems have various shortcomings, drawbacks, and disadvantages relative to certain applications. Accordingly, there remains a need for further contributions in this area of technology.
SUMMARY
One embodiment of the present invention is a unique method for brazing an assembly. Another embodiment is a unique method of heat treating an object. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for heat treating and/or brazing. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith.
BRIEF DESCRIPTION OF THE DRAWINGS
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
FIG. 1 schematically illustrates some aspects of a non-limiting example of a system for brazing an assembly in accordance with an embodiment of the present invention.
FIG. 2 illustrates some aspects of a non-limiting example of the assembly illustrated in FIG. 1 .
FIG. 3 illustrates some aspects of a non-limiting example of the assembly of FIG. 1 with a braze filler metal applied.
FIG. 4 illustrates some aspects of a non-limiting example of an assembly depicting braze filler metal having wetted undesirable portions of the assembly.
FIGS. 5, 5A and 5B illustrate some aspects of non-limiting examples of heat shields for shielding a portion of an object or assembly.
FIG. 6 illustrates some aspects of a non-limiting example of an assembly having a portion shielded by a heat shield in accordance with an embodiment of the present invention, depicting braze filler metal having flowed into a braze joint.
DETAILED DESCRIPTION
For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nonetheless be understood that no limitation of the scope of the invention is intended by the illustration and description of certain embodiments of the invention. In addition, any alterations and/or modifications of the illustrated and/or described embodiment(s) are contemplated as being within the scope of the present invention. Further, any other applications of the principles of the invention, as illustrated and/or described herein, as would normally occur to one skilled in the art to which the invention pertains, are contemplated as being within the scope of the present invention.
Referring to the drawings, in particular FIG. 1 , a non-limiting example of a system 10 for treating an object 12 in accordance with an embodiment of the present invention is schematically depicted. System 10 includes a furnace 14 having heating elements 16 , and a controller 18 . Controller 18 is operative to control the amount of heat supplied to object 12 via furnace 14 , e.g., operative to control the temperature of heating elements 16 . In one form, controller 18 is also operative to control the duration of heating. In other embodiments, the duration of heating may be manually controlled or may be controlled by one or more other systems.
Heating elements 16 are operative to heat object 12 in furnace 14 . In one form, furnace 14 and heating elements 16 are configured to heat object 12 by radiation. In other embodiments, furnace 14 and heating elements 16 may be configured to heat object 12 by convection and/or conduction in addition to or in place of radiation.
In one form, furnace 14 is sized to heat a single object 12 . In other embodiments, furnace 14 may be configured to heat a plurality of one or more types of objects. In one form, furnace 14 is a vacuum furnace, in which case system 10 includes means for drawing a vacuum in furnace 14 . The vacuum may be a partial vacuum or a substantially full vacuum, depending upon needs of the particular application. In one form, system 10 includes a vacuum pump 20 operative to partially or substantially fully evacuate gases from furnace 14 . In other embodiments, other systems for evacuating or purging gases from furnace 14 may be employed. Although the example of furnace 14 is described herein as a vacuum furnace, in other embodiments, furnace 14 may be any furnace or autoclave, and may have little or no atmosphere, an inert and/or other gas atmosphere or an ambient air atmosphere.
Referring to FIGS. 2-4 , some aspects of a non-limiting example of object 12 in accordance with an embodiment of the present invention are depicted. In one form, object 12 is a gas turbine engine component. In other embodiments, object 12 may be any device or structure. In one form, object 12 is an assembly that is to be brazed together, e.g., in furnace 14 . In other embodiments, object 12 may be one or more structures that are to be heat treated, e.g., in furnace 14 . In still other embodiments object 12 may be an object or assembly that is to be heat treated and brazed, e.g., in furnace 14 . In one form, object 12 is formed of a plurality of components or portions that are to be brazed together in furnace 14 . In the example illustrated in the drawings, e.g., FIG. 2 , object 12 is formed of portions 22 and 24 that are to be brazed together at a braze joint 26 . Portion 22 is relatively thin compared to portion 24 , and has a lower thermal mass than portion 24 . In other embodiments, object 12 may have any number of portions.
In order to braze portions 22 and 24 together, a braze filer metal 28 is applied to object 12 adjacent to braze joint 26 . Heating of portions 22 and 24 by heating elements 16 in furnace 14 raises the temperature of portions 22 and 24 , with the goal of melting braze filler metal 28 so that it flows into braze joint 26 . However, because portion 22 is thinner than portion 24 , portion 22 heats up faster than portion 24 , which results in braze filler metal 28 wetting the surface of portion 22 and flowing away from braze joint 26 because portion 22 reaches a temperature sufficient to melt braze filler metal 28 prior to portion 24 reaching the same temperature, which yields an undesirable result, depicted in FIG. 4 . The melted braze filler metal 28 is depicted in FIG. 4 as thicker lines on portion 22 of object 12 . In order to prevent the occurrence illustrated FIG. 4 , it is possible to heat object 12 up to a temperature below the solidus point of braze filler metal 28 over a longer time period to allow portion 24 and portion 22 to achieve relatively similar temperatures just below the solidus point of braze filler metal 28 . Once the temperatures of portions 22 and 24 are just below the solidus point, furnace 14 may be operated to slowly increase the temperature of object 12 in an attempt to melt braze filler metal 28 and cause it to flow into braze joint 26 . However, such an approach is a time consuming process, resulting in higher energy costs and lower product throughput.
Referring to FIG. 5 , in order to prevent portion 22 from achieving a temperature sufficient to melt braze filler metal 28 too soon, a heat shield 30 is employed. Heat shield 30 is formed and positioned on portion 22 to shield only portion 22 form heating elements 16 , and to not shield portion 24 from heating elements 16 . The radiation heat shield 30 may be positioned so that the radiation heat shield is supported by the assembly and the entire radiation heat shield 30 maintains a spaced-apart relationship with the braze filler metal 28 and the braze joint 26 both before and after melting the braze filler metal 28 to flow into the braze joint 26 as shown in FIGS. 5 and 6 . In one form, heat shield 30 is configured to shield portion 22 from radiation emanating from heating elements 16 to reduce radiative heat transfer to portion 22 . Heat shield 30 may also be configured to shield portion 22 from conduction and/or convection heating in addition to or in place of radiation heating. In one form, heat shield 30 is configured to conform to the shape of portion 22 . In other embodiments, other shapes may be deployed.
Heat shield 30 is formed of one or more thin sheets of metal. The thickness of the sheet metal may vary with the needs of the application. In one form, sheet metal having a thickness in the range of 0.001″ to 0.010″ is employed. In other embodiments, other sheet metal thicknesses may be employed, including less than 0.001″ thickness and/or more than 0.010″ thickness. In one form, heat shield 30 is a layer of sheet metal. In one form, the material used to form heat shield 30 is a refractory metal, for example and without limitation, molybdenum, tantalum, niobium or their alloys. In other embodiments, other metals may be employed, including other refractory metals and/or their alloys, as well as common sheet metal materials, for example and without limitation, stainless steels or nickel alloys, in addition to or in place of refractory metals. In one form, heat shield 30 is laminated, being formed of a plurality of layers of sheet metal, for example and without limitation, sheet metal formed of one or more of the materials listed above. In one form, heat shield 30 is formed by wrapping portion 22 from a single sheet of sheet metal. In one form, the wrapping is performed in a spiral fashion, winding along a length and/or width of portion 22 . In one form, the layers are formed as concentric layers, e.g., individual sheets wrapped around portion 22 and around each other. In various embodiments, each layer may also be formed by various means, including laser cutting, water cutting, electrical discharge machining and/or other techniques.
Referring to FIGS. 5A and 5B , in one form, heat shield 30 is configured to form a gap 32 between heat shield 30 and portion 22 , e.g., to prevent heat conduction from heat shield 30 to portion 22 . In one form, gap 32 is formed by one or more standoffs 34 disposed between heat shield 30 and portion 22 . In one form, standoff 34 is a ceramic powder or is formed of a ceramic powder. In other embodiments, standoff 34 may take other forms, for example and without limitation, ceramic rope and/or metallic wire. In still other embodiments, standoffs 34 may be formed in layers 36 that form heat shield 30 , e.g., dimples in one or more layers 36 . In yet other embodiments, heat shield 30 may not be configured to form a gap between heat shield 30 and portion 22 .
In one form, each layer 36 of heat shield 30 is also separated by a gap 32 , e.g., formed by standoffs 34 . In other embodiments, only some layers 36 may be separated to form gaps 32 therebetween. In still other embodiments, no gaps may be formed between layers 36 of heat shield 30 . In one form, heat shield 30 is configured to permit gases between heat shield 30 and object 12 , as well as between shield layers 36 to escape when a vacuum is drawn in furnace 14 . In one form, heat shield 30 is configured, e.g., by the number and locations of layers 36 and gaps 32 , to control the heat flux received by portion 22 from heating elements 16 , e.g., to achieve a desired heating rate and/or peak temperature of portion 22 . Heat shield 30 may also or alternatively be configured to control the cooling of portion 22 when furnace 14 is turned off and/or when object 12 is removed from furnace 14 , e.g., to yield a desired cooling rate of portion 22 . In various embodiments, one or more coatings, e.g., reflective and/or refractive coatings, may be deposited on one or more layers 36 in order to control the flow of heat to and/or from portion 22 . In addition, other materials, such as insulation materials or coatings may be deposited on heat shield 30 and/or between layers 36 of heat shield 30 in order to control the flow of heat to and/or from portion 22 .
In order to braze portions 22 and 24 together, braze filler metal 28 is positioned adjacent to braze joint 26 . Heat shield 30 is then positioned on portion 22 , and object 12 is placed into furnace 14 . In one form, a vacuum is drawn in furnace 14 , although in other embodiments a vacuum may not be drawn. In some embodiments, furnace 14 may be purged with an inert gas prior to heating. Heating elements 16 are activated to heat object 12 with heat shield 30 . Heat shield 30 prevents portion 22 from heating up too quickly, e.g., promoting a more uniform temperature distribution as between portion 22 and portion 24 . As a result, both portions 22 and 24 achieve a sufficient temperature to melt braze filler metal 28 so that it flows into braze joint 26 , e.g., as depicted in FIG. 6 , wherein the thick lines represent braze filler metal 28 within braze joint 26 . After braze filler metal 28 has flowed into braze joint 26 , the temperature inside furnace 14 is reduced, allowing object 12 to cool. Furnace 14 is then re-pressurized, e.g., brought up to atmospheric pressure, and object 12 is removed from furnace 14 . Heat shield 30 is then removed from object 12 . In some embodiments, heat shield 30 is configured to be reusable for subsequent objects 12 , e.g., of the same configuration.
In some embodiments, a heat shield such as heat shield 30 may be configured to control the heating rate and/or cooling rate of portion 22 of object 12 during heat treating of object 12 in order to obtain a desired microstructure in the portion covered by heat shield 30 , e.g., portion 22 , that is different from the microstructure of other portions of object 12 , e.g., portion 24 . This may be performed as a heat treat operation alone or in conjunction with a brazing operation.
Embodiments of the present invention include a method for brazing an assembly in a furnace, comprising: applying a braze filler metal adjacent to a joint in the assembly; providing a radiation heat shield conforming to a shape of only a portion of the assembly, wherein the radiation heat shield is configured to reduce radiative heat transfer to the portion of the assembly; positioning the radiation heat shield on the assembly; placing the assembly and the radiation heat shield in the furnace; and heating the assembly and the radiation heat shield in the furnace to melt the braze filler metal into the joint.
In a refinement, the method further comprises positioning the radiation heat shield to shield only the portion of the assembly from heating elements of the furnace.
In another refinement, the method further comprises configuring the radiation heat shield to form a gap between the radiation heat shield and the portion of the assembly.
In yet another refinement, the method further comprises supplying a standoff to form the gap.
In still another refinement, the standoff is formed in the radiation heat shield.
In yet still another refinement, the method further comprises forming the radiation heat shield as a plurality of layers, each layer being separated by a gap.
In a further refinement, the method further comprises forming each layer from sheet metal.
In a yet further refinement, the method further comprises providing standoffs configured to form the gap between each layer.
Embodiments of the present invention include a method for treating an object, comprising: supplying a laminated heat shield conforming to a shape of a portion of the object; positioning the laminated heat shield on the portion of the object; placing the object and the laminated heat shield in a furnace; heating the object and the laminated heat shield in the furnace; and cooling the object and the laminated heat shield, wherein the laminated heat shield is configured to control a cooling rate of the portion of the object shielded by the laminated heat shield.
In a refinement, the method further comprises drawing a vacuum in the furnace.
In another refinement, the laminated heat shield is formed from a refractory metal.
In yet another refinement, the laminated heat shield is formed of a plurality of layers of a sheet metal.
In still another refinement, the method further comprises forming the layers by wrapping the portion with a sheet of sheet metal.
In yet still another refinement, the wherein the wrapping is performed in a spiral fashion.
In a further refinement, the layers are concentric.
In a yet further refinement, the method further comprises forming a different microstructure in the portion of the object than the balance of the object.
Embodiments of the present invention include a method for treating an object, comprising: wrapping a selected portion of the object in a plurality of layers of a sheet metal; separating at least a portion of each layer of the sheet metal from an adjacent layer of the sheet metal; placing the object in a furnace; and heating the object in the furnace to braze the object and/or heat treat the object.
In a refinement, the method further comprises forming standoffs in at least one layer of the sheet metal.
In another refinement, the method further comprises applying a braze filler metal adjacent to a joint in the object.
In still another refinement, the method further comprises further comprising selecting the number of layers based on a desired cooling rate for the portion of the object.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment(s), but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as permitted under the law. Furthermore it should be understood that while the use of the word preferable, preferably, or preferred in the description above indicates that feature so described may be more desirable, it nonetheless may not be necessary and any embodiment lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow. In reading the claims it is intended that when words such as “a,” “an,” “at least one” and “at least a portion” are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. Further, when the language “at least a portion” and/or “a portion” is used the item may include a portion and/or the entire item unless specifically stated to the contrary.
|
One embodiment of the present invention is a unique method for brazing an assembly. Another embodiment is a unique method of heat treating an object. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for heat treating and/or brazing. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to liquid pumping and collecting apparatuses, and more particularly to a system for pumping underground liquid, such as groundwater samples, from small diameter wells. It should be noted, however, that the invention is also applicable and adaptable in various other applications that will occur to one skilled in the art from the disclosure herein.
2. Description of the Prior Art
Recent increases in public concern for the environment have resulted in various government-imposed environmental regulations with regard to groundwater quality and land-site cleanup projects. Among such regulations are requirements relating to the monitoring and sampling of water quality of aquifers as sources of drinking water. In response to these requirements, water quality analytic capabilities have been improved and water-sampling equipment has been developed. However, presently most sampling using bladder pumps employs permanently installed dedicated pumps in monitoring wells. Current portable equipment for the groundwater sampling is relatively heavy, bulky, and thus difficult to transport from one monitoring site to another.
One of the preferred types of pumps for groundwater sampling or other pumping applications is a submersible, fluid-actuated pump wherein the actuating fluid is preferably a gas such as compressed air. A flexible bladder member in this type of pump separates and isolates the interior of the pump into two chambers: a liquid chamber that contains the sample fluid and is in communication with both the pump inlet and outlet, and a gas chamber surrounding the first chamber, and connected to a source of the actuating gas, with the bladder disposed therebetween. The pumped liquid is conveyed through the pump by alternately pressurizing and venting or relieving the pressure in the gas chamber to contract and relax the bladder member, thus alternately decreasing and increasing the volume of the liquid chamber. The pumped liquid is drawn into the liquid chamber during such increases in volume under the influence of the natural hydrostatic head of the groundwater or other pumped liquids and is discharged through the pump outlet during such decreases in volume, thereby conveying the pumped liquid through the pump.
The conventional bladder pumps employ ball-type check valves that control flow of liquid trough the pump. However, the ball-type check valves have proven to be not very efficient, especially in low-flow applications where the velocity with which water enters the pump intake is low. Ball members of the check valves are prone to roll around valve seats and, thus are slow to respond to the change of the water flow direction.
The need therefore exists for a liquid sampling bladder pump with more efficient check valves.
SUMMARY OF THE INVENTION
The present invention alleviates the drawbacks of the prior art. The present invention provides a pump for a wide variety of applications, including, but not limited to, groundwater quality applications, withdrawing and collecting contaminated groundwater or other subterranean liquids from a landfill-site having a plurality of in-ground wells. The novel pump may be built with a small outside diameter, such as ¾″ or ⅞″ and is adapted to sample temporarily and/or permanently installed small diameter monitoring wells. The bladder pump of the present invention is particularly effective for conducting “low-flow sampling” from monitoring wells where minimal purging is undertaken prior to sample collection. Please note that low-flow refers to the velocity with which water enters pump intake and that is imparted to the formation pore water in the immediate vicinity of the well screen.
The preferred liquid sampling pump is an air-operated, gas-displacement bladder pump having a generally hollow cylindrical body submersible in the in-ground well. The pump body includes a liquid inlet with an inlet cone-shaped check valve for allowing one-way fluid flow from the in-ground well into the housing interior, and a liquid outlet with a similar outlet cone-shaped check valve allowing one-way fluid flow from the pump body interior to the discharge collection equipment. The cone-shaped check valves provide better effectiveness than conventional ball-type check valves.
An exemplary control apparatus in some applications for supplying and controlling an operating fluid for a gas-displacement pump supplies pulses of a pressurized operating fluid, such as air, into the pump body interior in order to forcibly displace and discharge liquid material through the outlet. Between pressurized pulses of the operating fluid, the control apparatus relieves the pressure of the other operating fluid in the pump body interior in order to permit liquid material to flow, under the influence of its own hydrostatic head, into the pump housing through the inlet.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent from a study of the following specification when viewed in light of the accompanying drawings, wherein:
FIG. 1 is a fragmentary longitudinal sectional view of a liquid sampling system;
FIG. 2 is a perspective view of a controller apparatus of FIG. 1;
FIGS. 3 a and 3 b are fragmentary cross-sectional views of upper and lower portions, respectively, of a liquid pump in accordance with the first embodiment of the present invention;
FIG. 4 is a cross-sectional view of a push-fit fitting;
FIG. 5 is a fragmentary cross-sectional view of a cone-shaped check valve in accordance with the present invention;
FIGS. 6 a and 6 b are fragmentary cross-sectional views of upper and lower portions, respectively, of a liquid pump in accordance with the second embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 of the drawings illustrates an underground liquid sampling system indicated generally by reference numeral 1 . For purposes of illustration, the liquid sampling apparatus is shown as installed in a monitoring well 2 . A fluid sampling pump 10 is disposed within the well casing 4 of the monitoring well 2 and is submerged beneath the level of the groundwater 6 to a suitable depth for obtaining representative groundwater samples.
As is explained in further detail below, the liquid sampling pump 10 in accordance with the present invention, is a bladder-type fluid-actuated pump, wherein the actuating fluid is a pressurized gas, preferably compressed air, and includes a plurality of inlet openings 39 and an outlet fitting 14 .
A liquid conduit 16 is sealingly connected at one end to the pump outlet fitting 14 to provide direct sample delivery to a sample collection vessel 17 . A pressurized gas conduit 18 is connected at one end to a fluid fitting 20 of the pump 10 . The other end of the gas conduit 18 is selectively and removably connected to a precision dual range controller 100 .
Because the pump is preferably of a lightweight construction, the conduits themselves can frequently be used to hold and retain the pump in its submerged position in the well 2 . Preferably, the pump 10 is provided with an attachment device (not shown) that allows users to support the pump in the well with a covered steel cable. It will be appreciated that any other appropriate means for holding and retaining the pump 10 in its submerged position in the well 2 , commonly known to those skilled in the art, may be used.
The precision dual range controller 100 is selectively and removably connected to the pump 10 by means of the external gas conduit 18 . The preferred controller 100 is a portable, lightweight unit and includes means for alternately positively pressurizing and venting or relieving the pressure of the actuating gas in order to operate the liquid sampling pump 10 , as is explained below.
FIG. 2 illustrates a preferred physical arrangement for the dual range controller 100 , including a carrying case 102 for housing and transporting the portable controller apparatus from one monitoring site to another. The carrying case 102 generally includes an upper portion 104 hingedly connected to a base portion 106 , carrying handle (not shown), and upper and lower latches 110 and 112 . The carrying case 102 is preferably composed of high impact-resistant materials known to those skilled in the art for purposes of protecting the components of the controller 100 . The dual range controller generally includes two separate, switchable, pressure regulated air supply circuits, preferably 0-50 psi and 0-100 psi, each having a dedicated pressure gauge 122 and 123 respectively, a fitting 120 to which the external gas conduit may be connected, a pressure gauge 118 used to monitor the air supply provided to the controller 100 , and various controls. To enable precision control of the flow from the bladder pump, the controller 100 is provided with separate precision electronic timers to control the flow air to and from the pump 10 , each of which is adjustable in the range of 0.1 to 10 seconds. The carrying case 102 is especially adapted for ease and convenience of transportation of the controller and related components to monitoring sites to which access is limited or difficult.
The various individual components of the preferred controller apparatus 100 are well known to those skilled in the art and thus are described only schematically in terms of their functions.
As illustrated in FIGS. 3 a and 3 b , the fluid sampling pump 10 in accordance with the first embodiment of present invention, includes a generally tubular pump casing 30 having a cylindrical wall 32 , a lower end 34 and an upper end 35 . The cylindrical wall 32 of the pump body 30 is swaged at the opposite lower and upper ends 34 and 35 thereof respectively. The lower end 34 of the pump body 30 is sealed with a bottom plug 38 . The upper end of the pump body 30 is closed with a top cap 40 . The casing 30 is swaged at its upper and lower ends to retain the bottom plug 38 and the top cap 40 . The top cap 40 is sealed to an internal surface of the wall 32 by means of O-rings 42 or other suitable sealing means known to those skilled in the art.
A bottom cap 60 is provided between the bottom plug 38 and the top cap 40 . The bottom cap 60 sealingly engages the wall 32 by means of O-rings 62 . The bottom cap 60 is provided with a communication passage 68 therethrough. The bottom cap includes an integrally formed bottom bladder mandrel 63 . However, a separate bottom bladder mandrel secured to the bottom cap by any appropriate means, is also within the scope of the present invention.
The interior of the pump body 30 is divided and isolated into two chambers by a generally cylindrical flexible bladder 50 having a central portion 51 and two opposite ends 52 . The bladder 50 defines a liquid chamber 55 in its interior and an annular fluid chamber 56 between an exterior of the bladder 50 and an interior wall surface of the pump body 30 . The bladder 50 is sealingly connected to a top bladder mandrel 70 at its upper end by means of O-rings 72 and a band clamp 74 , and to the bottom bladder mandrel 63 at its lower end by means of O-rings 64 and a band clamp 66 . The top bladder mandrel 70 is preferably threadedly attached to the top cap 40 . The top bladder mandrel 70 and the bottom bladder mandrel 63 are interconnected by a support member 54 . Preferably, the support member 54 is a solid rod. In this case, the top bladder mandrel 70 includes a number of apertures 79 providing the free flow of groundwater liquid between the liquid chamber 55 and the passage 75 in the bladder mandrel 70 , and the bottom mandrel 63 includes a number of apertures 69 providing the free flow of groundwater liquid between the liquid chamber 55 and the passage 68 .
However, the support member 54 may be in the form of a hollow tube provided with a number of apertures spaced at various locations along its longitudinal length in order to allow the free flow of groundwater fluid between the interior of the tube and the remainder of the liquid chamber 55 . In this case, no apertures 69 and 79 are formed in the mandrels 63 and 70 correspondingly.
A spring member, preferably a coil spring 36 , is disposed between the bottom plug 38 and the bottom cap 60 in order to bias the caps 40 and 60 toward the upper end of the pump casing 30 .
As illustrated in FIGS. 3 a and 3 b , the bladder 50 is formed with the reduced diameter ends 52 relative to the central portion 51 thereof. This allows for an increased stroke volume and, therefore, increased efficiency of the pump operation.
The top cap 40 is provided with an outlet liquid port 44 , and a fluid communication port 46 . The outlet fitting 14 is affixed to the liquid outlet port 44 . The actuating gas fitting 20 is affixed to the fluid communication port 46 . The fittings 14 and 20 are identical and may be conventional threaded fittings or any other appropriate fittings well known in the prior art. Preferably, push-fit barb fittings, illustrated in FIG. 4, are employed. They include a bore 14 ′( 20 ′), an O-ring seal 14 2 ( 20 2 ) and two sets of barbs 14 3 ( 20 3 ) and 14 4 ( 20 4 ) for sealing and security.
In the preferred embodiment, the lower end 34 of the pump casing 30 is provided with a plurality of liquid inlet apertures 39 in the wall 32 , located substantially between the bottom plug 38 and a bottom cap 60 . Preferably, the inlet apertures 39 are located in close proximity to each other forming a limited sampling area. This allows the pump 10 to sample a narrow stratum of liquid in the monitoring well. A mesh screen filter 37 , preferably, of stainless steel, is disposed within the casing 30 adjacent to the apertures 39 for filtering out solids greater than a predetermined size.
Furthermore, the top bladder mandrel 70 includes a communication passage 75 therethrough. An outlet cone-shaped check valve 80 for preventing backflow of the pumped liquid through the passage 75 to the liquid chamber 55 from the outlet port 44 is provided in the top cap 40 . Thus, when the pumped liquid, such as groundwater, is flowing through the pump in the direction indicated by flow arrows 87 , the groundwater passes around the outlet cone-shaped check valve 80 and through the outlet port 44 and the outlet fitting 14 . Backflow in the direction opposite that indicated by flow arrows 87 , is substantially prevented by sealing engagement of the outlet cone-shaped check valve 80 with a corresponding valve seat on the bladder mandrel
Correspondingly, an inlet cone-shaped check valve 90 for preventing backflow of groundwater or other pumped liquid through the inlet passage 68 and the inlet apertures 39 from the liquid chamber 55 is provided in the bottom cap 60 . The inlet cone-shaped check valve 90 , illustrated in detail in FIG. 5, comprises a housing 91 sealingly secured in the passage 68 by means of O-ring 92 , and a cone 96 trapped between valve seat 94 and cone retainer 93 . The housing 91 is provided with a communication port 95 selectively blocked and opened by the cone 96 .
Thus, when the pumped liquid, such as groundwater, is flowing through the pump in the direction indicated by flow arrows 87 (shown in FIG. 3 b ), the groundwater passes around the cone 96 and the cone retainer 93 and through the passage 68 into the liquid chamber 55 . Backflow in the direction opposite that indicated by flow arrows 87 is substantially prevented by sealing engagement on the cone 96 with the corresponding valve seat 94 .
Referring to FIGS. 1, 3 a and 3 b , the preferred fluid sampling pump 10 is actuated by means of actuating gas supplied to the fluid chamber 56 which is alternately and sequentially subjected to positive and negative or reduced pressures. The alternate pressurizing and depressurizing of the actuating gas in the gas chamber 56 causes the bladder 50 to alternately expand and contract, thus alternately and sequentially decreasing and increasing the volume of the liquid chamber 55 . During such increases in volume, the groundwater is drawn from the well 12 into the liquid chamber 55 through the inlet apertures 39 in the casing 30 and the passage 68 in the bottom cap 60 . During such decreases in such volume, the groundwater is forced out of the liquid chamber 55 through the passage 75 in the top bladder mandrel 70 and the outlet port 44 in the top cap 40 and is passed through the outlet fitting 14 and the groundwater conduit 16 to be collected in the sample collection vessel 17 . The cone-shaped check valves 80 and 90 prevent the water from being discharged through the inlet apertures or drawing in through the outlet port.
The capacity of the pump 10 may be changed in different versions of the pump by changing the diameter of the tubular pump casing 30 , thereby changing the amount of water drawn in and forced out during the alternate contractions and relaxations of the flexible bladder 50 . Preferably, the bladder pumps in accordance with the present invention, may be manufactured with the outside diameter ¾, ⅞ and 1″ depending on the particular application. Theoretically, increasing the length of the pump wall 32 and correspondingly increasing the length of the bladder 50 would also increase the stroke volume. However, the longer pumps are subject to hang up in the non-plumb monitoring wells. For this reason, the bladder pumps for well monitoring ought to be designed as short as possible.
It should be noted that the various components of the pump 10 , contacting the pumped liquid, are preferably composed of relatively lightweight and low-cost synthetic materials that will not be corroded when exposed to the groundwater and that will not otherwise affect the composition of the groundwater flowing through the pump. Examples of such materials include stainless steel, rigid polyvinyl chloride (PVC), DELRIN and polytetrafluoroethylene (PTFE) marketed under the DuPont Teflon® trademark. The flexible bladder is preferably composed of a flexible synthetic material that also will not corrode or affect the composition of groundwater flowing therethrough, such as Teflon®. The casing 30 of the pump is preferably made of stainless steel. One skilled in the art will readily recognize, however, that the various components of the fluid sampling apparatus may be composed of other suitable non-corrosive materials.
FIGS. 6 a and 6 b illustrates a liquid sampling pump 10 ′ in accordance with the second embodiment of the present invention. With the reference to FIGS. 6 a and 6 b , the parts in common with FIGS. 3 a and 3 b are designated by the same reference numeral. The pump 10 ′ includes a generally tubular pump casing 30 having a cylindrical wall 32 , a lower end 34 and an upper end 35 . The cylindrical wall 32 of the pump casing 30 is swaged at the opposite end 34 and 35 thereof. The lower end of the pump body 30 is sealed with a bottom plug 38 . The upper end of the pump body 30 is closed with a top cap 140 . The top cap 140 is formed integrally with a top bladder mandrel 143 provided with a communication passage 145 . The casing 30 is swaged at its upper and lower ends to retain the bottom plug 38 and the top cap 140 . The top cap 140 is sealed to an internal surface of the wall 32 by means of O-rings 142 or other suitable sealing means known to those skilled in the art.
A bottom cap 160 is provided between the bottom plug 38 and the top cap 140 . The bottom cap 160 sealingly engages the wall 32 by means of O-rings 162 . The bottom cap 160 is provided with an inlet liquid communication passage 168 therethrough. The bottom cap 160 is formed integrally with a bottom bladder mandrel 163 . The top and bottom bladder mandrels 143 and 163 respectively are interconnected with a tubular support member 54 .
A spring member, preferably a coil spring 36 , is disposed between the bottom plug 38 and the bottom cap 160 in order to bias the caps 140 and 160 toward the upper end of the pump casing 30 .
Furthermore, the lower end 34 of the pump casing 30 is provided with a plurality of liquid inlet apertures 39 in the wall 32 , located substantially between the bottom plug 38 and the bottom cap 160 . A mesh screen filter 37 is disposed within the casing 30 adjacent to the apertures 39 for filtering out solids greater than a predetermined size.
The interior of the pump body 30 is divided and isolated into two chambers by a generally cylindrical flexible bladder 50 having a central portion 51 and two opposite ends 52 . The bladder 50 defines a liquid chamber 55 in its interior and an annular fluid chamber 56 between an exterior the bladder 50 and the interior wall surface of the pump body 30 . The bladder 50 is sealingly connected to the top cap 140 and the bottom cap 160 at its opposite ends by means of O-rings 147 and 164 and band clamps 148 and 166 respectively. The tubular support member 54 is disposed within the liquid chamber 55 and includes a number of apertures 53 spaced at various locations along its longitudinal length in order to allow the free flow of groundwater fluid between the interior of the support member 54 and the remainder of the liquid chamber 55 .
As illustrated in FIGS. 6 a and 6 b , the bladder 50 is formed with the reduced diameter ends 52 relative to the central portion thereof. This allows for an increased stroke volume and, therefore, increased efficiency of the pump operation.
The top cap 140 is provided with an outlet liquid port 144 , and a fluid communication port 146 . The outlet fitting 14 is affixed to the outlet liquid port 44 . The actuating gas fitting 20 is affixed to the fluid communication port 146 . The fittings 14 and 20 are identical and may be conventional threaded fittings or any other appropriate fittings well known in the prior art. Preferably, push-fit barb fittings, described in detail above and illustrated in FIG. 4, are employed.
Moreover, the bottom cap 160 includes a cone-shaped check valve 90 for preventing backflow of groundwater or other pumped liquid through the inlet passage 168 and the inlet apertures 39 from the liquid chamber 55 . Similarly, the top cap 140 includes the cone-shaped check valve 90 for preventing backflow of groundwater or other pumped liquid from the outlet port 144 to the liquid chamber 55 . The cone-shaped check valve 90 is described in detail above and illustrated in FIG. 5 . The operation of the pump 10 ′ is similar to the operation of the pump 10 described in hereinabove.
Therefore, the novel arrangement of the liquid sampling bladder pump of the present invention as constructed in the above-described embodiments provides simplified field application and easy deployment in non-plumb wells, and allows for obtaining representative samples of groundwater or other liquids.
The foregoing description of the preferred embodiments of the present invention has been presented for the purpose of illustration in accordance with the provisions of the Patent Statutes. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment disclosed hereinabove was chosen in order to best illustrate the principles of the present invention and its practical application to thereby enable those of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated, as long as the principles described herein are followed. Thus, changes can be made in the above-described invention without departing from the intent and scope thereof. It is also intended that the scope of the present invention be defined by the claims appended thereto.
|
A liquid pump for pumping groundwater samples from small diameter sub-terrain wells. The pump comprises a tubular casing having swaged ends and provided with inlet apertures on its side wall, a top cap and a bottom cap each provided with a bladder mandrel, a coil spring biasing the caps, a flexible bladder separating the interior of the pump into a liquid chamber and a gas chamber, and a pair of poppet valves preventing backflow of the pumped liquid. The pump is actuated by alternately pressurizing and de-pressurizing the actuating gas, preferably air, in the gas chamber causing the bladder to alternately contract and relax. The bladder is formed with reduced diameter ends that allows for an increased stroke volume of the pump. The pump is operated by a precision dual range controller, specifically adapted for “low flow” sampling.
| 5
|
BACKGROUND
[0001] The invention relates to the field of synchronizing data between a core computer system and one or more devices which may connect to and interact with the core computer system from time to time. As an illustrative example for the purposes of this document, a personal financial management (“PFM”) software system is used as an example. A personal financial management software system can allow a user to view bank account balances and transactions, move money from one account to another, pay bills, conduct personal budgeting, and perform other functions.
[0002] In the prior art, a PFM software system stored user data on a core computer system. A user could use another computing device, such as a mobile computing device (“MCD”), to connect to the core computer system and download the user's data. Currently smart phones are popular MCDs. However, tablet computers, laptop computers, and other electronic devices can be used as MCD's. On the MCD the user can review his or her downloaded data. If the MCD remains connected to the core computer system, then the user can also change the data or perform other transactions with the core computer system. But if the user does not remain connected to the core computer system, then the user is limited to reviewing data downloaded to the MCD.
[0003] The prior art situation posed several inconvenient problems for the user and for the provider of the core computer system. First, a user who lost connectivity with the core computer system, such as due to loss of internet connection, lost the ability to edit data or conduct transactions. Second, even while editing data or conducting transactions, a user was faced with inherent slowness of the connection to the core computer system or slowness of the core computer system itself. Third, in order to support simultaneous on-line transaction processing for numerous users, both the core computer system and its connectivity for users needed to be very robust and therefore expensive. Also, connections with multiple devices must be managed.
SUMMARY
[0004] A system, method and software are needed which allow multiple devices to connect to and share data with a core computer system in a fashion that synchronizes data among the various devices. For maximum usability, the system, method and software should allow devices that periodically connect to the core computer system to conduct transactions and edit data when not connected to the core computer system. This will allow users not connected to the core computer system to still enjoy the full functionality of their software application. It will also allow users to enjoy the speed inherent in their MCD without experiencing slowness of a connection to a core computer system or slowness of the core computer system itself.
BRIEF DESCRIPTION OF DRAWINGS
[0005] FIG. 1 depicts a core computer system, its database, and information that it may contain.
[0006] FIG. 2 depicts connection of a core computer system with another device and the data and data record changes which may be shared between them.
DETAILED DESCRIPTION
[0007] Referring to FIG. 1 an example embodiment of the invented system is depicted. A core computer system 101 for a software application, such as a PFM program, is shown. The core computer system 101 has a database 102 on which data for the PFM for all of its users may be stored. The database 102 can include information such as a list of users 103 including user 1 , user 2 , . . . up to user n where n is a positive integer. That list of users can include various user information, such as user account information, security information, etc. For each user, such as user 2 , a list of enabled computing devices 105 is kept. These devices such as device 1 , device 2 , . . . device n, can include devices such as a desktop computer, a laptop computer, a notebook computer, a tablet computer, a smart phone, and another type of device capable of communicating with the core computer system 101 . Also for each user such as user 2 , the database 102 can contain data records 104 pertaining to that user. In the example of a PFM, the data records could include various information about bank accounts, account transactions, bills that need to be paid, bills that have already been paid, personal budget information, etc. For each device 105 that can connect to the core computer system for a particular user, in this case device 2 for user 2 , the database 102 may store a number of data changes 106 , such as data change δ 1 through data change δn, which need to be made to data on device 2 for user 2 in order to sync the data of device 2 with data in the database 102 of the core computer system.
[0008] In the example of a PFM software system, the data changes δ 1 through δn could be changes coming from third parties, such as interest paid on bank accounts reported by the relevant financial institutions and which need to be reflected on all copies of the user's data. Or the data changes could be due to changes in the database made by the user through a different device. For example, if the user connected to the core computer system through device 5 and entered a transaction, such as payment of a bill, then data reflecting that change would not exist on the copy of the user's data maintained in device 3 . Therefore the core computer system keeps a record that the data change made to the core computer system needs to be made for each other device up to device n. When each device connects to the core computer system, then the data change can be made to or published to that particular device. For more detail on this, see FIG. 2 .
[0009] Referring to FIG. 2 , a depiction of data change transactions between a core computer system and a device connectable to it is provided. The core computer system 201 has a database 202 for storing user data. The core computer system is at least periodically in connection with an MCD 203 . The connection can be via any desired connection means, including but not limited to the Internet. The MCD had an MCD data storage 204 where it can store user data. The database 202 of the core computer system may have changes to data for a particular user which need to be implemented on that user's devices. In that event, for each device, there will be an applicable set of data changes 207 on the core computer system which can be transmitted 205 to the MCD in order to update the MCD's data set. Likewise, then an MCD user is not connected to the core computer system and makes changes to his or her data, then those changes need to be reflected in the core computer system database data set. Therefore when the MDC is connected to the core computer system, the MCD data changes 208 are transmitted 206 to the core computer system and the contents of the core computer system are updated. This allows the data storage of the core computer system and the MCD to be brought into sync.
[0010] It is important for the core computer system to keep a record of the last changes to the data set on each of a user's devices. And the core computer must keep track of changes to its own data set which have not yet been made on the user's various devices. This will allow the core computer system to notify a user's device of the need to update its data set whenever a user's device connects to the core computer system, thus keeping data sets in sync. The core computer system can keep track of the types of changes on a record-by-record basis (such as created, updated, deleted) so that the next time a device connects to the core computer system, those data records can be updated in the device's data set. This could occur by the core computer system forcing the user device to update its data set, such as by the core computer system sending out a syncpackage of data to be updated, or by the user device requesting the core computer system to provide it with updated data. In the event that a syncpackage is used, it can be pre-filtered to send only the types of data changes desired rather than sending all data changes, if filtering is appropriate.
[0011] At the completion of the sync process, whether the core computer system is updating a user device or whether a user device is updating the core computer system, it is possible for the data changes which were stored for the sync process to be purged. This could occur by the device that is being updated sending a delete request or a sync token indicating that the desired data changes have been made successfully, so the record of those proposed data changes can be deleted.
[0012] It is also possible to set up the core computer system so that it keeps track of which devices know about which data changes. Therefore it is possible for the core computer system to separately notify each user device of the particular data changes that the device in question does not know about yet. That enables the core computer system to immediately bring any particular device up to date with its data changes as soon as that device connects to the core computer system. Because only the data which is changed is downloaded to the user device, data transfer is rapid. The user device can signal the core computer system that it successfully received the data changes with a handshake or other protocol. Then the core computer system starts with a blank slate of proposed data changes for that particular device until more data changes are made.
[0013] It is possible for the core computer system to require a user device to download a fresh complete data set instead of downloading just data changes. This could be done if the number of data changes is deemed too large and a complete data set download is preferable. Or it could be done if the user device data set is stale due to age, for example if a device has not connected to the core computer system for 90 days or some other predetermined period of time.
[0014] The core computer system can also be updated with push notifications (typically sent for individual changes). This allows the core computer system to push or force a data update on a user device rather than waiting for a device to request data sync. The core computer system can open a socket and talk to the user device to provide real time updates. Push notifications can be real-time daily, or according to whatever threshold the software designer feels is most appropriate.
[0015] On the user device side, data-state tracking can also be used, permitting the user device to keep track of all data records that were created, updated or deleted so that appropriate data changes may be sent to the core computer system. In such case, the user device notes which data changes have occurred since the last data sync and prepares them for upload to the core computer system when connection next occurs. The data changes can be ordered as desired to guarantee certain relationships (i.e., categories and transactions, so that a transaction is tied to an appropriate category, establishment of a new category when required to support the transaction, etc.). Then the user device can push the data to the core computer system.
[0016] The system can also be designed to maintain a status code for each proposed data change. Status codes can indicate which data changes were successful and which ones were not, returning a message to the user for unsuccessful data changes. Status codes can indicate a successful or unsuccessful data change, as well as action to be taken. For example, (i) clear the data state, (ii) keep it the same, (iii) show an error state.
[0017] The invention can be implemented as software that runs on a digital computer. The state of technology and trends as of the time of writing this document indicates that digital computers running software will be a preferred implementation for many years to come. For the purposes of this document, the term “digital computer” includes desktop computers, laptop computers, tablet computers, hand-held mobile electronic devices (including so-called smart phones), other mobile electronic devices, networked computers, mainframe computers, and other computing devices. Other computing devices may include analog computing devices, quantum computing devices, biological computing devices and other computing devices. Although the invention can be implemented as software operating on a computing device, the invention can also be implemented as firmware or it may be implemented in hardware or otherwise as desired. Such implementations are intended to be within the scope of the invention.
[0018] Commonly a computing device for using the invention will include a display device such as a screen or other image on which information can be displayed to a user, an input device through which a user can control the computing device, and a processor for carrying out computations as required by the invention. The computing device may also include a means for carrying wireless transmission and receipt of data, dynamic memory, static memory, a power source such as a battery, and other features.
[0019] While the present invention has been described and illustrated in conjunction with a specific embodiment, those skilled in the art will appreciate that variations and modifications may be made without departing from the principles of the invention as herein illustrated, described, and claimed. The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiment is to be considered in all respects as only illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
|
A data sync engine, a related method and software achieve keeping the data set of a core computer system and a mobile device in sync so that a user may perform operations using several different devices connectable to the core computer system.
| 7
|
BACKGROUND
[0001] A unique Scandinavian tradition is the creation of baskets for hanging on a Christmas tree. These baskets were created of paper that was cut and woven together to form a basket in which treats could be stored. The paper baskets were generally in the shape of hearts. The heart shaped baskets symbolized the love and beauty of Christmas while displaying an individuals' artistic flair.
[0002] For years, people have been displaying bumper stickers and other emblems on their vehicles (or other foreign objects) to show their support for a cause, support a candidate running for office, or to say something funny. However, once the bumper stickers have been applied to the surface of the object, they are difficult to remove. In some cases, the stickers have ruined the surface of the object to which they are applied.
[0003] What is needed in the art is a device that is easily removable from a surface, without ruining the surface, while still conveying an individual's viewpoint.
SUMMARY
[0004] The disclosure is directed toward a woven magnetic device. The woven magnetic device comprises a first member having a body with a top portion and a bottom portion opposite the top portion and the bottom portion has at least two fingers. The woven magnetic device also comprises a second member having a body with a top portion and a bottom portion opposite the top portion. The bottom portion has at least two fingers interwoven with the at least two fingers of the first member. The first member and the second member comprise a magnetic material.
[0005] The disclosure is also directed toward a method for making a woven magnetic device. The method comprises producing a first member having a body with a top portion and a bottom portion opposite the top portion and the bottom portion has at least two fingers. The method also comprises weaving at least two fingers of a second member with the at least two fingers of the first member. The second member has a body with a top portion and a bottom portion opposite the top portion and the bottom portion has the at least two fingers. The first member and the second member comprise a magnetic material.
BRIEF DESCRIPTION OF THE FIGURES
[0006] Referring now to the figures, wherein like elements are numbered alike:
[0007] FIG. 1 is a perspective view of a first member of an exemplary woven magnetic device;
[0008] FIG. 2 is a perspective view of a second member of an exemplary woven magnetic device;
[0009] FIG. 3 is a perspective view of the first member being woven with the second member to form an exemplary woven magnetic device;
[0010] FIG. 4 is a perspective view of an exemplary embodiment of the woven magnetic device;
[0011] FIG. 5 is a perspective view of a third member of another exemplary woven magnetic device;
[0012] FIG. 6 is a perspective view of the first member of FIG. 1 being woven with the third member to form another exemplary woven magnetic device;
[0013] FIG. 7 is a perspective view of another exemplary embodiment of the woven magnetic device;
[0014] FIG. 8 is a perspective view of two members utilized to create another exemplary embodiment of the woven magnetic device incorporating a design;
[0015] FIG. 9 is a perspective view of another exemplary embodiment of the woven magnetic device incorporating a design; and
[0016] FIG. 10 is a perspective view of another exemplary embodiment of the woven magnetic device incorporating a design.
DETAILED DESCRIPTION
[0017] Persons of ordinary skill in the art will realize that the following disclosure is illustrative only and not in any way limiting. Other embodiments of the invention will readily suggest themselves to such skilled persons having the benefit of this disclosure.
[0018] The present invention is a woven magnetic device that has an overall shape of a heart. The woven magnetic device adheres to metal objects and is removable. The woven magnetic device does not require additional adhesives to create the overall effect, since the magnetic material adheres to itself. The woven magnetic device can be displayed alone or can display support for a cause or convey a belief. The weaving of the magnetic material provides a three dimensional appearance to the woven magnetic device, which is desirable to an individual looking to make a statement.
[0019] A preferred embodiment is illustrated in FIG. 1 . A first member 10 includes a body 12 . The first member 10 body 12 has a top portion 14 and a bottom portion 16 . The top portion 14 can be of any shape, with a rounded configuration preferred, although other configurations are contemplated, as illustrated and further described in FIG. 8 . The bottom portion 16 is configured to have fingers 18 , 20 , 22 , 24 , 26 . The fingers are of equal length. Although five fingers are illustrated, any number of fingers may be utilized depending upon the intricacies of the design desired.
[0020] Referring now to FIG. 2 , a second member 28 is illustrated. The second member 28 includes a body 30 . The second member 28 body 30 has a top portion 32 and a bottom portion 34 . The top portion 32 can be of any shape, with a rounded configuration preferred, although other configurations are contemplated, as illustrated and further described in FIG. 8 . The bottom portion 34 is configured to have fingers 36 , 38 , 40 , 42 , 44 . The fingers are of equal length and shape. Although five fingers are illustrated, any number of fingers may be utilized depending upon the intricacies of the design desired. In each case, when weaving, the two members 10 , 28 should be the same, having an equal number, shape and length of fingers. The shape of the members and fingers may vary depending upon the design or pattern desired, as will be discussed further herein. It is also preferable for the first member 10 and the second member 28 to be two different colors, although one or any number of colors can be utilized, as will be discussed further herein.
[0021] It is also contemplated to cut the fingers on an angle (i.e., 45 degrees) to enhance the effect of the woven magnetic device on the viewer. By creating a beveled (or biased or cater-cornered or skewed or slanted or transversal) edge of the fingers, the woven magnetic device takes on a three-dimensional appearance which is visually appealing.
[0022] The size of the first member 10 and the second member 28 can vary depending upon the desired size of the resulting woven magnetic device. A preferred length of the first member 10 and the second member 28 is about 3.0 inches to about 8.0 inches, with about 3.8 inches to about 4.2 inches preferred. The width of the first member 10 and the second member 28 can be about 2.25 inches to about 5.5 inches, with about 2.5 inches to about 3.0 inches preferred. The length of the fingers can be about 2.0 inches to about 5.5 inches, with about 2.5 inches to about 2.7 inches preferred. The width of the fingers can be about 0.4 inches to about 1.0 inches, with about 0.42 inches to about 0.52 inches preferred.
[0023] When creating designs, as further explained herein, the width of the fingers will vary depending upon the desired design (See FIG. 8 ).
[0024] The first member 10 and the second member 28 comprise a piece of ferromagnetic or ferromagnetic material whose domains are sufficiently aligned so that it produces a net magnetic field outside itself and can experience a net torque when placed in an external magnetic field. The material can be iron, iron alloys, nickel, nickel alloys, cobalt, cobalt alloys, and combinations thereof. The magnetic material can have a thickness of about 0.02 inches to about 0.04 inches, with about 0.025 inches to about 0.035 inches preferred. The thickness of the material is dependent upon the type of material, and the use and size of the woven magnetic device.
[0025] Referring to FIG. 3 , an illustration of the weaving (or braiding or interlacing or lacing or intertwining or plaiting or entwining or merging or uniting or interweaving) of the first member 10 with the second member 28 in order to form an exemplary woven magnetic device is presented. In order to create the woven magnetic device, the first member 10 must be woven with the second member 18 . To start, freely movable finger 18 is woven through the fingers 44 , 42 , 40 , 38 , 36 of the second member 28 . At the base 46 of the fingers 36 , 38 , 40 , 42 , 44 of the second member 28 , finger 18 of first member 10 is disposed over finger 44 and then under finger 42 and then over finger 40 and then under finger 38 and finally over finger 36 . Next, finger 20 is disposed under finger 44 and then over finger 42 and then under finger 40 and then over finger 38 and finally under finger 36 . This process is repeated with each remaining finger (i.e., fingers 22 , 24 , 26 ) to create a woven pattern as illustrated in the magnetic woven device 48 in FIG. 4 . It is not important which member is utilized to start the weaving process, as long as the two members are braided together as described above. No adhesive is necessary to hold the fingers in place since the magnetic material adheres to itself. The first member 10 and the second member 28 are attracted to each other because of the magnetic property of the material and can be removable from each other with little force.
[0026] Another embodiment is illustrated in FIGS. 5, 6 , and 7 . In FIG. 5 , a third member 50 includes a body 52 . The third member 50 body 52 has a top portion 54 and a bottom portion 56 . The top portion 54 can be of any shape, with a rounded configuration preferred, although other configurations are contemplated, as illustrated and further described in FIG. 8 . The bottom portion 56 is configured to have fingers 58 , 60 , 62 , 64 , 66 . However, the fingers are not freely movable. The fingers are defined by the existence of slots (or openings) 68 disposed vertically along the bottom portion 56 creating interlocking fingers. The slots 68 are of sufficient length and width to receive the fingers of a mating member (i.e., first member 10 ). The slots 68 disposed at the end 70 of the bottom portion 56 are open for ease in receiving the final finger. The fingers are of equal length and shape. Although five fingers are illustrated, any number of fingers may be utilized depending upon the intricacies of the design desired.
[0027] Referring now to FIG. 6 , an illustration of the weaving (or braiding) of the first member 10 with the third member 50 in order to form an exemplary woven magnetic device is presented. In order to create the woven magnetic device, the first member 10 must be woven with the third member 50 utilizing the slots 68 . To start, finger 18 is woven through the fingers 66 , 64 , 62 , 60 , 58 of the third member 50 . At the base 72 of the fingers 58 , 60 , 62 , 64 , 66 of the third member 50 , finger 18 of first member 10 is disposed over finger 66 fed down through the first slot 68 to be under finger 64 , then finger 18 is fed up through the next slot 68 and then over finger 62 , then finger 18 is fed down through the next slot 68 to be under finger 60 and then finger 18 is fed up through the final slot 68 and positioned over finger 58 . Next, finger 20 of first member 10 is disposed under finger 66 and fed up through the first slot 68 to be over finger 64 , then finger 18 is fed down through the next slot 68 and then under finger 62 , then finger 18 is fed up through the next slot 68 to be over finger 60 and then finger 18 is fed down through the final slot 68 and positioned under finger 58 . This process is repeated with each remaining finger (i.e., fingers 22 , 24 , 26 ) to create a woven pattern as illustrated in the magnetic woven device 74 in FIG. 7 . In each case, when weaving it is ideal to have the two members 10 , 50 be of the same shape, with one of the members having slots instead of freely movable fingers. The shape of the members and fingers may vary depending upon the design or pattern desired, as will be discussed further herein. As stated above, no adhesive is necessary to hold the fingers in place since the magnetic material adheres to itself.
[0028] As illustrated in FIG. 8 , other woven designs are contemplated. The intricacies of the designs are dependent upon the manner of weaving, the number of fingers, the size of the fingers, the colors of the fingers, the designs on the fingers, and the desired pattern. It is contemplated to create curved fingers, fingers having specific shapes (i.e., cut-outs or jutting portions) to create a design or figure (i.e., hearts, stars, trees, crests, faces, people, etc.) within the woven magnetic device. For example, FIG. 8 illustrates a first member 76 and a second member 78 that can be woven as described above (illustrated using arrow 80 ) to create the woven magnetic device 82 having a design element 84 incorporated therein. In this case, the design element 84 is a pinwheel shape. Any design elements are contemplated as long as the fingers can be shaped to create a specific design.
[0029] The members may be of different colors or have graphics disposed on them so as to create a colorful device or a specific design once woven, as illustrated in FIGS. 9 and 10 . FIGS. 9 and 10 illustrate the use of graphics. Woven magnetic device 86 is colored green and when woven will display a white VT 88 (i.e., the abbreviation for Vermont). Likewise, magnetic woven device 90 is colored to resemble an American flag (i.e., red, white, and blue) so the red stripes 92 and white stripes 94 are woven together. A first top corner 96 of the magnetic woven device 90 is blue with a design of white stars while the second top corner 98 is green having a white VT. Various resulting graphic designs for the woven magnetic device are contemplated including, but not limited to, flags of countries (i.e., the United States, Denmark, Norway, Sweden, Canada, China, Japan, Germany, the Netherlands, Australia, South Africa, etc.), symbols for favorite destinations (VT, BI, etc.), designs for causes (i.e., “Support Our Troops”, the American Heart Association, Downs Syndrome, etc.), advertising for businesses or political candidates, funny sayings, inspirational sayings, driving messages, and messages of love.
[0030] The woven magnetic device provides an aesthetically pleasing means for an individual to convey messages to others. The design of the woven magnetic device ensures that the object to which it is applied is not damaged. Further, the properties of the magnetic material lend to the ability of the woven members to adhere to each other.
[0031] While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention.
|
A woven magnetic is disclosed. The woven magnetic device comprises a first member comprising a magnetic material and having a body with a top portion and a bottom portion opposite the top portion and the bottom portion has at least two fingers. The woven magnetic device also comprises a second member comprising a magnetic material and having a body with a top portion and a bottom portion opposite the top portion. The bottom portion has at least two fingers interwoven with the at least two fingers of the first member.
| 3
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is based on and claims the benefit of U.S. provisional patent application Ser. No. 60/778,182, filed Mar. 1, 2006, the content of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a laser for use in medical treatments. More particularly, the present invention relates to hand held laser for use in medical treatments.
BACKGROUND OF THE INVENTION
[0003] Lasers are being used more frequently in medical treatments to reduce blemishes on a patient's skin. Lasers are useful in removing port wine stains, scars and wrinkles from a patient's skin to improve the patient's appearance. Lasers are also useful in removing unwanted tattoos.
[0004] Many of the laser treatments require the laser to be mobile to treat the skin blemish. To accommodate the need to for the laser to be mobile, the size of the lasers are being reduced such that the laser can be housed in a hand held housing. However, the laser must supply enough energy to complete the selected procedure. The small size of the laser coupled with the energy delivery requirements has caused the lasers to have a tendency to heat up over time with use, and require the laser to be shut down to cool to a selected temperature.
[0005] Typically, water or another cooling fluid is utilized to remove the heat that is generated as the laser is utilized. However, because of the mobility and energy requirements of the laser, a circulating coolant may not remove a sufficient amount of heat to allow the laser to run continuously for an extended period of time without heating to excessive temperatures.
SUMMARY OF THE INVENTION
[0006] The present invention includes a hand held laser for treating a skin condition having a housing comprising a first end, a second end and a cavity therein wherein the cavity includes a substantially light reflective surface and wherein the housing comprises at least one fin extending from an exterior surface of the housing. The laser includes a flash lamp having a first axis and being retained within the cavity in a first selected position and a laser rod having a second axis and being retained within the cavity in a second selected position and wherein the first axis and the second axis are substantially parallel to each other, wherein as the flash lamp is pumped the laser rod produces a laser beam for treating the skin condition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of the hand-held laser of the present invention.
[0008] FIG. 2 is a sectional view of the hand-held laser of the present invention along section line 2 - 2 in FIG. 1 .
[0009] FIG. 3 is a sectional view along section line 3 - 3 in FIG. 1 .
[0010] FIG. 4 is a left side view of the main body of the laser of the present invention.
[0011] FIG. 5 is a left side view of the laser of the present invention.
[0012] FIG. 6 is a perspective view of a casing containing the laser of the present invention.
DETAILED DESCRIPTION
[0013] A hand-held laser of the present invention is generally illustrated in FIG. 1 at 10 . The hand-held laser 10 includes a housing 12 with a plurality of fins 14 extending from an exterior surface 16 and about a perimeter of the housing 12 . The plurality of fins 14 increase the surface area of the external surface 16 of the housing 12 which increases the rate at which heat is transferred from the laser 10 to the atmosphere proximate the laser 10 .
[0014] The housing 12 typically includes seventeen uniformly spaced fins 14 extending around the perimeter of the housing 12 . However, a housing 12 with one or more fins 14 is contemplated that may or may not extend around the entire perimeter of the housing 12 .
[0015] The housing 12 is typically constructed from stainless steel. Stainless steel is a desirable material of construction due to its strength, durability, resistance to corrosion, ability to reflect light beams and high heat capacity. However, other materials of construction of the housing 12 are also contemplated including, but not limited to gold, silver and titanium.
[0016] The housing 12 is typically of a unitary construction. However a housing 12 with two or more components secured together are also contemplated.
[0017] Left and right end caps 26 , 28 are attached to the left and right ends 18 , 20 , respectively, of the housing 12 . The left and right end caps 26 , 28 are typically attached to the left and right ends 18 , 20 of the housing 12 with threaded engagements of bolts 25 with threaded bores 27 proximate the corners of the left and right end caps 26 , 28 as illustrated in FIGS. 4 and 5 . The engagements of the left and right end caps 26 , 28 with the left and right ends 18 , 20 of the housing 12 typically form seals at seams 22 , 24 , respectively. However, it is also contemplated to utilize a gasket between the left and right end caps 26 , 28 and the left and right ends 18 , 20 , respectively, to form the seals.
[0018] A cooling medium, typically water, is supplied to the laser 10 through an inlet 30 , typically attached to the left end cap 26 . The cooling medium exits the laser 10 through an outlet 32 , typically attached to the right end cap 28 . The inlet 30 and the outlet 32 both have at least one ridge 34 , 36 , respectively, around the perimeter for securing tubes (not shown) thereto.
[0019] Referring to FIG. 2 , the cooling medium passes through a left passage 38 in the left end cap 26 and into a cavity 40 in the housing 12 where the cooling medium fills the cavity 40 . A glass tube 41 is positioned into the cavity 40 wherein the glass tube 41 is adjacent a cavity surface 39 . The glass tube 41 prevents corrosion to the cavity surface 39 which can be caused by contact between the cooling medium and the surface 39 defining the cavity 40 over time.
[0020] The cooling medium exits the right end 24 of the housing 12 and passes through a right passage 42 in the right end cap 28 and out of the laser 10 through the outlet 32 . Depending upon the configuration of the laser 10 , the flow of the cooling medium may be reversed.
[0021] A flash lamp 44 and a laser rod 46 are positioned in selected positions within the cavity 40 in a substantially parallel configuration. Ends 52 , 54 of the flash lamp 44 extend beyond the left and right ends 22 , 24 of the housing 12 and are positioned within through bores 56 , 58 in the left and right end caps 26 , 28 , respectively. Positioning the ends 52 , 54 of the flash lamp 44 within the through bores 56 , 58 secures the flash lamp 44 in a selected position within the cavity 40 . Referring to FIG. 5 , gaskets such as O-rings 31 are typically utilized to form a seal between the end caps 26 , 28 and the ends 52 , 54 of the flash lamp 44 to retain the liquid coolant within the cavity 40 .
[0022] Ends 60 , 62 of the laser rod 46 are positioned through bores 64 , 66 in the left and right end caps 26 , 28 , respectively such that the flash lamp ends 60 , 62 extend beyond the end caps 26 , 28 . Positioning the ends 60 , 62 within the through bores 64 , 66 secures the laser rod 46 in a selected position within the cavity 40 such that the axis 48 of the flash lamp 44 is substantially parallel to an axis 50 of the laser rod 46 . Gaskets such as O-rings 31 are utilized to form a seal between the end caps 26 , 28 and the ends 60 , 62 of the laser rod 46 to retain the liquid coolant within the cavity 40 .
[0023] The through bore 66 provides an opening through which a laser beam is directed from the hand held laser 10 . A diameter of the laser beam is equivalent to the diameter of the laser rod 46 which is typically about 5 mm. However the diameter of the beam, as well as a shape of the beam, can be varied by manipulating a collimator (not shown) positioned beyond the through bore 66 . The collimator is capable of reducing the diameter of the beam to less than one millimeter. It is also contemplated that the beam be separated into multiple beams through beam splitting techniques.
[0024] The laser rod 46 is typically an Er:YAG laser rod that is designed to deliver between about 1.2 J/cm 2 and about 1.5 J/cm 2 at a frequency of about 2940 nm. The laser rod 46 is typically about 5 mm in diameter and about 80 mm in length. However, other laser mediums besides an Er:YAG laser are also contemplated as well as a laser that delivers a different amount of energy at a different frequency. It is also contemplated to utilize a laser rod 46 having a diameter and length different than a 5 mm diameter and an 80 mm length, provided the laser rod 46 is of a size that can be utilized as a hand-held laser 10 .
[0025] Referring to FIG. 6 , power is supplied to the flash lamp 44 through an umbilical cord 60 that also supplies the cooling medium and other utilities including electricity and optionally a compressed coolant gas that may be required for the laser 10 to properly function. Typically, the umbilical cord 60 attaches to the left end cap 26 . However, the umbilical cord 60 can also be attached to the housing 12 as well as the right end cap 28 to supply the necessary utilities to the laser 10 .
[0026] Power is supplied through a connection 66 to the flash lamp 44 typically in intervals in rapid succession, otherwise referred to as “pumping”. As the flash lamp 44 is pumped, the flash lamp 44 supplies energy to the laser rod 46 in the form of light energy. The energized laser rod 46 then supplies the laser beam through an aperture 68 in the casing 62 that is utilized in the medical treatment.
[0027] As the flash lamp 44 is pumped and the laser rod 46 is energized, a significant amount of heat is generated. Some of the heat is removed from the laser 10 by circulating the cooling medium through the cavity 40 . As the cooling medium passes through the cavity 40 , the cooling medium contacts the laser rod 46 , the flash lamp 44 and the glass liner 41 to remove heat from the laser 10 . The cooling medium typically flows in a direction of arrows illustrated in FIG. 2 within the cavity 40 substantially along the axis 48 , 50 of the flash lamp 44 and the laser rod 46 while removing heat from the laser 10 .
[0028] Heat is also removed from the laser 10 by transferring heat into the atmosphere through the exterior surface 16 of the housing 12 that includes the plurality of fins 14 which increase the surface area of the exterior surface 16 . Typically, the laser 10 will be contained within an enclosed casing 62 where a forced gaseous cooling medium, typically air, is supplied to the casing 62 through the umbilical cord. The gaseous cooling medium passes over the outer surface of the laser 10 the plurality of fins 14 to remove heat from the housing 12 . The casing 62 also typically includes an outlet 64 for the forced gaseous cooling medium to exit the casing.
[0029] Heat is also removed from the laser through the end caps 26 , 28 which are in thermal contact with the housing 12 . Heat is dissipated through the end caps 26 , 28 and into the surrounding atmosphere, typically the forced gaseous medium, to aid in cooling the laser 10 . The end caps 26 , 28 are typically constructed of aluminum to minimize the weight of the laser 12 . However, other materials of construction of the end caps 26 , 28 are also contemplated.
[0030] Referring to FIGS. 3-5 , the cavity 40 has a substantially elliptical cross-section that is defined by the surface 39 which increases the efficiency of the laser 10 . The elliptical configuration redirects the light energy from the flash lamp 44 into the laser rod 46 more efficiently than other configurations of the cavity 40 , such as a circular cross-sectional cavity. The elliptical surface 39 is typically coated with a reflective material, typically gold, to increase the amount of light energy that redirected into the laser rod 46 . However other reflective materials such as, but not limited to, silver and titanium are also contemplated. Other cross-sectional configurations of the cavity 40 that are less efficient than an elliptical cross-sectional cavity 40 are also contemplated, including but not limited to including a circular cross-section.
[0031] 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.
|
A hand held laser for treating a skin condition includes a housing comprising a first end, a second end and a cavity therein wherein the cavity includes a substantially light reflective surface and wherein the housing comprises at least one fin extending from an exterior surface of the housing. The laser includes a flash lamp having a first axis and being retained within the cavity in a first selected position and a laser rod having a second axis and being retained within the cavity in a second selected position and wherein the first axis and the second axis are substantially parallel to each other, wherein as the flash lamp is pumped the laser rod produces a laser beam for treating the skin condition.
| 7
|
RELATED APPLICATION
This is a continuation-in-part of application Ser. No. 09/223,666, filed Dec. 30, 1998, entitled MODULAR STRUCTURAL MEMBERS FOR CONSTRUCTING BUILDINGS AND BUILDINGS CONSTRUCTED OF SUCH MEMBERS now U.S. Pat. No. 6,237,297, which claims benefit of No. 60/070,003 filed Dec. 30, 1997.
BACKGROUND OF THE INVENTION
A. Field of the Invention
This invention relates to the art of constructing buildings, especially relatively small and low cost residential, institutional and commercial buildings, utilizing modular prefabricated structural members therefor. More specifically, this application pertains to a novel apparatus and method for prefabricating the structural members.
B. Background of the Invention
Small buildings today are constructed using methods developed before the Industrial Revolution. These types of buildings, as opposed to steel frame building types, are constructed either by cutting up trees into boards of different sizes and nailing the boards together or by erecting stacks of stone or masonry held together with mortar. Historically, such raw materials have been delivered to the construction sites where they are then made into buildings by the process of assembling the cut-up parts of the trees and/or the blocks of stone or masonry into simple “post and beam” type structures the parts of which work independently of one another.
Heretofore, it has been attempted, with a good deal of progress having been made in the more recent past, to achieve factory production of buildings in various forms of modular, panelized and mobile home unit construction, but these never were and still do not represent and embody new technologies; they are simply examples of the same historical “post and beam” technology executed indoors-off-site instead of outdoors-on-site. However, although some cost savings may have been achieved through the use of modern techniques such as bulk raw material purchasing and through the utilization of newer and faster tools, the final products have not only remained basically the same but, because labor and materials are still being used inefficiently, are vulnerable to damage and destruction by fire, hurricanes, earthquakes, moisture and insects.
Building codes, which in the United States serve as minimum standards of construction quality, actually tend to exacerbate these inefficiencies by trying to mandate better quality and greater safety of buildings while anticipating the mediocre labor skills currently found on construction sites. Architects and engineers tend to design buildings in light of the government-specified parameters and then follow up by specifying the use of the already available construction materials and methods. This not only reinforces the use of existing methods but also inhibits innovation in building construction. The construction industry tolerates these disadvantages because a better way has not yet been found and perfected.
The availability and price of lumber have changed drastically over the past decade or so, with availability decreasing and price increasing. The deleterious results of indiscriminate tree cutting are giving rise to alarm over the ecological consequences of global deforestation and have led to great pressure, primarily from environmental groups around the world, on forest products companies and governments to control and slow down such activity. As a consequence, lumber has become increasingly more expensive as distances from source to destination increase transportation costs. Furthermore, skilled craftsmen such as carpenters and masons currently command very high salaries and, even worse, are neither as abundant nor as skilled as they once were. In sum, therefore, small buildings being currently constructed make inefficient use of raw materials, cost more to build, operate and maintain than is necessary, are highly combustible, and are expensive to reinforce to mitigate the threats of fire, earthquakes, hurricanes and floods.
OBJECTIVES AND SUMMARY OF THE INVENTION
An objective of the present invention is to provide a fixture that can be used to assemble a modular type structural member quickly and effectively.
A further objective is to provide a fixture which may be easily adapted to assemble or prefabricate modular structural members of various sizes and shades.
A further objectives and advantages is to provide a fixture which can assemble a structural member automatically.
In the above-mentioned co-pending application Ser. No. 09/223,666 a class of novel prefabricated hollow shell-type modular structural members is described, each of which members includes a triangulated wire core disposed between and secured to a pair of spaced shell panels defining the faces of the structural member, and which members are adapted, in appropriate forms and strengths, for serving as foundations, walls, floors, roofs and partitions of low cost, relatively small buildings. The modular structural members which, in their manufactured form, are adapted to be easily assembled and interconnected at the construction site so as to define both the structural configuration of the building (including its doors, windows and surface finishes) as well as the infrastructure for its life support systems (including its plumbing systems, electrical systems, heating, ventilation and air conditioning systems, fire protection systems, etc.) as the building is being erected.
A plurality of such modular structural members can be used per se either to form a complete self-contained building or to form a part of or an adjunct to an existing building for purposes of renovation and/or expansion, and which can also be used in conjunction with conventional building materials (steel, concrete and wood) to form composite building structures.
Generally speaking, the fundamental concept of the modular structure which is incorporated in the modular structural members disclosed herein and which may be briefly described as follows.
The strength of any structure results from a combination of the materials of which it is made and the shape or geometry of those materials. Stated in other words, strength is a function not only of the physical properties of the materials which are used but also of the manner in which they are used, i.e., of their geometric configurations.
A force applied to the top apex of a triangular structure will channel down the two sides of the triangle to the two points or apexes at the bottom. The two points at the bottom of the triangular structure will tend to be pushed outward by that force, i.e., away from each other, unless they are restrained and held in place. It is the bottom member of the triangular structure, of course, which holds those two points in place. This is an efficient system because (1) each member is in either simple tension or simple compression as the force imposed at the top of the triangular structure is resisted by the three members and as the load is transferred to the associated supports, and (2) the connections of the three members can be simple because they do not have to be strong enough to resist turning or bending.
It will also be understood that if several triangular structures are grouped together, the force applied thereto will be distributed throughout an appropriately larger number of members. For example, if a four-sided pyramidal arrangement of triangular structures is used instead of a single triangular structure, the applied force is distributed between eight members instead of three. Such an arrangement obviously increases the efficiency of the system.
It will further be understood that multiple pyramidal arrangements of triangular structures can be interconnected with each other horizontally and vertically as well. In such a system, as the number of connected pyramidal arrangements of triangular structures increases, the forces applied thereto in one area are distributed over a large network of members. Moreover, the individual members need not be very strong, since they work together. Thus, a large number of small members can coact to carry large loads, and by using the same size member repeatedly, a very large structure can be constructed.
In practical applications, the tops and bottoms of such triangular structures either per se or in pyramidal arrangements thereof can be individual members or they can be extensive flat plates. If they are plates, then they can form the solid faces of walls, floors, ceilings and roofs required to enclose building structures and their interior spaces. The plates transmit pressure loads applied to the surfaces of these plates to the network of frame members, in addition to resisting the forces in the top and bottom chords of the pyramids.
By applying the efficiencies of these principles to an entire structure, a building constituted by modular structural members according to the present invention can be made to be much stronger than one constructed by conventional methods. For small to medium-size buildings, the forces at the connections between the modular structural members will be small, which will permit simple connections. Using concrete as a covering for the shell panels of the structural members will result in buildings which will not burn.
For the purposes of clarity, by way of definition a building constructed of modular structural members according to the present invention may be considered as consisting of “components”, “elements” and “cells”. The components are the general working units or building blocks of the desired end product and are used for forming the foundation of the building structure as well as the walls, the floors, the roof and the interior partitions thereof. They are made in large sizes of up to 40 feet by 12.5 feet (12.2 m by 3.8 m) and in thicknesses from 4.5 inches to 1.5 feet (11.4 cm to 45.7 cm). The “elements” are smaller parts of a building including items such as windows, doors, cabinets, closets, and stairs. The “cells” are full building volumes which are prefabricated assemblies of components and elements such as entry foyers, bathrooms, and kitchens. In a building structure of the present invention, the components and cells are uniquely interconnected.
The components, elements and cells are designed to enable various materials to work together synergetically to perform the various functions required of the building. The technology underlying and incorporated in the system of the present invention facilitates both low volume manual and high volume automated manufacturing applications.
The components, i.e., the various modular structural members, are preferably fabricated from the same basic materials and by the same techniques. Each component has a block-like form which consists of two spaced parallel shell panels defining the sides and faces of the block and of an inner portion or core between the shell panels. In all components, the core between the associated two shell panels basically consists of a triangulated wire frame to which the shell panels are secured. To the extent there are any differences between some of the components, these differences are in the structural strengths, the architectural design details, and the thermal performance properties of the components.
The structural strength of each component varies by virtue of differences in the triangulation, the thickness, and the nature and strength of the material of which the “wire” of the wire frame is made (the material used for the “wire” may be steel, structural plastic, or any other comparable linear material); the material strength of the shell panels; and the depth or thickness of the component. The wire frame consists of zig-zag shaped wire “trusses” placed next to each other in the space between the shell panels and having their tips or apexes connected. The arrangement in particular is such that in each group of three adjacent wire trusses, the middle one thereof has its bottom apexes connected to the bottom apexes of the wire truss located on one side of the middle wire truss and has its top apexes connected to the top apexes of the wire truss located on the other side of the middle wire truss.
In addition, at each of the inside faces of the shell panels bounding the core-accommodating space therebetween, there are provided a set of mutually parallel first wire cables or chord members each of which extends along and is connected to the apexes of a respective one of the wire trusses in a direction parallel to the longitudinal axis of the wire core, and a set of likewise mutually parallel second wire cables or chord members each of which extends perpendicular to the first chord members and is connected thereto at irs intersections with the first chord members and the respective apexes of the various wire trusses. A plurality of anchors located at those intersections connect the chord members and the apexes of the wire trusses to the shell panels.
The shell panels can be made from a variety of materials including concrete, metal, combinations thereof, or other rigid panel material. The most typical is a layer of concrete into which the anchors are embedded. The concrete layer, which is about 2 inches (5.1 cm) thick, may be reinforced with plastic fibers and may additionally be reduced in weight by being transformed into cellular concrete through the incorporation therein of many small air bubbles or a cellular plastic foam. The shell casting material may vary in strength from 150 to 4,000 pounds per square inch (psi) in density from 30 to 120 pounds per cubic foot, as well as in insulating properties. These different shell panel characteristics result from variations in the proportions of the ingredients of the shell mixture that includes cement, sand, reinforcing fibers, and cellular foam. The shell panels are formed to provide the final exposed finish and texture thereof and, in conjunction with the wire frame core, to impart to the modular structural members the required structural load-bearing capacity.
For certain conditions, a metal shellpan may be embedded in the concrete shell panel. The shellpan is designed to provide additional strength, so as to enable the component to accommodate ducts or conduit for electrical wiring or to accommodate reinforcements for openings, holes to receive fasteners at the positions of various life support system parts, etc.
The thickness or diameter of the wire used to form the wire trusses varies from ⅛ inch (0.32 cm) to ½ inch (1.3 cm), and its strength varies further according to the strength of the material from which the wire is made. Moreover, as already pointed out, the apexes of the wire truss triangles are fastened to the perpendicularly intersecting first and second chord members and jointly therewith to the shell panels (and, where applicable, to the shellpans as well). The completed wire frame thus is a deep, three dimensional, open “mesh” consisting of interconnected triangulated shapes formed by small diameter lightweight wire. As a result, the shell panels and the wire frame members all work together to transfer and resist the forces acting on the various components.
The overall depth or thickness of the structural members will vary from 4½ inches (11.4 cm) in the case of a partition-forming component to 16 inches (40.6 cm) in the case of a large floor-forming component. Typically, as the depth increases, the wire size or thickness of the wire trusses will also increase. The greater depth, of course, increases the capacity of the structural member to resist loads perpendicular to its face (e.g., wind load for walls, floor load for floors, snow load for roofs).
Each modular structural member according to the present invention, therefore, becomes a complete, structurally integral unit. A wall-forming structural member or component actually performs structurally as a large beam (the height of a wall). Tension loads (pulling up on walls) thus are resisted by the entire length of the wall since, the stress from any one point is to be distributed throughout the entire wall-forming component by the interior wire frame. Correspondingly, a floor-forming component acts as a two way-slab spanning up to approximately 24 feet (7.3 m). As such, they are less vulnerable than conventional structures to failure when a section of continuous support is lost, such as due to foundation failure. The substantial portion of structural material is positioned on the outer faces of the component where the greatest efficiency can be attained in all conditions, including the most demanding ones.
In a finished building, furthermore, where the components are connected, the floor-forming components are connected to and supported by the wall-forming components in a way that is different from typical comparable structures. Floors of most conventional structures are supported on beams or joists which themselves are simply supported at their ends by the walls. While the walls do their job supporting the floor load which is brought to them by the floor, they do not help the floor in its job of supporting the weight of the floor load. The floor-forming components in a building according to the present invention are connected to the wall-forming components in a way that enables the walls to help the floor carry its load. The top and bottom shell panels of the floor-forming components are connected to the wall-forming components in a fashion establishing a moment connection between them.
More particularly, in the system of the present invention, at the regions of the floor-to-wall connections the triangulation of the wire trusses, i.e., the spacing of adjacent wire trusses from each other as well as the spacing of adjacent apexes thereof from each other, in the wall-forming components is more compact, which makes the connections stronger and helps the floor-forming component resist its tendency to bend under the load. Each such floor-to-wall connection is continuous along the entire perimeter of the floor-forming component. This substantially increases the load-bearing capacity of the floor-forming components as well as the wind load-bearing capacity of the wall-forming components. For example, engineering calculations indicate that the load-bearing capacity of an 18.8 square foot floor-forming component increases from 60 to 90 pounds per square foot by this connection method.
Furthermore, this changes the nature of the entire assembled structure. Instead of the building being an assembly of independent pieces (studs, joists, or blocks), it becomes a complete whole structural element. This provides excellent resistance to earthquakes, hurricanes and floods.
Advantageously, the structural member is assembled or prefabricated on a fixture formed of a plurality of posts. The posts have a holder at one end adapted to hold the several chords and other members defining a joint. At the opposite end, the posts are mounted on a structure including post rails which may be movable on rail guides. The post rails are used to move the posts and the chords attached thereto to a coupling member such as a welding gun. The coupling member permanently couples or secures the chords together to form the respective joints.
The posts can be formed into a three dimensional lattice defining the dimensions of the structural member. A plurality of guns may be provided to weld several joints simultaneously. In an advantageous arrangement the rail posts move toward the guns and the guns are activated when respective sensors detect the holders with the chords. In this manner the process, or at least the welding of the chords together is easily automated.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, characteristics and advantages of the present invention will be more clearly understood from the following detailed description when read in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic illustration, in perspective, of a section of a building structure according to the present invention and shows a group of modular structural members constituting two wall components, a floor component and two roof components, the various components being shown in the form of their triangulated wire cores only and without their associated shell panels;
FIG. 2 is a perspective illustration, on a somewhat enlarged scale, of the floor component, without its shell panels, constituting a part of the building structure shown in FIG. 1;
FIG. 3 is an elevational illustration, in perspective and on a reduced scale, of one of the wall components, without its shell panels, constituting a part of the building structure shown in FIG. 1, the wall component being illustrated as provided with vertically spaced horizontal compacted regions of its triangulated wire core designed for supporting respective floor components;
FIG. 3A is a schematic side edge view of the triangulated wire core structure of the wall component shown in FIG. 3;
FIG. 4 is a diagrammatic illustration of a first stage of the formation of the triangulated wire core of a modular structural member according to the present invention, this view showing the positioning of the first zig-zag shaped wire truss for the core of the structural member;
FIG. 5 is a diagrammatic illustration of the second stage of the formation of the triangulated wire core of a modular structural member according to the present invention, this view showing the positioning of the second zig-zag shaped wire truss relative to the first wire truss;
FIG. 6 is a diagrammatic illustration of the third stage of the formation of the triangulated wire core of a modular structural member according to the present invention, this view showing the positioning of a third zig-zag shaped wire truss for relative to the second wire truss;
FIG. 7 is a schematic sectional representation of a layer of cellular concrete used as a part of the shell panel of a modular structural member according to the present invention and illustrates the provision of collapsed air cells in the layer of concrete adjacent the outer surface of the shell panel;
FIG. 8 is a schematic cross-sectional view of a modular structural member according to the present invention and illustrates the same as constituted of two separate shell panels spaced from but connected to each other by a triangulated wire core;
FIG. 9 is an enlarged representation of a section of the structural member shown in FIG. 8 and illustrates certain details thereof;
FIG. 10 is a vertical section taken through a part of a building structure according to the present invention constituted of a vertical wall or partition component extending between and connected at its top and bottom edges to two associated vertically spaced floor/ceiling components, the section being taken along a plane located in front of a duct riser incorporated in the wall or partition component;
FIG. 11 is a sectional view similar to FIG. 10 but with the section being taken along a plane located axially of the duct riser incorporated in the wall or partition component;
FIG. 12 is an enlarged horizontal section through the connection region between the abutting vertical side edges of two horizontally aligned wall components and illustrates the interfitted male and female connector members of the joint (these are the same as the ones shown in FIGS. 10 and 11) prior to the activation and expansion of the male connector member of the joint;
FIG. 13 is a view similar to FIG. 12 but illustrates the male connector member of the joint after its activation and expansion in the female connector member of the joint;
FIG. 14 is an enlarged perspective illustration of a channel-shaped female connector member constituting a part of the joint shown in FIGS. 12 and 13; and
FIG. 15 is an enlarged perspective illustration of the activated and expanded male connector member of the joint shown in FIGS. 12 and 13;
FIGS. 16-18 show how the chords are assembled with an anchor to form joints for the structural member;
FIG. 19 shows an orthogonal view of a post terminating in holder;
FIGS. 20-24 show how the chords interact with the holder of FIG. 19 to form the joints;
FIG. 25 shows an orthogonal view of the fixture without the chords;
FIG. 26 shows a top view of the fixture of FIG. 25;
FIG. 27 shows an orthogonal view of the fixture with the chords in place and before the chords are welded; and
FIG. 28 shows a plan view of the fixture with chords in FIG. 27 .
DETAILED DESCRIPTION OF THE INVENTION
The structural members and building structures made from these members are first described. Referring now to the drawings in greater detail, a section of a gabled-roof building structure 20 is shown in FIG. 1 as being constructed of a multiplicity of modular structural members according to the present invention (obviously only a small number of them are shown) which constitute wall components 22 , floor components 24 (see also FIG. 2 ), and roof components 26 of the building structure. Although only arrangements of triangulated wires are shown in these views, each of the various structural members 22 , 24 and 26 actually has the form of a block composed, as shown in FIGS. 8 and 9, of a pair of shell panels 28 and 30 separated from one another by a space 31 and connected to one another by an intermediate triangulated wire core 32 located in the space 31 . The shell panels have been omitted from FIGS. 1 and 2 for the sake of simplicity. For ease of identification, furthermore, the shell panels 28 and 30 are hereinafter occasionally referred to as the interior shell and the exterior shell, respectively.
In the preferred embodiment of the invention, the shell panels 28 and 30 have the form of respective layers 28 a and 30 a of concrete. If deemed advisable for a particular type of building structure, a respective metal reinforcing plate or shellpan (not shown) may be embedded in each layer of concrete over substantially its entire expanse for enhancing the strength and fire resistance of the shell panels 28 and 30 individually and thereby of the structural members 22 , 24 and 26 composed thereof as well. Alternatively, however, the shell panels may be made of metal or other sufficiently strong and fire-resistant materials. In the illustrated embodiment, furthermore, certain adjuncts of the triangulated wire core 32 , shown in FIG. 9 and more fully described hereinafter, are also embedded in the layers of concrete and constitute means by which the shell panels 28 and 30 and their associated wire core are connected to each other. In the illustrated embodiment, furthermore (see FIG. 9 ), the outer face 28 b of the interior shell 28 is that face thereof which in use is directed toward and defines the boundary wall surface of the associated enclosed building space, while the outer face 30 b of the exterior shell 30 is that face thereof which in use is directed away from the enclosed building space. The inner faces 28 c and 30 c of the interior and exterior shells of a building component are, of course, those faces of the shells which are directed toward each other and between which the space 31 and the triangulated wire core 32 are located.
Referring now to FIGS. 4, 5 and 6 , according to the present invention the triangulated wire core 32 of the basic structural members 22 , 24 or 26 consists, as previously indicated, of a plurality of zig-zag shaped wire elements or “trusses” 34 placed next to each other across the width of the structural member, with their tips or apexes interconnected. To prepare such a core, a group of mutually parallel first wire cables or chord members, designated 32 a in FIG. 9, are laid out in a suitable jig or fixture (not shown) so as to extend in a direction parallel to the intended longitudinal axis of the wire core, and a group of mutually parallel second wire cables or chord members, designated 32 b in FIG. 9, are laid out in the same fixture crosswise over the first chord members.
A first zig-zag wire truss 34 a (FIG. 4) is then arranged along a first one of the longitudinal wire chord members 32 a in a substantially upright position in a plane which is slightly inclined relative to the vertical plane of the first longitudinal chord member in a direction away from the next adjacent longitudinal chord member, with the bottom vertices or apexes of the first wire truss 34 a located at respective intersections of the first longitudinal chord member with the cross chord members. A second zig-zag wire truss 34 b (see FIG. 5) is then placed next to the first wire truss is 34 a, with the bottom vertices of the second truss being located at the same intersections between the underlying longitudinal and cross chord members 32 a and 32 b as the bottom vertices of the first truss and with all those elements at each intersection being connected to each other by means of suitable anchor members. Thereafter, a third zig-zag wire truss 34 c (see FIG. 6) is placed next to the second wire truss, with the bottom vertices of the third truss being located away from the bottom vertices of the second truss and along a separate longitudinal chord member 32 a but with the top vertices or apexes of the third truss 34 c being located adjacent to the top vertices of the second truss.
The procedure is then continued as needed in the same fashion as described so far, until a core structure 32 of the desired length and width has been built up. It will be understood that care must be taken to ensure that in any group of three directly adjacent wire trusses across the width of the core structure, the middle one of those wire trusses has its bottom apexes connected only to the bottom apexes of the wire truss located on one side of the middle wire truss and has its top apexes connected only to the top apexes of the wire truss located on the other side of the middle wire truss. At that stage, an additional group of longitudinal chord members 32 d and an additional group of cross chord members 32 e are put in place on top of the assembled wire trusses, with the intersections of those chord members being positioned over the top apexes of the wire trusses, and the top apexes of the wire trusses together with the underlying intersecting longitudinal and cross chord members are connected to each other by respective sets of anchor members 32 f . Where the structural member is to include a shellpan within each of the concrete shell panels, it is further contemplated that the shellpans will be positioned across the entire expanse of the wire core structure at both faces thereof and hence in contact with the apexes of the wire trusses, for enabling the shellpans to be welded to the wire trusses and to the intersections of the longitudinal and cross chord members.
Attention is called to the fact that, although the arrangement of the zig-zag shaped wire trusses in a triangulated wire core for a modular structural member according to the present invention is normally uniform over the entire expanse of such member, that arrangement is modified somewhat, as shown in FIGS. 3 and 3A, in the case of the floor-to-wall connection region of a wall-forming component. For that situation, each wall-forming component 22 is provided with a more compact distribution of the wire trusses 34 at each level 22 a, 22 b, etc., where it is to be connected to a floor-forming component 24 . The narrower spacing of the adjacent wire trusses from each other and the narrower spacing of the adjacent apexes of each wire truss from each other, both of which are clearly visible in FIG. 3A, in conjunction with the fact that each floor-to-wall connection is continuous along the entire perimeter of the floor-forming component, ensures that the connections are stronger and helps the floor-forming component resist its tendency to bend under the load. This substantially increases the load-bearing capacity of the floor-forming components as well as the wind load-bearing capacity of the wall-forming components.
Reverting now to the assembly of the structural member, once the wire core structure 32 is complete, the opposite face regions of the core structure are introduced into a mold (this may be effected either simultaneously or sequentially, depending on the type of equipment available and on existing production requirements) which has the desired contours of the two shell panels 28 and 30 . Concrete, preferably admixed with air bubbles or a cellular plastic foam, is then poured into the mold and permitted to set so as to form the layers 28 a and 28 b with the grids of longitudinal and cross chord members 32 a - 32 b and 32 d - 32 e and the sets of anchors 32 c and 32 f embedded in the concrete and held firmly in place.
It should be noted at this point that the durability and the water resistance of the structural members or components 22 , 24 and 24 will be primarily a function of the surface density of the concrete utilized in the shell panels 28 and 30 . Durability, strength and water resistance of concrete advantageously increase with density, yet thermal values, fire performance characteristics, weight and cost decrease with higher densities. To take advantage of this property of the concrete, vibrations can be applied at the surface region 36 of the shell mixture (see FIG. 7) where the forms are in contact with the mixture, which results in a collapse of the air cells at that surface region while the air cells in the region 38 away from that surface remain fully expanded. Vibrations can also be transmitted into the mixture through the steel wire core structure to increase the density of the concrete at the juncture between the metal and the concrete. In this way, a density of the concrete which is in general correct for a particular component or structural load can be maintained without increasing it to address a surface requirement. This is especially useful for floor components and for the exterior faces of outside wall and roof components.
In this regard, it is well known that whereas rain and snow are one source of water problems for buildings, another one is condensation. The transmission of cold to the warm side of standard (non-cellular) concrete causes condensation to form on the warm side. Cellular concrete has thermal characteristics which are superior to standard concrete and, therefore, it assists in resisting the formation of moisture on the insides of wall and roof components. Experience with buildings indicates, however, that even when proper steps have been taken to resist water penetration, provision must nonetheless still be made for the escape of moisture which may accumulate. To this end it is contemplated by the present invention to design the shellpans incorporated in the concrete shell panels so as to include channels for directing moisture to holes through which it can escape.
It should also be noted that even though the basic structure of the wall, floor and roof components of the present invention is the same, there will nevertheless be some differences between certain ones of such components in terms of their structural strengths, architectural design details, and thermal performance. For example, it may be deemed advisable to provide an outside wall component or a roof component of a building structure with a thermal insulation material 35 (see FIG. 9) within the space 31 between the shell panels 28 and 30 occupied by the triangulated wire core. On the other hand, an inside wall component or a floor component of the building structure may not require as much insulation or, for that matter, may not require any insulation at all.
A practical example of an interconnection of a partition (inside wall) component between a ceiling and a floor is illustrated by FIGS. 10 and 11. As there shown, the partition component 40 is a block-shaped structure composed of a pair of spaced parallel concrete shell panels 42 and 44 which are connected to each other by a triangulated wire core 46 disposed in the space between the shell panels. Set into the molded concrete top and bottom edges 40 a and 40 b of the partition component are respective upwardly and down-wardly open identical female connector channels 50 of the type shown in FIG. 14, the function of which will be more fully explained presently. Above the top edge 40 a of the partition component there is located a downwardly projecting molded concrete ceiling ledge or molding 52 which has a bottom edge 52 a aligned with the top edge 40 a of the partition component 40 and supporting a molded-in downwardly open female connector channel 50 identical to the one in the partition component. The ceiling ledge 52 is shown as depending from a ceiling component 54 which could be either an adjunct of a roof component (not shown) or an adjunct of an upper floor component (not shown).
Correspondingly, located below the bottom edge 40 b of the partition component 40 is a floor component 56 which, like the partition component, is composed of two spaced parallel concrete shell panels 58 and 60 connected to each other by a triangulated wire core 62 . Here again, the floor component 56 could be the lowest level of the building structure or its bottom panel could be the ceiling component of a lower room. In a fashion similar to that of the ceiling component 54 , the floor component 56 has an upwardly projecting ledge or molding 64 the top edge 64 a of which is aligned with the bottom edge 40 b of the partition component and has an upwardly open molded-in female connector channel 50 . As an illustration of a utilitarian use of the partition component other than as a space divider, there is provided in the floor component a duct 66 , for example, for conducting a heating or cooling fluid from a source thereof, and a duct riser 68 is shown as ascending from the duct 66 through a sleeve-lined opening 65 in the floor component 56 (FIG. 11) into the interior of the partition component and terminating after a lateral bend 68 a in a discharge end 68 b outside the partition component and covered by a suitable register or grille.
The interconnection of the partition component 40 with the ceiling and floor ledges 52 and 64 is effected with the aid of a set of identical expansible/contractible male connector elements 70 , which correspond in shape to the connector channels 50 and in a more refined form are of the type shown in FIG. 15 . As there shown, each male connector element includes two jaw-like members 72 and 74 which have flat proximal faces 72 a and 74 a and are arranged, with the aid of guide pins 73 , to be linearly displaced toward and away from each other by means of a screw drive shaft 76 which is rotatably received in an internally threaded bore or sleeve 78 carried by the member 72 and is provided with a pair of spaced lateral projections 78 a and 78 b bracketing the ends of the shaft-receiving bore in the member 74 . The jaw-like members 72 and 74 further have identical upper parts in the form of ridges or ribs 72 b and 74 b of generally trapezoidal cross-section which project away from one another, and identical lower parts in the form of ridges or ribs 72 c and 74 c of generally trapezoidal cross-section which project away from one another, all such ribs or ridges being configured to fit into respective lateral recesses 50 a and 50 b (FIG. 14) of an associated one of the female connector channels 50 . The open mouth 50 c of each connector channel is sufficiently wide to permit passage of the contracted male connector element 70 . In the system of FIGS. 10 and 11, therefore, when both of the male connector elements 70 are expanded as shown in FIG. 10 (the upper male connector element in FIG. 11 is contracted), they cannot be extracted from the respective connector channels 50 , whereby the partition component 40 is securely locked to the upper ceiling component 54 as well as to the lower floor component 56 .
FIGS. 12 and 13 represent a connection between the vertical edges of two horizontally aligned and abutting exterior wall components 80 and 82 . The connection is, however, effected in exactly the same way, utilizing two confronting female connector channels 50 and a two-part expandable/contractable male connector element 70 , as the connections shown in FIGS. 10 and 11, the only difference being that in the system of FIGS. 10 and 1 the connection is vertical between two horizontal abutting edges whereas in the system of FIGS. 12 and 13 the connection is horizontal between two vertical abutting edges. Accordingly, a more detailed description of the connection shown in FIGS. 12 and 13 is not believed necessary.
Methods of prefabricating the structural members shall now be described in conjunction with FIGS. 16-28. As discussed above, the principal elements of each structural member, are chords which intersect at joints. Since the structural member has a modular design, the joints are positioned at predetermined locations and are typically spaced at equal distances from each other. As shown in FIG. 16, a typical joint 90 defines the intersection between several diagonal chords 34 , a parallel chord 34 a and a cross chord 34 b. These elements are held together by an anchor 91 and are mechanically joined to each other by any well known means such as by one or more weld zones. One such weld zone 92 is shown in FIG. 17 .
The chords 34 may be made from steel wire having a diameter of ⅛-½″. The choice of this dimension depends on a number of factors, including the designated use for the structural member, the load to be supported by the structural member, the dimensions of the structural member, the ratio of each chord length to its diameter, and so on. Frequently these factors are dictated by national or local building codes. Typically, for exterior walls the wires may have a diameter of ¼″, ⅜″-½″ for floors and roofs, and ¼″ for interior walls.
The anchor 91 may be made from steel, aluminum, an alloy or may be a plastic/metal composite. While in the Figures, the anchor 91 has generally a C-shape, it could have other shapes selected to support the various chords and other elements (discussed in more detail below) which may be attached to the structural member. Preferably, the anchor 91 is shaped to allow the chords to be welded to each other after the anchor 91 is installed. In FIG. 17 the anchor is shown remote from the joint so that the welds 92 can be seen better.
FIG. 19 shows the completed joint with the chords 34 , 34 a, 34 b welded to each other and held together by the anchor 91 .
A separate piece of wire may be used for each chord. Alternatively, as shown in FIGS. 16-18, a long piece of wire may be bent at the joints to form more than one chord.
While the joints described in FIGS. 16-18 could be assembled manually, for relatively large structural members (which most of them are expected to be), such a process may be too difficult, time consuming and impractical. Therefore a fixture 93 has been devised which can be used to perform this assembly automatically. The fixture is shown in detail in FIGS. 25 and 26 and is designed to hold the chords, anchors and any additional elements of a structural member together in a predetermined configuration until the joints are completed. Once a structural member is completed, it can be removed and the fixture may be used to assemble another structural member.
As shown in the Figures, fixture 93 is formed of a plurality of clusters 95 used to hold the joints during assembly, a plurality of posts, including short posts 96 and long posts 97 used for supporting the clusters, a plurality of vertical post rails 98 disposed in parallel to the parallel chords 34 a and used to support the posts 95 , 97 , and a plurality of guide rails 99 disposed in parallel to the cross chords 34 b. The post rails 98 are equipped with wheels 101 . The wheels 101 ride on guide rails 99 so that the whole fixture 93 can be moved as desired. The post rails are maintained at a predetermined positions by a spacer bar 100 .
Finally electric welding guns 102 are also provided which are operated by electrical controls to weld the chords.
FIG. 19 shows a typical arrangement for a cluster 95 attached to a long post 97 . It includes a horizontal member 97 a, a vertical member 97 b and a plurality of holding members 94 . Holding members preferably comprise remotely operated electromagnets, but may also includes permanent magnets, springs, clamps or any other electrical, hydraulic, pneumatic or other mechanical means of holding the joints 93 before and after welding, which can be remotely activated.
The fixture 93 is used as follows. First, the posts 95 , 97 are mounted on post rails 98 , the post rails are assembled on the guide rails 99 and their relative position is fixed by spacer bar 100 . The clusters 95 on the short posts 95 define the positions of the joints 90 on the back face of the structural member 24 and the clusters 95 on the long posts 97 define the positions of the joints 90 on the front face of the structural member 24 . In this manner, as described above, each joint 90 is located at a position consistent with the desired shape and configuration of structural member 24 and, thus, the fixture 93 defines the geometry of the structural member 24 during its assembly.
In addition, the welding guns 102 are also positioned so that they line up with the joints 90 .
Next, the chords are assembled at each joint 90 as illustrated sequentially in FIGS. 20-24. As seen in these Figures, the chords are mounted on the cluster 95 and maintained in position by the magnets 94 . Once all the chords are in position, the anchor 91 is positioned into place, as shown in FIG. 24 . Other elements may also be added at this point, such as doors, windows, etc. The resulting assembly is shown in FIGS. 27 and 28.
Once the chords are positioned, the joints are welded using electrical welding guns 102 . In the simplest case, the welding guns are manually or automatically positioned at each joint and the joints are welded. However, it is much more efficient to weld the joints automatically. Therefore, preferably the position of the assembly of chords is controlled by a motor 105 which may be used to move the post rails 98 along the guide rails. The motor 105 , holders 98 and the welding guns 102 may all be controlled by a control panel 107 which includes a microprocessor (not shown). Once the chords are positioned, the control panel 107 is activated. The panel then activates the motor 105 to move the post rails 98 so that the joints approach the welding guns. The welding guns 102 are equipped with sensors 102 a. As shown in FIGS. 27 and 28, the welding guns 102 may be arranged in two rows corresponding to the joints of the back and the front face. As each joint 90 approaches a corresponding welding gun 102 , it gets sensed by a sensor 102 a and the welding gun 102 is activated by the control panel 107 . The welding gun 102 then applies welds 92 to the joints 90 . The control panel 107 operates the welding guns for predetermined times calculated to generate welds of predetermined sizes. These sizes are dependent on the speed of the assembly and the time that each gun is operated.
After all the joins have been welded, the holders 94 can be deactivated thereby releasing the joints. The completed structural member 24 can then be removed and the fixture 93 can be reconfigured for another structural member.
In FIGS. 26 and 28 straight guide rails 99 are shown resulting in structural members that have planar front and back faces. However, these guides could also be curved, as shown in FIG. 28 by line C to make structural members with curved faces.
It will be understood that the foregoing description of the present invention is for purposes of illustration only, and that the various structural and operational features herein disclosed are susceptible to a number of modifications and changes none of which entails any departure from the spirit and scope of the present invention as defined in the hereto appended claims.
|
Novel prefabricated modular structural members for use in low cost construction of relatively small residential, institutional and commercial buildings with high degrees of resistance to damage by fire, hurricanes, earthquakes, moisture, etc., are disclosed. A structural member of this class basically consists of two spaced shell panels and an intermediate core. The core is a triangulated wire frame composed of a plurality of zig-zag shaped wire trusses having their sets of top and bottom apexes anchored to associated sets of longitudinal and transverse chords and the respective proximate inside faces of the shell panels. A fixture is provided which includes posts for holding the wires before they are welded. The posts and a coupling member such as a welding gun can move with respect to each other to form the joints between the wires.
| 8
|
BACKGROUND OF THE INVENTION
This invention relates to the manufacture of synthetic linear condensation polyester feed yarns for texturing processes, and is more particularly concerned with a method of producing feed yarns which will provide more uniform dyeability in products prepared from them.
Processes for preparing polyester yarns from ethylene glycol and dimethyl terephthalate by ester-interchange followed by polymerization, or from ethylene glycol and terephthalic acid by direct esterification followed by polymerization, are well known. A major problem has been to control these processes to provide uniform dyeability in products made from the yarns. Textile mills must be able to put yarns from different yarn packages into adjacent areas of the same fabric and then dye the fabric without obtaining "dye junctions" (color discontinuities) which detract from the appearance of the dyed fabric. In other words, yarns from different packages must be "mergeable". Yarn manufacturers have developed a system of selling yarns of equivalent dyeability under a given "merge number". When a process change occurs which affects the dyeability, a different merge number is assigned. However, the textile mills have had a constant problem in scheduling the use of packages having different merge numbers and in preventing accidental mixing of packages.
Control of dyeability when producing polyester texturing feed yarns is a particularly difficult problem. When the process for producing such yarns includes a separate drawing step, the dyeability can be adjusted somewhat by making adjustments in the draw ratio used. Increasing amounts of partially oriented feed yarns are now being produced by high speed spinning, e.g., as disclosed in Piazza and Reese U.S. Pat. No. 3,772,872. These yarns are draw-textured and no practicable way has been found to control dyeability by making adjustments in the draw-texturing process.
Normally, in the production of polyester textile yarns, an objective has been to avoid the presence of aliphatic ether groups in the polymer because of their undesirable effect on properties of the yarns. Processes have been devised to make possible reduction of ether content to less than 3 mole percent, e.g., as illustrated by Izard U.S. Pat. No. 2,534,028, Mellichamp U.S. Pat. No. 3,496,146 and Armstrong et al. U.S. Pat. No. 3,534,082.
The unexpected discovery has now been made that uniform dyeability can be achieved by controlled addition of diethylene glycol at levels less than about 3 mole % without significant effect on other properties of textile yarns.
SUMMARY OF THE INVENTION
The present invention is an improvement in a continuous process for producing polyester texturing feed yarn from ethylene glycol and dimethyl terephthalate or terephthalic acid in which a polymer of less than 3 mole percent ether content is prepared and melt-spun to form partially-oriented yarn or fully-drawn yarn. The improvement comprises adding diethylene glycol to increase the ether content of the polymer by 0.1 to 2 mole percent.
The invention is particularly useful for correcting for changes in dyeability. The dyeability of products prepared from the feed yarn is determined periodically and the amount of diethylene glycol added is adjusted to maintain a substantially uniform dyeability. As little as 0.1 mole percent change in the amount of diethylene glycol added can cause a change of about 1 percent (as defined below) in dyeability.
Preferably, diethylene glycol is added to increase the ether content of the polymer by 0.1 to 2 mole percent and the total ether content of the polymer is maintained between 2 and 4 mole percent. As illustrated in Example 3, operation under these conditions provides a much improved uniformity of dyeability in comparison to operation with no addition of diethylene glycol.
Preferably the total ether content of the polymer is maintained below 3 mole percent. Properties of textured yarn prepared from the feed yarn begin to be adversely affected at values above 3 mole percent although the yarns are generally satisfactory at somewhat higher total ether contents.
DETAILED DESCRIPTION
The deliberate addition of diethylene glycol in the preparation of polyethylene terephthalate is contrary to the normally accepted practice of seeking to prevent the presence of aliphatic ether groups in the polymer. It is surprising that useful degrees of dyeability improvement can be obtained with added diethylene glycol while still maintaining a desirably low ether content. In the present invention, the amount of diethylene glycol added is preferably such that the total ether content of the polymer remains below about 3 mole percent.
In order to determine the amount of diethylene glycol needed in the polymer to adjust dyeability level, it is necessary to measure the dyeability of the yarn under conditions simulating actual textile finishing conditions. To do this, the yarn is first textured under normal texturing conditions. Any of the standard texturing or draw texturing machines may be used, e.g., a Leesona 553 or an ARCT-480 texturing machine. Temperatures and tensions are adjusted to give satisfactory performance for the particular yarn being tested. After texturing, the yarns are put in a convenient form for test dyeing, such as a skein or a knit sock, and dyed along with a similarly prepared sample of control yarn under standardized dyeing conditions, preferably using a disperse dye which accentuates dyeing differences. After dyeing, the reflectance of the sample is measured on a colorimeter and K/S factor calculated from the equation
K/S= (1-R).sup.2 /2R
where R is the fractional reflectance measured at the wavelength of the maximum absorbence of the dye used. K/S values are determined for both test and control samples and the percent dyeability of the test sample is calculated from the expression
(K/S) test/(K/S) control × 100 = Percent dyeability
The amount of diethylene glycol needed in the polymer to adjust dyeability to the correct level may then be approximated by using the relationship
ΔDEG= 0.1 (A-B)
where
ΔDEG is the mole percent diethylene glycol needed
A = percent dyeability desired
B = percent dyeability measured.
In the typical manufacture of polyethylene terephthalate, ethylene glycol is reacted with dimethyl terephthalate or with terephthalate acid. The reaction is usually carried out in stages with the final polymerization stage occurring in a vessel maintained at a temperature of 275°-310° C. and under high vacuum. Excess glycol is removed through the vacuum system along with small quantities of monomer, oligomer and catalyst residues. It will be appreciated, therefore, that a portion of the added diethylene glycol will also be lost through the vacuum system. Since dyeability is a function of the amount of diethylene glycol in the final polymer, the amount of diethylene glycol added to the polymerization system will usually be more than the amount desired in the final polymer to allow for vapor loss. The exact amount lost through the vacuum system will depend upon the specific polymerization apparatus used and for that reason the amount of needed DEG calculated from dyeability tests must be corrected for vapor loss by a factor specific to the polymerization system being used. This factor may be easily determined by analysis of the ether content of polymer made with and without diethylene glycol addition. Once this "loss fraction" is determined, it may be used routinely with only an occasional redetermination, as the loss fraction for a given system remains reasonably constant. In standard commercial polymerization equipment, loss fractions are usually of the order of 0.4, i.e., the fraction of added DEG retained in the polymer is usually of the order of 60%.
Diethylene glycol provides aliphatic ether groups in the polymer molecule. The concentration of aliphatic ether groups can be determined by known analytical methods. One convenient method is based upon an analysis of the infrared absorbence of the polymer. A film is pressed from the polymer and an infrared absorbence scan made, and the relationship determined between the peak related to aliphatic CH stretching and the peak related to aromatic CH stretching. Other chemical methods are known. For example, a gas-chromatographic analysis may be used on depolymerized polymer. All such tests may be standardized against samples to which known amounts of diethylene glycol have been added.
In the examples, "relative viscosity" is the ratio of the viscosity of a solution of 0.8 grams of polyester, dissolved in 10 ml. of hexafluoroisopropanol containing 80 ppm H 2 SO 4 , to the viscosity of the H 2 SO 4 -containing hexafluoroisopropanol itself, both measured at 25° C. in a capillary viscometer and expressed in the same units.
Yarn break elongation (E) is measured on an Instron Tensile Tester using a sample length of 5 inches (12.7 cm) and a rate of elongation of 200% per minute.
In the examples, parts and percentages are by weight unless otherwise indicated.
EXAMPLE 1
A three vessel polyester continuous polymerization system is coupled to two spinning machines, one for spinning ordinary fully-drawn texturing feed yarns and the other for spinning draw-texturing feed yarns. Molten dimethylterephthalate and ethylene glycol containing manganese acetate and antimony trioxide are continuously fed to the first vessel where ester interchange is carried out. The catalyst concentrations are sufficient to give 125-135 parts per million Mn and 310-320 parts per million Sb in the polymer. The mole ratio of glycol to DMT is 2.0. To the liquid product of this "ester interchange" vessel is added sufficient phosphoric acid to give 185-190 parts per million phosphoric acid in polymer and a glycol slurry of TiO 2 in sufficient quantity to give a concentration of 0.3 weight percent TiO 2 in the polymer. The mixture is transferred to the second vessel where the temperature is increased and the pressure reduced as polymerization is initiated. Excess ethylene glycol is removed through the vacuum system. The low molecular weight polymer produced is then transferred to a third vessel (finisher) where the temperature is raised to 285°-290° C. and pressure reduced to about 1 mm. mercury. The polymer produced has a relative viscosity of 22 and an ether content of 1.07 mole percent. A portion of the polymer output is passed to one spinning machine where it is melt spun and drawn to give a 150 denier, 34-filament texturing feed yarn having a break elongation (E) of 31 percent. Another portion of the polymer output is transferred to a second spinning machine where it is melt spun at high speed (without a separate drawing step) to give a 34-filament draw-texturing feed yarn of 245 denier having a break elongation (E) of 131 percent.
Samples of the above-prepared yarns are then checked for dyeability as follows:
The partially-oriented yarn (131 percent E) is draw-textured on an ARCT-480 texturing machine using a spindle speed of 430,000 rpm, draw ratio of 1.58, a twist of 66 tpi, a first heated temperature of 210° C. (410° F.) and a second heater temperature of 230° C. (446° F.). Another similar yarn, chosen to be the reference standard for this test, is also textured in like manner on the same machine. Both test and reference yarns are made into skeins, scoured and dyed (together) at atmospheric pressure using a bath-to-fiber ratio of 191:1. The aqueous dye bath contains
3.6 percent (on wt. of fiber) C.I. disperse blue 60 (Latyl Brilliant Blue BG),
1 gr./liter anionic hydrocarbon sodium sulfonate (Avitone T),
0.75 gm./liter nonionic fatty alcohol ethylene oxide condensate (Merpol HCS),
2 ml./liter 50 percent o-phenylphenol (Carolid),
0.7 gm./liter monosodium phosphate (to give pH 5.5-6.0).
Skeins are introduced into the dye bath at 60° C., the temperature raised to 95° C. at a rate of 1° C./min., and then held at 95° C. for 40 minutes. The skeins are then rinsed, air-dried and examined for dye uptake on a Hunterlab Model D25M Colorimeter. Percent reflectance readings are converted to percent dyeability, assigning a value of 100 percent dyeability to the reference sample. The partially-oriented (131 percent E) test item is found to have a percent dyeability of 99.2.
The fully-drawn test yarn (31 percent E) is textured on a Leesona 553 texturing machine using a spindle speed of 210,000 rpm, a twist of 63 tpi, a heater temperature of 232° C. (450° F.) and a bottom overfeed of 1 percent. A fully-drawn reference yarn, from polymer similar to that of the reference sample used for the partially-oriented yarn, is textured in a similar fashion on the same machine. Test and reference samples are then made into skeins and dyed using the procedure described above. The reflectance of each sample is then measured and the percent dyeability of the test yarn (31 percent E) is calculated to be 98.5.
To illustrate the effect of adding DEG, it is then decided to raise the dyeability level of the texturing feed yarns to about 120 percent of the reference sample. By referring to the relationship ΔDEG= 0.1 (A-B), it is seen that such an increase could be expected by adding sufficient DEG to the polymerization system to give about 2 mole percent additional DEG in the final polymer. To the polymerization system operating as above, 3.0 weight percent (1.78 mole%) diethylene glycol is added to the feed glycol, this amount being 3.56 mole % DEG based on DMT. Other conditions are held constant. Using the procedure described above, partially-oriented yarn is produced, draw-textured and tested for dyeability, using the same procedures and reference standard used above for the partially-oriented yarn. Fully-drawn texturing feed yarns are also prepared, textured and tested for dyeability using the same procedures and reference standard used above for the fully-drawn yarn.
The polymerization and spinning system described above is operated continuously for a 21/2 day period with 3.0 weight percent of diethylene glycol being added to the feed glycol. During this period the amount of catalyst added is varied so that the manganese content in the polymer ranges from 135 ppm to 140 ppm, the antimony content of the polymer varies from 237 ppm to 378 ppm and the phosphoric acid content of the polymer varies from 153 ppm to 257 ppm. The polymer produced is repeatedly analyzed for aliphatic ether content and ethers are found to remain relatively constant at 2.97 ± 0.21 mole percent, a 1.9 mole % increase vs. the original ether content. Draw-texturing feed yarn spun from the polymer is found to maintain a percent dyeability of 120 ± 2. Fully-drawn texturing feed yarn spun from the polymer is found to maintain a percent dyeability of 123 ± 4 percent.
No deleterious effects of the diethylene glycol addition were noted. Both feed and textured yarn properties were found to be acceptable.
EXAMPLE 2
A continuous polymerization unit for preparing polyethylene terephthalate polymer from dimethyl terephthalate and ethylene glycol is operated at 93.3 percent of capacity and the polymer produced fed to a spinning machine where a 245-denier, 34-filament partially oriented texturing feed yarn is produced. The dyeability level is determined to be satisfactory. Then the throughput of the polymerization system is raised to 99.4 percent of capacity and a 2-3 percent loss in dyeability normally expected for such an increase in throughput is observed. To correct this, 0.3 mole percent (calculated on polymer) of diethylene glycol is added to the ethylene glycol feed system. The texturing feed yarn produced with added DEG is found to have substantially the same dyeability as that exhibited by the yarn made before the throughput change. No merge change is required.
EXAMPLE 3
This example illustrates the improvement in uniformity of dyeability provided by the present invention.
A continuous polymerization system for preparing polyethylene terephthalate from dimethyl terephthalate and ethylene glycol is operated at full capacity and the polymer produced fed to a spinning machine. The polymer produced is spun into a 34-filament partially-oriented draw-texturing feed yarn of 235 denier. Sufficient diethylene glycol is added to the glycol feed system to raise the ether level in the polymer by 1.2 mole percent, giving a total ether content of 2.1 mole percent. With the polymerization equipment operating under steady state conditions, several packages of partially oriented feed yarn are collected and draw textured under identical conditions on an ARCT-480 texturing machine. The textured yarns are then knit into panels, dyed at atmospheric pressure as in Example 1 and the dye level measured on a reflectance meter.
For comparison, the same system is operated without the addition of diethylene glycol but with all other conditions being the same. Ether content of the polymer is found to be 0.9 mole percent. The yarn produced is textured under the same conditions and on the same texturing machine as the yarn containing the higher ether content, and the textured yarn is knit, dyed and tested for dyeability level as before.
In comparing the uniformity of dye uptake of the two yarns tested, it is found that the textured yarn prepared from polymer to which diethylene glycol has been added gives, in four replicate tests, dye variances of 15.8, 17.3, 12.1 and 17.5. In contrast, the textured yarn prepared from polymer to which no diethylene glycol has been added is found, in three replicate tests, to give dye variances of 41.5, 51.8 and 40.3. These data indicate that the addition of diethylene glycol to the polymer gives a much improved uniformity of dyeability.
|
Polyester texturing feed yarns are produced by preparing an ethylene terephthalate polymer from ethylene glycol plus a small amount of diethylene glycol, and dimethyl terephthalate or terephthalic acid, and melt-spinning the polymer into filaments. The filaments may be partially oriented by spinning at high speed without cold drawing, or may be fully drawn after conventional spinning. The diethylene glycol is added in controlled amounts to provide uniform dyeability in fabrics prepared from the yarn after texturing.
| 2
|
This application is a continuation of U.S. patent application Ser. No. 583,647 filed Feb. 27, 1984, which issued as U.S. Pat. No. 4,620,487 on Nov. 4, 1986. This application is also related to U.S. patent application Ser. No. 596,968 filed Apr. 5, 1984, which issued as U.S. Pat. No. 4,633,787 on Jan. 6, 1987; to U.S. patent application Ser. No. 584,016 filed Feb. 27, 1984, which issued as U.S. Pat. No. 4,569,289 on Feb. 11, 1986; and to U.S. patent application Ser. No. 597,125 filed Apr. 5, 1984 which issued as U.S. Pat. No. 4,690,072 on Sept. 1, 1987.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a light weight gondola type open top railway car having an aerodynamically configured structure to increase its energy efficiency during transit in each a loaded and unloaded condition.
2. DESCRIPTION OF THE PRIOR ART
Gondola type open top railway cars are typically formed into trains and used to haul bulk cargoes, such as coal, grains or mining ores. Due to the typical specialized nature of the cargo, gondola type cars are often used to form a train consisting of only gondola cars and the train, frequently comprised of one hundred or more gondola cars pulled by one or more locomotives, hauls coal from a source, such as a Montana or Wyoming mine, to a user, such as a utility in the Midwest. After being unloaded, as by each car in the train being serially tipped upside down and dumped at a dumping station, the same train is pulled empty back to the coal source to be loaded, as by "flood" loading while moving and then repeats the trip. Due to the great frequency of the trips made and distances traversed each trip, and energy saving, generally measured in terms of reduced fuel consumption, which can be gained by making the cars easier to pull can be significant.
Conventional cars, for purposes of durability due to the rough service conditions they are subjected to, have generally been constructed of steel arranged to provide strength and durability and decreased aerodynamic drag has generally not been a design criterion.
SUMMARY OF THE INVENTION
A high sided, open topped gondola type railway car is constructed of lightweight materials, such as aluminum. The car body is designed to be aerodynamically efficient and is provided with members and surfaces which decrease the aerodynamic drag on the car and consequently reduce the energy required to move the car. Airfoil members attached to the upper end walls of the car are generally only efficient when the car is unladen or empty whereas the aerodynamic drag reducing body design is generally effective under all transit conditions of the car.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially cutaway side elevation view of a railway car of this invention;
FIG. 2 is a top plan view of the railway car shown in FIG. 1;
FIG. 3 is an enlarged end view of the railway car body shown in FIG. 1;
FIG. 4 is a cross sectional view of the car end shown in FIG. 3 as indicated by the section line 4--4;
FIG. 5 is a top view of the end of the car shown in FIG. 3;
FIG. 6 is an enlarged cross sectional view of the airfoil portion of the end of the car shown in FIG. 3 as indicated by the section line 6--6;
FIG. 7 is an enlarged top plan view of a portion of the car shown in FIG. 2;
FIG. 8 is a cross sectional view of FIG. 7 as indicated by the section line 8--8;
FIG. 9 is a cross sectional view of a strut member shown in FIG. 8, as indicated by the section line 9--9;
FIG. 10 is a side elevation view of a railway car having the features of this invention serially connected to other similar cars;
FIG. 11 is a top plan view of FIG. 10; and
FIG. 12 is an enlarged side elevation view of two cars serially connected.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows, in a partially cutaway side elevation view, a gondola-type railway car 2 having an aerodynamic body construction. FIG. 2 is a top plan view of the open top gondola-type car shown in FIG. 1.
Referring to FIGS. 1 and 2, car 2 is comprised of a cargo carrying structure having a first side wall 3, a second side wall 4, a first or front end wall 5 and a second or rear end wall 6. The side walls and end walls are substantially rigidly affixed to each other at corners 7, 8, 9 and 10.
A bottom closure means, such as a first bottom closure and shear plate member 11, a second bottom closure and shear plate member 12 and a depressed or lowered bottom closure member, generally indicated as 13, are sealingly engaged with the wall members to provide a cargo carrying structure having a substantial cubic capacity.
Car 2 has a first stub center sill 14, and a second stub center sill 15. Connected to each stub center sill 14 and 15 is a conventional coupler, such as couplers 16 and 17, respectively, which enable each end of the car to be connected to an adjacent car at each of its ends. Couplers 16 and 17 will generally be of the type which enable the car to be tipped upside down for dumping while remaining coupled to a car at each end.
Car 2 has adjacent each end an internally constructed bolster, such as bolsters 18 and 19. Wheel truck assemblies, such as conventional truck assemblies 20 and 21 are engaged with a bolster and stub center sill to rollingly support the cargo carrying structure.
To rigidify the sides of the car a plurality of vertically extending side support members 22 are rigidly affixed, as by welding, to an interior surface portion of each of the side walls of sides 3 and 4 of car 2. To further rigidify the cargo carrying structure of the car 2 a plurality of crossridge assemblies, such as assemblies 23, 24, 25 and 26 are provided to rigidly engage the bottom closure portions 11, 12 and 13 to sides 3 and 4.
Additionally a minor or mini crossridge assembly 27 is provided to further reinforce a portion of bottom closure portion 13 and a longitudinally extending web type reinforcing assembly 28 is preferably provided between crossridge assemblies 24 and 25, as best shown in FIG. 2.
As best shown in FIG. 7 side 3 from which a top portion has been cutaway to improve clarity, car 2 has a wall member 29 formed of a smooth surfaced plate or sheet, preferably formed of a lightweight material, such as an extruded weldable aluminum alloy.
Wall member plate 29 has an outer surface 30 and an inner surface 31. Rigidly attached, as by welding to inner surface 31, are the plurality of vertically oriented side support members 22. Also attached to a portion of inner surface 31 of plate 29 are vertical crossridge support posts, such as posts 32 and 33, for crossridge assemblies 23 and 24, respectively. This construction, as just described above, is typical of each side wall assembly 3 and side wall assembly 4 of car 2 in which a smooth, low air flow resistant surface, such as exterior surface 30 of side plate 29 is exposed to air flowing along the car during movement of the car.
Adjacent end 5 of car 2 is a laterally inward offset side portion 34 of side assembly 3. Offset side portion 34 is typical of the wall construction at each of the corners 7, 8, 9 and 10 of car 2. Each corner wall portion is offset from a main wall assembly 3 or 4 to provide a location for a plurality of ladder rungs, such as ladder rung 35, to prevent the ladder rung from extending out beyond exterior surface 30 of plate 29 of wall 3. The maximum distance between the exterior surfaces of main walls 3 and 4, i.e., the overall width, of car 2, is limited by railroad industry standards. As shown in FIG. 7, offset wall portion 34 is comprised of a plate member having a smooth outer or exterior surface 36, a laterally inwardly curved vertically extending portion 37 and a second terminal end portion 38 which is rigidly engaged, such as by welding, to a vertically extending bolster post 39 having an exterior curved surface portion 40 which forms an airflow efficient transitional configuration between surface 36 of wall portion 34 and surface 30 of plate 29 of wall assembly 3.
The offset wall portion at each corner of the car 2 is substantially the same as just described for offset wall 34 except some offset walls may have more ladder rungs spaced along it than others, depending on whether the rungs are for purposes of a train crewman standing on the rungs or for purposes of climbing to the top of the car to visually inspect the interior of the cargo structure of the cars.
Referring now to FIG. 8 in which the crossridge assembly 24 of FIG. 7 is shown, crossridge assembly 24 is comprised of crossridge vertical side post 33, a second crossridge vertical side post 41 affixed to side assembly 4, a substantially horizontal crossridge top chord member 42 which extends between a lower portion of each vertical posts 33 and 41 and a pair of diagonally extending support struts 43, each of which are rigidly engaged with member 42 adjacent a lower end portion 44. Each strut 43 diverges and extends vertically upwardly from its attachment to member 42 to have a second end portion 45 rigidly engaged to an inward facing surface of a vertical crossridge post 33 or 41 by being rigidly affixed to connective means, such as plates 46 which are welded, or otherwise rigidly engaged, with one of the post 33 or 41.
As best shown in FIG. 9, each of the diagonal struts 43 has an elliptical cross section in which the major axis of each strut is positioned to be substantially parallel to the longitudinal axis of car 2. Having each of the two struts in each of the four crossridge assemblies 23, 24, 25 and 26 oriented to present a smooth minimum surface profile to air flow through car 2 in an unloaded position presents another significant decrease in aerodynamic drag of the car 2.
Referring now to FIGS. 3, 4 and 5 which show, respectively, an enlarged end, side cross section and top view of end wall 5 of car 2, end wall 5 is comprised of a vertically extending plate member 50 having a plurality of horizontally extending support members 51 affixed to its exterior surface 52. At a lower portion adjacent a bottom closure plate a curved connective member 53, is rigidly affixed to each a floor closure member and shear plate, such as member 11 and plate 50 of end wall 5. As shown in FIG. 4, the terminal end 54 of curved terminal portion 37 of the offset side wall is substantially coterminus with the exterior-most portions 54' of the end wall support member 51.
Affixed to the upper end portion or top portion of end wall 5 is an air flow guide means as airfoil assembly 55. Airfoil assembly 55 is comprised of an uppermost airfoil surface member having a first convex curved portion 56, a second convex curved portion 57 and a connective portion 58. The airfoil member formed by the curved portions has an exterior surface 59 and an interior surface 60.
The airfoil member is rigidly connected to an end, such as end wall 5, of car 2 by appropriate means, such as vertically upward extending member 61 which is welded at a lower end portion 62 to plate 52 of end wall 5 and at an upper end 63 to a connective member, such as angled aluminum member 64 which is rigidly attached, such as by welding to a portion of the interior surface 60 of the airfoil member.
Interior of the cargo carrying structure of car 2 a non-retaining cargo means, such as members 65 and 66, connects an end portion 67 of curved portion 56 to an interior surface 68 of plate 5, as best shown in FIG. 4.
Member 65 is comprised of a first substantially horizontal member 69, a sloping connective member 70 and a second horizontal member 71. Member 66 is rigidly engaged to and extends between sloped member 70 and surface 68 of plate 50 whereby members 66 and 67 serve to rigidly engage the airfoil with the end wall 5 and, because members 66 and 67 extend the width of the interior of the car, prevent cargo, such as coal, from becoming lodged beneath the airfoil.
Airfoil interior support means, such as support plates 72, are rigidly affixed to portions of interior surface 60 of the airfoil and to a portion of end wall 5 to further secure the airfoil to the car and rigidify the shape of the airfoil.
A pair of side wall top chord members 73 and 74, as shown in FIGS. 3, 5 and 8 are attached along the top of side walls 3 and 4, respectively, and extend along and are rigidly engaged with each side of the airfoil to further rigidly attach the airfoil assembly to the car 2.
An airfoil assembly 55, as shown in FIGS. 1 and 2, is placed on each end wall 5 and 6 of car 2, the airfoils are positioned substantially as mirror images of each other and, as the airflow features are substantially identical at each end 5 and 6 of the car and at all the bolster posts 39, the car may be pulled in either direction with substantially the same air flow characteristics.
All the aerodynamic drag-reducing curved surfaces of this invention are designed to cause the air flowing over these surfaces to flow, or tend to flow, conformingly or non-separatingly substantially along the surface of the curve in a substantially smooth, or non-turbulent, manner to maintain or increase lip suction to reduce aerodynamic drag or, under some condition, provide a net force which induces the car in the direction of travel. FIG. 10 shows in a side elevation view a plurality of cars 2 serially connected to each other and FIG. 11 is a top plan view of FIG. 10. Thus arranged, such a plurality of cars couplingly engaged and connected to a force means, such as locomotive, form a cargo carrying unit made up of a plurality of interacting modules or cars.
Referring to FIGS. 10, 11 and 12, flow arrows are used to indicate the typical flow of air with respect to cars 2 as the cars are pulled in the direction of travel T indicated at a constant speed along a substantially horizontal railway track. References to front and rear or forward and rearward should not be construed as limitations, but merely as terms to show or explain directions of movements. As shown in FIG. 10, the air typically flows over the airfoil assembly designated 55a mounted on the rear end wall 6 of one car 2a and flows over the airfoil assembly designated 55b affixed to the upper portion of what serves as the front end wall 5 of the adjacent car 2b in the indicated direction of travel T. The air flow thus typically descends downwardly into the empty cargo space of the car and flows through the cargo space around and over the elliptical, diagonal struts (shown in FIGS. 1, 2, 8 and 9) and impinges on the interior surface of the rear end wall 6 which has an airfoil assembly designated 55c (see FIG. 10) affixed to its top portion. The impinging air forms a stagnation point or area on the bluff back or rear wall 6 of said adjacent car and attempts to radiate outwardly from this point or area. However, due to the bottom closure, side walls 3 or 4 and end wall 6 the air is forced to flow upward over the air flow and cargo funnelling connection means, designated 65 and 66 on FIG. 4, and over the leading edge surface and connective surfaces of the airfoil assembly or member 55c. At this point some of the air flow will separate from the surface of the airfoil assembly and flow to the next, or leading airfoil 55d of the next car 2c. However, some of the air, as best shown by the lower flow arrow between the cars in FIG. 12, will conformingly or non-separately flow along the trailing or second convex curved portion 57c of the airfoil assembly 55c and flow downwardly between the cars 2b and 2c where at least a portion of it will contact what is now, for airfoil assembly 55d, the leading or second convex curved portion 57d, and conformingly or non-separatingly flow over and along the top surface of airfoil assembly 55d and commence descending into the cargo space to repeat the cycle of flow at the next end wall. To be effective at reasonable forward velocities or speeds, such as above 15 mph., the second convex curved portions 57c and 57d should be of a size at least comparable to an arc of a circle having a 6-inch radius and the first convex curved portions 56c and 56d (see FIG. 12) should be comparable to an arc of a circle having a radius of at least 3 inches. The minimum dimensions are provided as indicative as the curve 56 of airfoil is, as best shown in FIG. 6, not a regular arc of a circle, but rather a multi-radius or developed curve.
For purposes of illustration only, one preferred embodiment of assembly 55 has a dimension along member 61 between member 69 and that portion of interior surface 60 to which member 63 is affixed of about 14 inches. Additionally the leading edge curve 56 at its furthest point away from member 61 is about 14 inches along a line substantially parallel to member 69. The dimension between member 61 and the surface of leading edge 56 along a line substantially parallel to member 69 at a point substantially 7 inches above member 69 is about 11.7 inches. The surface of trailing edge 57 is, at its furthest point from member 61, about 17 inches and is comprised of an arc of a circle having a radius of about 5.8 inches with the upper portion smoothly merging with transition surface 58.
In the top plan view of FIG. 11 air flow indicating arrows are used to indicate the typical flow of a majority of the air with respect to the sides of the cars when they are serially arranged as shown. As indicated by the arrows the air tends to flow smoothly, or non-turbulently, along the sides of the cars, flow conformingly along the curved surfaces of the bolster posts, along the offset side wall where a portion of the air flows to the offset side wall of the next car and some of the air, not indicated by flow arrows, will undoubtedly flow along the trailing curve of the side wall and impinge on various portions of the exterior surface of the next end wall. Here again, as with the interior surface of a back end wall, the air will form a stagnation point or area. However, due to the absence of the side walls and bottom closure, some of the air will radiate laterally outward and flow over the vertically extending convex curved surface connecting the end wall to each of the side walls, some of the air will flow upward and along the convex curved surface of the airfoil member and some will flow downward and over the convex curved surface 53 connecting the lower portion of the end wall to the bottom closure. Due to the sizes of these convex curved surfaces, all being at least as great an arc of a circle having a radius of 3 inches, the air will conformingly or non-separatingly flow onto the adjacent smooth surfaces, particularly the smooth exterior surfaces of the side walls, to reduce the turbulence which increases aerodynamic drag.
Generally speaking, sufaces having curves of less than 3 inches in radius are ineffective in reducing aerodynamic drag at the velocities or speeds at which railway cars of this type travel.
|
Air flow guide members at each end of the cargo carrying structure of an open top gondola type railway car, together with rounded transition or corner surfaces on the exterior of the car and aerodynamically shaped and oriented cross braces within the car serve to reduce aerodynamic drag on the car as it is moved. Additionally, to further enhance the energy efficiency of the car, the cargo carrying structure is formed predominantly of a light weight weldable metal, such as an aluminum alloy, and the side support members are placed on the interior wall of each side to provide a smooth, minimized air flow resistant side surface.
| 8
|
REFERENCE TO RELATED APPLICATIONS
[0001] This application is also related to co-pending U.S. patent application Ser. No. 11/109,016 filed Apr. 19, 2005.
[0002] This application is also related to co-pending U.S. patent application Ser. No. 11/445,793 filed Jun. 2, 2006.
[0003] This application is also related to co-pending U.S. patent application Ser. No. 11/500,053 filed Aug. 7, 2006.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to the field of solar cell semiconductor devices, and particularly to integrated semiconductor structures including a multijunction solar cell and a conducting via that allows both anode and cathode terminals to be placed on the back side of the cell.
[0006] 2. Description of the Related Art
[0007] Photovoltaic cells, also called solar cells, are one of the most important new energy sources that have become available in the past several years. Considerable effort has gone into solar cell development. As a result, solar cells are currently being used in a number of commercial and consumer-oriented applications. While significant progress has been made in this area, the requirement for solar cells to meet the needs of more sophisticated applications has not kept pace with demand. Applications such as satellites used in data communications have dramatically increased the demand for solar cells with improved power and energy conversion characteristics.
[0008] In satellite and other space related applications, the size, mass and cost of a satellite power system are dependent on the power and energy conversion efficiency of the solar cells used. Putting it another way, the size of the payload and the availability of on-board services are proportional to the amount of power provided. Thus, as the payloads become more sophisticated, the design efficiency of solar cells, which act as the power conversion devices for the on-board power systems, become increasingly more important.
[0009] Solar cells are often fabricated in vertical, multijunction structures, and disposed in horizontal arrays, with the individual solar cell connected together in a series. The shape and structure of an array, as well as the number of cells it contains, are determined in part by the desired output voltage and current.
[0010] Inverted metamorphic solar cell structures such as described in U.S. Pat. No. 6,951,819, the paper of M. W. Wanless et al., Lattice Mismatched Approaches for High Performance, III-V Photovoltaic Energy Converters (Conference Proceedings of the 31 st IEEE Photovoltaic Specialists Conference, Jan. 3-7, 2005, IEEE Press, 2005), and co-pending U.S. patent application Ser. No. 11/445,793 filed Jun. 2, 2006, of the present assignee, present an important development in future commercial solar cell products.
[0011] Since a solar cell is fabricated as a vertical, multijunction structure, one electrical contact is usually placed on the top surface of the cell, and the other contact on the bottom of the cell, to avoid internal interconnections which may affect reliability and cost. A variety of designs are also known in which both contacts are placed on one side of the cell, including as represented in U.S. patent application Ser. No. 11/109,016 of the instant assignee.
[0012] Prior to the present invention, there has not been a inverted metamorphic solar cell with both anode and cathode contacts on the same side of the cell.
SUMMARY OF THE INVENTION
1. Objects of the Invention
[0013] It is an object of the present invention to provide an improved multijunction solar cell with both anode and cathode contacts on the backside of the cell.
[0014] It is an object of the invention to provide an improved inverted metamorphic solar cell.
[0015] It is another object of the invention to provide an electrical interconnection via in a multi-solar cell structure that is fabricated on a substrate which is removed during processing.
[0016] It is still another object of the invention to provide a method of manufacturing an inverted metamorphic solar cell as a thin, flexible film with contacts on one side of the cell.
[0017] Additional objects, advantages, and novel features of the present invention will become apparent to those skilled in the art from this disclosure, including the following detailed description as well as by practice of the invention. While the invention is described below with reference to preferred embodiments, it should be understood that the invention is not limited thereto. Those of ordinary skill in the art having access to the teachings herein will recognize additional applications, modifications and embodiments in other fields, which are within the scope of the invention as disclosed and claimed herein and with respect to which the invention could be of utility.
2. Features of the Invention
[0018] Briefly, and in general terms, the present invention provides a method of manufacturing a solar cell by providing a first substrate; depositing on the substrate a sequence of layers of semiconductor material that forms at least one cell of a multifunction solar cell; etching a via from the top surface of the sequence of layers to the first substrate; providing a second substrate over the sequence of layers, and removing the first substrate.
[0019] In another aspect, the present invention provides a method of manufacturing a solar cell having a front side and back side by providing a first substrate; depositing on the substrate a sequence of layers of semiconductor material that forms at least one cell of a multijunction solar cell; providing a second substrate over the sequence of layers; and removing the first substrate. A first electrode is then formed on the back side of the solar cell, and an electrical connection is formed between the top cell of the multijunction solar cell and a second electrode on the back side of the solar cell.
[0020] In another aspect, the present invention provides a solar cell including a semiconductor body having a sequence of layers forming a multijunction solar cell including; a first solar subcell having a first band gap; a second solar subcell disposed over the first subcell and having a second band gap smaller than the first band gap; a grading interlayer disposed over the second subcell having a third band gap larger than the second band gap, and a third subcell disposed over the interlayer such that the third solar subcell is lattice mismatched with respect to the second subcell and has a fourth band gap smaller than the third band gap, with anode and cathode contacts on the backside of the solar cell.
[0021] In another aspect of the present invention provides a multijunction solar cell having a front side surface and a back side surface including a first solar subcell adjacent the front side surface having a first band gap; a second solar subcell disposed over the first subcell and having a second band gap smaller than said first band gap; a grading interlayer disposed over the second subcell and having a third band gap greater than the second band gap; and a third solar subcell adjacent the back side surface and disposed over the interlayer, the third subcell being lattice mismatched with respect to said second subcell and having a fourth band gap smaller than the third band gap. A via is formed in the first, second, and third solar cells with an electrical conductor extending through the via. An insulated contact pad is provided on the back side surface and electrically connected to the conductor to form a first terminal of the solar cell on the back side surface. A second terminal is formed on the back side surface by a metal layer making contact with a contact layer on the back side.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] These and other features and advantages of this invention will be better and more fully appreciated by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein:
[0023] FIG. 1 is an enlarged cross-sectional view of the solar cell structure according to the present invention at the end of the process steps of forming a multijunction solar cell on a first substrate;
[0024] FIG. 2 is a cross-sectional view of the structure of FIG. 1 with a via etched to the first substrate;
[0025] FIG. 3 is a cross-sectional view of the solar cell structure of FIG. 2 after the next process step according to the present invention including depositing a dielectric layer and a conductive layer in the via;
[0026] FIG. 4 is a cross-sectional view of the solar cell of FIG. 3 after the next process step according to the present invention in which a wafer carrier or surrogate second substrate is adhered to the “top” side of the solar cell structure;
[0027] FIG. 5 is a cross-sectional view of the solar cell of FIG. 4 after the next process step according to the present invention in which the first substrate is removed;
[0028] FIG. 6 is a cross-sectional view of the solar cell of FIG. 5 after the next process step according to the present invention in which a cap layer and metal contact layer is deposited on the structure;
[0029] FIG. 7 is a cross-sectional view of the solar cell of FIG. 6 after the next process step according to the present invention in which a cover glass is adhered to the solar cell structure on one side, and the surrogate second substrate removed on the other side; and
[0030] FIGS. 8A and 8B are top and bottom plan views, respectively, of a wafer including the solar cell of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] Details of the present invention will now be described including exemplary aspects and embodiments thereof. Referring to the drawings and the following description, like reference numbers are used to identify like or functionally similar elements, and are intended to illustrate major features of exemplary embodiments in a highly simplified diagrammatic manner. Moreover, the drawings are not intended to depict every feature of the actual embodiment nor the relative dimensions of the depicted elements, and are not drawn to scale.
[0032] FIG. 1 depicts the multijunction solar cell according to the present invention after formation of the three subcells A, B and C on a substrate. More particularly, there is shown a first substrate 101 , which may be either gallium arsenide (GaAs), germanium (Ge), or other suitable material. In the case of a Ge substrate, a nucleation layer 102 such as InGaP 2 , is deposited on the substrate. On the substrate, or over the nucleation layer 102 in the case of a Ge substrate, a buffer layer 103 of InGaAs, and an etch stop layer 104 of InAlP 2 are further deposited. A contact layer 105 of InGaAs is then deposited on layer 104 , and a window layer 106 of InAlP 2 is deposited on the contact layer. The subcell A, consisting of an n+ emitter layer 107 of InGaP 2 and a p-type base layer 108 of InGaP 2 , is then deposited on the window layer 106 .
[0033] Although the preferred embodiment utilizes the III-V semiconductor materials described above, the embodiment is only illustrative, and it should be noted that the multijunction solar cell structure could be formed by any suitable combination of group III to V elements listed in the periodic table subject to lattice constant and band gap requirements, wherein the group III includes boron (B), aluminum (Al), gallium (Ga), indium (In), and thallium (T). The group IV includes carbon (C), silicon (Si), germanium (Ge), and tin (Sn). The group V includes nitrogen (N), phosphorous (P), arsenic (As), antimony (Sb), and bismuth (Bi).
[0034] In the preferred embodiment, the substrate 101 is gallium arsenide, the emitter layer 107 is composed of InGa(Al)P 2 , and the base layer is composed of InGa(Al)P 2 . The use of parenthesis in the formula is standard nomenclature to indicate that the amount of aluminum may vary from 0 to 30%.
[0035] On top of the base layer 108 is deposited a p+ type back surface field (“BSF”) layer 109 of InGaAlP which is used to reduce recombination loss.
[0036] The BSF layer 109 drives minority carriers from the region near the base/BSF interface surface to minimize the effect of recombination loss. In other words, a BSF layer 109 reduces recombination loss at the backside of the solar subcell A and thereby reduces the recombination in the base.
[0037] On top of the BSF layer 109 is deposited a sequence of heavily doped p-type (such as AlGaAs) and n-type layers 110 (such as InGaP 2 ) which forms a tunnel diode which is a circuit element to connect cell A to cell B.
[0038] On top of the tunnel diode layers 110 a window layer 111 of n++ InAlP 2 is deposited. The window layer 111 used in the subcell B also operates to reduce the recombination loss. The window layer 111 also improves the passivation of the cell surface of the underlying junctions. It should be apparent to one skilled in the art that additional layer(s) may be added or deleted in the cell structure without departing from the scope of the present invention.
[0039] On top of the window layer 111 the layers of cell B are deposited: the emitter layer 112 , and the p-type base layer 113 . These layers are preferably composed of InGaP 2 for the emitter and either GaAs or In 0.015 GaAs for the base, respectively, although any other suitable materials consistent with lattice constant and band gap requirements may be used as well.
[0040] On top of the cell B is deposited a BSF layer 114 of p+ type AlGaAs which performs the same function as the BSF layer 109 . A p++/n++ tunnel diode 115 is deposited over the BSF layer 114 similar to the layers 110 , again forming a circuit element to connect cell B to cell C. A buffer layer 115 a , preferably InGaAs, is deposited over the tunnel diode 115 , with a thickness of about 1.0 micron. A metamorphic buffer layer 116 is then deposited over the buffer layer 115 a . The layer 116 is preferably a compositionally step-graded composition of InGaAlAs deposited as a series of layers with monotonically changing lattice constant that provides a transition in lattice constant from cell B to subcell C. The bandgap of layer 116 is 1.5 ev constant with a value slightly greater than the bandgap of the middle cell B.
[0041] In one embodiment, as suggested in the Wanless et al. paper, the step grade contains nine compositionally graded steps with each step layer having a thickness of 0.25 micron. In the preferred embodiment, the interlayer is composed of InGaAlAs, with monotonically changing lattice constant.
[0042] On top of the metamorphic buffer layer 116 another n+ window layer 117 is deposited. The window layer 117 improves the passivation of the cell surface of the underlying junctions. Additional layers may be provided without departing from the scope of the present invention.
[0043] On top of the window layer 117 the layers of subcell C are deposited; the n-type emitter layer 118 and the p type base layer 119 . In the preferred embodiment, the emitter layer is composed of GaInAs and the base layer is composed of GaInAs with about a 1.0 ev bandgap, although any other semiconductor materials with suitable lattice constant and band gap requirements may be used as well.
[0044] On top of the base layer 119 of subcell C a back surface field (BSF) layer 120 , preferably composed of GaInAsP, is deposited.
[0045] Over or on top of the BSF layer 120 is deposited a p+ contact layer 121 , preferably of p+ type InGaAs.
[0046] FIG. 2 is a cross-sectional view of the structure of FIG. 1 after the process step of a via 150 being etched from the top surface of the deposited layers 102 through 121 by dry or wet chemical processes to the substrate 101 .
[0047] FIG. 3 is a cross-sectional view of the solar cell structure of FIG. 2 after the next sequence of process step according to the present invention including depositing a back metal layer over the p+ contact layer 121 , and depositing a dielectric layer 161 in the interior of the via 150 and over a portion of the back metal contact layer. A conductive layer 162 is then deposited in the via 150 and over the dielectric layer 161 . The layer 162 serves as a wrap through front contact for the solar cell.
[0048] FIG. 4 is a cross-sectional view of the solar cell of FIG. 3 (how oriented with the substrate 101 at the top of the Figure) after the next process step according to the present invention. A wafer carrier or surrogate second substrate is adhered to the “top” side of the solar cell structure, which is now at the bottom of the Figure. In the preferred embodiment, the surrogate substrate is sapphire about 1000 microns in thickness, and is perforated with holes about 1 mm in diameter, spaced 4 mm apart, to aid in subsequent removal of the substrate.
[0049] FIG. 5 is a cross-sectional view of the solar cell of FIG. 4 after the next process step according to the present invention in which the first substrate 101 is removed by a lapping or grinding process.
[0050] FIG. 6 is a cross-sectional view of the solar cell of FIG. 5 after the next process step according to the present invention in which a cap layer is deposited over a portion of the nucleation layer in the region of the via 150 and metal contact layer is deposited over the cap layer, making electrical contact with the metal layer 161 inside the via 150 . An antireflective coating (ARC) layer is then applied over the surface of the nucleation layer.
[0051] FIG. 7 is a cross-sectional view of the solar cell of FIG. 6 after the next process step according to the present invention in which an adhesive is applied over the front metal layer and the ARC layer, and a cover glass is adhered to the solar cell structure. On the other side, the surrogate second substrate is then removed by dissolving the adhesive attaching it, or any other suitable technique.
[0052] FIGS. 8A and 8B are top and bottom plan views, respectively of a wafer including the solar cell of the present invention. In FIG. 8A , Cell 1 of each wafer is illustrated in greater detail with grid lines 501 , a bus 502 , and circular regions 503 in which a via 150 extends through the wafer such as shown in previous cross-sectional views.
[0053] FIG. 8B depicts the back side contact region 505 and a wrap through front contact region 504 with vias 503 corresponding to those shown in FIG. 8A .
[0054] It will be understood that each of the elements described above, or two or more together, also may find a useful application in other types of constructions differing from the types of constructions differing from the types described above.
[0055] While the invention has been illustrated and described as embodied in a multijunction inverted metamorphic solar cell, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
[0056] 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 equivalence of the following claims.
|
A method of forming a multijunction solar cell comprising an upper subcell, a middle subcell, and a lower subcell by providing a first substrate for the epitaxial growth of semiconductor material; forming a first solar subcell on said substrate having a first band gap; forming a second solar subcell over said first subcell having a second band gap smaller than said first band gap; forming a grading interlayer over said second subcell having a third band gap larger than said second band gap; forming a third solar subcell having a fourth band gap smaller than said second band gap such that said third subcell is lattice mismatched with respect to said second subcell; and etching a via from the top of the third subcell to the substrate to enable both anode and cathode contacts to be placed on the backside of the solar cell.
| 8
|
BACKGROUND OF THE INVENTION
This invention generally relates to a method for assuring enhanced signal integrity in various electronic components operating at higher frequencies. In particular, the present invention relates to a method for optimizing via structures in such components. More particularly, the present invention relates to a method for optimizing via structures for the enhanced high frequency performance of printed circuit boards and backplanes.
Today's electronic products, including computers, cellular telephones, and networking systems operate at ever increasing transmission data rates. At higher transmission data rates, resistance, dielectric absorption, and radiation losses, cross-talk, and structural resonances of passive interconnects can significantly degrade the quality of signals propagating through the interconnect. One of the primary circuit elements that attenuates and distorts analog, radio frequency and digital signals is the via. Via signal degradation is frequency/data rate dependent.
Numerous techniques have been used to mitigate the signal degradation problem including backdrilling of via stubs and removal of non-functional pads. These techniques, however, have seen limited, and to some extent, been subjectively applied in an attempt to improve the signal integrity of complex printed circuit boards and backplanes. It is, therefore, desirable to provide an objective, cost-effective method for the optimization of the shape and size of each via structure within such a printed circuit board or backplane. Additionally, it is desirable to provide such a method that is capable of being applied to other elements of an existing circuitry, such as collections of interconnect components (i.e., backplane assemblies that include vias, traces, and connectors) so as to enhance the circuit's overall signal integrity performance and thus its effectiveness for use at higher operating frequencies.
SUMMARY OF THE INVENTION
The present invention recognizes and addresses various of the foregoing limitations and drawbacks, and others, concerning prior art techniques aimed at improving high frequency performance for electronic circuitry Therefore, the present invention is directed to a method for optimizing via structures for the enhanced high frequency performance of printed circuit boards and backplanes.
It is, therefore, a principle object of the subject invention to provide a method of improving signal integrity performance of high frequency electrical circuits. More particularly, it is an object of the present invention to provide a method for optimizing at least one element of a circuit to improve its high frequency signal integrity performance. In such context, it is still a more particular object of the present invention to provide a method for optimizing a via structure's size and shape to enhance its high frequency signal integrity performance.
Still further, it is a principle object of this invention to provide a cost-effective optimization methodology for improving the signal integrity of an electrical circuit. In such context, it is an object of the present invention to provide a cost-effective methodology for improving the high frequency signal integrity performance of a via structure.
Additional objects and advantages of the invention are set forth in, or will be apparent to those of ordinary skill in the art from, the detailed description as follows. Also, it should be further appreciated that modifications and variations to the specifically illustrated and discussed features, method steps, and materials hereof may be practiced in various embodiments and uses of this invention without departing from the spirit and scope thereof, by virtue of present reference thereto. Such variations may include, but are not limited to, substitutions of the equivalent means, features, method steps, and materials for those shown or discussed, and the functional or positional reversal of various parts, features, method steps or the like.
Still further, it is to be understood that different embodiments, as well as different presently preferred embodiments, of this invention, may include various combinations or configurations of presently disclosed features, elements, method steps or their equivalents (including combinations of features or configurations thereof not expressly shown in the figures or stated in the detailed description).
These and other features, aspects and advantages of the present invention will become better understood with reference to the following descriptions and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and, together with the descriptions, serve to explain the principles of the invention.
In one exemplary embodiment, there may be provided an interactive method of optimization for manipulating the physical characteristics of a single or multiple vias within a PCB or backplane to enhance their high frequency performance. In general, such method involves subdividing the via into one or more of the following three different kinds of sections: a transmission line bend section, a non-uniform transmission line thru section, and a loaded non-uniform transmission line stub section. Where possible the PCB stackup should be designed so the stub section lengths (if any are present) are minimized.
The transmission line bend sections may be converted into lumped element series impedances and shunt element admittances. The physical dimensions of the bend section components may be adjusted until several second-level characteristics of the section's electrically equivalent sub-circuits are optimized. In the case of a single via, such optimization of a transmission line bend section is generally equivalent to minimizing the magnitude of the lumped element series impedances and shunt element admittances.
Further, the non-uniform transmission line thru sections may be converted into a series of discretized RLGC sub-circuits comprising one or more resistors, R, inductors, L, conductors, G, and capacitors, C. The physical dimensions of the thru section components associated with each sub-circuit may be manipulated until the values of R, L, G, and C are optimized. In the case of a single via, such optimization of a non-uniform transmission line thru section is generally equivalent to either 1 ) making the individual R, L, G, and C and associated discretized characteristic impedance values between adjacent sub-circuits as equal as possible, or 2 ) making the product of the series impedances and the shunt admittances as equal as possible.
Further still, the non-uniform stub transmission line sections may be converted into a series of discretized RLGC sub-circuits. The physical dimensions of the stub section components associated with each sub-circuit may be manipulated until the values of R, L, G, and C are optimized. In the case of a single via, such optimization of a non-uniform stub transmission line section is generally equivalent to making the magnitudes of series R and series L as large as possible and the magnitudes of shunt G and shunt C as small as possible.
Finally, the S-parameters of the via structure after optimization may be calculated to verify the optimization results. The present invention allows for constraints on the continued manipulation of the physical characteristics of the vias to avoid minute improvements in performance at exponentially greater and greater monetary costs.
BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
FIG. 1 is a pair of cross-sectional views of a standard printed circuit board showing the individual internal layers and a corresponding view showing the internal connections between the layers including a plurality of vias;
FIG. 2 is a pair of cross-sectional views of a printed circuit board as in FIG. 1 with prior art modifications to the via structures for the enhancement of signal integrity performance;
FIG. 3 is a baseline cross-sectional view of a printed circuit board indicating the individual internal layers and a corresponding partial cross-sectional view showing microstrip and stripline transmission line cross sections for the upper three layers of such printed circuit board;
FIG. 4 is a partial cross-sectional view of a printed circuit board showing the views of the single-ended stripline of FIG. 3 , as well as, the division of such stripline into identical length segments and its equivalent electrical circuit;
FIG. 5 is a pair of cross-sectional views of a printed circuit board showing the individual internal layers and a corresponding view showing the internal connections between the layers including a via thru section with an adjacent return via, and the equivalent circuit for the plurality of vias;
FIG. 6 is a pair of cross-sectional views as in FIG. 5 for a via thru section without an adjacent return via and it's equivalent circuit; and
FIG. 7 is a flowchart outlining the basic methodology of the present invention.
Repeat use of reference characters throughout the present specification and appended drawings is intended to represent the same or analogous features or elements of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to presently preferred embodiments of the invention, examples of which are fully represented in the accompanying drawings. Such examples are provided by way of an explanation of the invention, not limitation thereof. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention, without departing from the spirit and scope thereof. For instance, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. Still further, variations in selection of materials and/or characteristics may be practiced, to satisfy particular desired user criteria. Thus, it is intended that the present invention cover such modifications and variations as come within the scope of the present features and their equivalents.
As disclosed above, the present invention is particularly concerned with a method for optimizing via structures for the enhanced high frequency performance of printed circuit boards and backplanes 10 . Vias 12 degrade the signal integrity performance of printed circuit board interconnects because they attenuate and distort analog, radio frequency, and digital signals that propagate through them. The present invention may be used to optimize individual component structures that make up a via 12 , a collection of vias 12 , and even higher level interconnects such as printed circuit boards and backplane assemblies 10 containing vias 12 , interconnected traces, and connectors.
FIG. 1 shows a cross-section of a typical multi-layer printed circuit board 10 (PCB) with a plurality of vias 12 . A multi-layer PCB 10 is a printed board that consists of two or more planar conductive layers (L 1 , L 2 , L 3 , etc.) separated by one or more rigid or flexible planar insulating dielectric layers bonded together and electrically interconnected. An electrical connection between two or more patterns on different conductive layers is known as a via 12 . A buried via 14 is one that does not extend to the outer layers of a PCB 10 . A blind via 16 extends only to one outer layer. Blind and buried vias 14 and 16 are also known as interstitial vias. A plated through hole 18 (PTH) via extends through the entire PCB 10 (from the top outer layer to the bottom outer layer) and is capable of making electrical connection between conductive patterns on internal layers, external layers, or both.
A via 12 , regardless of its location, includes a number of components. At the least a via 12 includes a barrel 20 and one or more functional 22 or non-functional 24 pads. Where applicable, a via 12 may include a clearance region 26 (also called an anti-pad region) on those layers where the via 12 intersects that layer but must be electrically isolated from any conductive patterns located on such layer. A pad 22 or 24 is a localized conductive pattern that is electrically attached to the via 12 . If the pad 22 is also electrically connected to a conductive pattern (i.e., a signal trace, a ground or voltage plane, or a passive device, etc.) then it is a functional pad 22 .
FIG. 2 shows two methods currently in use to improve the signal integrity performance of a via 12 . It is common practice to remove non-functional pads 24 as a way to enhance the signal integrity performance of the via 12 . It is also common practice to remove the unused “stub” sections 28 of PTH vias 18 by backdrilling out the conductive portion of the via 12 that makes up the stub section 28 .
There are many problems with arbitrarily utilizing these commonly accepted methods without an optimization effort for each via 12 or the collection of vias 12 with a PCB or backplane 10 . There are situations where removing some of the non-functional pads actually degrades rather than improves signal integrity performance.
The method of the present invention involves subdividing the via 12 into one or more of the following three different kinds of sections: a transmission line bend section, a non-uniform transmission line thru section, and a loaded non-uniform transmission line stub section. Where possible the PCB stackup 10 should be designed so the stub section lengths 28 are minimized. The transmission line bend sections may be converted into lumped element series impedances and shunt element admittances, which are monotonically related to the scalable S-parameters of the circuitry including the non-optimized via 12 . Thus the iterative steps used in the process may be based on a straightforward sequential convergence algorithm.
The physical dimensions of the bend section components may be adjusted until several second-level characteristics of the section's electrically equivalent sub-circuit are optimized. Non-uniform transmission line thru sections and non-uniform stub transmission line sections may be converted into a series of discretized RLGC sub-circuits (see FIGS. 4–6 ). The physical dimensions of the thru section components associated with each sub-circuit may be manipulated until the values of R, L, G, and C are optimized.
To accomplish these conversions, signal traces and adjacent conductive plane regions may be formed into planar transmission lines as seen in FIG. 3 . A planar transmission line is a wave-guiding structure whose fundamental mode of propagation along the transmission line is essentially a transverse electromagnetic wave. Planar transmission lines suitable for transmission of high frequency or narrow pulse electrical signals have defined conductor and dielectric material dimensions and shapes that are uniform along their length. Transmission lines can be described by an equivalent electrical circuit composed of distributed resistance, inductance, conductance, and capacitance elements (i.e., an RLGC sub-circuit). A microstrip transmission line 32 configuration consists of a conductor that is positioned over and parallel to a conductive plane with a dielectric therebetween. A stripline transmission line 34 configuration consists of a conductor that is positioned between and parallel to two conductive planes with a dielectric among them. A balanced transmission line 36 is a two-conductor transmission line that has distributed resistance, inductance, conductance, and capacitance elements equally distributed between its conductors. An unbalanced transmission line 38 is a transmission line that has distributed resistance, inductance, conductance, and capacitance elements not equally distributed between its conductors. Non-equal trace widths are one way to create an unbalanced transmission line 38 . It is common practice to denote the signal trace layer as the reference layer for microstrip 32 and stripline 34 transmission line structures. In FIG. 3 , the single ended microstrip, the balanced differential microstrip, and the unbalanced differential microstrip are located on layer L 1 , even though the conductive plane on L 2 forms part of the transmission line structure. In a similar fashion, the single-ended stripline, balanced differential stripline, and unbalanced differential stripline are located on L 3 , even though the conductive planes on layers L 2 and L 4 also form part of the transmission line structure.
Because microstrips 32 and striplines 34 are uniform guided wave structures (e.g., their cross-sections do not change with distance along the line), they can be used to model the impact of signals propagating down the line through a series of identical lumped-element RLGC circuits 40 . As best seen in FIG. 4 and using the single-ended stripline 34 of FIG. 3 as an example, a transmission line is first divided into infinitesimally small increments, ΔZ. An electrically equivalent circuit 40 may be created based on the four physical phenomena all transverse electromagnetic wave mode transmission lines have in common. The series resistance, R, is used to quantify the conversion of signal power into heat inside the conductive regions of the transmission line. The shunt conductance, G, is used to quantify the conversion of signal power into heat inside the dielectric regions of the transmission line. Because transmission lines are guided wave structures, the bulk of the power contained in the propagating signal is in the electric and magnetic fields that exist in the dielectric regions surrounding the conductive portions of the transmission line. The capacitance, C, is used to quantify the impact the transmission line has on the electric field. A similar relationship exists between inductance, L, and the magnetic field. Altering the size and shapes of the conductors and dielectric materials used to create the transmission line will alter the values of R, L, G, and C.
When uniform transmission lines (such as microstrip 32 and stripline 34 interconnect traces) are connected to a via 12 , the via 12 and its localized surroundings may be divided into three different vertical regions: one or more bend regions, one or more stub regions, and one or more thru regions. The top and bottom surfaces that comprise these regions depend on the PCB stackup 10 and which layers incoming and outgoing planar transmission lines are routed on. A via bend section is that region of a via 12 connected to a planar transmission line. A bend signifies that the direction of the currents associated with the signal must change directions. In other words, the signal currents flowing horizontally along the interconnect traces must now flow vertically through the via 12 . As a general rule, the bend section consists of the vertical section of the via 12 located on the same layers used to create the signal trace transmission line structures. Because microstrip transmission lines 32 need two layers, a bend associated with a microstrip 32 encompasses at least two layers.
Similarly, a via stub section 28 is that portion of a via 12 which has one end that is not terminated. A via thru section or a via bend section cannot be part of a via stub section 28 . A via thru section is that portion of the via 12 which is required in order to complete an electrical circuit between an incoming and outgoing signal transmission line but is not part of a bend section. The electric and magnetic fields associated with the signal passing through the via 12 often extend into the regions between the conductive layers beyond the anti-pad boundary 26 .
When optimizing a via 12 one must include these regions 26 if the electric and magnetic fields contain a significant percentage of the energy contained in the signal. The penetration distance is dependent on a number of factors including the size and shape of the pad 22 and 24 and anti-pad 26 regions and thickness of both the conductive and dielectric layers in the region of interest. In PCB regions where the via density is high, which is often the case underneath connectors and high pin-count integrated circuits, the electric and magnetic fields generated by adjacent vias 12 can and do co-mingle. In those cases, the optimization of a given via 12 may also require the optimization of adjacent vias 12 .
FIG. 5 depicts an example of the conversion of a two via structure 52 into discrete segments for optimization. In this example, two microstrip transmission lines 32 are connected to a plated thru hole (PTH) via 18 . A buried via 14 is used to provide a direct current return path for the two microstrip lines 32 . The buried via 14 is positioned very close to the PTH via 18 so the electromagnetic fields generated by the currents in the two vias 14 and 18 are coupled. The vertical distance between layers L 1 and L 2 form a bend region. The vertical distance between layers L 11 and L 12 form a bend region. The remaining portion of the via 18 , layers L 2 through L 11 , form the thru section. There are no stub sections 28 in this configuration. One can define an equivalent circuit 40 for the thru section by dividing up the total height into a chain of series RL segments 54 and shunt GC segments 56 . The series R value can be computed from the resistance losses associated with the via segments defined in the region.
The series inductance can be computed from the magnetic field generated by the propagating signal between layers L 2 and L 3 . The shunt capacitance can be computed from the electric field generated by the propagating signal surrounding layer L 3 . The series impedance increases with the increasing separation between layers. The shunt admittance is dependent on how close the ground plane is to any non-functional pads. The shunt admittance of layer L 6 is greater than the shunt admittance of layer L 7 . The thickness of the conductive planes also impacts the shunt admittance. A thicker conductive layer has a lower admittance. Moving the conductive planes away from non-functional pads 24 , or removing a non-functional pad 24 increases the shunt admittance. Since optimization of the thru section generally requires the discretized characteristic impedance between the individual discretized RLGC circuits 40 to be as equal as possible, the pad 22 and 24 and anti-pad 26 diameters must be adjusted as needed to compensate for differences in dielectric material thickness, conductor thickness, etc. If adjustments of the pad/anti-pad diameters do not provide sufficient degrees of freedom, then the dielectric layer heights may require adjustment.
Note that a given transmission line structure is not limited to the four RLGC values noted herein. As long as expressions for series impedance and shunt admittance can be derived, the lumped element characteristic impedance of the transmission line structure can be calculated. As an example, consider the single via structure 62 shown of FIG. 6 . In such a case, there is no adjacent DC return current via, and the equivalent circuit 40 includes a series capacitance, C pp , that provides a return path for an AC displacement current.
Also note that as the frequency increases, the discretized characteristic impedance approaches that obtained for the two-via case 52 described above. If the DC return via in the two-via case 52 is not in the immediate vicinity of the via 12 being analyzed, then the model defined by FIG. 6 must be used. The important point to make here is that once a given via structure 62 is defined, it is possible to convert it into an discretized non-uniform transmission line structure on which known calculations may be performed to optimize the physical characteristics of the via 12 or collection of vias 12 .
FIG. 7 provides a flowchart 70 of the present invention's methodology for optimizing the high frequency performance of via structures 12 . As the present invention is primarily concerned with improving signal integrity, the first step of the process 72 is to choose a parameter that may be calculated to evidence improvement in the printed circuit board's signal integrity by manipulating the physical characteristic of the vias 12 . One such parameter is the S-parameter. Due to their inherent difficulty to calculate in an iterative process where equivalent electrical representations of physical parameters are being evaluated, the S-parameters are best represented in terms of series impedances, shunt admittances, or series discretized RLGC sub-circuits, where the values of R, L, G, C and the admittances and impedances may be quickly calculated. These may be chosen as the second level parameters 74 to determine optimization.
In order to calculate the second level parameters, the via must be subdivided into one of several types of transmission line segments 76 . These include transmission line bend sections, non-uniform transmission line thru sections, and loaded non-uniform transmission line stub sections, as necessary, to generate an electrical circuit equivalent to said at least one via structure. To ease the calculations and reduce reflective signal effects the stub section lengths of the vias should be minimized where possible 78 .
The transmission line segments may then be converted 80 into equivalent series impedances, shunt admittances, or and a series of discretized RLGC sub-circuits comprised of one or more resistors, R, inductors, L, conductors, G, and capacitors, C. The second level parameters for these equivalent circuits may be calculated as a baseline 82 . The physical characteristics of the vias 12 are then manipulated in a first direction 84 (i.e., increase or decrease the size of the hole or change its shape). The second level parameters are then recalculated 86 to determine if their values are moving in a direction desired by the user.
If the second level parameter values are moving towards an optimized value 88 , the physical characteristics of the vias may be further altered in the same manner 90 (i.e., if previously made smaller, make it smaller still) until such time that the calculated values of the second level parameters are either optimized 92 or until further optimization is cost prohibitive. If the second level parameters are not moving towards an optimized value 94 , the physical characteristics of the vias may be moved in the other direction 96 (i.e., if made smaller, then make it bigger) until such time the calculated values of the second level parameter are either optimized 100 or until further optimization becomes cost prohibitive. Optionally, the top level parameters may be calculated to ensure a high frequency performance improvement in the printed circuit board through the via's optimization.
Although a preferred embodiment of the invention has been described using specific terms and devices, such description is for illustrative purposes only. The words used are words of description rather than of limitation. It is to be understood that changes and variations may be made by those of ordinary skill in the art without departing from the spirit or the scope of the present invention, which is set forth in the following claims. In addition, it should be understood that aspects of various other embodiments may be interchanged both in whole or in part. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred version contained herein.
|
A method for enhancing the high frequency signal integrity performance of a printed circuit board (PCB) or backplane is provided. According to one embodiment of the present invention, the method involves the use of S-parameters as the primary cost factors associated with an iterative process to optimize the physical dimensions and shape of a single or a collection of vias within the PCB or backplane. In certain embodiments, the process involves the representation of the via components as equivalent lumped series admittances and impedances, as well as, RLGC sub-circuits upon which basic circuit analysis is performed to optimize secondary characteristics, for example, the maximization of the sub-circuit's resistance and/or the minimization of the sub-circuit's capacitance. The iterative process involves the alteration of physical dimensions and the shape of the via components such that the secondary characteristics are optimized.
| 7
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a rotary compressor, particularly to a variable-delivery vane-type rotary compressor which may be used as a refrigerant compressor for an air conditioner for a vehicle or the like.
2. Description of the Background Art
Generally, in order to control discharge in vane-type rotary compressor, a suction port being in communication with the interior of a cam ring is provided on a side-block which covers one end of the cam ring and the position of the suction port is changed, so that the starting position of compression caused by rotation of the vanes is changed.
For example, a variable-delivery vane-type rotary compressor, which is a background art of the present invention, includes an arc-shaped by-pass port, which is provided in a front plate so as to extend beside the cam surface of a cam ring, the end opening of which may open on any radial section of a working chamber, and a rotatable disc having an arc-shaped opening between the front plate and the cam ring. In this compressor, the rotatable disc may rotate by means of an electric motor provided within or outside the compressor so as to change the position of by-pass opening in order to control discharge.
However, since the rotatable disc rotates by means of the motor in these compressors, there is a disadvantage in that power consumption is increased. In addition, since various sensors, such as a pressure sensor, a temperature sensor and an air-quantity sensor, and electrical control circuits are used in order to control actuation of the motor, there are disadvantages in that construction of the compressor is complicated and the manufacturing cost is increased.
SUMMARY OF THE INVENTION
It is therefore a principal object of the present invention to eliminate the aforementioned disadvantage and to provide a rotary compressor which can automatically adjust its discharge according to the cooling load of an air conditioner. Another object of the invention is to provide a rotary compressor which has simple construction and which can decrease the manufacturing cost and fuel cost for an engine.
In order to accomplish the aforementioned and other specific objects, a rotary compressor, according to the present invention, includes passage means for defining a by-pass passage establishing communication between a low-pressure chamber and a compression chamber, the by-pass passage having end openings exposed to the low-pressure chamber and the compression chamber; and control means for mechanically controlling the amount of fluid by-passed from the compression chamber to the low-pressure chamber through the by-pass passage in accordance with pressure in the low-pressure chamber and a high-pressure chamber.
According to one aspect of the invention, a rotary compressor comprises:
a compressor housing defining therein an internal space which includes a low-pressure chamber connected to a low-pressure fluid source and a high-pressure chamber connected to a load;
introducing means for introducing a low-pressure fluid into the low-pressure chamber;
compression means for compressing the low-pressure fluid to a predetermined higher pressure, the compression means including a compression chamber for introducing the low-pressure fluid thereinto for compression;
passage means for defining a by-pass passage establishing communication between the low-pressure chamber and the compression chamber, the by-pass passage having end openings exposed to the low-pressure chamber and the compression chamber;
rotary closure member associated with one of the end openings of the by-pass passage for varying the open area of the end opening so as to control the amount of the low-pressure fluid by-passed from the compression chamber to the low-pressure chamber through the by-pass passage; and
actuating means for actuating the rotary closure member and for mechanically controlling the amount of the low-pressure fluid, which is by-passed from the compression chamber to the low-pressure chamber through the passage means, in accordance with pressures in the low-pressure and high-pressure chambers.
The rotary closure member may comprise a disc-shaped member in which a by-pass opening is provided at the circumference thereof, the disc-shaped member being rotatably provided on the peripheral wall of the compression chamber. The by-pass opening is preferably an arc-shaped opening extending beside the outer periphery and the end opening of the by-pass passage is preferably a long arc-shaped opening corresponding to the by-pass opening.
The actuating means may comprise:
an actuator cylinder, in which a piston is housed, the piston causing the disc-shaped member to rotate;
a control valve supplying pressure to the actuator cylinder thereby actuating the piston;
a control cylinder having a control chamber which is in communication with the low-pressure chamber;
a control assembly which is provided in the control cylinder and which moves in the direction of the axis thereof in accordance with pressures in the low-pressure and high-pressure chambers so as to actuate the control valve.
The control valve may comprise a poppet valve connected to the control assembly and a ball valve which can be in communication with the high-pressure chamber. The ball valve is preferably opened to allow the rotary closure member to rotate by means of the actuator cylinder so as to increase the open area of the end opening of the by-pass passage when discharge of the compressor is excessive relative to the cooling load of an evaporator connected to the compressor and wherein the poppet valve is opened to allow the rotatable disc to rotate by means of the actuator cylinder so as to decrease the open area of the end opening of the by-pass passage when discharge of the compressor is not enough to satisfy the cooling demand of the evaporator. The control assembly may comprise a bellows and a coil spring, a piston or a diaphragm.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood more fully from the detailed description given herebelow and from the accompanying drawings of the preferred embodiment of the invention. The drawings are not intended to imply limitation of the invention to this specific embodiment, but are for explanation and understanding only.
In the drawings:
FIG. 1 is a sectional view of the preferred embodiment of a variable-delivery vane-type rotary compressor according to the present invention;
FIG. 2 is a sectional view of the compressor taken along the line X--X in FIG. 1;
FIG. 3 is a perspective view of a rotatable plate used in the compressor;
FIG. 4 is a front sectional view of an actuator cylinder used in the compressor;
FIGS. 5 and 6 are front sectional views of a control assembly and control valves used in the compressor; and
FIG. 7 is a schematic view showing operation of the control assembly and the control valves.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, particularly to FIGS. 1 and 2, a variable-delivery vane-type rotary compressor, according to the present invention, includes a cylindrical cam ring 1. A cam surface 1a, which has an essentially elliptical cross-section, is formed on the inside surface of the cam ring 1. The cam ring 1 is equiped with front and rear plates 2 and 3 at both of open ends in order to cover the open ends of the cam ring 1. A cylindrical rotor 4 is rotatably housed in the cam ring 1 between the front and rear plates 2 and 3. A plurality of vanes 5 are inserted into the rotor 4. The vanes 5 can move inwardly and outwardly so as to be in slidable contact with the cam surface 1a. The cam ring 1, the front and rear plates 2 and 3, the rotor 4 and vanes 5 are housed in a cylindrical housing 6 having a bottom. The front open end of the housing 6 is covered with a head cover 7 which is fixed to the housing 6 by means of a bolt.
A pair of working chambers 10 are formed by the cam ring 1, the front and rear plates 2 and 3 and the rotor 4. As shown in FIG. 2, the working chambers 10 respectively are in communication with a pair of suction ports 11, the end openings of which are formed in the cam surface 1a. In addition, a pair of discharge ports 12 is formed on the cam ring 1 at a location corresponding to the clockwise end of the working chamber 10. The communication between a discharge chamber 13, which is formed in the housing 6, and the working chamber 10 is established by means of a discharge valve provided in the discharge port 12.
The aspirator chamber 14 is formed by the front plate 2 and the head cover 7. The head cover 7 is provided with an inlet 15 through which a refrigerant gas is supplied to the aspirator chamber 14. The refrigerant gas is supplied to each of the working chambers 10 through a pair of suction openings 16, which are formed on the front plate 2, and the suction port 11 formed in the cam ring 1.
In addition, a pair of arc-shaped by-pass ports 17 are formed on the front plate 2. As shown in FIG. 2, the by-pass port 17 extends along the working chamber 10 from a location, which is shifted clockwise from that of the verge 11a of the input port 11 beside the cam surface 1a, to a point near the discharge port 12 so as to establish the communication between the working chamber 10 and the aspirator chamber 14. A rotatable disc 18 is provided between the front plate 2, the cam ring 1 and the rotor 4. The rotatable disc 18 is rotatably supported about the axis of the rotor 4 so that the outer surface 18a of the rotatable disc 18 comes into contact with the inner surface 2a of the front plate 2. As shown in FIG. 3, the rotatable disc 18 is provided with a pair of arc-shaped by-pass openings 19 near the periphery thereof. The area of the by-pass port 17, which establishes the communication between the working chamber 10 and the aspirator chamber 14, can be adjusted by rotating the rotatable disc 18. When the area of the by-pass port 17 is increased, the amount of refrigerant by-passed from the working chamber 10 to the aspirator chamber 14 is increased so that the amount of discharge refrigerant is decreased. Conversely, when the area of the by-pass port 17 is decreased, the amount of discharged refrigerant is increased.
A ring plate 20 is provided between the front plate 2 and the head cover 7. The ring plate 20 comprises a plate portion 20a and a boss portion 20b. The plate portion 20a is in slidable contact with the opposing surface of the front plate 2 to the head cover 7 and the inner periphery of the boss portion 20b is in slidable contact with the outer periphery of the boss portion 2b of the front plate 2 so that the ring plate 20 can rotate. As shown in FIG. 2, the plate portion 20a of the ring plate 20 is provided with a pair of projecting portions 20c which project radially from the outer periphery of the plate portion 20a. The projecting portions 20c are connected to the rotatable disc 18 by means of a pair of actuating pins 21 which pass through the by-pass ports 17 of the front plate 2.
In addition, the head cover 7 is provided with an actuator cylinder 22. As shown in FIG. 4, the actuator cylinder 22 comprises a cylinder portion 23, a piston slidably inserted into a cylinder 23a of the cylinder portion 23, and an arm portion 26 connected to the piston 24 by means of a pin 25. The bottom end of the cylinder portion 23 is provided with a cylinder bottom 27. The cylinder bottom 27 is provided with a supply port 27a which is in communication with the interior of the cylinder 23a and to which pressure is supplied in order to actuate the piston 24. The actuator cylinder 22 is provided with a flange 27b which is used for mounting the actuator cylinder 22 on the head cover 7. The top end of the cylinder portion 23 is covered with a plate 28. A coil spring 29 is provided between the inside wall of the plate 28 and the piston 24 so as to bias the piston in the downward direction in FIG. 4. The end of the arm portion 26 is provided with a long groove 26a extending perpendicular to the axis of the pin 25. As shown in FIG. 2, the actuating pin 21 engages the groove 26a. When the piston 24 is moved along the axis thereof, the longitudinal movement of the piston 24 is transmitted to the rotatable disc 18 by means of the actuating pin 21 so that the rotatable disc 18 rotates about the axis of the rotor 4. Furthermore, the cylinder portion 23 is provided with a pair of slits 23b extending in the direction of movement of the arm portion 26 and the piston 24 so as to allow the piston to move smoothly.
FIGS. 5 and 6 show a control cylinder 20 provided in the head cover 7. A control assembly 31 is housed in the control cylinder 30 so as to be movable in the direction of the axis of the control cylinder 30. The control assembly comprises a bellows 33 and a coil spring 32. By means of the bellows 33, the interior of the control cylinder 30 is divided into a bellows chamber 33a formed in the bellows 33 and a pressure control chamber formed between the bellows 33 and the control cylinder 30. The bellows chamber 33a is maintained at an essentially vacuum pressure. On the other hand, the pressure control chamber is in communication with the aspirator chamber 14. In FIGS. 5 and 6, the left-hand end 34 of the control assembly 31 is in contact with the left-hand, inside wall 30a of the control cylinder 30. On the other hand, the right-hand end 35 of the control assembly 31 engages a poppet valve body 39. A coil spring 36 is provided between the right-hand, inside wall 30b of the control cylinder 30 and the right-hand end 35 of the control assembly 31 to allow the control assembly 31 to bias in the left-hand direction in the drawings so as to be balanced with the biasing force of the coil spring 32. As shown in FIGS. 5 and 6, a control valve 37, which comprises a poppet valve 38 and a ball valve 41, is also provided in the head cover 7. The poppet valve 38 comprises the poppet valve body 39 engaging the right-hand end 35 of the control assembly 31 and a poppet valve seat 40. The poppet valve 38 may be opened and closed in accordance with lengthwise movement of the control assembly 31. The ball valve 41 comprises a ball valve body 42, a ball valve seat 43, a spring washer 44 and a coil spring 45. The spring washer 44 is mounted on a wall 13a of the discharge chamber 13 which is in communication with the ball valve 41. The coil spring 45 is provided between the spring washer 44 and the ball valve body 42 so as to allow the ball valve body 42 to bias toward the ball valve seat 43. The tip of the poppet valve body 39 of the poppet valve 38 is connected to one end of a large diameter first needle portion 39a. The other end of the first needle portion 39a is connected to one end of a small diameter second needle portion 39b. The other end of the second needle portion 39b is in contact with the ball valve body 42 so that the ball valve 41 may be opened and closed in accordance with the longitudinal movement of the control assembly 31. In addition, a communication chamber 47 is formed so as to surround the connecting portion 39c disposed between the first needle portion 39a and the second needle portion 39b. The communication chamber 47 is in communication with a pilot-pressure supply opening 46 which is in communication with the supply port 27a of the actuator cylinder 22. The communication chamber 47 is also in communication with the poppet valve 38 and the ball valve 41 through first and second openings 48 and 49, respectively.
As shown in FIG. 1, a thrust bearing 50 is provided between the front plate 2 and the rotatable disc 18 in order to allow the rotatable disc 18 to rotate smoothly. Thrust load of the rotor 4, which thrusts rotatable disc 18 against the front plate 2, is applied to the thrust bearing 50 so that the rotatable disc 18 can rotate smoothly.
In addition, a circumferential groove 18c is formed on the inner periphery 18b of the rotatable disc 18. A seal member 52 is inserted into the groove 18c. The inner periphery of the seal member 52 is in slidable contact with a front-side shaft 4a of the rotor 4 and the outer periphery of the seal member 52 is in slidable contact with the inner periphery 18d of the groove 18c. The seal member 52 may prevent the medium-pressure refrigerant or lubricating oil in the groove of the rotor 4, in which the vanes are inserted, from running into the aspirator chamber 14 or a bearing 53 which supports the shaft 4a of the rotor 4.
Referring to FIG. 7, operation of the invention is described below.
The revolving shaft of the rotor 4 may be connected to an engine of a vehicle or the like to be actuated. When the rotor 4 is actuated to rotate clockwise in FIG. 2, the vanes 5 project radially due to centrifugal force and back pressure of the vanes 5. As a result, the tips of the vanes 5 remain in contact with the cam surface 1a of the cam ring 1 as they rotate. Refrigerant gas is supplied to the interior of the compressor through the inlet 15. The refrigerant gas is compressed to become high-pressure, high-temperature gas to be supplied to an evaporator not shown through the discharge chamber 13. In this case, when refrigerant gas supply exceeds demand of the evaporator, for example, when discharge of the compressor is excessive relative to the cooling load of the evaporator, the pressure of the refrigerant gas, which returns from the evaporator to the compressor, is decreased since a part of liquid refrigerant is not changed to refrigerant gas to transferred to the compressor. Therefore, the inlet pressure of the compressor is decreased so that the pressure in the control cylinder 30 is decreased. As shown in FIG. 6, when the pressure in the control cylinder 30 is decreased, the biasing force of the coil spring 32 of the control assembly 31 becomes larger than that of the coil springs 36 and 45 so that the right-hand end 35 of the control assembly 31 is longitudinally moved in the direction of the arrow A 1 in FIG. 7. As a result, the poppet valve 38 is closed and the ball valve 41 is opened. As shown in FIG. 7, the pressure in the discharge chamber 13, i.e. the discharge pressure of the high-pressure compressor is supplied to the cylinder 23a of the actuator cylinder 22 through the second opening 49, the communication chamber 47, the pilot-pressure opening 46 and the supply port 27a of the actuator cylinder 22, so that the piston 24 is upwardly moved in the direction of the arrow A 2 against the biasing force of the coil spring 29. As a result, the rotatable disc 18 rotates in the direction of the arrow A 3 to increase the area of the by-pass port 17 to decrease the discharge of the compressor, so that the optimum amount of refrigerant gas can be supplied to the evaporator. On the other hand, when discharge of the compressor is not enough for the cooling load of the evaporator, the pressure of the refrigerant gas returned from the evaporator to the compressor is increased. Therefore, the inlet pressure of the compressor is increased, so that the pressure of the control cylinder 30, which is in communication with the aspirator chamber 14, is increased. As shown in FIG. 5, when the pressure in the control cylinder 30 is increased, the biasing force of the coil springs 36 and 45 becomes larger than that of the coil spring 32 of the control assembly 31 so that the control assembly 31 is longitudinally moved in the direction of the arrow B 1 in FIG. 7. As a result, the ball valve 41 is closed and the poppet valve 38 is opened due to the biasing force of the coil spring 45. As shown in FIG. 7, when the poppet valve 38 is opened, high-pressure in the cylinder 23a of the actuator cylinder 22 is supplied to the pressure in the control cylinder 30, i.e. the low, inlet pressure of the compressor through the supply port 27a of the actuator cylinder 22, the pilot-pressure opening 46, the communication chamber 47 and the first opening 48, so that the piston 24 is downwardly moved in the direction of the arrow B 2 due to the spring force of the coil spring 29. As a result, the rotatable disc 18 rotates in the direction of the arrow B 3 to decrease the area of the by-pass port 17 to increase the discharge of the compressor, so that the optimum amount of refrigerant gas can be supplied to the evaporator.
A process for controlling the discharge according to the cooling capacity is described below. For example, in cases where the compressor is actuated when the temperature surrounding the evaporator is high, i.e. when the outside air temperature and the temperature in the vehicle are high in summer, large amount of refrigerant gas is required for cooling, so that the flow from an evaporator to the compressor is increased, thereby the pressure of the refrigerant gas supplied to the compressor is increased. In this case, the control assembly 31 is moved in the left-hand direction, so that the ball valve is closed. When the ball valve is closed, the pressure in the actuator cylinder 22 becomes low, so that the piston is moved downwardly. When the piston is moved downwardly, the rotatable disc 18 rotates counterclockwise, so that discharge of the compressor is increased. When the compressor is actuated to supply large discharge, the temperature in the vehicle is decreased so that the cooling load required is decreased. Therefore, the inlet pressure is decreased. On the other hand, since the discharge pressure in the discharge chamber 13 is increased, the discharge pressure of the compressor supplied to the ball valve body 42 of the ball valve 41 is increased so that the biasing force for closing the ball valve 41 is increased. Therefore, in order to decrease the discharge flow, smaller inlet pressure is required. As a result, since the compressor is actuated while it supplies large discharge, the interior of the vehicle may be fully cooled. In this case, the flow of the refrigerant passing through the pipe line between the evaporator and the compressor of the air conditioner is increased, so that the pressure loss in the pipe line is increased, thereby the inlet pressure is decreased. Therefore, large discharge may be maintained.
Conversely, when the temperature surrounding the vehicle is low, i.e. when the outside air temperature is low and the only humidity within the vehicle is to be decreased, the flow from the evaporator to the compressor is decreased so that the inlet pressure of the compressor is decreased since the flow of the refrigerant gas required is not so large. Therefore, the control assembly 31 is moved in the right-hand direction, so that the ball valve 41 is opened, thereby the pressure in the actuator cylinder 22 is increased to allow the piston 24 to move upwardly. As a result, the rotatable disc 18 rotates clockwise by means of the ring plate 20, so that the compressor is actuated to supply a small discharge. Since the dischare is small, the pressure in the discharge chamber 13 is decreased, so that the biasing force, by which the ball valve 41 is closed, is decreased. Therefore, in order to increase the discharge, higher inlet pressure is required. As a result, since the compressor can actuate while it supplies small discharge, it is possible to decrease power loss.
In the aforementioned preferred embodiment, although the bellows 33 is used in the control assembly, a piston, a diaphragm or the like can be substituted for the bellows 33.
While the present invention has been disclosed in terms of the preferred embodiment in order to facilitate better understanding of the invention, it should be appreciated that the invention can be embodied in various ways without departing from the principle of the invention. Therefore, the invention should be understood to include all possible embodiments and modifications to the shown embodiments which can be embodied without departing from the principle of the invention set out in the appended claims.
|
A variable-delivery vane-type rotary compressor includes passage means for defining a by-pass passage establishing communication between an aspirator chamber and a compression chamber, the by-pass passage having end openings exposed to the aspirator chamber and the compression chamber; and control means for mechanically controlling the amount of fluid by-passed from the compression chamber to the aspirator chamber through the passage means in accordance with pressure in the aspirator chamber and a discharge chamber.
| 5
|
BACKGROUND OF THE INVENTION
This invention relates to a permanent magnet actuator mechanism of the type described in my U.S. application Ser. No. 09/802,423 filed Mar. 9, 2001. In particular, the subject matter of this application relates to a valve unit having a permanent magnet actuator mechanism for displacement of a valve member between an open position and a closed position. The dual-magnet valve unit of this invention is fluid driven and includes an outer casing or housing such that the valve unit is a compact, self-contained unit that can be incorporated in a variety of applications requiring an on-off valve.
In operation, a first permanent magnet member co-acts with a second permanent magnet member in a master/slave relationship. The permanent magnet members in certain embodiments are positioned with the magnet members in mutual magnetic repulsion wherein displacement of one of the permanent magnet members automatically effects opposite displacement of the other of the permanent magnet members. In displaceable embodiment the magnet members are positioned in mutual attraction wherein displacement of one of the permanent magnet members automatically effects displacement of the other of the permanent magnet members in the same direction.
In a basic system the use of mutually displaceable permanent magnet members enables one of the permanent magnet members to be isolated by a barrier from the other permanent magnet member. This relationship is ideal where it is desired to isolate a fluid or gas from external contamination. In such a situation the displaceable valve member may be contained in a fluid conduit and magnetically displaced by the displacement of an external permanent magnet member external to the fluid conduit.
SUMMARY OF THE INVENTION
The dual-magnet valve unit of this invention incorporates certain of the concepts described in U.S. patent application Ser. No. 709/802,423, filed Mar. 9, 2001.
In the referenced application there is described an embodiment of a valve with an isolated slidable spool carried on one magnet member that is displaced on displacement of another magnet member. The second magnet number is separated from the first magnet member by a wall of a conduit in which the fluid to be regulated is transported. Each of the two magnet members is preferably an assembly of permanent magnets and pole pieces configured and arranged within a containment structure to maintain a magnetic repulsion that is effected dynamically on translocation of the magnet members.
In the valve embodiment of the referenced application, the prime mover to effect the translocation is an electromagnetic coil system. The coil system on activation is designed to generate a magnetic field to interact with the magnetic field of the second or outer magnet member to shift the magnet member and hence automatically displace the magnetic spool member in an opposite direction. The coil system is designed to allow this process to be reversed to return the magnetic spool member to its first position. When the spool member is located in one position or the other, no energy is required in the coil system to maintain the spool member in position.
As noted in the referenced description, other means may be employed as the prime mover. In many industrial environments, hydraulic or pneumatic control systems are available as a means to control or regulate components of system processes. Use of a fluid medium to actuate the dual-magnet unit of this invention enables a compact, relatively inexpensive valve unit to be constructed. The unit described in this application is adapted to include springs, if desired. However, typically in a fluid actuated unit, the power necessary to displace the master magnet member is readily available, and refinements in the force profile by use of springs is generally not necessary.
In translocation of the magnet members, substantial momentum is generated even though the distances of displacement are relatively small. When applied as a valve unit, the valve member displaces to a closure position and contacts a valve seat. The permanent magnets and poles forming the dis placeable spool member add a substantial mass that results in a significant momentum that must be dissipated on impact on the valve seat. In certain embodiments of this invention, the valve unit is improved by a spool design in the form of a poppet plunger having an integral shock absorber to absorb the repeated impact on each closure of the valve.
Translocation of the magnet members is preferred in a system where the prime mover is an electromagnetic coil system. Use of a coil system to maintain and not simply switch the position of the master magnet member is preferably avoided to prevent burn-out of the coil.
In a fluid activated system where the pressure of a motive fluid is continuously available, the master magnet member can be maintained in one of the two positions by use of the continuously available fluid pressure. In this situation magnetic attraction of the outer magnet member and inner magnet member can be used with codirectional location of the magnet members. To optimize the magnetic attraction to achieve the force of positioning of the slave member, particularly on closure of the valve, the master magnet member must be maintained at its stop position by the drive fluid. One advantage to this arrangement is that the slave member follows this master member and avoids the impact of automatic translocation in a repulsion system. In this manner, the complex shock absorber can be omitted.
In addition, other features are provided including containment structures for the magnet and pole assemblies which alternately are permanently sealed by welding or sealed with static O-rings for disassembly. Additionally, novel configurations of the pole pieces are designed to facilitate assembly and improve the magnetic coupling force.
The improved dual-magnet valve unit is provided with a cam operated indicator to provide a visual check of the valve state to determine if the valve is open or closed. In this embodiment, there is also provided a mounting base with coupling terminals for the fluid lines of the motive fluid that actuates the displacement of the master magnet member. Furthermore, by selective design of a constricted passage for the supply of the motive fluid, the speed of actuation of the master magnet member can be controlled and tailored for different applications.
The improved dual-magnet valve unit of this invention utilizes low cost cylindrical parts for the housing, which forms a chamber for the encased master magnet member to be displaced in the manner of a piston by selective supply of motive fluid. The motive fluid can be liquid or gas and the unit is particularly adapted to operate with pneumatic air systems common to industrial processing operations. The dual-magnet valve unit of this invention is designed as a general application valve unit where the transported fluid must be accurately measured and/or must be free from external contamination.
In the embodiments described, the first and second magnet members are each an assembly of five or six magnets. It is to be understood that the number of permanent magnets, and hence pole pieces, may vary according to the application and closure force needed for a particular pressure of the transport fluid.
These and other features are apparent from a consideration of the detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a first embodiment of the dual-magnet valve unit of this invention.
FIG. 2 is a cross-sectional view of the dual-magnet valve unit of FIG. 1 .
FIG. 3 is a cross-sectional view of the outer magnet ring assembly of the dual-magnet valve unit of FIG. 2 .
FIG. 3A is an end view of a ring pole in the outer magnet ring assembly of FIG. 3 .
FIG. 4 is a cross-sectional view of the transport fluid conduit assembly and inner magnet disk assembly of the dual-magnet valve unit of FIG. 2 .
FIG. 4A is an enlarged view of part of the magnetic disk assembly of FIG. 4 .
FIG. 5 is a perspective view of the plunger stop element of the dual-magnet valve unit of FIG. 2 .
FIG. 6 is a perspective view of the poppet member of the dual-magnet valve unit of FIG. 2 .
FIG. 7 is a perspective view of a second embodiment of the dual-magnet valve unit.
FIG. 8 is a cross-sectional view of the dual-magnet valve unit of FIG. 7 .
FIG. 9 is a cross-sectioned view of a third embodiment of the dual-magnet valve unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The fluid driven, dual-magnet valve unit of this invention, is designated generally by the reference numeral 10 . A first basic embodiment of the dual-magnet valve unit 10 is described with reference to FIGS. 1–4 and is identified by the reference numeral 12 . A second mountable embodiment of the dual-magnet valve unit 10 is described with reference to FIGS. 7 and 8 and is identified by the numeral 14 . A third embodiment of the dual-magnet valve unit 10 that utilizes magnetic attraction, and is described with reference to FIG. 9 and is identified by the reference numeral 250 .
Referring to the exploded view of FIG. 1 , the basic bistable dual-magnet valve unit 12 has a containment housing 16 comprising an outer casing 18 with a removable end cap 20 . The outer casing 18 and end cap 20 contain a displaceable first magnet member 22 comprising an outer magnet ring assembly 24 and a displaceable second magnet member 26 comprising an inner magnet disk assembly 28 .
Isolating the annular outer magnet ring assembly 24 from the cylindrical inner magnet disk assembly 28 is a transport fluid conduit assembly 30 . The transport fluid conduit assembly 30 comprises a high pressure cylindrical tube 32 having first and second specialized end fittings 34 and 36 , which provide for connection of conventional fittings of a fluid line (not shown) for the controlled fluid transported through the dual magnet actuator unit. It is to be understood that the controlled transport fluid is the liquid or gas that is regulated by the bistable valve unit of this invention and differs from the drive fluid which is a liquid or gas that is employed as the pressure medium that comprises the external prime mover for actuating the valve unit.
The transport fluid conduit assembly 30 contains the second inner magnet disk assembly 28 and isolates the transport fluid from the first outer magnet ring assembly 24 and prevents the transport fluid from contact with or contamination by the drive fluid. For example, the pressurized drive fluid comprises air in a pneumatic system that actuates the valve unit for a liquid in a processing system where the liquid flow is required to start and stop. As noted in the referenced patent application, the hermetically isolated inner magnet disk assembly acting as a valve poppet does not affect the volume of the transport fluid unlike a typical globe valve or gate valve where the valve stem enters into and withdraws from the transport fluid during closing and opening of such valves.
Referring in addition to FIG. 2 , the cross-sectional view of the basic dual-magnet valve unit 12 illustrates the assembled components which are substantially symmetrical about a common axis. The outer casing 18 , however, has side entry ports 38 and 40 for connection of conventional fittings (not shown) for the drive fluid supply lines 42 and 44 .
The supply of the pressurized drive fluid is regulated by a conventional control system for selective delivery of a pressurized drive fluid to one of the two entry ports 38 and 40 for displacement of the outer magnet ring assembly 24 in an annular chamber 46 . The annular chamber is defined by the inner wall 48 of the outer casing 18 , a unitary containment end 50 of the outer casing 18 , the removable casing end cap 20 and the cylindrical tube 32 of the conduit assembly 30 .
The annular chamber 46 is effectively divided into two compartments 52 and 54 by an O-ring seal 56 that seats in a groove 58 in a raised perimeter seal seat 60 in a casing 62 of the outer magnet ring assembly 24 . The entry ports 38 and 40 communicate with the compartments 52 and 54 , respectively, by a constricted passage 63 , which is sized to control the speed of actuation. Other valving in the drive fluid control system may provide an alternate means of controlling the actuation as desired.
The outer magnet ring assembly 24 functions in the manner of a floating piston between end stops 64 and 66 . The end stops 64 and 66 limit the displacement of the outer magnet ring assembly 24 and are formed by the inside wall 68 of the containment end 50 of the outer casing 18 and the inside wall 70 of the end cap 20 .
In operation, when the pressurized drive fluid is admitted through port 40 with pressure in port 38 relieved, the outer magnet ring assembly 24 is driven to the inside wall 68 of the containment end 50 of the outer casing 18 as shown in FIG. 2 . Notably, the inner magnet disk assembly 28 is automatically driven by magnetic repulsion to its displacement limit in the opposite direction. When the pressurized drive fluid is admitted through port 38 with pressure in port 40 relieved, the outer magnet ring assembly 24 is driven to the opposite stop 66 against the inside wall 70 of the end cap 20 . Again, by magnetic repulsion the inner magnet disk assembly 28 is automatically displaced to its opposite displacement limit.
The removable end cap 20 permits installation of the outer magnet ring assembly 24 and may be press-fit to the outer casing 18 with an O-ring seal 72 as shown, or secured by threading, or alternately by soldering, brazing or welding for a permanent assembly.
Referring also to FIG. 3 , the annular casing 62 of the outer magnet ring assembly 24 has a first end 74 with a circular opening 76 sufficiently large to slidably engage the high pressure cylindrical tube 32 of the transport fluid conduit assembly 30 and sufficiently small to seat a first ring pole 78 a of the six alternating ring poles 78 and five ring magnets 80 of the magnet subassembly 82 of the outer magnet ring assembly 24 . The opening 76 has an internal groove 84 to seat an O-ring seal 86 for sealing the magnet subassembly 82 from the drive fluid contained in the annular chamber 46 .
It is to be understood that the O-ring seals used in the bistable dual-magnet valve unit 10 may be replaced with other seals or packings depending on the application of the unit. Also, as noted certain seals may be eliminated where components are permanently joined by soldering, brazing or welding.
The opposite end 88 of the casing 62 of the outer magnet ring assembly 24 has a circular opening 90 sized to permit installation of the ring poles 78 and ring magnets 80 . The magnet subassembly 82 is retained by an annular end cap 92 and retainer clip 94 that seats in a groove 96 in the opening 90 . A spacer 98 between the end cap 92 and the end ring pole 78 b is sized to clamp together the ring poles 78 and ring magnets 80 of the subassembly 82 on assembly.
To facilitate assembly and improve the magnetic flux directed at the inner magnet disk assembly 28 , the ring poles 78 have a slightly smaller inside diameter than the ring magnets 80 and include radial ears 99 as shown in FIG. 3A .
Referring also to FIG. 4 , the transport fluid conduit assembly 30 and contained inner magnet disk assembly 28 are shown in cross section without the other components for clarity. The specialized end fittings 34 and 36 at opposite ends of the high pressure tube 32 have an external hex head portion 100 for gripping with a wrench when connecting the carrier fluid line when installing the dual-magnet valve unit 10 in a system. This portion of the end fittings 34 and 36 can be tailored for the type of connector required for the carrier fluid line.
The end fittings 34 and 36 have differing internal portions 102 and 104 to accommodate the different functional ends 106 and 108 of the inner magnet disk assembly 28 .
The end fitting 34 has an internal fluid passage 110 that has a constricted internal port 112 to the internal chamber 114 of the fluid transport conduit assembly 30 . The blunt internal end face 116 forms a stop 117 for a corresponding plunger stop element 118 . As shown in the perspective view of FIG. 5 , the plunger stop element 118 is in the form of a truncated cylindrical disk with chordal side faces 120 , and a gap 122 that forms a fluid by-pass 121 . Curved side faces 123 provide a slide guide for the displacement in the cylindrical tube 32 of the conduit assembly 30 . The plunger stop element 118 is secured on a post 119 of an end cap 124 that is connected to a cylindrical plunger casing 126 for containing the inner magnet subassembly 128 of the inner magnet disk assembly 28 . The assembled inner magnet disk assembly 28 forms a poppet plunger.
The magnet subassembly 128 has a spacer 130 at the end of an alternating series of disk poles 132 and disk magnets 134 . The plunger casing 126 is spaced from the high pressure tube 32 of the conduit assembly 30 to provide transport for fluid flow and this creates part of the gap between the outer magnet subassembly 82 and the inner magnet subassembly 128 . The series of six disk poles 132 and five disk magnet 134 are arranged for magnetic repulsion with the ring poles 78 and ring magnets 80 of the outer magnet subassembly 82 as taught in the referenced patent application.
The end fitting 36 has the internal portion 104 formed with an internal passage 138 having a constricted port 140 with a flared or conical valve seat 142 . The inner magnet disk assembly 28 has a poppet member 144 with a specially formed cone 146 , shown in the perspective view of FIG. 6 . The cone 146 preferably has the cross-sectional configuration of a gothic arch for strength and durability. The cone 146 provides the complimentary seating member for the valve seat 142 when the inner magnet disk assembly 28 operates as a poppet plunger and is displaced by magnetic force against the end fitting 36 . This force is maintained by the mutual magnetic repulsive forces and the cone 146 seats forcefully on the valve seat 142 to seal the internal passage 138 .
The plunger casing 126 is constructed similar to a shell casing with a unitary base 148 recessed from an end portion 150 that provides a socket for a shock absorber 151 as shown in greater detail in the enlarged view of FIG. 4A . The shock absorber 151 has a shock absorber cup 152 with a lip 154 having a seating flange 156 and locking ridge 158 to retain the cup 152 with the cup bottom 160 displaced from the base 148 of the plunger casing 126 . Similarly, the poppet member 144 has a base 162 with an enlarged end 164 that seats in the cup 152 with a substantially square flange 166 displaced from the seating flange 156 of the lip 154 of the cup 152 . The rounded corners 155 of the flange 166 of the poppet member 144 and the curved side faces 123 of the disk-shaped plunger stop element 118 are sized to slidably engage the inside wall 157 of the high pressure tube 32 .
Since the force required to seal the internal passage 138 may be considerable, depending on the transport fluid pressure, the dynamics of displacing the inner magnet disk assembly 28 or poppet plunger results in a substantial momentum that must be dissipated without damage to the cone 146 of the poppet member 144 . The flexure of the cup 152 to the plunger case base 148 , which acts as a stop, and the contact of the poppet member flange 166 against the cup seating flange 156 , which acts as a cushioned stop, absorb the shock of valve closure.
The use of the shock absorber 151 between the poppet member 144 of the plunger or inner magnet disk assembly 28 to cushion the impact of the cone 146 with the valve seat 142 of the conduit assembly 30 substantially improves the cycle life of the magnetic valve unit 10 . It is to be understood that a combination shock absorber and poppet member of different configuration may be designed according to the particular specifications of the environment of use including flow rates, fluid pressure, fluid consistency, and other parameters affecting design. This design selection also applies to the materials used in the valve unit where components are in contact with caustic or acidic transport fluids. For most applications stainless steel pressure tubes and fittings are preferred with the poppet member 144 fabricated of a polyether-ether keytone (PEEK™) and the shock absorber cup 152 fabricated from a polytetrafluoroethylene compound (TEFLON™). Housings, casings and other parts not in contact with the transport fluids may be fabricated from aluminum or other high-strength, light-weight material.
Referring now to the perspective view of FIG. 7 , the bistable dual-magnet valve unit 10 shown therein is an alternate mountable embodiment 14 . In FIG. 7 , and in the cross-sectional view of FIG. 8 , the elements and components of the valve unit 14 are identical to those of FIGS. 1–6 and are each identified by the same reference numeral except where modified and renumbered as set forth herein.
In FIGS. 7 and 8 , a modified outer casing 170 of the valve unit 14 seats in a cradle mount 172 . The outer casing 170 , as shown in FIG. 8 , has circumferential grooves 174 at each end which are engageable by a semi-circular angular ridge 176 on a raised end 178 of the cradle mount 172 and by a similar angular ridge 180 on an end plate 182 . The end plate 182 is coupled to the cradle mount 172 by screws 184 (shown in phantom) to clamp the casing 170 to the cradle mount 172 .
The cradle mount 172 has a curved bed 186 that is complimentary to the circular casing 170 . When the end plate 182 is secured to the cradle mount, the angled ridges 176 and 180 wedge the circular casing 170 firmly to the curved bed 186 . The cradle mount is provided with two recessed mounting holes 188 to attach the coupled valve unit 14 to a desired mounting surface.
A location pin 190 projecting from the bed 186 of the cradle mount 172 is positioned into a complimentary locator bore 192 in the casing 170 for properly orienting the outer casing 170 on the bed 186 . In this manner, the side entry ports 194 and 196 in the casing 170 are aligned with connecting ports 198 and 200 in the bed 186 of the cradle mount 172 . The ports 198 and 200 have seals 202 and communicate with passages 203 and 204 that connect with terminal ports 206 (shown in dotted line). The drive fluid lines thereby connect to the terminal ports at the side of the cradle mount 170 . Because of the relocation of the side entry ports 194 and 196 to accommodate the mounting holes and locator pin on the bed, side entry ports 194 and 196 communicate with an annular chamber 212 that is effectively divided into two compartments 214 and 216 by two O-rings 220 on a modified containment housing 222 of the outer magnet ring assembly 24 .
The modified dual-magnet valve unit 14 of FIGS. 7 and 8 includes a state indicator 224 for indicating whether the valve unit 14 is in an open or closed state. The indicator 224 is constructed with a shell 226 seated in the modified outer casing 170 . The shell 226 has a transparent lens 228 for viewing an indicator 230 projecting from a pivotal cam ring 232 . The cam ring has a cam member 234 that engages a central groove 236 in the modified containment housing 222 of the outer magnet ring assembly 24 . Linear displacements of the outer magnet ring assembly 24 translate to an 90° angular displacement of the cam ring 232 and indicator 230 . The indicator 230 has a suitable marking such as an arrow (not shown) to indicate the state of the valve unit 14 . It is to be understood that this feature can be included on the basic unit 12 without the cradle mount by suitable modification.
Referring to the cross-sectional view of FIG. 9 , an alternate embodiment of the dual-magnet unit 10 is shown and identified by the reference numeral 250 . The dual-magnet unit 250 utilizes magnetic attraction between the outer first magnet member 252 and a second inner magnet member 254 . Although similar in construction to the bistable dual-magnet units 12 and 14 of the previously described embodiments, the dual-magnet unit of FIG. 9 is not inherently bistable, requiring the continuous application of the drive fluid to maintain the full displacement of first outer magnet member for transfer of the magnetic attraction force to the inner magnet member 254 . The elements of the dual-magnet unit 250 are substantially the same as the elements of the prior embodiment and common reference numerals are used except for significantly modified structures. Notably, the permanent ring magnets 80 and disk magnets 134 are arranged with their polarity for mutual attraction, as represented by the composition arrows, as contrasted with the mutual repulsion of the units 12 and 14 shown in FIGS. 2 and 8 .
As shown in FIG. 9 , a modified outer casing 256 and connected end cap 250 house the outer first magnet member 252 , the second inner magnet member 254 and the transport fluid conduit assembly 30 . The outer first magnet member 252 is in the form of the annular outer magnet ring assembly 24 of FIG. 2 with a casing 62 having a raised seal seat 60 with an O-ring seal 56 to divide the annular chamber 46 into two compartments 52 and 54 . Each compartment has an entry port, 38 and 40 with a constructed passage 63 to controal the speed of actuation as previously described.
The outer magnet ring assembly 24 functions as a floating piston between end stops 64 and 66 as noted. However, to maintain the outer magnet ring assembly 24 against a particular end stop, the pressurized drive fluid initiating the displacement to the stop must be maintained. The inner magnet disk assembly 28 , with its shorter displacement distance, follows the outer magnet ring assembly 24 and is urged against one of the end fittings 34 and 36 . For simplicity, end fittings 36 is welded to the high pressure tube 32 of the transport fluid conduit assembly 30 . The opposite end fitting 34 retains the O-ring assembly as previously described to enable disassembly, if necessary. As noted, many of the O-ring, press fit or shrink fit connections can be replaced with premanent assemblies using soldering, brazing or welding.
The end fitting 36 has the internal passage 138 with the flared or conical valve seat 142 axially positioned for contact by the poppet member 144 . The poppet member 144 is in the form of a simplified cone 260 which seats in the end socket 262 of the plunger casing 126 . Since the inner magnet disk assembly 28 follows displacements of the outer magnet ring assembly 24 and is not translocated in the opposite direction as in the previously described embodiments, the velocity of displacement can be controlled and the shock absorber for the cone 260 is not required.
The inner magnet disk assembly 28 includes the plunger stop element 118 ; as previously described, which contacts the stop 117 formed by the end face 116 of the end fitting 34 .
The pressurized drive fluid is selectively admitted through ports 38 and 40 as previously described. However, while in the previous embodiments the pressure may be pulsed to effect the displacement and then relieved, in the embodiment of FIG. 9 , the pressure must be maintained in the selected compartment to maintain the outer magnet ring assembly 24 against one of the stops 64 and 66 to optomize the force of attraction with the inner magnet disk assembly 30 .
While, in the foregoing, embodiments of the present invention have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such detail without departing from the spirit and principles of the invention.
|
A dual-magnet valve unit having a first master magnet ring assembly with an outer casing slidably contained within an outer housing that forms a chamber with the casing of the master magnet ring assembly and a second, slave magnet disk assembly with an outer tube and a poppet member in the form of a cone and displaceable within the inner transport fluid conduit, the inner transport fluid conduit having a valve seat contactable by the cone of the poppet member to block fluid flow through the fluid conduit in one position of the slave magnet disk assembly and displaceable from the cone to pass fluid flow through the fluid conduit in an opposite position of the slave magnet disk assembly, the master magnet ring assembly being displaced by selective supply of a motive fluid to the chamber to displace the master magnet ring assembly from one position to another, which automatically displaces the slave magnet ring assembly.
| 5
|
FIELD OF THE INVENTION
The present invention relates to systems and methods of operation thereof for variably controlling internal combustion engine intake and exhaust valves. More specifically, it relates to camless engine valve systems and methods of operation in engines used to eliminate the need for external exhaust gas recirculation and air throttling.
BACKGROUND OF THE INVENTION
Conventional automotive internal combustion engines operate with one or more camshafts controlling the timing and lift of the intake and exhaust valves, according to a predetermined lift schedule. With this type of mechanical structure, the lift schedule is fixed. However, under different engine operating conditions, the optimum lift schedule varies. Thus, the lift schedule must be a compromise of the optimum lift schedule needed for the different operating conditions. To accommodate full throttle engine operation, which requires significant air intake, an aggressive lift schedule must be used. At part load operating conditions, however, the intake air must then be throttled to prevent too much air from entering the cylinder. Consequently, this causes parasitic losses due to the throttling.
It is desirable to eliminate throttling losses by eliminating the need for an air throttle, without losing the effective compression ratio. One possible way to accomplish this is to close the intake valve before piston bottom dead center (BDC) during the intake stroke. However, the gas in the cylinder will then experience expansion during the end of the intake stroke with resultant cooling. Cooling of the gas can be detrimental to engine performance. Therefore, the need arises for a way to maintain the proper temperature of the gas at combustion when it undergoes a cooling due to expansion during the end of the intake stroke. This would improve combustion characteristics and provide better fuel economy.
Further, in internal combustion engines used in vehicles today, some of the exhaust gas is recirculated, by an external exhaust gas recirculation (EGR) system, to control the nitrogen oxide formation and to retain the maximum unburned hydrocarbons in the cylinder and allow for hotter intake gas for better evaporation of fuel. It is desired to eliminate the need for an external EGR system to reduce the cost and complexity that yields increased maintenance requirements. Additionally, for environmental reasons, it is desired to maintain as much of the unburned hydrocarbons in the cylinder as possible rather than allowing them to flow out in the exhaust.
It is understood that the distribution of unburned hydrocarbons in the cylinder charge at the beginning of the exhaust stroke is uneven. A substantial part of the unburned hydrocarbons that come out of the piston ring crevices at the end of the expansion stroke remain concentrated in the bottom part of the cylinder near the piston. If this part of the cylinder charge can be prevented from being discharged into the exhaust port, a substantial reduction in hydrocarbon emissions can be achieved. Thus, in order to maintain the greatest amount of unburned hydrocarbons within the cylinder, it is desired that the part of the exhaust charge with the highest concentration of unburned hydrocarbons be prevented from flowing out through the exhaust port. Furthermore, if some hot gas can temporarily reside in the intake port, it will increase the intake air temperature, which promotes better evaporation of fuel injected into the port, especially during engine cold start and warm-up. This, too, improves hydrocarbon emissions.
The enhancement of engine performance attainable by varying the acceleration, velocity and travel time of the intake and exhaust valves in an engine is well known and appreciated in the art. The increasing use and reliance on microprocessor control systems for automotive vehicles and increasing confidence in hydraulic and electric as opposed to mechanical systems is now making substantial progress possible. The almost limitless flexibility with which the intake and exhaust events (timing strategy) can be varied in an engine with a camless valvetrain can lead to substantial improvements in engine operation.
However, none of the present systems and methods of operation provide a variable engine valve control system that substitutes for the external EGR system in today's engines to reduce harmful emissions by returning a portion of unburned hydrocarbons back to the cylinder while at the same time promoting better evaporation of fuel, while also eliminating air throttling losses without reducing the effective compression ratio and while avoiding problems caused by low air temperature resulting from early intake valve closure. The present system optimizes engine performance, especially at part load engine operation.
SUMMARY OF THE INVENTION
In its embodiments, the present invention contemplates an electrohydraulically operated valve control system cooperating with a piston and cylinder in an internal combustion engine. The valve control system includes an intake port, coupled to the cylinder, having an intake valve operatively associated therewith, with the intake valve selectively closable before and after piston bottom dead center, and an exhaust port, coupled to the cylinder, having an exhaust valve operatively associated therewith. The valve control system further includes a heat exchanger having a heat exchange mechanism, an exhaust gas inlet and an exhaust gas outlet, and an intake air inlet and an intake air outlet, with the exhaust inlet being coupled to the exhaust port and coupled through the heat exchange mechanism to the exhaust outlet. The intake outlet is coupled to the intake port and is selectively coupled to an intake inlet though the heat exchange mechanism and around the heat exchange mechanism. The heat exchanger further has a means for selectively routing intake air through the heat exchange mechanism whereby the amount of intake inlet air that passes through the heat exchange mechanism is a function of the closing of the intake valve relative to the piston's bottom dead center position.
The present invention further contemplates a method of operating an engine valve control system in an internal combustion engine. The method includes the steps of opening an intake valve of a cylinder, selectively heating ambient intake air prior to entry into the engine cylinder, and closing the intake valve prior to a piston's bottom dead center position during an intake stroke within the cylinder whereby the intake air will be at an ambient temperature when the piston reaches a position of bottom dead center.
Accordingly, an object of the present invention is to provide a camless valvetrain system capable of eliminating the need for intake air throttling while still maintaining the effective compression ratio and adequate ignition characteristics.
It is a further object of the present invention to achieve the above noted object of the present invention and further to eliminate the need for an external EGR system by returning the portion of exhaust gas in the cylinder with the highest concentration of unburned hydrocarbons to the intake port during the exhaust stroke.
It is an advantage of the present invention that the need for air throttling will be eliminated without reducing the effective compression ratio and without adversely affecting ignition characteristics.
It is a further advantage of the present invention that nitrogen oxide and hydrocarbon emissions will be reduced while eliminating the need for an external EGR system and allowing for better fuel evaporation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing a single valve assembly of an electrohydraulic camless valvetrain in accordance with the present invention;
FIG. 2 is a circular diagram illustrating the duration and timing of intake and exhaust events of engine valves in accordance with the present invention;
FIGS. 3A and 3B show a schematic diagram of an engine cylinder and engine valves in two stages of an exhaust stroke in accordance with the present invention;
FIGS. 3C and 3D show a schematic diagram of an engine cylinder and engine valves in two stages of an intake stroke in accordance with the present invention; and
FIG. 4 is a schematic diagram of an intake air heat exchanger in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a single engine valve assembly 8 that forms part of a valvetrain controlled by a electrohydraulic camless valve system (not shown). While this figure is the preferred embodiment for the valvetrain, other hydraulic and electrical systems can also be used to variably control engine valves. An electrohydraulic valvetrain is shown in detail in U.S. Pat. No. 5,255,641 to Schechter, which is incorporated herein by reference.
A single engine valve assembly 8 of an electrohydraulically controlled valvetrain is shown in FIG. 1. An engine valve 10, for inlet air or exhaust as the case may be, is located within a cylinder head 12. A valve piston 26, fixed to the top of the engine valve 10, is slidable within the limits of a piston chamber 30.
Fluid is selectively supplied to volume 25 above piston 26 from a high pressure oil source 40 and a low pressure oil source 42 hydraulically connected through a high pressure line 44 and a low pressure line 46, respectively, to a high pressure port 48 and a low pressure port 50, respectively.
Volume 25 can be connected to high pressure oil source 40 through a solenoid valve 64 or a check valve 66, or to low pressure oil source 42 through a solenoid valve 68 or a check valve 70. A volume 27 below piston 26 is always connected to high pressure oil source 40. A fluid return outlet 72 provides a means for returning to a sump (not shown) any fluid that leaks out of piston chamber 30. High pressure solenoid valve 64 and low pressure solenoid valve 68 are activated and deactivated by signals from a microprocessor controller 74.
Engine valve opening is controlled by high-pressure solenoid valve 64 which opens, causing valve acceleration, and closes, causing deceleration. Opening and closing of low pressure solenoid valve 68 controls engine valve closing.
During engine valve opening, high pressure solenoid valve 64 opens and the net pressure force acting on piston 26 accelerates engine valve 10 downward. When high pressure solenoid valve 64 closes, pressure above piston 26 drops, and piston 26 decelerates pushing the fluid from volume 27 below it back into high pressure oil source 40. Low pressure fluid flowing through low pressure check valve 70 prevents void formation in volume 25 during deceleration. When the downward motion of engine valve 10 stops, low pressure check valve 70 closes and engine valve 10 remains locked in its open position.
The process of valve closing is similar, in principle, to that of valve opening. Low pressure solenoid valve 68 opens, the pressure above piston 26 drops and the net pressure force acting on piston 26 accelerates engine valve 10 upward. When low pressure solenoid valve 68 closes, pressure above piston 26 rises, and piston 26 decelerates pushing the fluid from volume 25 through high-pressure check valve 66 back into high-pressure oil source 40.
The flexibility with which the timing and lift of intake and exhaust valves can be continuously varied allows great flexibility in optimizing engine performance for many different engine operating conditions, including part load engine operating conditions.
FIGS. 2, 3A, 3B, and 3C show variable valve timing in which early intake valve opening and exhaust valve closing aids engine operation for certain engine operating conditions by eliminating the need for an external EGR system. The variable timing for closing 101 of an exhaust valve 100 and opening 103 of an intake valve 102 in a cylinder 112 is shown such that, at part-load, closing 101 and opening 103, respectively, takes place substantially in advance of a piston 110 reaching top dead center (TDC) 104 so that the exhaust charge is split into two parts. Exhaust valve 100 and intake valve 102 are preferably each electrohydraulically controlled in the same manner as engine valve 10 shown in FIG. 1, although other camless engine valve systems can also be used.
As a result of the timing of the valve closings and openings, a first part of the exhaust gasses, comprising the upper part of the cylinder content, is expelled into an exhaust port 106 during the first portion of the exhaust stroke, as shown in FIG. 3A. A second part of the exhaust gasses, comprising the lower part of the cylinder content, is expelled into an intake port 108, as shown in FIG. 3B. The second part will contain a higher concentration of unburned hydrocarbons than the first part since a substantial portion of the unburned hydrocarbons are concentrated in the bottom part of the cylinder 112.
When piston 110 begins its intake stroke, the gas previously expelled into intake port 108 returns to cylinder 112 as part of the intake charge, as shown in FIG. 3C. This assures that a substantial amount of the unburned hydrocarbons produced during each cycle will be introduced back into cylinder 112 from intake port 108 and can then participate in the next combustion cycle. The quantity of the exhaust gas thus retained in the cylinder can be controlled by varying the timing of exhaust valve closing 101 and intake valve opening 103. The second part of exhaust charge returned to the cylinder restricts the quantity of nitrogen oxide produced in the next cycle, thus reducing harmful emissions and eliminating the need for an external EGR system.
As an additional benefit, the temporary residence of the second part of the exhaust charge in intake port 108 preceding each intake stroke will also promote better evaporation of the fuel injected into port 108 due to the high temperature of the gas. This is especially beneficial during engine cold start and during engine warm-up.
As an alternative, it should be noted that retention of some of the exhaust gas in cylinder 112 in the gas splitting strategy can also be accomplished by delaying exhaust valve closing significantly past TDC 104. In this case, practically the entire exhaust charge is expelled into exhaust port 106, and some of it returns to cylinder 112 at the beginning of the intake stroke. There is, however, no assurance that the gas that returns represents what was previously in the lower part of cylinder 112, and, hence that the highest concentration of unburned hydrocarbons is maintained in cylinder 112.
FIGS. 2, 3C, and 3D show intake valve closing 113 in which the variable timing of closing 113 is such that, at part-load, intake valve closing 113 takes place substantially before piston bottom dead center (BDC) 114, trapping a variable volume of intake air in cylinder 112 initially at approximately barometric pressure. This facilitates unthrottled engine operation at part load, eliminating the need for intake air throttling. To restrict the quantity of air inducted into cylinder 112, intake valve 102 is closed far in advance of BDC 114, thus reducing the volume of the trapped intake charge. The mixture of intake air, fuel and exhaust gas that was inducted at near barometric pressure will then be subjected to expansion during the remainder of the intake stroke. The intake air expansion after intake valve closure will cause an associated cooling. The drop in intake charge temperature associated with its expansion may lead to excessively low temperature at the end of the compression stroke, which can be deleterious to the combustion process.
To prevent this, the intake air can be heated. One way to accomplish this heating is through heat exchange with the exhaust gas. The intake air, then, is subjected to heating in advance of its induction into cylinder 112. This heating of intake air will assure that, after the expansion caused cooling in the cylinder, the temperature of the intake charge is approximately equal to the ambient temperature of the air before the expansion.
FIG. 4 illustrates a heat exchanger 116 that selectively preheats the intake air prior to entering intake port 108. Heat exchanger 116 includes intake inlet 122 for receiving ambient air, with a mass air flow sensor 124 mounted at inlet 122. Mass air flow sensor 124 monitors the total mass of inlet air flowing into intake inlet 122. Intake inlet 122 divides into a bypass duct 126 and a heat exchange inlet duct 128. The intake air can be routed through a heat exchange mechanism 118 via heat exchange inlet duct 128, where the air temperature is increased. A heat exchange outlet duct 130 connects to the bypass duct 126, which leads to an air intake outlet 132.
Heat exchanger 116 further includes an exhaust gas inlet 134, connected between exhaust port 106 and heat exchange mechanism 118, and an exhaust gas outlet 136 also connected to heat exchange mechanism 118. A directional control valve 120 can be rotated to vary the percentage of the total mass air flow that is directed through the heat exchanger from 0 to 100%, and, in this way, control the temperature of the air inducted into cylinder 112.
Air flowing through heat exchange mechanism 118 is heated so that, after expansion, the temperature of the intake charge is not below the ambient temperature. Thus, the heating of the air before induction into cylinder 112 cancels the cooling effect of expansion, so that at the start of the compression stroke, the gas in cylinder 112 is below atmospheric pressure but at approximately ambient atmospheric temperature. These are the same conditions that would prevail in cylinder 112 at this point in the cycle if the intake air was throttled, except that there was no throttling and consequently, no pumping loss.
During the subsequent compression stroke, the intake charge is subjected to full compression determined by the geometric compression ratio. Since the effect of expansion cooling was cancelled out by the air heating, the charge expansion during the intake stroke has no detrimental affect on the rest of the cycle.
As an alternative to early intake valve closure, it should be noted that the air flow control at part-load can also be accomplished by closing intake valve 102 late after BDC 114 rather than before BDC. The effect of reduced effective compression ratio can still be alleviated by air heating, but the loss of heat to cylinder walls can be substantial. Thus, early intake valve closing is the preferred arrangement.
While certain embodiments of the present invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims.
|
A variable engine valve control system and method of operation thereof wherein each of the reciprocating engine valves is hydraulically or electrically controlled and can vary its lift schedule for various engine operating conditions. During part load operation of the engine, the intake valve is opened and the exhaust valve is closed during the exhaust stroke, prior to a piston's top dead center position, so that the intake port receives exhaust gas, which is then returned to the cylinder during the intake stroke to eliminate the need for an external exhaust gas recirculation system and to improve fuel evaporation into the intake air. Further, during part load, the intake valve is closed before the end of the intake stroke and the intake air is heated by a heat exchanger prior to entry into the cylinder to eliminate the need for air throttling without compromising the compression ratio and ignition characteristics.
| 5
|
FIELD OF THE INVENTION
[0001] The present invention relates to a Kraft pulping process employing modified cooking technology in conjunction with polysulfide pulping technology in a cooking vessel to obtain higher pulping yields than previously obtained with either modified cooking or polysulfide pulping.
BACKGROUND OF THE INVENTION
[0002] Polysulfide (PS) is a pulping additive which has been used commercially to increase pulping yield. A higher pulping yield improves process economics by decreasing wood consumption and/or increasing pulp throughput. Polysulfide is commercially produced by catalytic oxidation of part of the sulfide ions contained in Kraft pulping alkali solution, often called “white liquor” in the art of Kraft pulping. This oxidation process is currently the most commercially viable technology that converts sulfide in white liquor to polysulfide, giving the resultant liquor an orange color. Polysulfide alkali liquor thus is also called “orange liquor” in the art.
[0003] Polysulfide is found to be effective in increasing pulping yield only when it is applied to the beginning of a cook, e.g., to an impregnation stage where the temperature is typically below ˜140° C. (˜284° F.) and a retention time of typically 15-45 minutes. At or above ˜140° C. (˜284° F.), polysulfide starts to decompose rapidly and loses its effectiveness as a pulping yield enhancer. Pulping yield increase from polysulfide pulping is found to increase proportionately with amounts of polysulfide added to the beginning of a cook (up to about 7% polysulfide charged on wood). Thus in polysulfide pulping, all polysulfide liquor (orange liquor) is most preferably added to the beginning of a cook so as to maximize pulping yield increase. This feature works well with conventional Kraft pulping. In conventional Kraft pulping, which had been the only commercial practice until the late 1970s, the total alkali charge required for a cook is added to the beginning of the cook.
[0004] In modified Kraft pulping (modified cooking) developed in the late 1970s, the total alkali charge is divided into at least two and often more than two additions. Typically, only about 45-75% of the total alkali is added to the beginning of a modified cook. By splitting the total alkali charge into several additions to different cooking stages, alkali concentration profile in modified cooking is more even throughout the cook than in conventional Kraft cooking. Of particular importance is the concentration of effective alkali (EA) in the early cooking stage, where the cooking temperature goes from an impregnation temperature of typically ≦135° C. (≦275° F.) to full cooking temperature, typically between 150 to 175° C. (302 to 347° F.). When the EA concentration is too high in this early cooking stage, excessive losses occur in pulping yield and pulp strength. Therefore, modified cooking with a more even alkali profile, particularly a lower EA concentration in the early cooking stage, results in significantly higher pulping yield and pulp strength than conventional Kraft pulping, where the total alkali charge is all added to the beginning of a cook and the EA concentration is high at the early stage.
[0005] However, when current commercial polysulfide pulping technology is applied to modified cooking, only 45-75% of the total available polysulfide is added to the beginning of a cook, since only 45-75% of the polysulfide-containing alkali liquor is added to the beginning of the cook. As a result, compared to conventional cooking with polysulfide, only a fraction of the total pulping yield increase is realized because the yield increases are proportional to the amount s of polysulfide added to the beginning of a cook as discussed before. This means that in the prior art, current modified cooking cannot take full advantage of polysulfide pulping for maximum yield increases. In other words, the current modified cooking technology is not completely compatible with the current commercial polysulfide pulping technology.
[0006] The present invention overcomes the aforementioned incompatibility of modified Kraft pulping with current commercial polysulfide pulping technology. It obtains all benefits of modified cooking as compared to conventional cooking, and the full yield improvement of polysulfide pulping.
SUMMARY OF THE INVENTION
[0007] The invention comprises a method directed to Kraft pulping employing a modified cooking process in conjunction with polysulfide pulping technology in a cooking vessel to obtain higher pulping yields than is obtained with modified cooking without polysulfide, conventional cooking with polysulfide or polysulfide pulping applied to modified cooking as taught in the prior art. In the present invention, the entire cooking alkali dosage required in the form of polysulfide liquor is added to the beginning of a cook, usually an impregnation stage, as in the case of conventional cooking. At the end of the impregnation stage, when all polysulfide has essentially reacted with lignocellulosic material to increase pulping yield at temperature below ˜135° C. (˜275° F.), at or below which no significant carbohydrate degradation occurs, e.g., near the end of the impregnation stage, part of the cooking liquor (first quantity) high in effective alkali (EA) concentration is removed from the cooking process and replaced with a cooking liquor (second quantity) low in EA concentration and that is removed from another process point, and which may be equal to, greater than, or smaller than the first quantity. The removed first quantity of cooking liquor is then added elsewhere in the pulping process, where the EA concentration is low, for instance near where the second quantity of cooking liquor is removed. By performing this cooking liquor “exchange,” the full yield benefit from polysulfide pulping is realized while at the same time a more uniform EA concentration profile is achieved to obtain the benefits of higher pulp yield and strength from modified cooking.
[0008] More specifically, the invention comprises, in an embodiment, the steps of: (a) adding the total alkali charge in the form of polysulfide liquor to the first stage of a cook operated at between 100-140° C. within about 15-45 minutes; (b) at the end of the first stage, removing from the vessel a first quantity of cooking liquor relatively high in effective alkali (EA) concentration, which is to be added back to the vessel in a later stage; (c) adding to the end of the first stage a second quantity of cooking liquor, which was removed from a later stage of the cook and is relatively low in EA concentration; (d) heating the cook to full cooking temperature; (e) wherein the second quantity cooking liquor is removed about 0-200 minutes after the full cooking temperature is reached; (f) adding the first quantity of cooking liquor to the vessel to a later stage in the cooking process than its point of removal, or to another cooking process; and (g) continuing cooking to completion. The quantities, as well as the removal and addition points or times, of the first and second cooking liquors are controlled to obtain an EA concentration profile that is similar to that of current modified cooking and more uniform than that of conventional Kraft cooking.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The foregoing, as well as other objects and advantages of the invention, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein:
[0010] FIGS. 1 a & 1 b are schematic flow diagrams of a cooking process according to a preferred embodiment of the present invention;
[0011] FIG. 2 is a chart comparing the screened pulp yield increases of modified cooking (MC-Ref), conventional Kraft with polysulfide (CK-PS), modified cooking with polysulfide (MC-PS), and modified cooking with the enhanced polysulfide process of the invention (MC-EPS), relative to conventional Kraft (CK), at 15 Kappa number from laboratory cooking of mixed southern US hardwoods with 0.05% (on OD wood) anthraquinone added;
[0012] FIG. 3 is a chart comparing the screened pulp yield increases of modified cooking (MC-Ref), conventional Kraft with polysulfide (CK-PS), modified cooking with polysulfide (MC-PS), and modified cooking with the enhanced polysulfide process of the invention (MC-EPS), relative to conventional Kraft (CK), at 30 Kappa number from laboratory cooking of southern pine with 0.05% (on OD wood) anthraquinone added;
[0013] FIG. 4 is a chart comparing the screened pulp yield increases of conventional Kraft with polysulfide (CK-PS), modified cooking with polysulfide (MC-PS), and modified cooking with the enhanced polysulfide process of the invention (MC-EPS), relative to conventional Kraft (CK) at 30 Kappa number from laboratory cooking of another southern pine furnish with no anthraquinone added;
[0014] FIG. 5 shows an exemplary embodiment of the present invention in a vertical single-vessel continuous digester, wherein the cook zones are all co-current;
[0015] FIG. 6 shows another embodiment of the present invention in a continuous digester wherein the last cooking stage runs in a counter-current mode; and
[0016] FIGS. 7 a & 7 b show an exemplary installation of the present invention in a battery of batch digesters.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The cooking process of the present invention is indicated generally for a pulping process with one impregnation stage and one concurrent cooking stage at 10 in FIG. 1 a . According to the present invention, 100% of the required alkali dosage, in the form of polysulfide (PS) liquor stream 11 , is added with wood chips stream 12 to the impregnation stage 13 of a reaction vessel (digester), e.g., at the top of a continuous digester. After reaction at up to ˜135° C. (˜275° F.) for about 15-60 minutes, when essentially all polysulfide has reacted with lignocellulosic material to stabilize carbohydrates for pulping yield increase, a first quantity 14 of the post-impregnation liquor is removed from the total post-impregnation liquor 15 , which is relatively high in EA concentration. A second quantity 16 of liquor relatively low in EA concentration is removed from another process point, which is at least 30 minutes after the target full cooking temperature has been reached in the cooking stage or at the end of the cooking stage, and added back to the reaction vessel at or immediately downstream of the process point where the first quantity of the higher EA liquor was removed. The second quantity may be equal to, greater than or smaller than the first quantity of the cooking liquor removed. The removed first quantity of cooking liquor high in EA concentration is sent to another process, e.g., another pulping process with or without the use of polysulfide.
[0018] Another embodiment of the present invention is depicted in FIG. 1 b . The pulping process 10 ′ consists of one impregnation stage 13 ′ and two concurrent cooking stages. According to the present invention, 100% of the required alkali dosage, in the form of polysulfide (PS) liquor stream 11 ′, is added with wood chips stream 12 ′ to the impregnation stage 13 ′ of a reaction vessel (digester), e.g., at the top of a continuous digester. After reaction at up to ˜135° C. (˜275° F.) for about 15-60 minutes, when essentially all polysulfide has reacted with lignocellulosic material to stabilize carbohydrates for pulping yield increase, a first quantity 14 ′ of the post-impregnation liquor is removed from the total post-impregnation liquor 15 ′, which is relatively high in EA concentration. A second quantity 16 ′ or 17 ′ of liquor relatively low in EA concentration is removed from another process point, which is at least 30 minutes after the target full cooking temperature has been reached in the first cooking stage, or at the end of the first cooking stage or alternatively at the end of the second cooking stage, and added back to the reaction vessel at or immediately downstream of the process point where the first quantity of the higher EA liquor was removed. The second quantity may be equal to, greater than or smaller than the first quantity of the cooking liquor removed. The removed first quantity of cooking liquor high in EA concentration is added back to the reaction vessel downstream of its removal point, at or immediately downstream of the removal point for the second quantity of cooking liquor.
[0019] The terms of downstream and upstream are referenced to the free liquor flow direction inside the cooking vessel in a continuous digester, or to the process time of a batch cooking system with multiple batch digester vessels. By adjusting the quantities of the first and the second of cooking liquor and the process points for their removal and addition, one skilled in the art of Kraft pulping is able to achieve a relatively even EA concentration profile in the subsequent cooking stages (Cook Stages 1 and 2), comparable to that obtained from current modified cooking. Thus, the present invention enables one to achieve the full potential benefits of pulp yield increases from PS pulping, as well as the higher pulp yield and strength from a more even EA concentration profile as obtained in modified cooking, thereby overcoming the incompatibility of prior art modified cooking when using commercially available polysulfide pulping technologies.
[0020] Yet another embodiment of the present invention is to (a) add the total required alkali charge in the form of polysulfide cooking liquor (orange liquor) to the very first stage of a cook, usually an impregnation stage, and control the stage conditions, typically around or below 135° C. (275° F.) for 15-45 minutes, such that essentially all polysulfide has reacted with lignocellulosic material and no substantial carbohydrates degradation and polysulfide thermal decomposition occur; and (b) adjust the amounts of the first quantity and the second quantity of liquors to be removed from certain process points and to be added back to the cook at other process points, as well as their relative removal and addition process points, so as to keep the maximal concentration of effective alkali at or below 18 g/L as NaOH (0.45M NaOH or 14 g/L as Na 2 O) throughout all cooking stages that follow the impregnation stage.
[0021] Alternatively, the present invention can be practiced where the maximal effective alkali concentration in all cooking stages that follow the impregnation stage is controlled to be at or below 24 g/L as NaOH (0.6M NaOH or 18.6 g/L as Na 2 O).
[0022] Another way to practice the present invention is to control the maximal alkali concentration at or below 12 g/L as NaOH (0.3M NaOH, or 9.3 g/L as Na 2 O) in all cooking stages that follow the impregnation stage.
EXAMPLES
Example 1
[0023] Table 1 summarizes the pulping yields from cooking mixed southern US hardwood furnish to 15 Kappa number at the laboratory. These results are also depicted in FIG. 2 .
[0024] CK-Ref denotes reference cooks of conventional Kraft cooking, which is comprised of: (a) heating up the chips with low-pressure steam at ˜100° C. (˜212° F.) for 10 minutes in a laboratory digester vessel equipped with external circulation and an electric heater; (b) draining off all free steam condensate; (c) adding all cooking alkali liquor (in form of white liquor with a sulfidity of ˜30% on active alkali (AA) basis), corresponding to EA/wood charge of 20.0% as NaOH (15.5% as Na 2 O) at the beginning of a cook, and bringing the cooking liquor/wood ratio to 3.5 by adding the proper amount of water to the cook; (d) heating up the cook from about 60° C. to 120° C. in 15 minutes; (e) maintaining the cook at 120° C. for 30 minutes to effect an impregnation stage; (f) heating up the cooking to full cooking temperature of about 160° C. (320° F.) in 30 minutes and maintaining the cook at this temperature for 100 minutes to reach a target Kappa number of ˜15; (g) cooling the cook down to below 100° C.; (h) washing the cooked chips with tap water; (i) processing the washed cooked chips into fibers (pulp) by mechanical mixing in a dilute water suspension; and (j) screening the pulp using a laboratory flat screen with 0.25 mm (0.01″) slots before determination of pulping yield, rejects, Kappa number and other pulp properties.
[0025] MC-Ref denotes reference cooks carried out with a modified cooking process, comprising essentially the same steps as outlined above for the CK-Ref cooks, expect for step (c), adding only 65% of the total alkali charge at the beginning of a cook, and step (f), adding the second EA addition equal to 20% of the total alkali charge to the cook by a metering device before heating up the cook to 157° C. (˜315° F.) in 30 minutes, maintaining the temperature for 45 minutes before adding the third EA addition equal to 15% of the total alkali charge, and continuing the cook at this full cooking temperature for another 150 minutes to reach a target Kappa number of ˜15.
[0026] CK-PS and MC-PS represent polysulfide (PS) cooks performed using the aforementioned CK-Ref and MC-Ref procedures, respectively, and instead of white liquor using PS liquor, produced by catalytic oxidation of white liquor, containing an amount of total polysulfide equivalent to 0.7% charge on wood and with a sulfidity of ˜14% on AA. In addition, a charge of anthraquinone (AQ) equal to 0.05% on wood was added to these PS cooks with the first EA charge at the beginning of a cook.
[0027] The MC-EPS cooks were done using the present invention, and were performed in the following steps: (a) heating up the chips with low-pressure steam at ˜100° C. (˜212° F.) for 10 minutes in a laboratory digester vessel equipped with external circulation and an electric heater; (b) draining off all free steam condensate; (c) adding 0.05% AQ and the total required alkali charge in the form of PS liquor (containing an equivalent of 0.7% PS on wood with a sulfidity of 14% on AA basis), corresponding to EA/wood charge of 20.0% as NaOH (15.5% as Na 2 O) at the beginning of a cook, and bringing the cooking liquor/wood ratio to 3.5 by adding proper amount of water to the cook; (d) heating up the cook from about 60° C. to 120° C. in 15 minutes; (e) maintaining the cook at 120° C. for 30 minutes to effect an impregnation stage; (f) collecting a first quantity of cooking liquor relatively high in EA concentration, in an amount equivalent to about 1.2 times the total wood charge by weight through a cooling device from the digester vessel for use in the next MC-EPS cook; (g) adding to the digester vessel via a metering device a second quantity of cooking liquor relatively low in EA concentration collected from a previous MC-EPS cook; (h) heating up the cook to full cooking temperature of about 157° C. (315° F.) in 30 minutes and maintaining the cook at this temperature for 45 minutes; (i) collecting a second quantity of cooking liquor in an amount equivalent to about 1.2 times the total wood charge by weight through a cooling device from the digester vessel and storing this second quantity of cooking liquor relatively low in EA concentration for use in the next MC-EPS cook; (j) adding to the digester vessel via a metering device the first quantity of cooking liquor collected from a previous MC-EPS cook, and maintaining the full cooking temperature during this liquor exchange; (k) continuing the cook at this full cooking temperature for another 150 minutes to reach a target Kappa number of ˜15; (l) cooling the cook down to below 100° C.; (m) washing the cooked chips with tap water; (n) processing the washed cooked chips into fibers (pulp) by mechanical mixing in a dilute water suspension; and (o) screening the pulp using a laboratory flat screen with 0.25 mm (0.01″) slots before determination of pulping yield, rejects, Kappa number and other tests.
[0000]
TABLE 1
Pulp Yields at 15 Kappa Number for Southern US Mixed Hardwoods.
MC-
MC-
Cook Type
CK-Ref
MC-Ref
CK-PS
PS
EPS
Screened Yield, % on Wood
47.1
48.0
49.2
49.4
50.4
Increase Over CK-Ref, %
—
0.9
2.1
2.3
3.3
Increase Over MC-Ref, %
1.2
1.4
2.4
0.05% AQ (anthraquinone) added to all PS and EPS cooks
[0028] The results show that modified cooking of southern US mixed hardwood to 15 Kappa number (MC-Ref) resulted in a pulp yield increase of about 0.9% on wood over conventional reference cooks (CK-Ref). Charging the total required alkali charge in the form of PS liquor containing about 0.7% PS and 0.05% AQ, both on OD wood basis, to the beginning of a conventional Kraft cook (CK-PS) increased the pulp yield by about 2.1% over conventional reference cooks, and about 1.2% points over the MC-Ref cook. As expected based on teaching from the prior art, when 65% of the total PS liquor was added to the beginning and the balance of the PS liquor to the subsequent cooking stages of a modified cook (MC-PS), the total pulp yield increase was only 1.4% on wood over that of the MC-Ref (2.1% over CK-Ref), which is significantly lower than the expected sum of (0.9%+2.1%)=3.0% yield increases from both modified cooking and PS addition. When applying the present invention, i.e., the enhanced PS process with modified cooking (MC-EPS), the total pulp yield increase was found to be 3.3% on wood, which is approximately the sum of the 0.9% increase from modified cooking over conventional Kraft cooking and the 2.1% expected from PS pulping.
Example 2
[0029] Similar results were found in laboratory pulping of southern pine, as summarized in Table 2 and depicted in FIG. 3 . The cooking procedures were the same as those described in Example 1 for each type of cook.
[0030] Modified cooking (MC-Ref) to about 30 Kappa number was found to increase pulping yield by ˜0.5% on wood over conventional Kraft reference (CK-Ref) cooks. Adding 0.05% AQ and 0.7% PS to CK cooks increased the pulp yield by about 1.7% on wood. As expected based on teaching from the prior art, performing PS pulping with MC cooking without the use of the present invention, i.e., splitting the total alkali charge into multiple additions and only adding about 65% of total alkali charge to the beginning of a cook, the total pulp yield increase was only ˜1.5% over CK-Ref and 1.0% over MC-Ref, significantly lower than the expected sum of ˜2.2% (˜0.5% from modified cooking and 1.7% from PS addition). When applying the present invention using the enhanced PS process concept, the total pulp yield increase in the MC-EPS cooks was ˜2.3% over that of CK-Ref and ˜1.8% over that of MC-Ref cooks.
[0000]
TABLE 2
Pulp Yields at 30 Kappa Number for Southern Pine Furnish 1.
MC-
MC-
Cook Type
CK-Ref
MC-Ref
CK-PS
PS
EPS
Screened Yield, % on Wood
44.6
45.1
46.3
46.1
46.9
Increase Over CK-Ref, %
0.5
1.7
1.5
2.3
Increase Over MC-Ref, %
—
1.2
1.0
1.8
0.05% AQ added to all PS and EPS cooks
Example 3
[0031] In another laboratory pulping study using a different southern pine furnish, but without adding AQ to any cooks, the results also clearly show the significant advantage of the present invention. The cooking procedures were the same as those described in Example 1 for each type of cook.
[0032] As can be seen in Table 3 and FIG. 4 , adding the total required alkali charge in the form of PS liquor (containing 0.7% PS on wood) to the beginning of a cook (CK-PS) was found to increase the pulp yield by about 1.0% on wood. As expected based on teaching from the prior art, performing PS pulping with modified cooking without the use of the present invention, i.e., splitting the total PS liquor into multiple charges and only adding about 65% of total PS liquor to the beginning of a cook (MC-PS), the total pulp yield increase was only ˜0.6% over CK-Ref. When applying the present invention using the enhanced PS pulping concept with modified cooking (MC-EPS), the total pulp yield increase in the MC-EPS cooks was ˜1.0% over that of CK-Ref cooks.
[0000]
TABLE 3
Pulp Yields at 30 Kappa Number for Southern Pine Furnish 2.
Cook Type
CK-Ref
CK-PS
MC-PS
MC-EPS
Screened Yield, % on Wood
45.4
46.4
46
46.4
Increase Over CK-Ref, %
—
1.0
0.6
1.0
No AQ added to any cooks
[0033] The above three examples clearly demonstrate the advantages of the present invention over the prior art in the use of polysulfide pulping with modified cooking processes.
Example 4
[0034] FIG. 5 illustrates an exemplary embodiment of the present invention in a vertical single-vessel continuous digester 20 comprising one impregnation stage 21 at the top, and three co-current cook stages 22 , 23 and 24 below the impregnation stage. A first circulation loop 25 exits the digester at the end of the impregnation stage and re-enters the impregnation stage near the upper end of the digester. A second circulation loop 26 exits the digester at the end of the first cook stage 22 and re-enters the first cook stage near its upper end. A third circulation loop 27 exits the digester at the end of the second cook stage 23 and re-enters the second cook stage near its upper end. Wood chips 28 , usually after steaming for pre-heating and air removal, and 100% of the total required alkali charge in the form of PS liquor 29 are fed to the top of the digester, i.e., the beginning of a cook. The chips and cooking liquor move downward from the top to the first set of screens 30 , typically in 30-45 minutes within a temperature range of ˜110° C. to ˜135° C. in this so-called impregnation stage. At the end of this impregnation stage essentially all PS has reacted with woody components, rendering the carbohydrates in wood chips more stable against alkali-catalyzed degradation and a higher pulping yield. A first quantity 31 of cooking liquor, relatively high in EA concentration, is removed via the first set of screens 30 immediately after the impregnation stage near the top of the digester as shown in FIG. 5 . A second quantity 32 of cooking liquor, relatively low in EA concentration, is removed from the last (lowest) set of screens 33 as shown in FIG. 5 . Alternatively, but not shown, the second quantity of cooking liquor can be removed from the second last (middle) set of screens 34 . The removed first quantity of cooking liquor 31 is added back to the digester at the third circulation loop 27 as shown in FIG. 5 , or alternatively, but not shown, at the second circulation loop 26 . The removed second quantity 32 of cooking liquor is added back to the digester at the first circulation loop 25 as shown in FIG. 5 , or alternatively (not shown), at the second circulation loop.
[0035] Amounts of the first and the second quantities of cooking liquor removed from certain process points and added back to other process points should be adjusted to achieve the most preferred EA concentration profile in all cooking stages that follow the impregnation stage. Consideration should also be given to the liquor removal and addition locations with regard to hydraulic balance of the digester, as well as to the ease of chip column movement for improved digester operational stability.
[0036] By practicing the present invention, the EA concentration profile in PS pulping with modified cooking in a continuous digester is more even than that in a conventional Kraft cook, retaining all essential benefits from modified cooking. At the same time, since all PS is put to use at the beginning of the cook, maximum pulp yield increase from PS pulping is realized.
Example 5
[0037] FIG. 6 illustrates another embodiment of the present invention in a continuous digester 20 ′ running the last cooking stage 24 ′ in a counter-current mode. The third, and last, circulation loop 27 ′ in this embodiment exits the digester at the end of the third cook stage 24 ′ and then re-enters an earlier point in the third cook stage. The first quantity 31 ′ of cooking liquor relatively high in EA concentration is removed from the first set of screens 30 at the end of the impregnation stage 21 and added to the last circulation loop 27 ′. The second quantity 32 ′ of cooking liquor, relatively low in EA concentration, is removed from the middle extraction 35 (taken from the digester at the second last set of screens 34 ) and added to the first circulation loop 25 , whose inlet is located downstream of the removal point for the first quantity of liquor.
[0038] As discussed before, amounts of the first and the second quantities of cooking liquor removed from certain process points and added back to other process points should be adjusted to achieve the most preferred EA concentration profile in all cooking stages that follow the impregnation stage. Consideration should also be given to the liquor removal and addition locations with regard to hydraulic balance of the digester, as well as to the ease of chip column movement for improved digester operational stability.
Example 6
[0039] FIGS. 7 a & 7 b illustrate the application of the present invention in a battery of batch digesters 410 , 420 , 430 and 440 capable of running modified batch cooking. For each digester the 100% required alkali dosage in the form of polysulfide (orange) liquor is added to the beginning of a cook, either together with wood chips or after all required wood chips have been added. Each batch digester, e.g., digester #1, is equipped with a cooking circulation loop 411 , consisting of a set of drainer (extraction screen) 412 , a circulation pump 413 and a heater 414 . The first quantity of cooking liquor 44 high in effective alkali is removed from digester vessel #1 that is just at the end of the impregnation stage, and added to another digester (vessel #4), which completed the impregnation stage and has undergone substantial cooking, e.g., at least 30 minutes at cooking temperature and after the second quantity of cooking liquor low in effective alkali was removed from this vessel. The second quantity of cooking liquor 46 low in effective alkali concentration, removed from digester #3 is added to digester vessel #2 after the first quantity of cooking was removed.
[0040] Alternatively, the first quantity and second quantity of removed liquor may be stored in separate liquor tanks before being pumped into another digester at a different cooking stage to achieve the preferred alkali concentration profile.
[0041] As can be seen, according to the invention a cooking liquor of relatively high effective alkali concentration is “exchanged” with a cooking liquor of relatively low effective alkali concentration, wherein the cooking liquors of relatively high and low concentrations, respectively, are extracted from the cooking process at different process points or times and reinserted or recycled into the cooking process at other points or times.
[0042] While particular embodiments of the invention have been illustrated and described in detail herein, it should be understood that various changes and modifications may be made in the invention without departing from the spirit and intent of the invention as defined by the appended claims.
|
A method for Kraft pulping employing a modified cooking process in conjunction with polysulfide pulping technologies to obtain higher pulping yields than obtained in the prior art. The total required alkali charge (polysulfide liquor) is added to the beginning of a cook, and after all polysulfide has essentially reacted with lignocellulosic material at temperature below that at which no significant carbohydrate degradation occurs, a first quantity of the cooking liquor high in effective alkali (EA) concentration is removed from a first point in the pulping process and replaced with a cooking liquor low in EA concentration removed from another process point. The first quantity is then added elsewhere in the pulping process, where the EA concentration is low. This cooking liquor “exchange” obtains the full yield benefit from polysulfide pulping and a more uniform EA concentration profile to retain the major benefits of modified cooking.
| 3
|
FIELD OF THE INVENTION
The invention relates to a removably-mountable integral lighting system and, more particularly, to a removable bicycle light assembly.
BACKGROUND OF THE INVENTION
Bicycle lighting systems which are operable from batteries or miniature generators are well known in the art. Most bicycle lighting systems consist of a headlamp for providing adequate light to illuminate the path that lies ahead of the bicycle. Other known bicycle lighting systems may also include a high-visibility tail lamp to indicate the presence of the bicycle to vehicles that are following the bicycle. Moreover, bicycle lighting systems are required safety devices for people bicycling at dusk or in darkness. Such lighting devices must be lightweight so as not to add too much weight to the bicycle and are also preferably aesthetically pleasing.
One limitation of prior art bicycle lighting systems is that most are multi-part assemblies with a separate headlight, a tail light and a power supply, all interconnected by open wiring. Such systems are unnecessary during daylight hours and add needless weight to the bicycle. In addition, they are time consuming to install and/or remove and subject to theft when the bicycle is left unattended.
For example, U.K. Patent No. 13,344 to Harton describes a bicycle lighting system including separate electric head and tail lamps arranged so that they may be independently switched on and off. The headlamp is secured to the bicycle head tube near the handle bar; while the tail lamp is attached to the rear wheel support frame. A batteries box and control switches assembly are secured to the frame of the cycle and connected to the lamps by wiring.
In U.S. Pat. No. 1,439,430to Lyhne, it is taught battery covers for supporting and protecting batteries to be used for lighting on bicycle. The battery container is to be clamped in a bicycle frame and to be connected to the lamps.
U.S. Pat. No. 3,894,281 to Bloomfield teaches a vehicle lighting system that utilizes both generating means and battery means to provide constant lighting whether the bicycle is moving or not. The headlamp and the tail lamp are separately mounted on different parts of the bicycle.
U.S. Pat. No. 4,019,171 to Martelet teaches a velocity-responsive lighting system including light means that are periodically illuminated in sequence for a period determined by the velocity of the vehicle. The switch and circuit assembly is secured to the horizontal top tube of the bicycle, while the rear light assembly is secured to the rear fender by a U-shaped bracket. The magnetically responsive switch assembly is attached to seat stay support member.
Other single lamp bicycle layout systems have been constructed to be removable. For example, U.S. Pat. No. 1,848,235 to Wiley discloses a lamp mounting which is detachably securable to a mud guard of a bicycle or a motorcycle. The bracket readily conforms to the contour of mud-guards of various shapes and dimensions. The device provides a releasable clamping member by which the mounting may be firmly secured against displacement on a mud-guard without requiring the drilling of holes on the mudguard.
U.S. Pat. No. 4,204,191 to Daniels discloses a bicycle lighting system which provides a turn indication feature. The housing for the battery power and the circuit is removably mounted upon an upstanding strut of the bicycle frame. The headlamp, the tail lamp, and the indicator lamp are each separately secured to other parts of the bicycle. Similarly, Spingler in U.S. Pat. No. 4,325,108 teaches a rechargeable battery unit that is removably attached to a bicycle. The device includes a transfer switch to permit selective energizing of a headlamp and/or tail lamp from a battery or from a generator.
U.S. Pat. No. 4,555,656 to Ryan discloses a generator and rechargeable battery system for a bicycle. The battery system is secured to the seat tube of the bicycle. The headlamp is separately mounted to the handle bar, while the tail lamp is attached to the rear "mud-guard" of the bicycle.
None of the illustrated prior art bicycle lighting systems discussed includes an integral, one-piece, lighting assembly which is completely removably mounted on a bicycle. In each of the prior systems, the power supply, the headlamp, and the tail lamp are separately mounted on different parts of the bicycle. The present invention overcomes many of the disadvantages of known bicycle lighting systems by adapting an integral lighting system to secure as a totally removably-mountable lighting assembly for a bicycle. Such a lighting system can be mounted to the bicycle when it is needed and removed and safely stored when it is not. Thus, no extra weight is being "carried along" on the bicycle when no lighting system is needed. Further, the integral lighting system of the present invention can be completely removed from the bicycle to prevent theft of the system when the bicycle is left locked but unattended. The present integral lighting system is portable and can be secured in a backpack or briefcase.
Moreover, the specific construction of the present assembly provides a beam of light from the headlamp that is steady and does not jump from side-to-side as the rider of the bicycle moves the handle bar to turn or maneuver the bicycle. This is due to the fact that the headlamp is secured to the bicycle's frame, which will only move slightly from side-to-side while the handlebars are moved through large angles. Handlebar-mounted headlamps necessarily move through the same angle that the handlebar does.
SUMMARY OF THE INVENTION
The present invention relates to a removably-mountable integral lighting system having an elongate housing assembly including means for receiving a battery and adapted for removable securement to a structural member; a first lighting assembly mounted to a forward end of the housing and electrically connected to the battery for being illuminated; and a second lighting assembly mounted to the rear end of the housing and electrically connected to the battery for being illuminated. The length of the mounting assembly can be adjusted to accommodate attachment to different sizes of bicycles.
Accordingly, an object of the present invention is to provide an integral bicycle lighting system, or device, that can be totally and easily mounted on, and removed from, a bicycle.
Another object of the present invention is to provide an integral bicycle lighting system, or device, that can be easily mounted, whether or not using the tire pump peg of the bicycle, on any size of bicycle by simply extending or shortening the lighting device itself.
A further object of the present invention is to provide an integral bicycle lighting system, or device, having both the headlamp and the tail lamp remain in the optimum positions relative to the bicycle frame.
Still a further object of the present invention is to provide an integral bicycle lighting system, or device, with the headlamp projecting the light unencumbered, while not interfering with the rotation of the handle bars nor interfering with the use of the front brakes.
Yet another object of the present invention is to provide an integral bicycle lighting system, or device, with a tail lamp mount that stays close to the seat tube or seat stay so as not to interfere with the rider's legs as he or she pedals the bicycle.
Still another object of the present invention is to provide an integral bicycle lighting system, or device, that is battery powered and will operate whether the vehicle, such as a bicycle, is moving or not.
A further object of the present invention is to provide an integral bicycle lighting system, or device, that is lightweight, and can be actuated by a manual switch, and whose power supply is rechargeable by household current via a transformer.
A still further object of the present invention is to provide an integral bicycle lighting system that can be taken apart, folded and stored in a backpack or briefcase.
Yet another object of the present invention is to provide an integral bicycle lighting system, or device, that can be mass produced at reasonable costs.
Yet a further object of the present invention is to provide an integral bicycle lighting system that gives out a beam of light from the headlamp that is steady and does not jump from side-to-side as the rider of the bicycle jerks the handle bar from side-to-side.
Still another object of the present invention is to provide an integral bicycle lighting system in which the angles of both the headlamp and the tail lamp can be readily adjusted.
Another object of the present invention is to provide an integral bicycle lighting system that has no exposed wires.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and for further objects and advantages thereof, reference may now be added to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a side plan view of a bicycle having a removably-mountable integral bicycle lighting system constructed with the principles of the present invention, mounted along and under its horizontal top tube;
FIG. 1A is a partial side view of the head tube of a bicycle illustrating a feature related to mounting of the present lighting system;
FIG. 2 is a perspective view of one embodiment of a removably-mountable integral bicycle lighting system constructed in accordance with the principles of the present invention;
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2;
FIG. 4 is an exploded perspective view of the removably-mountable integral bicycle lighting system of FIG. 2 illustrating some of the internal components of a removably-mountable integral bicycle lighting system;
FIG. 5 is a cross-sectional view taken along line 5--5 of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present bicycle lighting system is adapted for removable inclusion on most types of modern bicycles or similar riding conveyers. Referring first to FIG. 1, there is shown a conventional modern bicycle 200 which includes a frame 201, a pair of handle bars 202, a seat 204, a pair of wheels 206 and 208 and pedals 210 adapted for driving the rear wheel through a chain and sprocket mechanism. The frame 201 consists of a top tube 68, to which a head tube 65 and seat tube 62 are integrally attached. A down tube 63 is attached at the lower rear portion of the head tube 65. At the juncture of the down tube 63 and seat tube 62 is the bottom bracket 214 which mounts the pedals 210 and drive sprocket mechanism. The front wheel 208 is mounted between a front fork 212, which is attached to the handle bars 202 for steering. Two seat stays 66 extend downward and backward from the seat tube 62 on either side of the rear wheel 206. Two chain stays 220 extend backward from the bottom bracket 214 on either side of the rear wheel 206. The rear wheel's axle is mounted at the junction of the chain stays 220 and seat stays 66 on either side of the rear wheel 206. As seen in FIG. 1A, certain bicycles include a tire pump peg 67 formed on the rear of the head tube 65 for use in mounting a tire pump to the frame of the bicycle. As can be seen in FIGS. 1 and 1A, many modern bicycles have no mudguards covering the wheels of the bicycle thus limiting the mounting location for bicycle lighting systems for use on the bicycle.
Referring to FIG. 1, there is shown a side plan view of a bicycle having mounted along its horizontal top tube 68 a removably-mountable integral bicycle lighting system 10 constructed in accordance with the principles of the present invention. The bicycle lighting system 10 is situated between the head tube 65 and the seat tube 62 and, in this embodiment, is mounted on the top tube 68 using an auxiliary clamp 54. For a bicycle that is equipped with a tire pump peg, as illustrated in FIG. 1A, the auxiliary clamp 54 is not needed to mount the lighting system 10 onto the bicycle, as will be further discussed below.
As can be seen from FIG. 1, the lighting system of the present invention 10 includes an elongate tubular assembly formed of a battery chamber 38 which is closed at the rear end by an internal contact plug 27 (not shown). The forward end of the tubular assembly mounts a head lamp 52, which is attached by a holder 42 which allows adjustment of the headlamp angle and, thus, the angle of the light shining in front of the bicycle 200. A battery pack end cap 34 is inserted into the battery pack 38. An electrical contact post 21 or 19 (not shown) on the forward end of the battery pack end cap 34 is inserted into the rearward end of the internal contact plug 27 (not shown). Cap 34 is affixed to a cylindrical rear mount 18 by means of a spring biased adjustable spring clamp means (not shown). Spring clamp means recesses to secure the tubular assembly just below the top tube 68 of the bicycle 200, wedged between the head tube 65 and the seat tube 62 by the force of the spring bias. Affixed to rear mount 18 is a conduit 16 which mounts a tail lamp 12. The angle of tail lamp 12 may be adjusted by rotating it on the rear end of conduit 16.
Referring now to FIG. 2, there is shown a perspective view of one embodiment of a removably-mountable integral bicycle lighting system 10 constructed in accordance with the principles of the present invention along with fragmentary portions of the horizontal top tube 68 of a bicycle. A first, or forward, lighting assembly comprises a headlamp holder or conduit 42, a headlamp angle quick release lever 48, and a headlamp 52. In this particular embodiment, an auxiliary tire pump peg 44 is fitted along the underside of the battery pack 38. Furthermore, a recess 134 adapted to engage a bicycle frame tire pump peg 67 (not shown) is provided on the frontal surface of the battery pack 38. A female portion 46 of a T-slot mounting is also formed along the upper side of the battery pack 38. As shown in FIGS. 1 and 2, the front end of the lighting system 10 can also be held to the bicycle to the top tube 68 by a T-slot clamp 54 which mounts the male portion 56 of the T-slot mounting sliding engagement with the female portion 46 of the T-slot mounting. Clamp 54, thus, serves to hold the front end of the lighting system 10 to the top tube 68. The front of the lighting system 10 butts up against the back of the head tube 65 (as shown in FIG. 1) so that there is no transverse pressure of the lighting system or device 10 against the T-slot clamp 54, since the male T-slot clamp 54 is not all the way into the female portion 46 of the T-slot and does not contact the rearmost portion of the female T-slot. Near the front and on the underside of the battery chamber or pack 38 is an on-and-off toggle switch 45 which is connected to enable manually actuating both the headlamp 52 and the tail lamp 12. Also provided near the rear of the battery chamber 38 are screw holes 36 for receiving threaded screws to fasten the battery chamber 38 to the internal contact plug 27 (not shown) as discussed below inside the battery chamber 38. Beneath and near the front or forward portion of the battery chamber 38 is a battery recharger receptacle 47. The batteries mounted within the battery chamber 38 can be recharged by means of household current (via a transformer) connected to the system through this receptacle 47.
Still referring to FIG. 2, the middle assembly of the lighting system 10 includes a battery housing for receiving a plurality of longitudinally abutting and series connected direct-current batteries. Although conventional cylindrical, D-size dry cell batteries are shown, other sizes, shapes and types of batteries could be used. At the rear of the middle assembly are a washer 17 and two cam levers 28. In use, one terminal of each cam lever 28 abuttedly engages the surface of the washer 17. Spring 26 allows for misadjustment of the length of the elongate lighting system 10. Directly rearward from the battery pack 38 is the battery pack end cap 34.
Rearward from the washer 17 is the second, or rear, lighting assembly comprising a compression-type spring 26 followed by an internally threaded washer 24. The internally threaded washer 24 fits over a threaded shaft 22 comprising a length adjuster which can be screwed in and out along the horizontal axis of the lighting system 10. Firmly attached on the rearward portion of the threaded shaft 22 is the rear mount 18. The rear mount 18, the quick release lever 15, the tail lamp holder 16, and the tail lamp 12, together with the quick release lever 14 for adjusting tail lamp angle make up the remainder of the rear lighting assembly. FIG. 2 shows that the rear mount 18 is positioned abuttedly against the front surface of the seat tube 62 via a lower V-block 116. The upper V-block 114, in turn, abuttedly engages the rear underside of top tube 68.
Referring now to FIG. 3, there is shown a cross-sectional view taken along line 3--3 of FIG. 2. The cross-section of coiled electrical cord is shown as 61. A negative electrical wire 67 and a positive electric wire 65 emerge from the coiled cord 61 for making the necessary electrical connection. The battery pack end cap 34 surrounds and encompasses the threaded shaft length adjuster 22. Internal spline 59 in the battery pack end cap 34 slides into a groove 72 formed along the length of the threaded shaft length adjuster 22 and, thus, prevents the shaft 22 from rotating out of position with respect to the battery pack end cap 34. This, in effect, assures that the entire lighting system 10 does not rotate out of its proper position with respect to the bicycle frame 201.
Referring now to FIG. 4, it can be seen that the length of the lighting system 10 can be adjusted by rotating the internally threaded washer 24 along the length of the threaded shaft length adjuster 22. The internally threaded washer 24 can be moved along the helical grooves extending the entire length of the threaded shaft length adjuster 22 by simply rotating it either clockwise or counter-clockwise. The closer the washer 24 comes to the rearmount 18, the shorter the overall length of the lighting system 10 becomes. The forward portion of the threaded shaft length adjuster 22 slides into the cavity of the battery pack end cap 34 as the length of the lighting system 10 is shortened.
Still referring to FIG. 4, to mount the lighting system 10 along and beneath the top tube of the bicycle, it is necessary to adjust the internally threaded washer 24 by rotating it so that the entire system 10 will be about 3/8 shorter than the space between the head tube 65 and the seat tube 62 of the bicycle to which the system is to be mounted. During length adjustment, the two cam levers 28 should be in their downward position, that is, the long dimension of the levers should extend perpendicular to the axis of the battery housing so that the compression-type spring 26 is also in its relaxed (uncompressed) state. The rearward surface of washer 17 abuts the forward end of spring 26. The forward portion of the threaded shaft length adjuster 22 slides into the battery pack end cap 34. For the purpose of length adjustment, the threaded shaft length adjuster 22 should slide into the battery pack end cap 34 to the extent that the vertical surface of the internally threaded washer 24 abuts the compression-type spring 26 which, in turn, abuts one radially extending surface of washer 17. The opposite surface of washer 17 abuts the battery pack end cap 34.
When the length of the lighting system 10 has been properly adjusted, the lighting system 10 is placed in its mounting position just under, and substantially parallel to, the top tube of the bicycle. Then, both cam levers 28 are rotated 90° in a forward and upward direction so that the long dimension of levers 28 is parallel to the axis of the battery housing. Rotation of the cam levers 28 in this direction presses the flat surface 13 of the levers against the forward surface of washer 17. The rearward surface of washer 17 also compresses helical spring 26. Spring 26, in turn, presses against the forward vertical surface of the internally threaded washer 24. The washer 17 has an internal circular hole large enough to slide unhindered along the entire length of the threaded shaft length adjuster 22. Spring 26 must be made from a very stiff material, so that its effective length does not vary much as it is compressed. When the cam levers 28 are rotated 90° in a forward and upward direction (i.e., in a "locked" position in which the long dimension levers are parallel to the battery housing), the entire rearward assembly is moved toward the rear of the bicycle, thus extending the length of the light system 10.
A flat surface 13 on cam levers 28 protrudes about 3/4". Rotating levers 28 in a forward and upward direction so that the long dimension of the levers is parallel to the axis of the battery holder should, therefore, extend the length of the entire lighting system 10 by about 3/4". However, as mentioned above, the length of the entire system has been previously adjusted to be only 3/8" shorter than the space between the head tube 65 and the seat tube 62 of the bicycle to which the system is to be mounted. Therefore, when the cam levers 28 are rotated in a forward and upward direction, the system's length increases by about 3/8", compressing the spring 26 by about 3/8" in length at the same time. That is, when spring 26 is compressed, it is about 3/8" shorter than when it is in its relaxed, uncompressed condition. In this way, spring 26 presses the forward and rearward halves of the system away from one another. This force holds the entire lighting system 10 in place in between the head tube 65 and the seat tube 62 of the bicycle to which the system is mounted. The force also pushes washer 17 against flat surface 13 of levers 28 to insure that the levers do not rotate back to their downward (unlocked) position. Spring 26 also has another function, in that it allows "misadjustment" of overall length when the internally threaded washer 24 is initially positioned. For example, if the internally threaded washer 24 has been posi-tioned so that the length of the assembly of the lighting system 10 is about 1/4" or 1/2" shorter than the space between the head tube and the seat tube of the bicycle, instead of the preferred 3/8" distance as mentioned above, spring 26 will allow for this misadjustment by compressing its length more or less as required when the cam levers 28 are rotated 90° in a forward and upward position to lock the system in place.
The internal parts of the battery pack 38, the internal contact plug 27 in the battery pack, the interior of the battery pack end cap 34, and the threaded shaft length adjuster 22 are each provided with either a longitudinally extending groove or a mating spline to engage one another to prevent any rotation of the internal components of the lighting system 10. Thus, when the lighting system is assembled, all these components are positioned in their correct rotational orientation with respect to each other. That is, the headlamp 52 and the tail lamp 12 protrude off to the left side of the bicycle and in a direction parallel to the ground. In this configuration, spline 25 of the internal contact plug 27 is received into groove 60; spline 23 of the battery pack mid cap 29 is also received into groove 60 of the battery pack 38; and the internal spline 59 of the battery pack end cap 34 is received into groove 72 of the threaded shaft length adjuster 22.
The coiled electrical cord 61 is connected to both the positive electrical contact post 19 and the negative contact 21 in order to complete the power circuit to the tail lamp 12. The coils in the cord 61 accomodate changes in overall length of the lighting system 10. FIG. 4 illustrates the use of five batteries 37 in series inside the battery housing or battery pack 38. Normally, five D-cell batteries are used, each with 1.25 volts, although other configurations are possible. The battery pack 38 is provided with three screw holes 36 which receive threaded screws 35 to secure the internal contact plug 27 in place within the battery pack by means of holes 33 formed in the internal contact plug 27 in alignment with holes 36 of the battery pack 38. The internal contact plug 27 includes a contact spring 31, for electrical engagement with the negative pole of the batteries.
Still referring to FIG. 4, the front end of the outer housing of the lighting system 10 includes a recessed hole 134 for engaging the tire pump peg on the rear of the head tube of a bicycle. Also at the forward end of the housing is a headlamp conduit 42 which is preferably hollow and includes an externally threaded shaft that passes through a transversely extending aperture in the rear of the headlamp assembly 52. A quick-release lever 48 for headlamp 52 is internally threaded and is received onto the threaded shaft at the end of the conduit 42. When the lever 48 is rotated in a clockwise direction, the lever presses against the bore of the headlamp assembly to lock it into position against the end of the conduit 42. When the lever 48 is rotated in a counter-clockwise direction, as shown by arrow 102, it no longer presses the headlamp assembly against the end of conduit 42, so the headlamp 52 can rotate freely about the threaded shaft upon which it is mounted in either an upward or a downward direction as shown by arrows 104 to adjust the angle of the headlight beam. When the desired angular position of the headlamp assembly has been attained, lever 48 is turned clockwise to again lock the headlamp 52 against further movement.
For purposes of storage, the elongate housing can be separated into two pieces at the junction of battery pack 38 and battery pack end cap 34. When assembled, the electrical contact 21 is retained inside the internal electrical contact plug 27 by a clip (not shown). For separation, simply pull the battery pack end cap 34 rearward. Further, the tail lamp holder 16 can be folded back 180° to reduce the length of the stored piece.
The height of the tail lamp assembly is adjustable by a mechanism that is similar to the one described above for adjusting the angle of headlamp 52. This allows the height of the tail lamp to be adjusted in order to clear any packs or racks that may be attached to the bicycle or the seat. When the quick-release lever 15 is rotated in the direction as shown by arrows 98, the conduit 16 can be rotated in the direction as shown by arrows 96. Similarly, the quick-release lever 14 is rotated clockwise to lock the tail lamp 12 into position. When the quick-release lever 14 is rotated in a counter-clockwise direction, as shown by arrows 92, the tail lamp 12 can be rotated in a direction as shown by arrows 94.
Referring now to FIG. 5, there is shown a longitudinal cross-sectional view taken along line 5--5 of FIG. 2. Here it is shown that the lighting system 10 is controlled by toggle 45 of the on/off switch 132. The auxiliary tire pump peg 44 is shown to be situated on the underside of the battery housing near the front portion of the lighting system 10. The positive contact post 19, together with its negative electrical contact 21, is connected to the coiled cord 61 through a connecter 124. At the rear of lighting system 10 the tail lamp holder 16 receives the coiled cord 61 therein. Wiring continues through conduit 16 to the tail lamp (not shown). When the system is mounted on a bicycle frame, the upper V-block 114 and the lower rearward V-block 116 engage the lower side of the top tube 68 and forward side of the seat tube 62 of the bicycle, respectively, as illustrated in FIG. 2. The two V-blocks, 114 and 116, prevent the lighting system 10 from rotating and also center the system under the top tube 68 and against the seat tube 62.
Referring to FIG. 5, there is shown a schematic circuit of the lighting system 10. None of the wires are exposed to the outside but, rather, are contained within the housing unit itself for protection. Schematic line 140 represents the connection of a lead from the negative pole of the rearmost battery 37 to the recharger receptacle 47 (not shown). Contact plate 142 includes two contacts, the first of which is connected to wire 143 that extends directly to the battery recharger receptacle 47 (not shown) so that the lighting system 10 can be recharged regardless of the position of the on/off switch 132; the second contact of plate 142 is connected to wire 146 that is, in turn, connected to the on/off switch 132 to interrupt current to both the headlamp 52 and the tail lamp 12 when the switch is turned to its "off" position. The headlamp 52 is connected to a positive lead 144, and to the negative pole of the last battery through schematic line 138. The tail lamp 12 is connected to a positive lead represented by schematic line 136 and joins lead 144. The tail lamp 12 is also connected to the negative pole of the rearmost battery through coiled cord 61, connector 124, electrical contact 21, and spring 31.
The lighting system 10 is preferably constructed from lightweight but sturdy plastic or metal alloy. Both the tail lamp conduit 16 and the headlamp conduit 42 can be constructed from acrylonitrile-butadiene-styrene terpolymers (ABS) plastic or aluminum alloy. The casing of battery pack 38 and the threaded shaft length adjuster 22 are preferably made from ABS plastic. Because of the strength requirements, washer 17, quick release levers 14, 15 and 48 and cam levers 28 are preferably constructed from light metal or alloy, such as aluminum or aluminum alloy. Springs 26 and 31 are constructed from steel. Model U70sheadlamp from Germany, available in this country from the Union Frondenberg U.S.A. Co. in Olney, Illinois, has been used satisfactorily for headlamp 52. Likewise, a Model S70 lamp from the same source is also satisfactory for tail lamp 12.
It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description. While the method and device shown and described have been characterized as being preferred, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the invention as defined in the following claims.
|
The present invention relates to a removably-mountable integral lighting system having an elongate battery housing which includes a first lighting assembly mounted to its forward end, and a second lighting assembly mounted to its rear end. Each end of the housing includes means for engaging a structural member. The length of the housing can be axially adjusted to allow removable mounting of the system between the structural members of a vehicle and to accommodate mounting spaces of different sizes. The elongate housing includes at least two sections which are axially movable with respect to one another and are spring biased to allow compression of the spring when one end of the housing is moved toward the other for producing a force of securement when the housing is positioned in a space between two structural members which space is smaller than the overall length of the housing in an uncompressed state.
| 1
|
REFERENCE TO RELATED DOCUMENTS
Reference is made to Berman U.S. Pat. No. 3,930,507 issued Jan. 6, 1976 for an adjustable oral airway, to Berman U.S. Pat. No. 2,599,521 issued June 3, 1952 for a respiratory device and to the references cited in each patent. The proximal location of an airway with respect to the pharynx, epiglottis, vallecular and trachea of a patient may be seen in FIG. 10 of Berman Pat. No. 3,930,507.
BACKGROUND OF THE INVENTION
The device shown in Berman Pat. No. 2,599,521 is used for the purposes of aiding the breathing of anesthetized or otherwise unconscious patients and such device is now well-known in the medical profession as the Berman Oral Airway. The Berman Oral Airway, and later devices modeled thereafter, is employed in the practice of surgery and medicine by insertion into the mouth and pharynx of a patient to provide a channel for respiratory purposes.
The adjustable oral airway of Berman Pat. No. 3,930,507 shows an airway having two sections slideable with respect to each other and joined at the distal end.
SUMMARY OF THE INVENTION
The Berman Intubating Pharyngeal Airway of the present invention briefly, but not by way of limitation, provides a tubular airway having an openable side to allow passage of appropriate medical and surgical applicances, such as an endotracheal tube, into the larynx and trachea without the use of a laryngoscope. The side opening airway permits blind oral intubating of the larynx and esophagus with ease even in difficult cases of cardiopulmonary-resuscitation and anesthetic procedures.
The intubating airway is designed to place an endotracheal tube into the larynx and trachea while at the same time providing an adequate pharyngeal airway itself.
The lateral opening at the side of the airway allows the airway to be removed from the mouth, leaving endotracheal tube in place. The airway is designed primarily to place the endotracheal tube into the trachea and at the same time provide an adequate pharyngeal airway by itself. The extra large lumen of the airway separates the tongue from the pharynx allowing a wider unobstructed air passageway from the lips to the larynx.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side view of a preferred embodiment of the intubating airway of the present invention, showing the hinge side.
FIG. 2 is a view of the opposite side of the intubating airway of FIG. 1 showing the longitudinal side opening.
FIG. 3 is a proximal end view of the intubating airway of FIG. 1.
FIG. 4 is a cross-sectional view taken across line 4--4 of FIG. 3.
FIG. 5 is an enlarged cross-sectional view taken across line 5--5 of FIG. 1.
FIG. 6 is an enlarged cross-sectional view taken across line 6--6 of FIG. 1.
FIG. 7 is a cross-sectional view similar to that of FIG. 6 but showing the airway in its closed position.
FIG. 8 is a fragmentary distal end view as seen across line 8--8 of FIG. 1.
FIG. 9 is a side view of a first modified embodiment of the intubating airway of the present invention. The side opening is visible.
FIG. 10 is a view of the opposite, hinge side of the intubating airway of FIG. 9.
FIG. 11 is a cross-sectional view taken across line 11--11 of FIG. 9.
FIG. 12 is a cross-sectional view taken across line 12--12 of FIG. 10.
FIG. 13 is a view similar to that of FIG. 11 but showing the airway in its open position.
FIG. 14 is a cross-sectional view taken across line 14--14 of FIG. 10.
FIG. 15 is a side view of a second modified embodiment of the intubating airway of the present invention.
FIG. 16 is a view of the opposite side of the intubating airway shown in FIG. 15.
FIG. 17 is a proximal end view of the intubating airway shown in FIG. 15.
FIG. 18 is a rear view of the intubating airway shown in FIG. 15.
FIG. 19 is a cross-sectional view taken in line 19--19 of FIG. 17.
FIG. 20 is a cross-sectional view taken across line 20--20 of FIG. 15.
FIG. 21 is a cross-sectional view taken across line 21--21 of FIG. 15.
FIG. 22 is a view similar to that of FIG. 15 with the plug closure removed.
FIG. 23 is a cross-sectional view taken across line 23--23 of FIG. 22.
FIG. 24 is a side view of the plug closure shown in FIG. 15.
FIG. 25 is a cross-sectional view taken across line 25--25 of FIG. 24.
FIG. 26 is a side view of a third modified embodiment of the intubating airway of the present invention.
FIG. 27 is a cross-sectional view taken across line 27--27 of FIG. 26.
FIG. 28 is a proximal end view of the cap closure of the third modified embodiment as shown in FIG. 26.
FIG. 29 is a side view of a fourth modified embodiment of the intubating airway of the present invention.
FIG. 30 is a cross-sectional view taken across line 30--30 of FIG. 29.
FIG. 31 is a cross-sectional view taken across line 31--31 of FIG. 29.
FIG. 32 is a view of the embodiment of the intubating airway of FIG. 29 shown in place in the mouth of a patient with an endotracheal tube positioned therethrough. The patient is shown in partial sagittal section.
DESCRIPTION OF THE INVENTION
With reference to the drawing, a preferred embodiment of the invention is shown in FIGS. 1-8 and comprises a intubating airway 10 having a flanged proximal end 12 and an enlarged rounded distal end 14 with an intermediate curved tubular section 16 between the proximal and distal ends.
Tubular section 16 is substantially uniform in cross-section and comprises two longitudinal sections 18 and 20 joined on one side of tube 16 by a hinge 22 and having a mating opening 24 extending longitudinally of tube 16 on the opposite side thereof from hinge 22. Longitudinal opening 24 extends fully from end to end of intubating airway 10, including the proximal and distal ends thereof, whereby the airway may be opened or closed at longitudinal opening 24 by rotation about hinge 22. This feature may be seen in a comparison of FIGS. 6 and 7.
Intubating airway 10 may be molded of a suitable autoclavable material sufficiently rigid to maintain its shape and sufficiently plastic to permit flexibility in each and in opening and closing longitudinal opening 24. In particular, hinge 22 may be a molded hinge having an outer flex portion 26 adjacent proximal end 12 and an inner flex portion 28 adjacent distal end 14. Due to the longitudinal curvature of tube 16, it will be noted that upper and lower hinge members 26 and 28, respectively, are not co-axially aligned and hinge 22 accordingly has a degree of flexibility and plasticity to enable opening and closing of longitudinal opening 24.
Longitudinal opening 24 has a tongue and groove closure wherein tongue 30 is an integral part of upper section 18 and mating groove 32 is an integral part of and is defined in lower section 20.
With reference now to the first modified embodiment of the invention as shown in FIGS. 9-14, intubating airway 10a comprises an integral flanged proximal end 12a, an expanded integral ball distal end 14a and a longitudinally curved tubular mid-section 16a having a longitudinally extending open side 24a and an opposite hinge side 22a, all substantially similar to similar portions of the preferred embodiment.
Longitudinal opening 24a is a snap-closure comprising a longitudinal male member 30a formed integrally with upper section 18a of tube 16a and a longitudinal female member 32a formed and defined in lower section 20a of tube 16a. The snap-closure and opening may be seen in a comparison of FIGS. 11 and 13.
A second modified embodiment of the invention is shown in FIGS. 15-25. Intubating airway 10b comprises an integral flanged proximal end 12b, an inner expanded rounded distal end 14b and an intermediate longitudinal curved tubular section 16b having a longitudinal opening 24b along one side thereof. Longitudinal opening 24bis large enough to pass laterally such suitable surgical and medical devises as an endotracheal tube 50 such as is shown in FIG. 32 in connection with another embodiment. Longitudinal opening 24b does not close by hinge action as is the case in the former embodiments and there is no hinge member per se in the present embodiment although the inherent flexibility of the material from which intubating airway 10b is molded will yield some degree of variability in the transverse dimension of longitudinal opening 24b. In the present embodiment, longitudinal opening 24b may be closed by a longitudinal plug closure 40b which is adapted to snap laterally or slide longitudinally into longitudinal opening 24b and thereby close the same. Plug closure 40b comprises a longitudinal body section 42b having upper and lower grooves 44b and 46b, respectively, to engage upper and lower jaws 31b and 33b, respectively, of longitudinal opening 24b. The main body portion 42b is longitudinally curved in accordance with longitudinal curvature of tubular section 16b and is provided with a flanged outer end 48b which acts as a handle for ease of insertion or removal of plug closure 40b with respect to longitudinal opening 24b. As with flanged proximal end 12b, flanged outer end 48b has the additional function of being a bite block which helps to secure the laryngoscopic intubating airway at the patient's mouth to prevent undesirable inward displacement thereof down the patient's throat.
A third modified embodiment of the invention is shown in FIGS. 26-28 and comprises intubating airway 10c, substantially similar to intubating airway 10b of the second modified embodiment, having a similar flanged proximal end 12c, an expanded rounded distal tip 14c and an intermediate longitudinally curved tubular member 16c having a longitudinal opening 24c along one side thereof.
A cap closure 40c is provided to close opening 24c by securing over the outside of tubular member 16c. Cap closure 40c is accordingly a channel member having a substantially U-shaped cross-section and is curved longitudinally in accordance with the curvature of tubular portion 16c.
A fourth modified embodiment is shown in FIGS. 29-32 and comprises a intubating airway 10d having a flanged proximal end 12d, an expanded rounded distal end 14d and an intermediate longitudinally curved tubular section 16d having a longitudinal opening 24d along one side thereof. Extending into longitudinal opening 24d, and partially obstructing the same, are a plurality of retaining pins 35d which are preferably molded integrally with tubular portion 16d. It is the function of retaining pins 35d to retain a tube such as endotracheal tube 50 from unwanted lateral displacement through opening 24d or, conversely, to prevent unwanted lateral displacement of intubating airway 10d with respect to endotracheal tube 50. Retaining pins 35d are provided with a degree of flexibility sufficient to permit lateral passage of endotracheal tube 50 into or out of opening 24d when so intended and manually manipulated by qualified personnel. Retaining pins 35d obviate the need for other closure members and opening 24d but, nevertheless, such a closure member as cap closure 40c may be provided if desired.
Also shown in connection with the fourth embodiment is a second set of flanges 13d located on tubular member 16d a spaced distance from proximal end 12d, the function of all such flanges being to locate the intubating airway against longitudinal displacement with respect to the patient's mouth and throat. As may be seen in FIG. 32, flanged proximal end 12d engages against the patient's lips to limit inward displacement of the airway while flanges 13d lock inside patient's teeth to prevent unwanted outward displacement of the airway. It may be seen that the tubular construction of the airway together with the side opening thereof provides an airway of unparalleled usefulness.
While the foregoing is illustrative of preferred and modified embodiments of the invention it is clear that other modifications may be had within the scope of the invention.
A preferred material from which the airway may be molded or otherwise formed is polyethylene.
|
A intubating pharyngeal airway having a side access for passage of a tube on the said airway comprising a flanged stop at the proximal end, a curved airway central tubular member and a distal ball tip adapted to fit into the vallecular. The side opening may be expanded or closed by means of either a hinge on the opposite side wall of the tube or by a cap or insert closure.
| 0
|
FIELD OF THE INVENTION
[0001] This invention relates, in general, to an exercise device and relates more particularly, though not exclusively, to an exercise device which can allow the user to perform multiple exercises on one and the same machine or piece of equipment.
BACKGROUND OF THE INVENTION
[0002] The present invention in aspect provides an exercise device which includes at least one pair of independently movable leg supports which are pivotally connectable to a main body support to raise and lower, either separately and/or together, a user's legs during exercise between upper and lower positions and an adjustment device to allow the positions of said upper and lower positions to be changed.
SUMMARY OF INVENTION
[0003] In a further aspect of the invention there is provided an exercise device which includes at least one pair of independently movable leg supports which are pivotally connectable to a main body support to raise and lower a user's legs, either separately and/or in unison, during exercise between upper and lower positions, a C-shaped support member having a pair of side arms and a vertical link arm whereby the side arms are pivotally mounted to provide a swivelling or swinging action for said vertical link arm, and wherein at least one pair of said leg supports are pivotally attached to opposing sides of said vertical link to allow a swivelling or swinging movement for said leg supports.
[0004] Preferably said exercise device further includes an adjustment device to allow the positions of said upper and lower positions to be changed. Preferably a seat is attached to the uppermost of said side arms.
[0005] In a further aspect of the invention there is provided an exercise device which includes at least one pair of independently movable leg supports which are pivotally connectable to a main body support to raise and lower, either separately and/or together, a user's legs during exercise between upper and lower positions, and means for allowing said at least one pair of independently movable leg supports to be swung in a plane transverse to the plane of the raising and lowering movement of said leg supports.
[0006] Preferably said exercise device includes an adjustment device to tilt up or down the operating position of said at least one pair of leg supports. In a further aspect said exercise device includes a base frame which can be moved along a floor and is adapted to be clamped to said floor and a main frame which can be reciprocally moved relative to said base frame. Preferably said means for allowing said at least one pair of independently movable leg supports to be swung in a plane transverse to the plane of the raising and lowering movement of said leg supports includes a turntable having said pair of leg supports attached thereto.
[0007] In practical embodiments said exercise devices may include one or more additional exercise components which can be selectively activated by a control means.
[0008] Additional exercise components may include a rowing device, a rhythmic movement of said exercise device, an oscillating shoulder pad, a pair of oscillating posterior seats, vibrationary devices, heating devices and any other suitable devices in various combinations. It is preferred that said control means can control individual exercise elements or combinations thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] In order that the invention may be more readily understood and put into practical effect, reference will now be made to the accompanying drawings which illustrate an especially preferred embodiment of the invention. In the drawings:
[0010] FIG. 1 is a perspective view of an exercise device made in accordance with the invention;
[0011] FIG. 2 is a side view of the exercise device shown in FIG. 1 ;
[0012] FIG. 3 is a plan view of the exercise device shown in FIG. 1 ;
[0013] FIG. 4 is a partial plan view similar to that of FIG. 3 showing an oscillating seat option;
[0014] FIG. 5 is a longitudinal cross-sectional view of the exercise device shown in FIG. 1 ;
[0015] FIG. 6 is an enlarged partial longitudinal cross-sectional view similar to that of FIG. 5 showing one end of the exercise device shown in FIG. 1 ;
[0016] FIG. 7 is an enlarged partial longitudinal cross-sectional view similar to that of FIG. 5 showing the other end of the exercise device shown in FIG. 1 ;
[0017] FIG. 8 is a planar cross-sectional view adjacent the top of the exercise device shown in FIG. 1 ;
[0018] FIG. 9 is a cross-sectional view along and in the direction of arrows 9 - 9 of FIG. 6 ;
[0019] FIG. 10 is a similar view to that of FIG. 6 showing adjustment of the leg members of the exercise device shown in FIG. 1 ;
[0020] FIG. 11 is a view similar to FIG. 6 of a second embodiment of an exercise device made in accordance with the invention;
[0021] FIG. 11A is the same view as FIG. 11 showing movement of the exercise device;
[0022] FIG. 12 is a cross-sectional view along and in the direction of arrows 12 - 12 of FIG. 11 ;
[0023] FIG. 13 is a cross-sectional view along and in the direction of arrows 13 - 13 of FIG. 11 ;
[0024] FIG. 14 is a cross-sectional view along and in the direction of arrows 14 - 14 of FIG. 11 ;
[0025] FIG. 15 is a view similar to FIG. 7 of the second embodiment of the exercise device;
[0026] FIG. 16 is a cross-sectional view along and in the direction of arrows 16 - 16 of FIG. 15 ;
[0027] FIG. 17 is a cross-sectional view along and in the direction of arrows 17 - 17 of FIG. 15 ;
[0028] FIG. 18 is a cross-sectional view along and in the direction of arrows 18 - 18 of FIG. 17 ;
[0029] FIG. 19 is a side view of the lower support frame of the second embodiment of the exercise device;
[0030] FIG. 20 is a plan view of the upper and lower frames of the second embodiment of the exercise device;
[0031] FIG. 21 is a view similar to FIG. 6 of a third embodiment of an exercise device made in accordance with the invention;
[0032] FIG. 22 is a cross-sectional view along and in the direction of arrows 22 - 22 of FIG. 21 ;
[0033] FIG. 23 is a cross-sectional view along and in the direction of arrows 23 - 23 of FIG. 21 ;
[0034] FIG. 24 is a cross-sectional view along and in the direction of arrows 24 - 24 of FIG. 21 ;
[0035] FIG. 25 is a cross-sectional view along and in the direction of arrows 25 - 25 of FIG. 22 with the leg supports in the horizontal position;
[0036] FIG. 26 is a similar view to that of FIG. 25 with the leg supports in a raised position;
[0037] FIG. 27 is a similar view to that of FIG. 25 with the leg supports in a lowered position;
[0038] FIG. 28 is a similar view to that of FIG. 15 of a fourth embodiment of an exercise device made in accordance with the invention; and
[0039] FIG. 29 is a cross-sectional view along and in the direction of arrows 29 - 29 of FIG. 28 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] In the drawings there is shown an exercise device 10 which is capable of performing many different movements to allow different exercises to be undertaken by a user (not shown). The exercise device 10 has a wedge shaped body 12 formed from various panels which are attached to a main frame 14 . A control panel 16 has buttons, switches, etc which, when activated, provide operational control for the various movements realised by the exercise device. The nature of the control panel 16 will not be further described as the switching functions can be programmed or actioned by a skilled electrical engineer. For example, the control panel 16 can be replaced by a touch screen panel mounted on a swivel pendant. The pendant could be swivelable 180° to allow for easy access when programming of the exercise device is required. The required electronics/hydraulics can be housed in a control box 17 inside wedge shaped body 12 . If desired, a hand held remote control (not shown) could emulate the functions of control panel 16 , or could replace control panel 16 . Located inside main frame 14 is a main electric motor 18 coupled to a reduction gearbox 20 . A main shaft 22 extends from either side of reduction gearbox 20 to provide the majority of rotation transmission to various components of exercise device 10 . A secondary drive shaft 24 is driven by main shaft 22 by sprockets 26 , 28 and chain 30 .
[0041] A first exercise is a rowing exercise where a rowing handle 32 is movable in the direction of arrows 34 ( FIG. 5 ) and shown in faint lines 32 a . Rowing handle 32 can be any suitable shape, but generally has two rotatable hand grips 36 and a shaft 38 which can be rotated to provide the up and down movement indicated by arrows 34 . Shaft 38 is coupled to a lobe 40 having an offset pin 42 which is coupled to a connecting rod 44 at one end 46 . The other end 48 of connecting rod 44 is coupled to a further offset pin 50 on a further lobe 52 extending from a rotatable shaft 54 supported by bearings 56 . A sprocket 58 is secured to shaft 54 and rotated by sprocket 60 ( FIG. 8 ) via chain 62 . A clutch 64 will selectively cause rotation of sprocket 60 from main shaft 22 .
[0042] In use, when clutch 64 is activated from control panel 16 , sprocket 60 will cause rotation of sprocket 58 through chain 62 and shaft 54 will rotate to cause further lobe 52 to rotate and cause a reciprocal motion of connecting rod 44 . The connection of connecting rod 44 to lobe 40 on shaft 38 will result in the up and down motion of rowing handle 32 . When a user is seated on exercise device 10 and holds hand grips 36 , this enables the user to undertake the rowing exercise from a seated position. For a variation, shaft 38 can be split (not shown) to provide independent up and down movement for each rowing handle 32 . The split shaft arrangement could have the split shafts driven independently to allow a selection of parallel movements of the rowing handles 32 together, or separately in opposing directions.
[0043] A second type of exercise is the rhythmic movement of the exercise device 10 per se. A pair of wheels 66 provides a pivot point for lifting the exercise device 10 from the opposite end. A pair of triangles 68 at the opposite end has link rods 70 at their vertices. Triangles 68 are rotated by a shaft 72 driven by a sprocket 74 through chain 76 via sprocket 78 . Sprocket 78 is coupled to secondary drive shaft 24 and is activated through clutch 80 from control panel 16 . In order to provide the lift of exercise device 10 from the floor 82 , eccentric stub axles 84 from shaft 72 are coupled to triangles 68 in an offset disposition.
[0044] In use, when clutch 80 is activated from control panel 16 , sprocket 78 will cause rotation of sprocket 74 through chain 76 and shaft 72 will rotate to cause triangles 68 to rotate and lift exercise device 10 from floor 82 by moving a respective vertex along the floor 82 . The vertex will slide along the floor through the eccentricity of stub axles 84 to raise exercise device 10 from the floor 82 for the first half of its movement and then lower the exercise device 10 in its second half of its movement. This movement will provide a gentle rocking motion. This motion can be activated in combination with any one of the other exercises to stimulate the blood and lymphatic circulatory systems.
[0045] A third type of exercise uses an oscillating shoulder pad 86 which is disposed between two stationary cushions 88 . A shaft 90 is secured centrally to a base 92 and projects through aperture 94 of body 12 . Shaft 90 has a pivot pin 96 which is attached to brackets 98 on main frame 14 . A connecting rod 100 is pivotally attached at one end of shaft 90 and pivotally attached at the other end to a lobe 102 through offset pin 104 . Lobe 102 rotates with sprocket 106 through chain 108 via sprocket 110 attached to secondary drive shaft 24 . A clutch 112 is activated from control panel 16 for selectively controlling operation of pad 86 . If desired, pad 86 , or any of the pads, can include a heating coil 114 to take the chill off the pad 86 and a vibratory device 116 to stimulate the blood supply.
[0046] In use, when clutch 112 has been activated shoulder pad 86 will oscillate in the direction of arrows 118 in a forwards/backwards motion. Shoulder pad 86 will move in a tilting action through the pivoting action of shaft 90 about pivot pin 96 . Shaft 90 will pivot through its coupling to connecting rod 100 and the rotation of offset pin 104 on lobe 102 .
[0047] A fourth type of exercise uses a pair of oscillating posterior seats 120 , 122 ( FIGS. 1 , 2 , 3 and 10 ). Seats 120 , 122 have stub shafts 124 which are slidably but non-rotatably located in hollow shafts 126 . Hollow shafts 126 are pivotally attached to bracket 128 on main flame 14 through pivot pin 130 . Hollow shafts 126 are oscillated by a pair of connecting rods 132 pivotally attached at a respective end of shafts 126 and pivotally attached at the other ends to lobes 134 through offset pins 136 . Lobes 134 rotate with sprockets 138 through chain 140 via sprockets 142 attached to secondary drive shaft 24 . A clutch 144 is activated from control panel 16 for selectively controlling operation of seats 120 , 122 .
[0048] The operational movement of seats 120 , 122 is identical to that of the movement of shoulder pad 86 and, accordingly, does not have to be repeated. Seats 120 , 122 will move in opposing directions as indicated by arrows 146 , 148 . Seats 120 , 122 are removable from shafts 126 to allow the use of a fifth exercise option.
[0049] The fifth exercise option is a single swivelable seat 150 . Seat 150 has a stub shaft 152 which is slidably but non-rotatably located in a hollow bore of extension arm 154 . Extension arm 154 extends at right angles from the top side arm 156 of a C-shaped support 158 . C-shaped support 158 has a lower side arm 160 and a link arm 162 . Side arms 156 , 160 are pivotally attached to frame 14 by pivot pins 164 , 166 respectively. A further extension arm 168 extends from lower side arm 160 in the manner of a bell crank and is pivotally attached at its free end to a connecting rod 170 . Connecting rod 170 is pivotally attached at its other end to a lobe 172 through offset pin 174 . Lobe 172 rotates with sprocket 176 through chain 178 via sprocket 180 attached to main drive shaft 22 . A clutch 182 is activated from control panel 16 for selectively controlling operation of seat 150 .
[0050] In use, when clutch 182 has been activated seat 150 will swivel in the direction of arrows 184 in a swivelling sideways motion. C-shaped support 158 will pivot around pivot pins 164 , 166 through its coupling to connecting rod 170 and the rotation of offset pin 174 on lobe 172 . As seat 150 is located within extension arm 154 on C-shaped support 158 , seat 150 will move in its swivelling sideways motion.
[0051] A sixth exercise option is a pair of leg raisers in the form of padded longitudinal leg supports 186 , 188 . Supports 186 , 188 can be any suitable shape and are not restricted to the bi-pillow arrangement shown. Each support 186 , 188 is pivotally attached to axle 190 on either side of link arm 162 of C-shaped support 158 in a lever action. A frame element 192 provides a pivot arm 194 which at each respective free end is pivotally attached to a respective link 196 . Each link 196 is pivotally coupled to a respective connecting rod 198 . A respective rotatable lobe 200 is driven by a respective gear box 202 through electric motors 204 . Offset pins 206 on each lobe 200 will allow a reciprocal motion when lobes 200 are rotated. As each support 186 , 188 is connected to a separate electric motor 204 each support 186 , 188 can be moved independently of the other.
[0052] In use, each leg support 186 , 188 can be raised and lowered in an up and down motion as indicated by arrow 208 . The phantom lines 210 , 212 indicate this movement. Each electric motor 204 is activated from control panel 16 to allow the leg supports 186 , 188 to be raised together, or in opposite directions. Rotation of lobes 200 from gearboxes 202 will allow connecting rods 198 to move up and down and through the pivotal connections of links 196 allow pivot arms 194 to raise and lower leg supports 186 , 188 about axle 190 in a lever action. As leg supports 186 , 188 are pivotally attached to link arm 162 through axle 190 , the leg supports will also move in synchronism when seat 150 is activated.
[0053] The position of leg supports 186 , 188 can also be varied. Each gearbox 202 is secured to a base plate 214 and a swing plate 216 . Each swing plate 216 is coupled to a pivot pin 218 through link arm 162 . An extension arm 220 is mounted perpendicular to base plates 214 to provide a pivot 222 at the free end of extension arm 220 . A hydraulic cylinder 224 is attached to pivot 222 at one end and to the end of piston 226 of hydraulic cylinder 224 at the other end. Piston 226 is attached to link arm 162 through pivot pin 228 .
[0054] The operation to vary the starting position for the leg supports 186 , 188 will now be described. Turning to FIG. 10 , leg supports 186 , 188 are at their lowest angle. When connecting rod 198 raises and lowers leg supports 186 , 188 they will move between the position shown in FIG. 10 to a horizontal position. To allow movement from the horizontal position to the position shown by 212 in FIG. 5 , hydraulic cylinder 224 can be actuated from control panel 16 . The outward movement of piston 226 will cause motors 204 to rotate anticlockwise ( FIG. 10 ) and lower the position of gearboxes 202 . Connecting rod 198 will be pulled downwardly causing leg supports 186 , 188 to be raised as indicated by arrow 230 . The length of extension of piston 226 from hydraulic cylinder 224 will determine a new lowermost position for leg supports 186 , 188 .
[0055] In an alternative arrangement (not illustrated) a single motor—with associated control apparatus—can be employed to allow for the desired movement of the leg supports 186 , 188 , either separately or in unison.
[0056] The preferred embodiment includes a plurality of exercise components which can be operated independently or in various combinations to suit requirements. Although the preferred embodiment describes the use of sprockets, chains, lobes, offset pins, connecting rods the invention is not limited to that particular type of construction or operation. It is clear to the man skilled in the art that there are many options for providing the various movements required by the exercise components and accordingly, the invention is not limited to the particular constructions or operations shown. The exercise device described could include all the options described in the preferred embodiment or a sub-set thereof.
[0057] Further modifications and additions may be made to the overall device in accordance with the invention, as for example by the incorporation of means/equipment allowing the user to perform exercises additional to those previously described. In particular a further pair of leg supports may be provided at the other end of the device, that is the end remote from the leg supports 186 , 188 . Once again, this further pair of leg supports is adapted to be movable either separately or together.
[0058] FIGS. 11 to 20 show a second embodiment of an exercise device. The same reference numerals have been used for similar components to reduce repetition of description.
[0059] The exercise device in FIGS. 11 to 20 has a rectangular base frame 338 and a main frame 340 on which most components are fitted. Base frame 338 has wheels 342 which allows the exercise device to be readily moved into position. Once in position, the exercise device can be set into a locked non-movable position on floor 82 by releasable locking clamps 344 . Main frame 340 can be moved in a reciprocal movement relative to base frame 338 by lineal bearings 346 which link the base frame 338 to main frame 340 . The relative movement is a result of a coupling of one end of link arm 348 to a pin 350 which is affixed to base frame 338 . The other end of link arm 348 is coupled to a radially offset pin 352 on pulley 354 rotatably attached to main frame 340 . Pulley 354 is driven by clutch 356 which is powered by motor 358 . The backwards and forwards motion caused by the relative movement of base frame 338 with respect to main frame 340 will provide a gentler rocking motion than the triangles 68 of the first embodiment.
[0060] The longitudinal leg supports 186 , 188 are operated in a different manner to the leg supports 186 , 188 shown in FIGS. 1 to 10 of the first embodiment. Each leg support 186 , 188 is pivotally attached through pins 360 to brackets 362 secured to arm member 364 . Arm member 364 is pivotally mounted about pivot pin 366 which is attached to a support 368 projecting from a frame element 370 . Frame element 370 is connected to a turntable frame 372 which rotates with pin 374 . Pin 374 is coupled to arm 376 which causes rotation of pin 374 through the backward and forward motion of arm 376 . Arm 376 is attached to crank 378 which is moved by link arm 380 . Link arm 380 is coupled to a bell crank 382 from clutch 384 which is driven by motor 18 . Accordingly, arm member 364 and turntable frame 372 will rotate by movement of arm 376 about bearing 386 attached to main frame 340 . In this manner, leg supports 186 , 188 together with seats 120 , 122 can be swivelled from side to side to provide a twisting exercise for the back.
[0061] Leg supports 186 , 188 can be moved in a scissor action or together. The leg supports 186 , 188 do not require separate motors as described in FIGS. 1 to 10 but obtain their movement from motor 18 . Clutches 388 drive pulleys 390 through chains 392 with bell cranks 394 linked to drive arms 396 . The other ends of drive arms 396 are pivotally attached to extensions 398 . Rotation of bell cranks 394 will result in upward and downward pivotal movement of leg supports 186 , 188 .
[0062] Seat 122 and leg supports 186 , 188 can also be raised and lowered together as best seen in FIG. 1 IA. Turntable frame 372 and arm member 364 can be pulled from the position shown in FIG. 11 , to the position shown in FIG. 1 IA through the pivoting about arm 376 . The pivoting is caused by ring 400 which surrounds a sleeve 402 over pivot pin 366 . Ring 400 is coupled to a potentiometer 404 and a linear actuator 406 which are pivotally held at their other ends on bracket 408 secured to main frame 340 . As can be seen from FIG. 1 IA, retraction of rod 412 of linear actuator 406 will cause seat 122 and leg supports 186 , 188 to be pulled downwardly, which is the lower plane for several of the exercises. It will also allow the exercise device to be used as a flexion/distraction table for treatment of a patient with a prolapsed disc. By controlled movement of linear actuator 406 additional leg movement exercises are possible as well. The linear actuator 406 will also allow the operating position of leg supports 186 , 188 to be set at a particular angle, or allow a predetermined degree of lowering of leg supports 186 , 188 and seat 122 to occur. Leg supports 186 , 188 are independent of one another and can have their movements controlled independently in both the horizontal and vertical dispositions as required. It is also preferred that the leg supports 186 , 188 automatically return to their neutral position i.e. horizontally disposed in a straight-ahead position when the particular exercise has been completed. In this position, leg supports 186 , 188 are locked and held by a hand operated, side locking device (not shown).
[0063] In FIGS. 15 to 20 there is shown a knee extension device 300 at one end—of the exercise device 10 . A pair of foot plates 302 are attached to a tube or rod 304 through an arm 306 . The tubes or rods 304 slide within a bearing block 308 , which is secured, to a main frame 310 . At the opposite end of tube or rod 304 is a connecting crank 312 , which is pivotally mounted between tube or rod 304 and an endless chain 314 . Chain 314 is located on sprockets 316 , 318 attached to rotatable shafts 320 , 322 . Shafts 322 are connected to clutches 324 through chain 328 and pulley 326 . A rotatable shaft 330 rotates clutches 324 and is driven by chain 332 , which is coupled to the main electric motor 18 .
[0064] In use, knee extension device 300 can be used in conjunction with rowing handles 32 for combination exercises using the arms and legs together simultaneously. The hands hold the rowing handles 32 and the feet are placed on the foot plates 302 . The foot plates 302 are moved backwards and forwards together, singly or in an alternate manner depending on the exercise selection. As tubes or rods 304 are connected to connecting crank 312 , rotation of sprockets 316 , 318 will cause the reciprocal motion of tubes or rods 304 as indicated by arrows 334 and shown in phantom lines on FIG. 17 . Connecting crank 312 will be moved with endless chain 314 between sprockets 316 , 318 . This movement will cause tubes or rods 304 to be withdrawn or extended through bearing block 308 . If required, tubes or rods 304 can be telescopically configured, as shown, to allow for adjustment of the length of movement.
[0065] The rowing exercise device shown in FIGS. 15 and 16 is very similar to that shown in the first embodiment and similar reference numerals have accordingly been used. The embodiment shown in FIGS. 15 and 16 has individual control for both rowing handles 32 as each is coupled to respective clutches 64 . Clutches 64 are driven by belts 336 via pulleys on main shaft 22 . In all embodiments the length of rowing handles 32 may be adjustable e.g. by telescopic sleeves to suit the differing sizes of the participant.
[0066] In FIGS. 11 and 12 the oscillating posterior seats 120 , 122 of the first embodiment operate in a similar manner. The single oscillating seat 150 of the first embodiment has been substituted by having seats 120 , 122 being able to oscillate in a horizontal manner. This improvement provides the advantage of seat 150 without having to remove seats 120 , 122 .
[0067] The exercise device shown in this embodiment allows exercise options not available on prior alt machines. If the rowing handles 32 are lowered to a horizontal position, and the leg supports 186 , 188 are moved in a scissors action, a swimming type action can be simulated. Various movements are possible as follows:—
[0068] (a) scissors type movement of arms and legs with left leg up whilst right arm is down and right leg down whilst left arm is up—and then a reverse of these movements.
[0069] (b) dolphin type action with both legs moving up with both arms moving up and then both legs moving down as both arms move down.
[0070] (c) reverse dolphin action with both arms up as both legs are down and then both arms down as both legs are up.
[0071] For additional exercise strengthening, the leg supports 186 , 188 and rowing handles 32 could be subject to variable resistance to provide a selection of reactive forces. Similarly, foot plates 302 could be subject to variable resistance and could move together or in a walking motion.
[0072] FIGS. 21 to 27 show a third embodiment of a part of the exercise device. The same reference numerals have been used for similar components to reduce repetition of description. In this embodiment, the raising and lowering of seats 120 , 122 and leg supports 186 , 188 shown in FIGS. 11 and 1 IA 5 through pivoting about arm 376 has been removed. The scissor type action of leg supports 186 , 188 is similar in action to that shown in FIGS. 11 to 20 . Arm member 364 of the second embodiment is no longer connected to pin 366 and has simplified construction. Turntable frame 372 is coupled to pin 374 which rotates in bearing 500 secured to main frame 340 . Turntable frame 370 includes an angled arm member 502 , side support members 504 and rear member 506 . As a link arm is attached at one end to a pivot 508 on main frame 380 , turntable frame 372 will swivel from side to side with rotation of bell crank 382 . As leg supports 186 , 188 together with seats 120 , 122 are attached to turntable frame 372 through angled arm member 502 , leg supports 186 , 188 and seats 120 , 122 will be swivelled from side to side to provide a twisting exercise for the back.
[0073] The raising and lowering of leg supports 186 , 188 uses the movement of drive arms 396 through rotation of bell cranks 394 as discussed with reference to the second embodiment. The angle of the range of movement of leg supports 186 , 188 can be controlled by moving drive arms 396 towards or away from motor 18 . This is best seen in FIGS. 24 to 27 . A bifurcated arm member 510 has a fork 512 which supports drive half axles 514 which include bell cranks 394 . The other end of each arm member 510 includes a pivotal plate 516 which is pivotally mounted to drive shaft 24 .
[0074] In order to hold bifurcated arm members 510 in position a U-shaped bracket 518 is used. Bracket 518 has main arms 520 and a cross arm 522 . The free ends of main arms 520 are pivotally attached to half axles 514 . A linear actuator 524 is pivotally attached to rear member 506 at one end and is pivotally attached to cross arm 522 at the other end. FIGS. 25 and 27 show the operation of the adjustment of the range of movement of leg supports 186 , 188 . FIG. 25 shows the neutral position where the leg supports 186 , 188 are in the horizontal position. In FIG. 27 the ram 526 of linear actuator 524 has been retracted which will tilt bifurcated arm member 510 away from the position shown in FIG. 25 . Accordingly, drive arms 396 will be forced upwardly which will lower leg supports 186 , 188 because of the pivotal connections. Conversely, the extension of ram 526 will cause leg supports 186 , 188 to be raised. Leg supports 186 , 188 can thus be moved to a predetermined position. If required, the leg supports 186 , 188 can then be moved up and down by movement of drive arms 396 through bell cranks 394 .
[0075] The leg supports 186 , 188 in this embodiment will allow the following features to be realised:—
[0076] (1) Move up to approximately 60 degrees from the horizontal and down again together.
[0077] (2) Move one leg up approximately 60 degrees whilst the other leg is lowering down to the horizontal or to approximately 15 degrees below horizontal.
[0078] (3) Move one leg up and down only whilst the other is stationary.
[0079] (4) Swivel from side to side approximately 25 degrees from the horizontal.
[0080] (5) Swivel to one side only approximately 25 degrees and then return to the horizontal.
[0081] (6) Lower from the horizontal in one degree increments to 25 degrees to enable functioning as a Flexion/Distraction table.
[0082] (7) Lowering of legs together to approximately 45 degrees and then returning to approximately 5 degrees above horizontal.
[0083] (8) Movement so that wherever the legs finish when an exercise program is completed the legs will always come back again to their horizontal starting position.
[0084] (9) Ability of the legs to move in combination with the rowing handles 32 with the two legs lowering as the rowing handles 32 move forward and vice versa or for the right leg to lower as the left rowing handle moves forward whilst the left leg lifts whilst the right rowing handle moves back and vice versa.
[0085] (10) Ability for one leg and one rowing handle only to move together whilst the other leg and rowing handle remain stationary.
[0086] (11) Ability of the legs to be controlled in their movement from one degree to any desired setting up to 100 degrees of their possible movement when moving up or when swivelling to the side.
[0087] FIGS. 28 and 29 show a fourth embodiment of the exercise device, namely a knee curl device 530 . The same reference numerals have been used for similar components to again reduce repetition of description. The knee curl device has a pair of leg members 532 which has an angled section 534 which is received in a rotatable journal 536 . At the end of leg members 532 is provided a pair of foot plates (not shown) but similar to foot plates 302 . A coupling lever 538 is located in journal 536 to provide a pivotal movement of leg member 532 . A connecting rod 540 is pivotally linked to coupling lever 538 at one end and to offset pin 542 on rotatable disk 544 at the other end. A clutch 546 will provide rotation of disk 544 through shaft 548 . Clutch 546 is driven by chain 550 from shaft 552 . Shaft 552 is driven by chain 554 from shaft 556 . In order to apply a resistance to movement of disk 544 a braking unit 558 is provided. The resistance can be controlled and clutch 546 will be disengaged, when required, so the user can press against leg members 532 rather than have the legs raised and lowered via drive shaft 552 .
[0088] In use, in the lowered position the legs are bent. When the leg members 532 rise they lift up and out, thus lifting and straightening the leg. When the leg members 532 lower, the legs also lower and bend back to the rest position. This action therefore exercises the knee joint. The function can be performed as a dual leg exercise with both legs rising and lowering together or as a split leg function with one leg rising and straightening whilst the other lowers and bends. If an adjustable elbow joint (not shown) is provided at the bend of leg member 532 , then by adjusting the elbow joint on the leg members 532 can be re-positioned to a near vertical position for a Hip Flexor Function. From this position the leg members 532 lift straight up and down with the legs in a bent position throughout, rather than out and up and then down and in the Knee Curl. The effects of the Hip Flexor Function with the legs being raised and lowered in a bent position will cause rotation at the hip thus exercising the hip joint. The Hip Flexor Function can also be undertaken as a dual leg or split bar function. Both the Knee Curl and Hip Flexor Functions can be undertaken as one leg only functions and both can be combined with a dual leg or split leg rowing function with one or two arms rowing. Each rowing handle 32 may be automatically locked into a vertical upright position when not in use. Similarly, each oscillating cushion 86 , 120 , 122 may be automatically locked into a horizontal position when not in use via a hydraulically operated solenoid (not shown) for each rowing handle and for each cushion.
[0089] Other variations to the construction and operation of the exercise device are envisaged. Front arm bars may be fitted or the existing rowing bars 32 may be adjusted in length and position to allow a scissor type arm movement in combination with the legs lifting up and down from a seated position. Side arm bars may be fitted or the existing rowing bars 32 may be adjusted in length and position at the head of the exercise device so that from a supine position the bars will move up and down in a rowing type action with graded resistance, either together or in opposite directions. These side arms could also slide up and down vertically from a prone position and also have graded resistance. The head end of the exercise device could be extended to allow for the addition of a height adjustable seat. From a safety aspect, safety bars can be fitted to one or both sides of the exercise device to prevent a user from rolling or falling off the exercise device. Any of the devices which include a clutch can be provided with a variable resistance component similar to braking unit 558 . Braking unit 558 could also be replaced by hydraulic cylinders or other suitable devices.
[0090] Throughout this specification the use of sprockets and chains, and belts and pulleys has been described. It is clear to a man skilled in the art that the invention is not limited to these drive means as they could be replaced by any other suitable drive means.
[0091] The invention will be understood to embrace many further modifications as will be readily apparent to persons skilled in the alt and which will be deemed to reside within the broad scope and ambit of the invention, there having been set forth herein only the broad nature of the invention and a certain specific embodiment thereof by way of example.
|
The present invention provides an exercise device ( 10 ) which includes at least one pair of independently movable leg supports ( 186, 188 ) which are pivotally connectable to a main body support ( 12 ) to raise and lower, either separately and/or together, a user's legs during exercise between upper and lower positions and an adjustment device ( 198, 224 ) to allow the positions of said upper and lower positions to be changed.
| 0
|
This application is a continuation of U.S. Ser. No. 13/291,811, filed Nov. 8, 2011.
TECHNICAL FIELD OF THE INVENTION
The invention relates to drill steel members for a roof drilling system used in mines.
BACKGROUND OF THE INVENTION
In the mining industry, it is known to support the roof of a mine by drilling vertical holes in the overhead rock strata, and then installing roof bolts into the newly drilled holes. The roof bolts are generally installed into the drilled holes with an adhesive to further secure the bolts within the drilled holes. The bolts secure a metal plate that is positioned to support the rock strata to prevent collapse of the mine roof.
To drill holes in the rock strata, a roof drilling machine is utilized. The drilling machines include a drill driving device and drill steel members. A carbide bit is attached to one end of the final drill steel member, to drill the holes in the mine roof. These drill steel members are generally coupled on the other end to the drill driving device by a chuck located on the drilling machine. This driving device rotates the drill steel member, and thus the drill bit, to remove material and debris from the drilled hole. Many drilling machines incorporate a vacuum suction collection system wherein the drill steel member is a hollow steel tube having a central passage, and the drill bit includes a passageway open to the central passage. The vacuum system collects the debris as it is passed through the bit passageway and the central passage during drilling of the rock strata.
In elevated height mines, the drill steel members are provided with a sufficient length for drilling the desired seam, without the need to replace or extend the drill steel member. In low height mines the hole is initially drilled with a shorter drill steel member, often known as a starter, and then the starter is replaced with additional sections of drill steel, such as drivers, extensions and finishers, to drill the remaining depth of the hole. The additional sections are joined together by component parts that include, for example, a drill bit seat, male and female connectors, and a drive end component. The components are attached or configured to connect to the ends of the drill steel members or sections.
According to one system, a drill steel section is cut to the desired drilling length for a particular member and then the ends of the section are beveled and then component parts are welded onto the corresponding ends of the drill steel section.
Many drawbacks for this manufacturing method exist. Welding components and drill sections can induce stress fractures and misalignments.
Other methods have been developed. U.S. Pat. No. 3,554,306 discloses a vacuum drill rod system utilizing tubular members. The tubular members have hexagonal inner and outer cross sectional perimeters which interact with comparable outer and inner cross sectional perimeters of cooperating elements when the rod system is connected to achieve concurrent rotation of the elements of the system. However, this system suffers the drawback that the drill steel rods have hexagonal cross sections that are rotated within the drilled hole. Such rods have been known to cause excessive sound levels within the mine due to the rattling or impact of the hexagonal surface of the drill steel against the round drilled hole.
U.S. Pat. No. 6,189,632 discloses a drilling system utilizing round, hollow drill steel members interconnectable by short components. The short components include a male component machined onto an end of the drill steel member and a corresponding female coupling. The male component comprises an extension with a cross-section defining an external hexagonal perimeter, and the corresponding female coupling element has a cross-section defining an internal hexagonal perimeter, the female component press fit onto the male component. One drawback of this described system is that the drill steel member must be precisely machined to length and must have the aforementioned machined end.
U.S. Pat. No. 6,598,688 discloses a drilling system incorporating a drill member having a central through bore and opposite open ends. The drill member has a cross section that defines a circular outside perimeter and a polygonal inside perimeter. The polygonal inside perimeter allows for convenient coupling of the drill member to drill bits at one end and to a motorized drill driving device at an opposite end. The polygonal inside perimeter allows for coupling of the drill members to other drill members using couplings. In order to couple the drill member to a motorized drill driving device, a base assembly is used. The base assembly includes a stub member and a base member. The base member includes a bottom fixture having a cross section defining a polygonal outside perimeter for being received into a correspondingly shaped socket or chuck of the motorized drill driving device. The base member includes a socket having a polygonal inside perimeter. The base member also includes a collar for receiving axial force from the drill driving device. The stub member includes a bottom fixture having a cross section defining a polygonal outside perimeter that is received into the socket formed in the base member. The stub member further includes a flange that is supported on an internal shoulder within the socket of the base member. In this way, the axial force exerted on the base member by the drill driving device is transferred to the flange of the stub member. The stub member further includes a stub shaft extending upwardly from the flange and having a cross section defining an outside polygonal perimeter, sized and shaped to snugly fit within the open end of the drill member. The socket of the base member is sized such that the drill member fits over the stub shaft and is partially recessed into the socket to press against a top side of the flange of the stub member. In this way, the axial thrust from the base member to the flange is transferred to the end face of the drill member.
The present inventor has recognized the desirability of providing a drilling system for drilling holes for mine roof bolts which does not require undue machining of the drill steel, which does not require the drill steel to be cut to predetermined lengths and which does not produce excessive noise. The present inventor has recognized the desirability of providing a drilling system that does not require special adaptors or parts to couple the drill members or “drill steel” to the chuck of the drill driving device.
SUMMARY OF THE INVENTION
The invention provides an improved drill member, or “drill steel,” for use in a drilling system for installing roof bolts in a mine. The invention provides an improved drilling system incorporating the drill member. The drill member comprises an elongated tube having a central through bore and opposite open ends. The tube has a cross section that defines a circular outside perimeter along most of its length and a polygonal inside perimeter throughout its length. At least one end portion of the drill member tube has a polygonal outside perimeter. The end portion can be inserted into a corresponding socket of the drill chuck having a polygonal inside perimeter. The need for a stub member and base member as described in U.S. Pat. No. 6,598,688 is obviated. The polygonal inside perimeter of the drill member tube allows for convenient coupling of the drill member to drill bits at one end and to a motorized drill driving device at an opposite end. The polygonal inside perimeter allows for coupling of the drill members to other drill members using couplings.
The drill members can be cut to any length and the cut open end can accommodate components or interposed couplings without the need for machining a specialized coupling element or configuration onto the member. Additionally, the round outside perimeter allows the drill steel to be more quietly rotated within the drilled hole.
Numerous other advantages and features of the present invention will be become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a prior art drill system, in use in a mine;
FIG. 2A is an enlarged plan view of the prior art drill components of the drill system of FIG. 1 ;
FIG. 2B is an exploded view of the prior art drill components of FIG. 2A ;
FIG. 3A is an enlarged plan view of the prior art drill member of the drill components shown in FIGS. 2A-2B ;
FIG. 3B is a side view of the prior art drill member of FIG. 3A ;
FIG. 4A is a side view of a first embodiment drill member according to the invention;
FIG. 4B is a right side end view of the first embodiment drill member shown in FIG. 4A ;
FIG. 5A is a side view of a second embodiment drill member according to the invention;
FIG. 5B is a right side end view of the second embodiment drill member shown in FIG. 5A ;
FIG. 6 is a sectional view of a drill member of FIG. 4A or 5A in a chuck of a drilling head;
FIG. 6A is a sectional view taken along line 6 A- 6 A of FIG. 6 ; and
FIG. 7 is an enlarged plan view of the assembled, extended drill components of the drill system of FIGS. 4A-5B .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While this invention is susceptible of embodiment in many different forms, there are shown in the drawings, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated.
This application is a continuation of U.S. Ser. No. 13/291,811, filed Nov. 8, 2011 and incorporates that application in its entirety.
FIG. 1 illustrates a prior art roof drilling machine 20 as described in U.S. Pat. No. 6,598,688. The machine 20 is designed to operate within low seams 21 , such as seams of coal. The drilling machine includes a chassis 22 that is supported on wheels 24 from the mine floor 25 . Articulated boom components 28 support a drill head 34 that is a motorized drill driving device.
A base assembly 42 is fit onto, and into, the drill head 34 . The base assembly 42 is used to couple a lowest drill member 46 d to the drill head 34 . A drill bit 56 is fixed to an end of the highest drill member 46 a via a bit seat 59 . Drill members 46 a , 46 b , 46 c extend from the lowest drill member 46 d into the drilled hole 47 into the roof 48 .
The hole 47 is initially started by the drill member 46 a extending from the base 42 , and the drill members 46 b , 46 c , 46 d are progressively added, as needed, as the bit 56 progresses into the rock. The drill members 46 a , 46 b , 46 c , 46 d are connected by interposed connectors or couplings 49 , shown in detail in FIGS. 5E and 5F .
Once the hole 47 is drilled, an anchor 64 mounted on a shank 68 , is inserted into the hole 47 and a threaded end 69 of the shank receives a nut 72 . The nut 72 is tightened to secure a roof plate 76 against the roof 48 .
FIGS. 2A-2B illustrate, as an example, the drill members 46 a , 46 b , coupled together and coupled to the base 42 , and the bit 56 via a bit seat 59 . The drill members 46 a , 46 b (and also 46 c , 46 d , not in use yet in the configuration shown in FIGS. 2A-2B ) each comprise an elongated tube having a round outside perimeter 112 c and a hexagonal inside perimeter 112 d defining a central through bore 112 and opposite open ends 112 a , 112 b (shown in FIGS. 3A, 3B ).
The bit seat 59 includes a bit shank 59 a and a base shank 59 b each having polygonal, preferably hexagonal, outside perimeters. The drill bit 56 includes a socket 57 having a polygonal, preferably hexagonal, inside perimeter 57 a . The bit shank 59 a and a button clip 59 c fit within the socket 57 and are used together to tightly engage the bit seat 59 to the bit 56 as explained in U.S. Pat. No. 6,189,632, herein incorporated by reference. The outside perimeter 59 b of the bit seat shank 59 b is shaped to snugly fit within the open end 112 a of the drill member 46 a . The seat 59 also includes a rounded flange 59 d that matches the outside diameter of the drill member 46 a.
FIGS. 3A, 3B illustrate that the members 46 a , 46 b , 46 c , 46 d each has a cross section that defines the circular outside perimeter 112 c , and the polygonal inside perimeter 112 d , defining the through-bore 112 .
Returning to FIGS. 2A-2B , the base assembly 42 includes a stub member 120 , and a base member 126 . The base member 126 includes a bottom fixture 131 having a cross section defining a polygonal outside perimeter 131 a . The polygonal outside perimeter 131 a is provided by a square lug portion 170 shown in FIGS. 6A and 60 and described below. The outside perimeter 131 a is sized to be received into a correspondingly shaped socket (not shown) of the motorized drill driving device 34 to couple the fixture 131 and the drill driving device 34 for mutual rotation. The base member 126 includes a collar 134 for receiving axial (upward) force from the drill driving device 34 .
FIGS. 4A-5B illustrate drill members 146 , 246 according to the present invention.
A first embodiment drill member of FIGS. 4A-4B includes a tube 148 having a cylinder portion 150 having a circular perimeter 152 throughout most of its length. The tube has an overall length “A.” The length “A” can be any practical length but preferably is 24 inches, 36 inches or 48 inches. The perimeter has a preferred diameter D 1 of about 0.95 inches or 1.25 inches.
The tube 148 also includes an end portion 156 having a polygonal outside perimeter 160 . Preferably the polygonal outside perimeter 160 is hexagonal and has a flat-to-flat dimension F 1 of about 0.87 inches or 1.12 inches. Preferably, the end portion has a length B of less than one foot and preferably about 6 inches and is machined into the circular perimeter that otherwise defines the cylindrical portion 150 . The tube 148 has an inside through-opening 168 having a polygonal inside perimeter 170 . Preferably, the polygonal inside perimeter 170 is hexagonal and has a flat-to-flat dimension F 2 of about 0.63 inches or 0.82 inches. Preferably, the polygonal inside perimeter 170 has a point to point dimension F 3 of about 0.71 inches or 0.92 inches.
A second embodiment drill member of FIGS. 5A-5B includes a tube 248 having a cylinder portion 250 having a circular perimeter 252 throughout most of its length. The tube has an overall length “G.” The length “G” can be any practical length but preferably is 144 inches. The perimeter has a preferred diameter J 1 of about 0.95 inches or 1.2 inches. The tube 248 also includes end portions 256 , 257 each having a polygonal outside perimeter 260 . Preferably the polygonal outside perimeter 260 is hexagonal and has a flat-to-flat dimension K 1 of about 0.87 inches or 1.12 inches.
Preferably, the end portion has a length H of less than one foot and preferably about 6 inches and is machined into the circular perimeter that otherwise defines the cylindrical portion 250 . The tube 248 has an inside through-opening 268 having a polygonal inside perimeter 270 . Preferably, the polygonal inside perimeter 270 is hexagonal and has a flat-to-flat dimension K 2 of about 0.63 inches or 0.82 inches. Preferably, the polygonal inside perimeter 270 has a point to point dimension K 3 of about 0.70 inches or 0.92 inches. The drill member 246 is especially suitable as drill member stock that can be cut to desired lengths in the mine. Each part of a cut drill member 246 would thus include an end portion 256 , 257 .
The drill members 146 , 246 are preferably composed of 4130 30CrMo.
FIG. 6 illustrates how either drill member 146 , 246 is coupled directly to a chuck 300 of a drilling head 34 . The chuck 300 includes a generally cylindrical body 302 of steel or iron and has a countersunk axial bore 306 . The bore 306 includes three regions of differently sized and shaped sockets that are adaptable to receive different types of drilling elements. A top region 308 has a large square cross-section 308 a . A next region 310 has a large hexagonal cross-section 310 a . A lower region 312 has a smaller hexagonal cross-section 312 a . The hexagonal cross-section 312 a of the lower region 312 is sized and shaped to snugly surround the outside polygonal perimeter of the end portion 156 , or the end portion 256 , 257 , of either drill members 146 , 246 . A bottom shoulder 320 defines a bottom opening 322 and supports an end face 330 of either member 146 , 246 in order to urge the drill member 146 or 246 axially during drilling.
The chuck 300 includes keys 336 , 338 insertable into key ways (not shown) of the drilling head 34 to lock the chuck 300 for rotation to the drilling head 34 for motorized turning during drilling operation.
As illustrated in FIG. 7 , a drill member 146 can be used to initially engage into the chuck 300 (shown schematically in phantom) of the drilling head at a base end 146 a and receives a drill bit 56 and coupling 59 on the distal end 146 b . As the drilled hole extends into the rock, an additional drill member 146 ′ can be coupled between the base end 146 a of the drill member 146 and the chuck 300 of the drilling head 34 . The member 146 ′ can be configured as a preconfigured piece such as a drill member 146 or can be a cut off section from a drill member 246 , sized to suit. Multiple added drill members 146 ′ can be added via couplings 49 as the drill assembly extends deeper into the rock. The drill member 246 includes end portions 256 , 257 that are each configured to engage into the chuck of the drilling head. Thus, a drill member 246 can be cut to provide two lengths of drill member, equal lengths or not equal lengths that can be used to sequentially couple to the chuck of the drilling head. In effect, a first cut-off portion of a drill member 246 can be drilled into the rock and then the second cut-off portion of the drill member 246 can be coupled to the chuck and to the training end of the first cut-off portion to continue drilling.
The coupling elements 49 , 59 and the drill 56 are configured and coupled to the drill members 146 , 146 ′ using the inside polygonal perimeters of the drill members as described in the embodiment of FIGS. 2A and 2B .
The drill members 146 , 246 can be cut to any length, and the resultant cut open end can accommodate components without the need for machining a specialized coupling element or configuration. Additionally, the round outside perimeter of the tubes 148 , 248 allows the drill member to be more quietly rotated within the drilled hole 47 .
The inventive method is further characterized in that suction can be applied to the chuck 300 through the opening 322 of the chuck 300 to collect debris produced by the action of the drill bit 56 , through the interior polygonal through opening of the drill members and couplings.
From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims.
|
A drilling system for drilling vertical holes in a mine roof includes a chuck configured to be driven in rotation by a motorized drill head. The chuck is cylindrical has a bore having a first polygonal inside perimeter. A drill member has an elongated hollow body with a cross section defining a circular outside perimeter over most of its length and a constant, second polygonal inside perimeter along substantially the entire length of the drill member. The drill member has at least one end region having a first polygonal outside perimeter that is sized to fit into the first polygonal inside perimeter to rotationally engage the drill member with the chuck. Drill bits having a bit fixture having a cross section with a second polygonal outside perimeter are sized and configured to fit snugly inside the second polygonal inside perimeter to be mounted to the drill member opposite the chuck.
| 4
|
BACKGROUND OF THE INVENTION
In the art and practice of high speed lithographic printing, ink is more or less continuously conveyed from a suitable input device by means of a series of coextensive rollers to a planographic printing plate where the image portions of the printing plate accept ink from one or more of the last of a series of inking rollers and transfers a portion of that ink to a printing blanket as a reverse image from which a portion of the ink is transferred in the form of a right reading image to paper or other suitable substrate. It is also essential in conventional lithographic printing processes that dampening water containing proprietary additives be conveyed more or less continuously to the printing plate where by transferring in part to the non-image areas of the printing plate the water operates to keep those non-image areas free of ink.
In practical printing press systems, the ink is continuously made available in varying amounts determined by cross-press column input control adjustments to all parts of the printing plate, image and non-image areas alike; and in the absence of dampening water, the printing plate will accept ink in both the image and non-image areas of its surface.
Lithographic printing plate surfaces in the absence of imaging materials have minute interstices and an over hydrophilic or water-loving character to enhance retention of water rather than ink on the surface of the plate. Imaging the plate creates oleophilic or ink-loving areas according to the desired format that is to be printed. Consequently, when both ink an water are presented to an imaged plate in appropriate amounts, only that ink tending to reside in non-image areas becomes disbonded from the plate. In its simplest view, this action accounts for the continuous ink and water differentiation at the printing plate surface, which differentiation is essential and integral to the lithographic printing process.
Controlling for the correct amount of dampening water input during lithographic printing has been an industry-wide problem ever since the advent of lithography. Doing so requires continual operator attention since each column adjustment of ink input may require a change in dampener input. Balancing the columner ink input across the width of the press with the non-columner or uniform dampener input across the width of the press is at best a compromise. Consequently, depending upon which portion of the image format the operator has adopted as his standard of print quality at any given time during the printing run, he may need to adjust the ink input at correspondingly-located cross-press positions, which inadvertently also changes the water balance at that position. Conversely, the operator may adjust the dampener input for best ink and water balance in one inking column across the press which action may adversely affect the ink and water balance at one or more other cross-press locations. Adjustments such as these tend to occur repeatedly throughout the whole press run, resulting in slight to major differences in the quality of the printed output throughout the run. In carrying out these adjustment operations, the resulting copies may or may not be commercially acceptable, leading to waste in manpower, materials, and printing machine time.
Means for correcting this inherent fault in conventional lithography have been addressed such as by use of keyless inkers; none have achieved industry-wide success. Certain of these methods also involve eliminating the dampening system or eliminating operator control of the dampening system.
Certain commercially successful newspaper printing configurations rely on the inking train rollers to carry dampening water directly to the printing plate. Notable among these are the Goss Metro, Goss Metroliner, and the Goss Headliner Offset printing presses which are manufactured by the Graphic Systems Division of Rockwell International Corporation. In these alternative configurations, the input dampening water is deposited onto the ink of an inking vibrator drum such that both ink and water are subsequently and continuously transferred to the inking form rollers for deposition onto the printing plate. In another variation, the input dampening water is applied in a more-or-less conventional way directly to the printing plate by means of separate dampening rollers and dampening water input system. In systems of either type, regardless of the method whereby the water is introduced, it is well known that some of the water works its way into the ink and back down through the return-side of the inking train of rollers and may ultimately be introduced into the ink input system itself. In any case, these conventional lithographic systems require considerable operator attention to maintain ink and water balance and they produce more product waste than desired.
Keyless inking systems have been disclosed that purport to eliminate operator attention to column control of inking by elimination of adjustable inking keys and to thereby minimize much of the aforementioned disadvantages of conventional lithography. None of these systems adequately addresses both of the major problems encountered in attempting to control keyless lithographic printing. The first of these is that an ink metering method is required that continues to function despite the presence of up to about 40% water in the ink without allowing temporarily-free water that may appear to interfere with the ink-metering function. Secondly, the unused or non-uniform portion of the ink film that is being continuously presented to the printing plate must be continuously scraped-off the return side of the inking system to enable continuous presentation of the uniform ink film to the plate by the input side of the inker. This scraped-off film is not uniform in ink and water composition. Since it would not be economically feasible to continuously discard the unused ink and that ink/water mixture must be homogenized either by selectively removing water from the mixture and returning it to the inking system or by thoroughly intermixing the unused ink with fresh replenishment ink and returning the mixture to the inking system. We have found that water removal is unnecessary and in the present invention means is provided to accommodate the dampening water that is naturally acquired in the unused ink during the practice of more-or-less conventional lithographic printing and thereby achieve simplified keyless inking control capability heretofore not practical or possible.
DESCRIPTION OF THE PRIOR ART
Warner in U.S. Pat. No. 4,287,827 describes a novel printing press system for using an inking roller that is manufactured to have bimetal surfaces for instance, chromium and copper, which different roller surfaces are claimed to simultaneously carry dampening solution and ink, respectively, to the form rollers of a simplified inking system. Warner thereby avoids the necessity for an independent dampening system of rollers. However, the Warner technology does not specify continual removal of unused ink and water mixture from the inking train of rollers, which is a distinct departure from the present invention.
A number of celled or recessed or analox type ink metering rollers have been described in trade and technical literature. The American Newspaper Publishers Association (ANPA) describes in U. S. Pat. No. 4,407,196 a simplified inking system which uses chromium or hardened steel or hard ceramic materials like tungsten carbide and aluminum oxide as the metering roller. These hard materials are advantageously used to minimize roller wear in a celled ink metering roller inking system operating with a continuously scraping coextensive doctor blade.
Another patent relating to the use of a keyless ink system in which water is present in the ink is U.S. Pat. No. 4,527,479 by H. Dahlgren. In this arrangement, a portion of the excess ink and water mixture unused by the printing plate is continuously removed from the system by means of a rider roller that is in contact with an ink form roller which is in turn in contact with the printing plate. The ink and water mixture that is scraped from the rider roller is returned to a reservoir which acts as the primary source of the input ink/water mixture.
SUMMARY OF THE INVENTION
In the present invention, location of the dampening system is not critical and can be positioned either to supply water directly to the plate cylinder or at some other location such as at a vibrator drum to which ink is also being supplied. Provided is an ink circulating and mixing system which receives both new or replenishment ink and the ink and water combination that is continuously returned from a scraper blade located on a celled metering roll. The ink circulating and mixing system functions to assure an inherently uniform cross-press ink and water ratio that remains consistent throughout and this system consists of an ink pan, pump and appropriate conduits, an ink pan level controlling system, and an ink reservoir of such volume and design that it assures the ink being fed to the metering roller is uniform in water content and composition at any given instant of time despite the existence of the continual cross-press water-to-ink ratio differences of the unused or scraped ink previously referred to. The ink circulation system is designed to continuously collect and distribute the ink and water mixture from the reservoir through a plenum or series of orifices directed to uniformly redistribute the ink and water mix across the press width thereby assuring instantaneously uniform water content of the ink that is being introduced to the metering roller. The metering roller can be one of the type shown and described in U.S. Pat. Nos. 4,537,127, 4,567,827, and 4,601,242, to Fadner, or any hard oleopohilic/hydrophobic roller as substantially therein defined, all of which are assigned to the same assignee as the present application.
It is therefore a principal object of this invention to provide a simplified lithographic printing system having fewer materials controls than are required in prior art lithographic and planographic systems.
An additional object of this invention is to provide a keyless means for conveying ink that contains natural quantities of dampening water to a more-or-less conventional lithographic printing plate in quantities appropriate for proper image differentiation at the printing plate.
It is a further object of this invention to provide a novel ink-pan and ink-recirculating-system that functions to assure that the water content in the ink is maintained in a thoroughly homogenized condition thereby negating buildup of free water anywhere in the inking system which would result in debonding of the ink from the metering roller or inking rollers or printing plate image areas.
These and other objects and advantages of the invention will be in part obvious and in part explained by reference to the accompanying specifications and drawings in which:
FIG. 1 is a schematic side elevation of a press utilizing the improved inking system of this invention and showing alternative locations where water can be supplied to the system.
FIG. 2 is a perspective view of the improved ink pan and ink roll portion of this invention showing the pan partially in section.
FIG. 3 is a side elevation showing the improved ink pan and circulating system similar to the construction illustrated on the left side of FIG. 1, excepting a water-last dampening system employing an inked set of damper rollers is depicted, which number and type of rollers functions to avoid the usual water-interference effects of water-last dampening.
DESCRIPTION OF THE PREFERRED EMBODIMENT
To more clearly understand the invention reference is made to the drawings and more particularly to FIG. 1 in which numerals 10 and 11 represent the left and right hand blanket cylinders that together cooperate to print on a web traveling therebetween as indicated by the directional arrow 12. The plate cylinder, inking system, and fluid dampening systems associated with blanket cylinder 10 are arranged somewhat differently from those associated with blanket cylinder 11. The selection as to which arrangement is to be used is a matter of choice since both are relatively conventional in their makeup. Referring first to the remainder of the dampening and inking systems associated with blanket cylinder 10, the plate cylinder 15 is contacted by two ink form rollers 16 which are in turn contacted by a celled metering roller 20. The celled metering roller 20 is preferably of the type described and claimed in U.S. Pat. Nos. 4,537,127, 4,567,827 and 4,601,242 which were cited previously. In the dampening arrangement associated with plate roll 15 there is provided a rubber form roller 21 and a copper covered or Rilsan covered oscillating transfer roller 22. The water is contained in a pan tray 23 and a pan roller 24 is used to pick up water from the pan 23 to bring it into contact with a spiral brush roller 25 that is rotating in a direction opposite to the direction of rotation of pan roller 24. It should be recognized that virtually any known dampening system can be used in similar manner.
With this or other input arrangement water is transferred onto the transfer roller 22 and from there to the dampener form roller 21. The form roller 21 is positioned in a water-first sequence so that, during each revolution of press, plates are first subjected to water from the dampener form roller 21 before ink is applied to the surface of the plates by means of the rubber covered ink form roller. An alternative water-last dampening configuration is depicted in FIG. 3.
In the arrangement shown in the right side of FIG. 1 of the drawings the blanket cylinder 11 is in contact with plate cylinder 30 and this is in turn contacted by rubber form rollers 31. In this arrangement ink is supplied to a vibrator drum 32 by means of a celled metering roller 35 which is of the same type as the metering roll 20 and this roller in turn transfers a metered quantity of ink to a rubber covered transfer roller 36. As clearly shown in the drawing, roller 36 is in contact with the copper vibrator drum 32 so that ink is deposited thereon. Dampening water is applied to the vibrator drum 32 in much the same manner as water was supplied in the arrangement shown in the left side of the FIG. 1 drawing. For instance, a water pan 40 contains a pan roller 41 that is contacted by a counter rotating spiral brush roll 42 that flicks water onto the water transfer roller 43. Transfer roller 43 is in contact with the vibrator drum 32 so that the drum then carries both water and ink to the transfer rolls 31 thence to the printing plate. Other dampening water input means can be used and the spiral brush method is indicated here only for illustrative purposes.
The most significant part of the present invention is the inking system that is used to supply ink to the plate and blanket cylinders. This system, makes it possible to supply a uniform mixture of ink and water to the printing plate and thereby maintain the high print quality characteristic of conventional lithography. In this arrangement the inking system is identified generally by the numeral 50 and is used to deliver this uniform mixture of ink and water to the celled metering rollers 20 and 35. Water in this system is not deliberately added to the ink but rather results naturally from water picked up by the ink contacting the printing plate and which by means of the return or unused portion of that ink passes or transfers backward down through the various form and metering rollers eventually entering the ink reservoir. The inking arrangement comprises an ink pan 51 that includes a tray portion 52 for holding the combined ink and water mixture in proximity to the pan roller. The tray portion is made up of a first longitudinally extending wall 53 that defines the ink input side of the tray and a second longitudinally extending wall 54 that has a wall area of lower height than the first wall area 53. The second or exiting wall area of lower height defines an outflow weir 55 that determines the depth of the ink and water mixture contained in the tray portion 52.
Adjacent to and formed integrally with the tray portion 52 is a reservoir or sump portion 60 that must contain from about 5 to about 30 gallons of operating ink volume. A minimum volume is essential to help maintain consistent ink composition despite continual or intermittent relatively small additions of scraped-off ink containing water and of fresh or replenishment ink to the pan 51. As can best be seen in FIG. 2 of the drawings, the reservoir portion of the ink pan assembly is designed to help assure that all of the ink and ink and water mixture in the reservoir flows readily toward the reservoir drain. Pumping means 61 is connected to the bottom of reservoir 60 and has a circulation pipe 62 which leads to orifices or nozzles 63 that are mounted to introduce the circulating ink and water mixture into the input side of the tray portion 52 along the entire width thereof. As can be seen in FIG. 2, the circulation pipe 62 may be connected to a manifold 65 that in turn feeds the plurality of nozzles 66 that are disposed along the entire width of the tray portion 52.
Mounted within the tray portion 52 is a rubber-covered pan roller 70 that rotates in the direction indicated in FIG. 1 of the drawings so that it tends to convey the ink and water mixture introduced on the inflow side of the tray portion toward the outflow weir 55, while at the same time delivery a portion of the ink and water mixture to the nip between pan roller 70 and metering rollers 20 and 35. As the drawings indicate the pan roller 70 is located a predetermined distance from the wall portion 53 and 54 so as to increase the pumping action of the pan roller, thereby moving the ink and water mixture through the tray portion. Preferably metering rollers 20 and 35 are in positive interference with the pan roller so that the flat portion of the nip formed by this positive interference ranges from about 1/8" to 1/2". In actual construction is preferred that the tray portion be defined by a bottom wall that has an arcuate shape that substantially conforms to the curvature of the outer surface of the pan roller, although obviously this exact configuration is not necessary in all instances.
Another element of the overall apparatus is the provision of a scraping blade 75 which preferably is made of prehoned Swedish spring steel and is advantageously mounted against the upward rotary side of the metering roller 20 and 35. During operation it is preferred that the blade make an angle with the tangent to the metering roller of 30° plus or minus 5°. This specification is critical to efficiency of scraping action and not to the spirit of the invention. The blade, metering roller and pan roller must be mounted such that the continuously scraped off unused ink (containing water picked up by the ink at the plate) falls directly and cleanly into the pan in such a manner that all of the scraped off ink and water mix is continuously and rapidly assimilated into the circulation system ink flow. This may advantageously be accomplished by having the scraped-off ink and water mixture fall directly into the input side of the space formed between the concentric ink pan element and the ink pan roller. As noted above, the positional relationship between the blade, the metering roll, and the pan roller is important to efficient operation of this system and in this regard the metering roller and the pan roller should be disposed in such a way wherein the axis of rotation of the pan roller lies in a plan not more than about 30° from a plane passing vertically through the axis of the metering roll.
In operation the system may initially be supplied by means of fresh input device 100 with ink containing no water and the printing operation commences by having the ink pan roller 70 delivering ink to the metering rollers 20 and 35 which then deliver ink onto the transfer, vibrator, and form rollers according to the configuration being used, which ultimately delivers the ink to the printing plate mounted on the plate cylinder. As operation of the apparatus continues water is picked up by the ink and is gradually returned to the ink pan roller through the inking train and a gradual increase of water present in the inking system occurs. In this regard it is important that the reservoir contain an amount of ink ranging from about 5 to 30 gallons so that the percentage of water content in the ink never builds up to more than about 40%. Water contents higher than this generally will exceed an ink's capacity to convey water as a mixture on the inking rollers during operation. During operation fresh ink containing no water is added by input device 100 to the reservoir 60 to make up for ink used up in the printing process. Although important to the operation of this invention, it is apparent that any of the fluid level maintaining devices which are known in the art can be used to maintain the operating volume of ink pan fluid within the necessary limits. Consequently no particular device is specified in this disclosure.
It should be appreciated that other and further embodiments of the invention may be devised without departing from the basic concept thereof.
|
A keyless inking system for lithographic printing presses wherein an ink/water mixture is contained in an ink pan having a tray portion within which an ink roller is mounted whereby ink/water mixture enters the tray portion on one side and is drawn by the ink roller to the other side of the tray in the nip between the ink roller and a celled metering roller thereby delivering an excess of the mixture to the celled metering roller, the balance of the mixture being conveyed over a weir into a reservoir for continuous mixing and recirculation back to the pan, and wherein the excess ink/water mixture on the metering roller is continuously scraped off by means of a doctor blade and wherein the metered portion of the ink/water mixture remaining in the metering roller's cells is delivered in part into the inking train of a more-or-less conventional lithographic printing press.
| 1
|
FIELD OF THE INVENTION
The invention relates generally to a highly durable RFID tag package and, more particularly, to a tire and RFID tag assembly incorporating a highly durable RFID tag package.
BACKGROUND OF THE INVENTION
Incorporation of an RFID tag into a tire can occur during tire construction and before vulcanization or in a post-cure procedure. Such tags have utility in transmitting tire-specific identification data to an external reader. UHF (ultra-high frequency) tags are typically small and utilize flexible antennas for the transmission of data. In commercially available RFID devices, the antennas are connected to solder leads of a circuit board onto which the device's integrated circuit board is mounted. When embedded into a tire, such as during within a tire sidewall during the tire construction, the device is subjected to the stress endemic to tire operation and performance. Such forces may act to cause failure of the RFID tag or failure in the mechanical and electrical connections between end of the antenna and the circuit board solder leads. Failure of the RFID tag in any form is undesirable and it is important that the RFID package be capable of ensuring the mechanical and electrical integrity of the tag antenna and the electronic circuit board throughout the tire life cycle. Accordingly, there remains a need for a UHF RFID tag package that is readily incorporated into a tire; provides the requisite durability to maintain antenna to circuit board integrity during the life of the tire and the service life of the tag.
SUMMARY OF THE INVENTION
According to an aspect of the invention, a tire and RFID tag combine as an assembly including a tire having a tag mounting surface and a tag package mounted to the tag mounting surface. The tag package may include a carrier substrate having a die receiving surface and at least one interconnection tab mounted to the die receiving surface and composed of electrically conductive material. The tag package further includes an antenna having an end connected to the interconnection tab on the die receiving surface and an antenna segment extending outward from the carrier substrate. The tag package further includes an integrated circuit die mounted to the die receiving surface and having at least one electrical contact in contacting engagement with the interconnection tab.
Pursuant to another aspect of the invention, the antenna is a dipole antenna (but may be other known antenna configurations) formed by first and second antenna members having inward ends connected to respective first and second interconnection tabs on the die receiving surface and outer antenna segments extending outward from the carrier substrate. The integrated circuit die provides electrical contacts in contacting engagement with the first and second interconnection tabs.
In a further aspect of the invention, a cap member or, alternatively, a cylindrical encapsulating member, may be utilized for enclosing the integrated circuit die, the carrier substrate, and the inward ends of the first and second antenna members; the outer antenna segments of the first and second antenna members extending outward from the cap member or encapsulating member in operable position against respective portions of the tire tag mounting surface.
Definitions
“Aspect ratio” of the tire means the ratio of its section height (SH) to its section width (SW) multiplied by 100% for expression as a percentage.
“Asymmetric tread” means a tread that has a tread pattern not symmetrical about the center plane or equatorial plane EP of the tire.
“Axial” and “axially” means lines or directions that are parallel to the axis of rotation of the tire.
“Camber angle” means the angular tilt of the front wheels of a vehicle. Outwards at the top from perpendicular is positive camber; inwards at the top is negative camber.
“Circumferential” means lines or directions extending along the perimeter of the surface of the annular tread perpendicular to the axial direction.
“Equatorial Centerplane (CP)” means the plane perpendicular to the tire's axis of rotation and passing through the center of the tread.
“Footprint” means the contact patch or area of contact of the tire tread with a flat surface at zero speed and under normal load and pressure.
“Groove” means an elongated void area in a tread that may extend circumferentially or laterally about the tread in a straight, curved, or zigzag manner. Circumferentially and laterally extending grooves sometimes have common portions. The “groove width” is equal to tread surface area occupied by a groove or groove portion, the width of which is in question, divided by the length of such groove or groove portion; thus, the groove width is its average width over its length. Grooves may be of varying depths in a tire. The depth of a groove may vary around the circumference of the tread, or the depth of one groove may be constant but vary from the depth of another groove in the tire. If such narrow or wide grooves are substantially reduced depth as compared to wide circumferential grooves which the interconnect, they are regarded as forming “tie bars” tending to maintain a rib-like character in tread region involved.
“Inboard side” means the side of the tire nearest the vehicle when the tire is mounted on a wheel and the wheel is mounted on the vehicle.
“Lateral” means an axial direction.
“Lateral edges” means a line tangent to the axially outermost tread contact patch or footprint as measured under normal load and tire inflation, the lines being parallel to the equatorial centerplane.
“Net contact area” means the total area of ground contacting tread elements between the lateral edges around the entire circumference of the tread divided by the gross area of the entire tread between the lateral edges.
“Non-directional tread” means a tread that has no preferred direction of forward travel and is not required to be positioned on a vehicle in a specific wheel position or positions to ensure that the tread pattern is aligned with the preferred direction of travel. Conversely, a directional tread pattern has a preferred direction of travel requiring specific wheel positioning.
“Outboard side” means the side of the tire farthest away from the vehicle when the tire is mounted on a wheel and the wheel is mounted on the vehicle.
“Radial” and “radially” means directions radially toward or away from the axis of rotation of the tire.
“Rib” means a circumferentially extending strip of rubber on the tread which is defined by at least one circumferential groove and either a second such groove or a lateral edge, the strip being laterally undivided by full-depth grooves.
“Sipe” means small slots molded into the tread elements of the tire that subdivide the tread surface and improve traction, sipes are generally narrow in width and close in the tires footprint as opposed to grooves that remain open in the tire's footprint.
“Slip angle” means the angle of deviation between the plane of rotation and the direction of travel of a tire.
“Tread element” or “traction element” means a rib or a block element defined by having a shape adjacent grooves.
“Tread Arc Width” means the arc length of the tread as measured between the lateral edges of the tread.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described by way of example and with reference to the accompanying drawings in which:
FIG. 1 is a break-away view of a tire with a RFID tag mounted or embedded onto the tire inner sidewall.
FIG. 2A is an exploded assembly view of a RFID tag.
FIG. 2B is an assembled view of the RFID tag package of FIG. 2A shown prior to application of an outer coating.
FIG. 2C is an assembled view of the finished RFID cylindrical tag package.
FIGS. 3A , 3 B, 3 C, and 3 D are sequential perspective views of a first assembly sequence of the RFID tag package.
FIG. 3E is an tubular packaged tag.
FIGS. 4A , 4 B, 4 C, and 4 D are sequential perspective views of a second assembly sequence of the RFID tag package.
FIGS. 5A , 5 B, 5 C, and 5 D show an alternative through bore connection between a tag and antenna elements.
FIGS. 6A , 6 B, 6 C, and 6 D show alternative connection schemes between a tag and antenna elements.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIGS. 1 , 2 A-C, an electronic tire tag 16 is of a conventional commercially configured type and includes an antenna formed by a pair of coiled antenna segments 40 , 42 . An integrated circuit package (IC) 6 is mounted to a carrier substrate 22 and includes interconnection leads 38 extending from opposite IC package sides respectively. The antenna 40 , 42 is electrically connected to the IC leads 38 and is suitably tuned to a predetermined radio frequency “f” for receiving RF signals, referred to herein as interrogation signals, from an external transceiver (not shown).
Operatively, the interrogation signal is received by the antenna 40 , 42 from a remote transponder (not shown) and transmitted to the integrated circuitry within the package 36 . The integrated circuit within the package 36 processes the RF interrogation signal into a power signal for powering a logic circuit that includes conventional ROM, RAM, or other known types of memory storage devices and circuitry. Data transmission from the storage devices is thereby enabled and stored data is transmitted by the antenna 40 , 42 back to an external reader or transponder (not shown). The tag 16 may be incorporated within various products and utilized to communicate stored data relating to such products to the remote reading device.
The electronic tire tag 16 is preferably wrapped with a suitable green rubber material (not shown) to form a green rubber patch (not shown) that is vulcanized and fixedly secured to a tire (not shown). Alternatively, the tag 16 may be incorporated within the green tire prior to tire cure.
Referring initially to FIGS. 1 , 2 A-C collectively, a tag and tire assembly 10 is shown. A conventionally configured tire 12 includes an inner lining 14 to which a RFID tag assembly 16 is incorporated. In the embodiment shown, without any intent to limit the invention, the RFID tag assembly 16 is attached to the inner lining 14 (but may also be embedded in any layer of the sidewall) by a suitable commercial grade adhesive 20 . Other locations or tire components may be utilized if desired without departing from the invention. The tire 12 with the tag assembly 16 incorporated therein is mounted conventionally to a rim 18 .
The RFID assembly 16 includes a carrier substrate 22 having a top support surface 24 on which a pair of spaced apart conductive contact pads 26 , 28 are mounted. In general, the support surface 24 includes spaced apart contact pad receiving locations 30 , 34 separated by a medial RFID device receiving location 32 between locations 30 , 34 . An RFID electronic package 36 encased within a cover 37 is mounted to the support surface 24 at the medial location 32 as shown in FIG. 2A . Attachment may be by any suitable means such as adhesive. The package 36 includes an array of contact legs 38 along opposite sides. In its intended location at location 32 , the contact legs 38 will establish electrical and mechanical contact with the contact pads 26 , 28 on support surface 24 .
The RFID tag assembly 16 further includes a dipole antenna (but can be other antenna types) comprised of coiled antenna segments 40 , 42 . The antenna segments 40 , 42 have a respective inward end 44 , 46 that is coupled to the contact pads 44 , 46 by suitable means such as solder. While the ends 44 , 46 are shown as straightened portions of the coiled segments 40 , 42 , the ends may be in a coiled configuration if so desired. The tag assembly 16 of FIG. 2B may be incorporated into a tire as shown in FIG. 1 by adhesive application 20 or other suitable means. So located, the antenna segments 40 , 42 , and the substrate 22 will be supported by mounting surface portions of the tire inner liner 14 . Stresses introduced into the tire and acting upon the assembly 16 will be accommodated by flexure of the segments 40 , 42 that extend from the substrate 22 . The tag assembly 16 is thus durable and capable of withstanding the highly stressed environment of a tire cavity.
In order to make the assembly 16 even more durable, an encapsulating casing 48 may be secured to encase the substrate, the RFID package 36 and the inward ends 44 , 46 of the antenna segments 40 , 42 as shown in FIG. 2C . The casing 48 may be formed of plastics or other suitable material. The casing 48 is preferably of tubular form as shown. The tubular form of the casing 48 will protect the electronic components and connections therein from potentially damaging contact with foreign objects and the stresses acting on the assembly 16 from the tire and tire operation, as well as in shipping and handling of the assembly 16 prior to and during incorporation into a tire.
In FIGS. 3A-3D an opened or already opened IC package is shown. The connections made to the leads of the package were made to the antenna instead. The RFID die 54 is removed from an IC package and replaced. The die connections are made directly to the antenna segment ends 44 , 46 . The die 44 is mounted directly to the substrate support surface 24 . The die 54 includes an integrated circuit 56 and peripheral contacts 58 . A contact pad 60 of conductive material is applied to the substrate surface 24 . Placement of the die 44 on the contact pad 60 establishes electrical contact between the die contacts 58 and the substrate pad 60 . The die 44 is held in place on substrate surface 24 by suitable means such as adhesive.
The coiled ends 62 , 64 of the antenna segments 40 , 42 are attached to the substrate pad 60 by suitable means such as adhesive or solder, whereby electrically connecting the antenna through pad 60 to the IC on the die 44 . The cover 37 may be affixed as shown in FIG. 3C by adhesive or other means to complete the assembly as shown in FIG. 3D . The coiled antenna segments 40 are directly coupled at the coiled inner ends 62 , 64 to the pad 60 and extend free of the sealed compartment formed by the cover 37 and the substrate 22 . Placement of the completed assembly into a tire is achieved by affixing the substrate to a tire mounting surface such as the inner liner by suitable means such as adhesive. The antenna segments 40 , 42 rest against the tire mounting surface but preferably extend adhesive free from containment of cover 37 and substrate 22 . Accordingly, as with the embodiment of FIGS. 2A-D , the RFID tag assembly 16 is sealed, durable, and capable of withstanding the use-induced stresses of the tire. FIG. 3E shows a tubular casing surrounding the RFID package of FIG. 3C as an alternative packaging configuration. The tubular casing 66 provides a protective enclosure of the RFID electronics package during shipment, handling, installation, and tire use.
FIGS. 4A-D show another alternative embodiment of an RFID Assembly 68 . The cover 70 is removed (or an already opened package is used) in FIG. 4B to illustrate placement of the die 54 on the support surface 24 of the substrate 22 . The conductive pad 60 is secured to the surface 24 as with the embodiment of FIGS. 3A-D discussed previously. A series of depending support legs 72 are secured to opposite sides of the substrate 22 and each leg 72 includes a bend 71 transitioning into a support foot 73 that is generally coplanar with the underside of the substrate 22 . A medial portion of each side of the substrate is support leg-free to allow access to the contact pad 60 by the coiled ends 62 , 64 of antenna segments 40 , 42 as will be appreciated in FIGS. 4C and 4D . The cover 70 is attached over the substrate 22 and sealed by suitable means such as adhesive compound. The completed assembly 16 of FIG. 4D is attached to a tire surface such as the inner liner by adhesive applied to the underside of the substrate 22 as well as the undersides of the feet 73 of the support legs. The resultant tag 16 is durable and the legs 72 aid in attachment of the unit 16 to the tire by increased anchoring provided by adhesive connection of the feet 73 to the tire surface.
FIGS. 5A-C show an alternative configuration for the RFID tag assembly 16 . Contact pads 74 , 76 , 78 , 80 are secured to top and bottom surfaces of the substrate 22 . An IC die 56 is mounted to a top surface of the substrate and includes contacts 58 along opposite die sides. Alternately, the contacts could also be inductively coupled using a ferrous material. Plated through holes 82 extend through the substrate 22 and are positioned to electrically connect the contact pads 74 , 78 on one substrate side with the pads 76 , 80 on the opposite substrate side (not shown). The coiled ends 64 , 66 of the antenna segments 40 , 42 are secured to the pads 76 , 80 and electrically connect with the die contacts 58 through the plated through holes 82 , 84 . Free segments 50 , 52 of the antenna segments 40 , 42 , respectively, project free from the substrate 22 as with the embodiments shown and discussed previously. It will be appreciated that the assembly of FIG. 5C may be incorporated into a tire by adhesive attachment of the substrate 22 to a tire surface as described previously. Preferably, however, the electronic die and substrate with the ends 64 , 66 of the antenna segments 40 , 42 will be encased within a tubular casing 86 as shown in FIG. 5D to better protect the electronic tag during shipping, attachment to a tire, and tire use.
FIGS. 6A-6D show other alternative embodiments for the RFID tag assembly 16 . In FIG. 6A , the RFID package 36 provides edge contacts that are directly coupled to the ends 62 , 64 of the antenna segments 40 , 42 by suitable means such as solder. The electronics package 36 may then be encased into a tubular package as shown in FIG. 6B . FIG. 6C shows a die configured having dependent contact legs 38 that are attached directly to the coiled antenna segment ends 62 , 64 . FIG. 6D shows encasement of the package of FIG. 5C within a tubular casing 88 for added protection and durability as described previously.
From the foregoing, it will be understood that the subject invention satisfies a need for a UHF RFID tag package that is readily incorporated into a tire; provides the requisite durability to maintain antenna to circuit board integrity during the life of the tire and the service life of the tag. The tag assemblies described readily integrate 0.8 and 1.4 pitch coil antennas directly into a plastic IC package either by opening the IC package and keeping the die intact ( FIGS. 2A-2D ) or by opening the IC package and removing the die ( FIGS. 3A-D ). In the first approach, the connections made to the leads are made directly to the antenna instead. The possibility of failure of a lead to IC connection is thereby eliminated. A portion (inward coiled end) of the antenna is embedded in the IC when it is re-sealed to further secure the integrity of the antenna to IC attachment.
In the latter approach of FIGS. 3A-3D , the die is replaced on the carrier substrate and the die connections are made to the antennas. Likewise, inward coiled ends of the antenna segments are embedded in the IC when it is re-sealed.
Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. It is, therefore, to be understood that changes can be made in the particular embodiments described which will be within the full intended scope of the invention as defined by the following appended claims.
|
A tire and RFID tag combine as an assembly to include a tire and a tag package mounted to a tire tag mounting surface. The tag package includes a carrier substrate having a die receiving surface and one or more interconnection tabs mounted to the die receiving surface. The tag package further includes a dipole antenna or other antenna configuration formed by first and second antenna members having inward ends connected to respective first and second interconnection tabs on the die receiving surface and outer antenna segments extending outward from the carrier substrate. An integrated circuit die mounts to the die receiving surface and has electrical contact(s) in contacting engagement with the interconnection tab(s). A cap member or, alternatively, a cylindrical encapsulating member, may be utilized for enclosing the integrated circuit die, the carrier substrate, and the inward ends of the first and second antenna members; the outer antenna segments of the first and second antenna members extending outward from the cap member or encapsulating member in operable position against respective portions of the tire tag mounting surface.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 11/018,594, filed Dec. 20, 2004, which claims priority to Japanese Application No. 2003-429276, filed Dec. 25, 2003, both of which are hereby incorporated herein in their entirety by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a capsule with improved disintegration comprising low-substituted cellulose ether that is mainly used for food and pharmaceutical products and to a method for preparing the same.
2. Description of the Related Art
Generally, a shell of a hard or soft capsule comprises a water-soluble shell-forming component such as gelatin, agar, carrageenan, hydroxypropylmethylcellulose and the like. And a hard capsule is prepared, for example, by filling a content into a hard capsule shell formed by adhering an aqueous solution of gelatin onto a mold pin and drying the solution.
On the other hand, a soft capsule is prepared, for example, by encapsulating a content by a soft capsule shell that are obtained by forming a gel from a shell base substrate comprising gelatin, water and a plasticizer.
However, the conventional shell for the capsule described above has the following problems:
(1) Because eicosapentanoic acid (hereafter referred to as “EPA”), docosahexaenoic acid (hereafter referred to as “DHA”), ∃-carotene or the like, which is believed to be generally effective for the prevention of lifestyle diseases and the like, has many double bonds within the molecule, it is very easily oxidizable substance. Furthermore, because the substance has unpleasant taste and odor, it cannot be generally admixed to food as it is. Consequently, the substance is ordinarily used as health food sealed in a soft capsule. A method of adding the substance to food after sealing in a soft capsule is widely known (Japanese Patent Application Unexamined Publication No. 60-102138/1985, Japanese Patent Application Unexamined Publication No. 60-66935/1985, and Japanese Patent Application Unexamined Publication Nos. 2-203741/1990 and 5-65222/1993). However, although the methods can veil the unpleasant taste and odor, an oxidation of content cannot be completely prevented, so that the peroxide value increases as time passes, and the content turns yellow.
(2) Because the capsule used in pharmaceutical products or health food is generally required to have good intragastric dissolution after intake and the content's efficacy is displayed quickly, the improvement of the dissolution of a capsule has been an important problem to be solved. But nevertheless, water-soluble polymers that are soluble in water but do not disintegrate and tend to form a thick gel film are presently used for the capsule base substrate.
SUMMARY OF THE INVENTION
In view of the above problems, it is an object of the present invention to provide a capsule that has good disintegration properties and that can quickly display its content's efficacy as well as a method for preparing the same.
As a result of intensive studies to attain this object, the inventors have focused on the various properties of low-substituted cellulose ether that does not dissolve but swells in water, and dissolves in an alkaline aqueous solution, and completed the present invention by finding that favorable disintegration properties are achieved and the content's efficacy can be quickly displayed and the drug does not undergo denaturation when using low-substituted cellulose ether as a base substrate for the capsule.
Therefore, the present invention provides a capsule comprising the following low-substituted cellulose ether and a method for preparing the same.
According to the present invention, provided is a capsule comprising a shell comprising low-substituted cellulose ether.
Moreover, according to the present invention, provided is a method for preparing a hard capsule comprising a low-substituted cellulose ether comprising a step of covering a pin for forming the hard capsule with the low-substituted cellulose ether by immersing the pin in an aqueous alkaline solution of the low-substituted cellulose ether; a step of forming the low-substituted cellulose on the surface of the pin into a gel by further immersing the covered pin in an aqueous acid solution; a step of washing by immersing in water the pin whose surface has been covered with the gel; and a step of drying.
According to the present invention, provided is a method for preparing a soft capsule comprising a low-substituted cellulose ether comprising a step of casting an aqueous alkaline solution of the low-substituted cellulose ether to obtain a sheet; a step of forming a gel sheet of the low-substituted cellulose by immersing the obtained sheet in an aqueous acid solution; a step of washing by immersing the gel sheet in water; a step of drying; and a step of molding by introducing the dried gel sheet into a film-introducing part of a gelatin soft capsule molding apparatus.
Furthermore, according to the present invention, provided is another method for preparing a hard capsule comprising a low-substituted cellulose ether comprising a step of preparing an aqueous solution by dispersing the low-substituted cellulose ether in water and further dispersing it by a shearing force; a step of covering a pin for forming the hard capsule with the low-substituted cellulose ether by immersing the pin in this dispersion; and a step of drying.
Furthermore, according to a present invention, provided is another method for preparing a soft capsule comprising low-substituted cellulose ether comprising a step of preparing a dispersion by dispersing the low-substituted cellulose ether in water; a step of applying a shearing force to the dispersion; a step of forming a sheet by casting the dispersion to which the shearing force have been applied; a step of drying the obtained sheet; and a step of molding by introducing the dried sheet into a film-introducing part of the gelatin soft capsule molding apparatus.
The capsules comprising the low-substituted cellulose ether of the present invention are useful because their disintegration is good, the content's efficacy can be quickly displayed, and the drug hardly undergoes deterioration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the present invention, low-substituted cellulose ether has properties that it is insoluble in water, but swells by absorbing water, and is soluble in an aqueous alkaline solution. A typical example may include low-substituted hydroxypropylcellulose, which is currently commercially available under the trade name “L-HPC” by Shin-Etsu Chemical Co., Ltd. The low-substituted cellulose ether is listed in Japanese Pharmacopoeia and is widely used as a disintegrating agent that is formulated in a tablet especially in the field of pharmaceutical materials.
Cellulose is generally insoluble in water, but if a hydrogen atom of the hydroxyl group of the glucose ring constituting the cellulose is substituted with an alkyl group or a hydroxyalkyl group, then the cellulose becomes soluble in water depending on the degree of substitution. However, in many cases, cellulose in which the degree of substitution is low does not dissolve in water, swells, and dissolves in an aqueous alkaline solution. In most cases, when a powder of low-substituted cellulose ether is dispersed in water, a part of the cellulose ether swells.
If the substitution degree is high, then cellulose ether becomes soluble in water but conversely loses the solubility in an alkaline solution. Therefore, if such water soluble cellulose ether is used, then it is impossible to obtain a gel of the present invention.
The cellulose ether used in the present invention may be cellulose ether having the substitution degree of 0.05 to 1.0 for the low substitution or cellulose ether having the substitution degree of 0.1 to 0.8 for solubility in an aqueous alkaline solution. More specific examples are the low-substituted cellulose ethers described below: Low-substituted methylcellulose having a substitution degree of 0.16 to 0.84 for a methoxyl group; low-substituted hydroxyethylcellulose having a substitution degree of 0.1 to 0.5 for a hydroxyethoxyl group; low-substituted hydroxypropylcellulose having a substitution degree of 0.1 to 0.5 for a hydroxypropoxyl group; low-substituted hydroxypropylmethylcellulose having a substitution degree of 0.1 to 0.5 for a methoxyl group and a substitution degree of 0.1 to 0.5 for a hydroxypropoxyl group; and low-substituted carboxylmethylcellulose and a sodium salt thereof having a substitution degree of 0.1 to 0.8 for a carboxymethyl group.
The substitution degree of low-substituted cellulose ether can be determined by the method mentioned in Japanese Pharmacopoeia.
A method for preparing low-substituted cellulose ether are widely known in the art and disclosed in Japanese Patent Examined Application No. 57-53100/1982, for example. That is, alkali cellulose can be prepared by immersing a pulp sheet serving as a starting material in an aqueous alkaline solution such as sodium hydroxide, or by mixing pulverized pulp in an aqueous alkaline solution, or by adding a base to a dispersion of pulp powder in an organic solvent, or by the other method.
Next, the alkali cellulose may be placed in a reactor. Following the addition of an etherification agent such as propylene oxide, ethylene oxide or the like, the alkali cellulose may be heated to react so as to obtain cellulose ether.
After the reaction, the crude cellulose ether may be transferred to another tank where the alkali is neutralized with acid so as to obtain a solid material. The solid material is washed, dried, and pulverized into powder as a final product.
Alternatively, the crude cellulose ether may be completely or partially dissolved in water immediately after the reaction and then be neutralized, and the precipitated cellulose polymer may be collected and then washed, dried, and pulverized.
Examples of the base used for the alkali solution may include potassium hydroxide, sodium hydroxide or the like. The concentration of the base is determined appropriately, depending on the kind and substitution degree of substituent of the cellulose ether used. The typical concentration may be preferably 2 to 25% by weight, more preferably 3 to 15% by weight. In a typical example, low-substituted hydroxypropylcellulose having a substitution degree of 0.2 may be dissolved in 10% by weight of NaOH.
It should be noted that there are cases in which the solution is transparent and cases in which it is not completely transparent, due to the difference in the distribution of the substituent group. In the latter case, the cellulose ether is considered to be dissolved when the viscosity of the solution has clearly risen.
Examples of the acid to be used may include hydrochloric acid, sulfuric acid, acetic acid and the like and it may be preferable that the concentration corresponds to an amount that can stoichiometrically neutralize the concentration of the aqueous alkaline solution used.
In general, two methods described below can be given as examples of the methods for preparing a capsule comprising low-substituted cellulose ether of the present invention using the low-substituted cellulose ether described above.
In a first method, a pin for forming a hard capsule is immersed in an aqueous alkaline solution in which the low-substituted cellulose ether is dissolved, then the pin is lifted up and then immersed in an aqueous acid solution to cover the pin with a gel film of the low-substituted cellulose ether which contains the salt generated in the reaction of the aqueous acid solution and the aqueous alkaline solution. The pin covered with the gel film are then immersed in water for washing and later dried, thus obtaining a hard capsule-forming body.
It may be preferable that the concentration of the aqueous alkaline solution of the low-substituted cellulose ether is such that the solution is viscous enough that dripping of the solution is reduced to a minimum when the pin is drawn up from the solution. The concentration of 10 to 30% by weight may be particularly preferable. There is no particular limitation regarding the pin for forming the hard capsule and any pin as known in the art can be used. By immersion in the aqueous acid solution, the aqueous alkaline solution contained by the low-substituted cellulose ether which is present on the surface of the pin is neutralized. A gel film of the low-substituted cellulose ether is formed and the pin is covered with the gel film. At this time, the salt formed by the neutralization is present in the gel film, but the salt will be removed by washing in the subsequent step. There is no particular limitation regarding the drying and any of the drying methods known in the art can be used. The thickness of the capsule containing the low-substituted cellulose ether can be adjusted by the concentration of the aqueous alkaline solution of the low-substituted cellulose ether or the like, but the thickness may be preferably 10 to 50 μm.
In a method for preparing a soft capsule, the aqueous alkaline solution of the low-substituted cellulose ether may be cast on a substrate, then the cast portion is immersed in an aqueous acid solution, and while still containing the resulting salt, the gel sheet of low-substituted cellulose is formed. After immersing the gel film sheet in water for washing, it is washed and dried. The obtained gel sheet can be molded by introducing the gel sheet preferably into a film-introducing part of a gelatin capsule molding apparatus.
In this method for preparing a soft capsule, the concentration of the low-substituted cellulose ether in the aqueous alkaline solution may depend on the ease of the casting. It may be preferable that the concentration is 10 to 30% by weight. The casting may be performed by applying the low-substituted cellulose ether on a known substrate of glass or synthetic resin such as polyethylene terephthalate, polypropylene or the like, and adjusting the thickness of the applied low-substituted cellulose ether with a doctor blade, thus obtaining a sheet of the low-substituted cellulose ether. The gel sheet is a sheet in which the surface of the low-substituted cellulose ether sheet has been formed into a gel. There is no particular limitation to the gelatin capsule molding apparatus and any apparatus known in the art can be used, such as the rotary soft capsule R&D model SSC-A3 by Sankyo Co., Ltd., for example. The thickness of the sheet before the introduction into the gelatin capsule forming apparatus may be preferably 0.05 to 0.20 μm, and the thickness of the sheet obtained after the molding with the gelatin capsule-forming apparatus may be preferably 0.03 to 0.15 mm.
After washing, the gel pin or the gel sheet may be immersed in a plasticizer solution containing glycerin, propylene glycol, ethylene glycol or their derivative or an aqueous solution containing the same, and may be impregnated with the plasticizer. With subsequent drying, it may be possible to obtain even a softer hard capsule or soft capsule. Instead of the plasticizer solution, it may be also possible to add an appropriate amount of starch, pullulan or chitin in order to adjust the disintegrating properties. The amount of plasticizer may be preferably 10 to 30% by weight and the concentration of the plasticizer solution may be preferably 10 to 50% by weight.
Another method for preparing the capsule comprising the low-substituted cellulose ether may comprise steps of dispersing the low-substituted cellulose ether in water, applying a shearing force to the dispersion, immersing a pin in the cellulose ether dispersion which has been subjected to the shearing force, washing and drying so as to obtain a hard capsule forming body.
The dispersion of the low-substituted cellulose ether can be prepared by using preferably 2 to 10 parts by weight of low-substituted cellulose ether in 100 parts by weight of water. Application of the shearing force may be performed by collision of the low-substituted cellulose ether against each other, collision of the cellulose ether against a collision board, shear-triturating, for example. However, there is no limitation to this, and as long as being dispersed by wet pulverization is done, any method can be applied. There is no particular limitation to the pin, and a pin similar to the pin described above may be used. The surface of the pin may be covered by immersing it in this dispersion. Drying may performed by any known method. The thickness of the capsule comprising the low-substituted cellulose ether can be adjusted preferably in the range of 0.03 to 0.2 mm, more preferably in the range of 0.05 to 0.15 mm.
Another method for preparing a soft capsule can comprise steps of forming a cellulose ether dispersion, which has been obtained by applying a shearing force similarly as described above, into a sheet by casting or the like; drying; and introducing the sheet preferably into the film-introducing part of a gelatin capsule molding apparatus so as to form the soft capsule, for example. The casting and the gelatin capsule molding apparatus may be the same as described above.
In order to provide the capsule shell with softness, the plasticizer solution containing glycerin, propylene glycol, ethylene glycol or their derivative, or an aqueous solution containing the same can be added to the dispersion which has been subjected to shear-triturating. The resulting mixture can be used in the same manner so as to form soft as well as hard capsules. Furthermore, at this point, starch, pullulan or chitin instead of the plasticizer solution can be added in an appropriate amount in order to adjust the disintegration properties.
There is no particular limitation regarding the apparatus for preparing the cellulose ether dispersion obtained by collision of the low-substituted cellulose ether with each other, by collision of the low-substituted cellulose ether against a collision board, or by shear-triturating. Examples of the suitable apparatus may include vibration ball mills, colloid mills such as the Masscolloider or the Cerendipitor by Masuko Sangyo Co., Ltd., homomixers and propeller-type homogenizers. The homogenizers may preferably include the homogenizer by Sanwa Machine Co., Inc., which subjects the low-substituted cellulose ether to collisional friction by discharging a treating liquid from a slit of a valve with high pressure; the Ultimaizer System by Sugino Machine Limited; the Microfluidizer by Mizuho Industrial Co., Ltd.; the Gaulin high-pressure homogenizer; and an ultrasonic homogenizer that utilizes vibration of ultrasonic waves such as the ultrasonic homogenizer by Nippon Seiki Co., Ltd. These homogenizers are preferably used for preparing homogeneous dispersions. Furthermore, it is also possible to use dispersions that have been repeatedly treated by these apparatuses.
The present invention is explained in detail below through examples as well as comparative examples, but the present invention is not construed as limited to the embodiments below.
Example 1 and Comparative Example 1
The 10 g of low-substituted hydroxypropylcellulose powder (L-HPC by Shin-Etsu Chemical Co., Ltd; a substitution degree of 0.2) was dissolved in 90 g of an aqueous 10% by weight NaOH solution.
A male pin and a female pin for capsule formation with an internal diameter of 5 mm were immersed in the NaOH solution, and then immersed in an aqueous 10% by weight hydrochloric acid solution, resulting in a state in which a gel film of low-substituted hyroxypropylcellulose containing the salt covers the pins. After the pins with the gel film were immersed in water and washed, the pins were then dried at 30° C. to obtain a hard capsule containing vitamin C. Gelatin capsules were also prepared by a conventional method. The capsules were subjected to a disintegration test according to Japanese Pharmacopoeia on six capsules each.
The soft capsules comprising L-HPC disintegrated within 1 minute, while the gelatin capsules disintegrated in the range of 3 to 5 minutes.
Also, observing the yellowing change of the vitamin C in the capsules stored at 40° C. for one month, there was clearly less yellowing in the capsules of the present invention than in the gelatin capsules.
Example 2 and Comparative Example 2
The 10 g of low-substituted hydroxypropylcellulose powder (L-HPC by Shin-Etsu Chemical Co., Ltd; a substitution degree of 0.2) was dissolved in 90 g of an aqueous 10% by weight NaOH solution.
The solution was cast on a polyethylene terephthalate sheet (width: 400 mm width, length: 600 mm length and thickness: 50 μm) on a table coater by Hirano Tecseed Co., Ltd. The sheet was coated with a blade to a thickness of 15 mm. Then, the cast portion along with the sheet of polyethylene terephthalate was immersed for 2 minutes in a vat holding a 12% by weight hydrochloric acid solution, washed by immersion for 3 minutes in a vat holding tap water, and then immersed in an aqueous 10% by weight glycerin solution for 1 minute. Then, the cast portion was dried for 24 hours at 20° C. to produce a dried sheet having thickness of about 150 μm. The Oval-5 soft capsules containing refined sardine oil were prepared by stamping the sheet in use of a rotary die. Soft capsules comprising gelatin were also prepared in the same method. The capsules were subjected to the disintegration test according to Japanese Pharmacopoeia on six capsules each.
The soft capsules comprising L-HPC disintegrated within 1 minute, while the gelatin capsules disintegrated in the range of 3 to 5 minutes.
Example 3 and Comparative Example 3
The 100 g of low-substituted hydroxypropylcellulose powder (L-HPC by Shin-Etsu Chemical Co., Ltd; a substitution degree of 0.2) was dispersed in 900 g of water and treated 10 times with a Cerendipitor by Masuko Sangyo Co., Ltd. to obtain the dispersion. After a male pin and a female pin for capsule formation having an internal diameter of 5 mm were immersed in the dispersion, lifted up and dried at 30° C. to obtain a hard capsule forming body containing vitamin C inside. Gelatin capsules were also prepared in a conventional method. The capsules were subjected to the disintegration test according to Japanese Pharmacopoeia on six capsules each.
The soft capsules comprising L-HPC disintegrated within 1 minute, while the gelatin capsules disintegrated in the range of 3 to 5 minutes.
Also, observing the yellowing change of the vitamin C in the capsules stored at 40° C. for one month, there was clearly less yellowing in the capsules of the present invention than in the gelatin capsules.
Example 4 and Comparative Example 4
After 100 g of low-substituted hydroxypropylcellulose powder (L-HPC by Shin-Etsu Chemical Co., Ltd; a substitution degree of 0.2) was dispersed in 900 g of water, this dispersion was treated 10 times by the Microfluidizer 110-EH by Mizuho Industrial Co., Ltd., at a pressure of 172 MP. The resulting dispersion was cast on a polyethylene terephthalate sheet (width: 400 mm width, length: 600 mm length, thickness: 50 μm) with the table coater by Hirano Tecseed Co., Ltd. The sheet was coated with a blade to a thickness of 15 mm. The sheet was then dried for 24 hours at 20° C. so as to produce a dried sheet having thickness of about 150 μm. The Oval-5 type soft capsules containing refined sardine oil were prepared by stamping the sheet with a rotary die machine. Soft capsules comprising gelatin were also prepared in the same manner. The capsules were subjected to the disintegration test according to Japanese Pharmacopoeia on six capsules each.
The soft capsules comprising L-HPC disintegrated within 1 minute while the gelatin capsules disintegrated in the range of from 3 to 5 minutes.
|
A capsule with good disintegration properties that can quickly display its content's efficacy as well as a method for preparing the same are provided. More specifically, provided is a capsule comprising a shell comprising low-substituted cellulose ether. Also, provided is a method for preparing a hard capsule comprising the low-substituted cellulose ether comprising a step of covering a pin for forming the hard capsule with the low-substituted cellulose ether by immersing the pin in an alkaline solution of the low-substituted cellulose ether; a step of forming the low-substituted cellulose on a surface of the pin into a gel by further immersing the covered pin in an aqueous acid solution; a step of washing by immersing the pin whose surface has been covered with the gel in water; and a step of drying.
| 0
|
FIELD OF THE INVENTION
This invention relates to the automatic sewing of predefined stitch patterns within an automatic sewing machine system. In particular, this invention relates to an automatic selection of the predefined stitch patterns that are to be sewn within an automatic sewing machine.
BACKGROUND OF THE INVENTION
The manner in which a stitch pattern is selected within an automatic sewing machine has become increasingly more important in the field of automated sewing. The operator of an automatic sewing machine must quickly and efficiently select the appropriate stitch pattern that is to be sewn in order to achieve a high volume of sewing. This has led to various approaches as to how to communicate the selected pattern to the sewing machine. One approach has been to provide an array of pattern selection buttons or switches on a control panel associated with the sewing machine. Each pattern selection button is associated with a stored stitch pattern residing in an electronic memory that is to be called forth for execution by the sewing machine. This approach works well for a limited number of stitch patterns requiring a relatively small number of pattern selection buttons. It is to be appreciated that this approach becomes less attractive as the number of stitch patterns to be selected becomes relatively high. It is furthermore to be appreciated that even a few stitch patterns will require an appreciable control panel to accommodate the pattern selection buttons. It is still furthermore to be appreciated that the increasing number of pattern selection buttons increases the likelihood of operator confusion and the possibility of pressing the wrong button.
OBJECTS OF THE INVENTION
It is therefore an object of this invention to provide a pattern selection system within an automatic sewing machine that allows the operator to efficiently select a stitch pattern to be sewn.
It is another object of this invention to provide a pattern selection system within an automatic sewing machine that allows an operator to select from a relatively large number of stitch patterns in such a manner as to minimize any confusion to the operator.
SUMMARY OF THE INVENTION
The above and other objects are achieved according to the present invention by providing a pattern selection system having a relatively small number of pattern selection switches. Each pattern selection switch may be assigned a particular stitch pattern that is stored in memory. The assigning of the stitch patterns occurs in a series of communications between the operator and the pattern selection system. These communications include the displaying of the stitch pattern assignment to the operator as it is being made. The pattern selection system thereafter displays the stitch pattern assignment each time the pattern selection switch is activated.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features of the invention will now be particularly described with reference to the accompanying drawings in which:
FIG. 1 is an overall view of an automatic sewing machine having a pattern selection panel;
FIG. 2 is a block diagram of the pattern selection system which interfaces with the pattern selection panel;
FIG. 3 illustrates circuitry within the pattern selection system;
FIGS. 4A-4F are a flow chart illustrating the flow of computer commands within the pattern selection system so as to facilitate the selection of a pattern; and
FIG. 5 illustrates a table of values utilized within the flow chart of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an automatic sewing machine 10 having a moveable workpiece support piece 12 is generally illustrated. The workpiece support 12 is positioned relative to a needle 14 of the automatic sewing machine 10 by positioning apparatus which is not shown. The positioning apparatus is responsive to a predefined pattern of movement usually stored within an electronic memory. This predefined pattern of movement includes positioning information for the workpiece support 12 as well as commands for the reciprocating needle 14. It is to be appreciated that such predefined patterns of movement stored in electronic memory are well known in the art.
A particular predefined pattern of movement for the workpiece support 12 is communicated to the automatic sewing machine 10 via a pattern selection panel 16. The pattern selection panel 16 includes a display portion having six individual alpha numeric displays 18, 20, 22, 24, 26, and 28. The pattern selection panel 16 furthermore includes four pattern selection buttons 30, 32, 34, and 36. Each of these pattern selection buttons preferably bears an alphabetic label such as A, B, C and D as shown. The pattern selection panel 16 furthermore includes a pair of directional selection buttons 38 and 40 which preferably have upward and downward arrows as shown. As will be explained in detail hereinafter, the directional selection buttons 38 and 40 are operative to change a stitch pattern number displayed on the alpha numeric displays 18 through 28. This change of the displayed stitch pattern number is always associated with one of the pattern selection buttons 30 through 36. In this manner, a particular stitch pattern number can always be associated with a particular pattern selection button. The particularly displayed stitch pattern can be thereafter selected by depressing the particular pattern selection button. The operator can always visually confirm that the appropriate stitch pattern has been selected prior to pressing a "start" button 42.
Referring to FIG. 2, a pattern selection system which interfaces with the pattern selection panel 16 is generally illustrated. The pattern selection system is seen to include a central processor unit 44 which communicates with a program memory 46, a keyboard/display interface unit 48 and a pattern data memory unit 50 via a data bus 52, an address bus 54, and a data control bus 56. The central processor unit is preferably an INTEL 8085 microprocessor utilizing the INTEL Multibus structure so as to communicate with compatible eight bit units. In this regard, the keyboard/display interface unit 48 is preferably the INTEL 8279 keyboard/display interface. It is to be appreciated that the memory units 46 and 50 as well as the keyboard display interface 48 are addressed via the address bus 54, controlled by control signals appearing on the control bus 56 so as to either transmit or receive data via the data bus 52.
Referring to the keyboard/display interface unit 48, it is seen that this unit communicates with pattern selection circuitry 57 associated with the panel 16. In this regard, the keyboard/display unit 48 is operative to communicate with the display circuit portion of the pattern selection panel 16 via a bus 58. On the other hand, the keyboard/display unit 48 is operative to communicate with the various button switches on the pattern selection panel 16 via a bus 60. As will be explained in detail hereinafter, the keyboard/display interface unit 48 provides display information over the bus 58 which results in a display of alpha numeric characters on the alpha numeric displays 18 through 28. The keyboard/display interface 48 also monitors the status of the pattern selection buttons 30 through 36 as well as the directional pattern selection buttons 38 and 40 and the "start" button 42. The status of each button switch on the pattern selection panel 16 is queried via the bus 60. The status of a given switch is relayed back to the interface unit via a common line 61.
Referring now to FIG. 3, the electrical circuitry 57 within the pattern selection panel 16 is illustrated in detail. In particular, the electrical circuitry is illustrated in association with the buses 58 and 60 from the keyboard/display interface unit 48. In accordance with the invention, the bus 58 carries eight bits of character generation code for a seven segmented character display. These coded bits from the keyboard/display interface unit 48 are applied to an octal buffer circuit 62 which provides an appropriate current interface to the base inputs of eight separate drive transistors 64, 66, 68, 70, 72, 74, 76 and 78. The octal buffer circuit is preferably a 74 LS244 chip available from various semi-conductor manufacturers. This octal buffer circuit is capable of handling the base current of the drive transistors 64 through 78. The emitter of each of the drive transistors 64 through 78 is connected to a common voltage supply source V s which is preferably ±5 volts. The collectors of the drive transistors 64 through 78 are connected to current drive lines 80, 82, 84, 86, 88, 90, 92, and 94. A current is produced on a respective current drive line when the drive transistor associated therewith becomes conductive by virtue of the bias voltage dropping low at its respective base terminal. This occurs when the respective output of the octal buffer circuit 62 associated with the base input drops logically low.
Each current drive line is individually tapped by one of six character display circuits 96, 98, 100, 102, 104 and 106. Each character display circuit comprises eight light emitting diodes each of which is connected to a respective current drive line. This diode circuit is illustrated for the character display circuit 96. Each of the light emitting diodes is commonly connected to an output circuit such as 108 for the character display circuits 96. The output circuit 108 is seen to comprise a grounded transistor 110 having an amplifier 112 connected to its base terminal. It is to be appreciated that each of the character display circuits has an output circuit such as 114, 116, 118, 120 and 122 associated therewith. The input to the amplifier within each output circuit is a logic level voltage which has been inverted by an inverting amplifier associated therewith. These inverting amplifiers are illustrated within a hex inverter circuit 124. Each inverting amplifier within the hex inverter circuit 124 receives a logic level voltage signal from a line decoder circuit 126. The line decoder circuit 126 receives three coded bits from the bus 60 which define in binary the identity of each of the character display circuits. The identity of a given character display circuit is decoded by the line decoder circuit 126 so as to produce a logically low or binary zero signal at the output of the line decoder circuit associated with the particular character display circuit. For example, the character display circuit 96 would be identified by three binary zero bits appearing on the respective bit lines within the bus 60. This would be decoded by the line decoder circuit 126 so as to produce a logically low signal only on the output line associated with an inverting amplifier 128 within the inverter circuit 124. The logically low voltage level would be inverted by the amplifier 128 so as to produce a logically high voltage signal applied to the amplifier 112 which in turn causes the grounded transistor 110 to become conductive. In this manner, the light emitting diodes within the character display circuit 96 become conductive in response to any current appearing on a current drive line associated therewith. The current drive lines 80 through 94 will be individually providing drive currents to respective light emitting diodes within the character display circuit 96 in response to a character generation code. The character generation code originates from a display memory within the keyboard/display interface unit 48 and is forwarded to the octal buffer circuit 62 via the bus 58. The amplifiers within the octal buffer circuit will drop logically low in accordance with the character generation code so as to allow the corresponding drive transistors to become conductive. It is to be appreciated that the character generation code is a standard seven segmented display code wherein individual line segments within a Figure "8" may be individually illuminated so as to thereby define alpha numeric characters. Referring to FIG. 1, it is seen that the alpha numeric display 28 has the numeral "8" displayed thereon. This would require the seven individual segments comprising the character "8" to be illuminated. This is accomplished by causing the seven corresponding light emitting diodes in the character display circuit 106 to become conductive. It is to be noted that the eighth light emitting diode is that of a decimal point which is not shown in any of the alpha numeric displays of FIG. 1. It is to be appreciated that each of the illustrated alpha numeric displays, 18, 20, 22, 24 and 26 in FIG. 1 are also responsive to the character display circuit associated therewith. In this regard, the character display circuit 96 is associated with the alpha numeric display 18 whereas the character display circuit 98 is associated with the alpha numeric display 20, the character display circuit 100 is associated with the alpha numeric display 22, the character display circuit 102 is associated with the alpha numeric display 24 and the character display circuit 104 is associated with the alpha numeric display 26. It is furthermore to be appreciated that an eight bit character generation code for each display circuit resides within the display memory in the keyboard/display interface unit 48. This character generation code is forwarded over the bus 58 in conjunction with a three bit identification of the particular display circuit via the bus 60. In this manner, the keyboard/display interface unit 48 continually maintains the display portion of the pattern selection panel 16.
Having now discussed the manner in which the keyboard/display interface unit controls the display portion of the pattern selection panel 16, it is now appropriate to turn to the monitoring of the various button switches present on the pattern selection panel 16 by the same unit. In this regard, it will be remembered that the pattern selection panel preferably includes four pattern selection buttons, two directional pattern selection buttons, and one "start" button. The status of each button switch appearing on the pattern selection panel 16 is monitored as follows. The keyboard/display interface unit 48 is operative to identify each button switch by a particular three bit binary code appearing on the bus 60. This three bit binary code is applied to a line decoder 130 which responds by producing a logically low signal on one of the seven output scan lines associated therewith. These output scan lines are labelled 132, 134, 136, 138, 140, 142 and 144. Each of these output scan lines is connected to a terminal of one of the button switches 30 through 42. The other terminal of each button switch is connected to the common line 61. The common line 61 is connected to the return line input terminal of the programmable keyboard/display interface unit 48. In the preferred embodiment, the keyboard/display interface unit is an INTEL 8279 which possesses such a return line input.
The keyboard/display interface unit 48 is operative to monitor this return line input in conjunction with the identification of each of the individual button switches 30 through 42. In this regard, the keyboard/display interface unit sequentially identifies each of the button switches via the bus 60 so as to cause each output scan line 132 through 144 to sequentially drop logically low. In the event that a particular switch has been depressed, current will flow from the return line input terminal through the common line 61 when the scan line associated with the depressed switch drops logically low. This current flow will be noted by the keyboard/display interface unit which will store a binary zero in the keyboard memory location associated with that output scan line. On the other hand, if the switch associated with an energized scan line is open, then the keyboard memory location associated with that output scan line will remain equal to binary one.
Having now described the pattern selection system, it is appropriate to turn to the overall control of this system by the central processor unit 44. Referring to FIGS. 4A through 4F, a flow chart illustrating the operation of the central processor unit 44 within the pattern selection system is illustrated. It is to be appreciated that this flow chart is illustrative of a computer program resident within the program memory 46. In this regard, the instructions within the program memory 46 are sequentially read from program memory 46 via the data bus 52 so as to allow the central processor unit 44 to execute each instruction thus received. As will become apparent hereinafter, the central processor will typically be communicating with the keyboard/display interface unit 48 so as to control the selection of a pattern and the display of a numerical designation for a previously selected pattern before the stitch pattern is run on the automatic sewing machine. The actual execution of the stitch pattern will thereafter take place when the central processor unit 44 accesses the stored pattern data resident within the pattern data memory 50. It is to be noted that this accessing of the actual pattern data and implementing the sewing pattern is well known in the art of automatic sewing.
Referring to FIG. 4A, the program begins with a step 200 wherein certain software references used within the program are initialized to zero. The central processor unit next proceeds to a step 202 wherein a "file value" table is established. Referring to FIG. 5, the "file value" table is particularly illustrated. The "file value" table is preferably located within a portion of the program memory 46 occupying eight separate storage locations which are separately addressable. In this regard, the first storage location is addressed by noting the base address of the "file value" table. The seven remaining storage locations are each separately addressable by adding the appropriate numerical value to the base address of the "file value" table.
It is to be noted that the "file value" table is broken into two separately addressable storage locations for each pattern selection switch. In this regard, the first storage location in each grouping is initially all zeroes. The second storage location in each grouping is denoted as containing the binary code for the particular scan line associated with the pattern selection switch. This is the binary code which identifies a particular storage location within the keyboard memory of the keyboard/display interface unit 48. In this regard, it will be remembered that the keyboard/display interface unit monitors the status of each switch and stores the binary status thereof in a keyboard memory location. The address of these respective keyboard memory locations is the same as the binary code utilized to identify the scan lines. In this regard, the three bit binary code for scan line 132 is preferably "000", whereas the three bit binary code for the scan line 144 is "110". The binary status for the pattern selection switch 30 would hence appear in a storage location within the keyboard memory having an address of "000". By the same token, the binary status for the "start" switch 42 would appear in a storage location within the keyboard memory having an address of "110".
Referring to FIG. 4A, the central processor now proceeds to a step 204 wherein the keyboard memory location associated with the scan line 144 is read. It will be remembered that the keyboard memory location associated with the scan line 144 will have a three bit address of "110". This address is provided to the keyboard/display interface unit 48 via the address bus 54 in conjunction with a read control signal for the keyboard memory via the control bus 56. The information stored within the thus addressed keyboard memory location will be provided to the central processor 44 via the data bus 52. It will be remembered that the keyboard/display interface unit 48 continually monitors the status of each button switch on the pattern selection panel 16. In this regard, the keyboard memory location associated with the scan line 144 will only be zero when the "start" button 42 has been depressed. Accordingly, the central processor asks in a step 206 whether the binary status of the memory location read in step 204 is equal to zero. In the event that the "start" button has not been depressed, the central processor unit proceeds along a "NO" path to a step 208 wherein the keyboard memory location associated with the scan line 132 is read. This keyboard memory location will have a keyboard memory address of "000" which is addressed and read in much the same manner as has been previously described with respect to the reading of the keyboard memory location in step 204. The central processor next asks in a step 210 as to whether the binary status of the thus read memory location equals zero. In this regard, it will be remembered that a binary status of zero is an indication that the pattern selection button 30 has been depressed. In the event that this has occurred, the central processor proceeds along a "YES" path to a step 212 wherein the software reference "file index" is set equal to zero. The central processor now proceeds to a step 214 in FIG. 4C. In this regard, it is to be noted that the path from step 212 to step 214 in FIG. 4C is connected by the common junction labelled B. This practice occurs throughout FIGS. 4A-4F wherein paths are to be joined between the figures. Step 214 calls for the generation of an address within the "file value" table utilizing twice the software reference "file index". This is done by adding the base address of the "file value" table in FIG. 5 to twice the numerical value of the software reference "file index". In this instance the numerical value of "file index" is zero by virtue of step 212, this will mean generating an address equal to the base address of the "file value" table.
It is to be appreciated that the "file index" may also have been set equal to certain other values upstream of step 214. In particular, if the pattern selection button 30 had not been depressed, the central processor would have proceeded along the "NO" path from the step 210 to a step 216. The central processor would have read the keyboard memory location associated with the scan line 134 and thereafter inquired as to whether or not the binary status of the thus read memory location was equal to zero in a step 218. It will be remembered that this memory location will contain the binary status of the pattern selection button 32. In the event that the pattern selection button 32 has been depressed, the binary status will be at zero causing the computer to proceed along a "YES" path to a step 220. The software reference "file index" will be set equal to one in step 220 before proceeding via common junction C to the step 214 in FIG. 4C. Referring again to step 218, it is to be noted that if the pattern selection button 32 has not been depressed, then the "NO" path will proceed to a set of steps 222 and 224 wherein the status of the pattern selection button 34 will be checked. In the event that button 34 has been pressed, the central processor will set the "file index" equal to two in a step 226 and proceed to step 214 via common junction D. On the other hand, if the pattern selection button 34 has not been depressed, the central processor will proceed along a "NO" path to a set of steps 228 and 230 wherein the status of the pattern selection button 36 will be checked. In the event that the pattern selection button 36 has been depressed, the "file index" will be set equal to three in a step 232 before proceeding to step 214. It is to be noted that if none of the pattern selection buttons have been depressed, the central processor will proceed along a "NO" path out of step 230 and return to step 204 via common junction E. The status of the various pattern selection buttons as well as the "start" button will again be checked following this return to step 204. Referring again to step 214, it is seen that the generated address will vary in accordance with the numerical value of the "file index". In particular, the multiplication of the "file index" by two before adding the base address of the file table thereto will result in a generated address equal to the base address plus 2, 4, or 6. Referring to FIG. 5, it is seen that the various generated addresses of step 214 identify the first storage location in each pair of storage locations associated with a pattern selection switch. The contents of each of these storage locations is initially zero. As will be described in detail hereinafter, these storage locations will ultimately contain an assigned numerical value for the particular pattern selection switch. Referring to step 234 in FIG. 4C, the central processor reads the particular memory location pointed to by the generated address of step 214. The central processor will thereafter in a step 236 inquire as to whether or not the contents of the memory location equals zero. This will initially be the case with respect to all such memory locations within the "file value" table of FIG. 5. The central processor will hence proceed along a "YES" path to a step 238. The central processor will set the software reference "file number" equal to zero and proceed to a step 240.
The central processor now proceeds to write character generation codes for the message "FILE----". These codes are written into the display memory of the keyboard/display interface unit 48. This is accomplished by addressing the display memory within the keyboard/display interface unit 48 and thereafter generating a "write" control signal on the control bus 56. The eight bits of data for each character to be displayed is forwarded to a specific location within the display memory. The specific location within the display memory will have a three bit address corresponding to the identification of the associated display circuit appearing on the bus 60. Each bit of data will define whether or not a light emitting diode in the display circuit associated with the memory location is to be activated. In this manner, the letter "F" will ultimately be generated by the display circuit 96 whereas the letter "I" will be generated by the display circuit 98, the letter "L" will be generated by the display circuit 100, the letter "E"0 will be generated by the display circuit 102 and the display circuits 120 and 122 will each generate a blank. It is to be appreciated that the operative control of each of the display circuits 96 through 106 is by the keyboard/display interface unit 48.
The thus displayed message appearing on the pattern selection panel 16 will alert the operator of the machine that a stitch pattern file has not been previously assigned to the depressed pattern selection button. The thus displayed message will be maintained for at least one half second by virtue of step 241. The central processor 44 will now await a communication from the operator as to the assignment of a numerical value identifying a stitch pattern file. Referring now to step 242, the central processor generates the address of the memory location within the "file value" table corresponding to "2× file index +1". Referring to FIG. 5, it will be seen that the base address of the "file value" table is added to the resulting sum of "2× file index +1" in order to address the second memory location associated with each pattern selection switch. These storage locations are seen to contain the binary code for the particular scan line associated with the designated switch. For instance, if the pattern selection switch 32 had been noted as being depressed in step 218, then the "file index" would be equal to 1. This would result in a numerical value of "3" being added to the base address of the "file value" table in step 242. This would result in an address for the memory location containing the binary code for the scan line 134. The central processor proceeds in a step 244 to read the binary code of the particular scan line stored in the memory location pointed to by the generated address. It will be remembered that the binary code for a particular scan line is also the address of the keyboard memory location within the interface unit 48 containing the binary status of the pattern selection button associated with the scan line. This keyboard memory location is addressed in a step 246. The binary status of the addressed keyboard memory location is checked in a step 248. If the binary status is equal to zero, the central processor unit pursues the "YES" path to a step 250. It is to be noted that the binary status of the keyboard memory location addressed in step 248 can only be zero if the pattern selection switch associated with the identified scan line remains depressed. This identified scan line must be the same scan line as was previously identified in steps 208 through 232.
Referring to step 250, it is seen that the central processor reads the keyboard memory location associated with scan line 140. It will be remembered that the scan line 140 is associated with the "up" button switch 38. The status of this switch is stored in a predetermined keyboard memory location which can be specifically addressed in step 250. Specifically, the address of the keyboard memory location is the same as the three bit binary code for the display circuit associated with the switch 38. The central processor inquires as to whether the contents of the read memory location are equal to zero in a step 252. If the "up" button has been depressed, the central processor proceeds along a "YES" path to a step 254 wherein the current value of the software reference "file number" is checked for being at its maximum. In this regard, the preferred embodiment of the invention arbitrarily has set a maximum of 32 stitch pattern files which may be selected. The central processor hence asks whether the current value of "file number" is less than this maximum number. If it is not, then the central processor proceeds along a "NO" path marked by the letter G back to step 42. Steps 242 through 248 will again keep monitoring the status of the particular pattern selection button that has been previously depressed. The central processor will continue to cycle and exit out of the "NO" path to the extent that a maximum file number condition exists. Referring now again to step 254, if the current value of the software reference "file number" is less than the maximum, then the central processor proceeds along the "YES" path to a step 256 wherein the current value of the software reference "file number" is increased by 1. It will be remembered that the software reference "file number" is initially zero and hence will first become one in step 256. The central processor now proceeds via common junction F to a step 258 of FIG. 4E wherein the character generation codes for the decimal equivalent of the current value of "file number" are written into display memory locations associated with display circuits 104 and 106. This will effectively change the displayed message appearing on the display portion of the pattern selection panel 16 from a blank reference to that of a "FILE 1". The central processor now proceeds to a step 260 wherein a half second delay is introduced allowing the operator time to react to the displayed message. The central processor next proceeds on a path marked by the letter G back to step 242 of FIG. 4D. The path G appears on FIGS. 4F, 4E and 4D and serves as a return path to step 242 from a number of different points within the program. It will be remembered that step 242 in conjunction with steps 244 and 246 is operative to consult the "file value" table and inquire as to whether or not the previously depressed pattern selection switch remains depressed. In the event that this particular pattern selection switch remains depressed, the central processor will again execute steps 250 through 258 wherein the current value of the file number is increased by one if the "up" switch 38 remains depressed.
Referring to step 252 again, it is to be noted that the central processor will proceed along a "NO" path if the "up" button has not been depressed. In other words, the central processor has noted that the operator of the machine does not wish to increase the numerical value of the displayed pattern file number. The central processor proceeds along the "NO" path from step 252 to a step 262. The central processor in step 262 reads the memory location associated with a scan line 142. It will be remembered that the scan line 142 is associated with the "down" button 40 so that the read keyboard memory location in step 262 contains the status of this button switch. This status is checked in a step 264 which notes a depressed condition of the "down" button 40 when the contents of the read memory location are equal to zero. In the event that the "down" button is not depressed, the central processor proceeds along a "NO" path to the line G which returns to step 242 in FIG. 4D. Referring again to step 264, in the event that the "down" button is depressed, the central processor proceeds along a "YES" path to a step 266 wherein the current value of the software reference "file number" is checked. In particular, the current value of the software reference is checked for being greater than one. In the event that the "file number" is not greater than one, the "NO" path is pursued out of step 266 and the central processor unit returns to step 242 via path G. The central processor will again check to see whether the previously depressed pattern selection switch remains so depressed in steps 244 and 246 as has been previously described.
Referring again to step 266, if the current value of the "file number" is greater than one, then the central processor proceeds along a "YES" path to a step 268 wherein the current value of the software reference "file number" is decreased by one. The central processor now proceeds to step 258 wherein the decimal equivalent of the current value for the software reference "file number" is written into the display memory locations associated with display circuits 104 and 106. The numerical value will hence be displayed on the display portion of the pattern selection panel for one half second as required by step 260. The central processor then proceeds to a step 242 and again checks as to whether or not the previously depressed pattern selection button remains so depressed in steps 244, 246 and 248.
Referring to step 248, it is to noted that when the pattern selection switch being monitored by steps 242 to 246 is no longer depressed, the binary status will change to a non zero state. This will cause the central processor to proceed along a "NO" path out of step 248 to a step 270. It is to be noted that at this juncture, the operator has elected to assign the displayed pattern file number to the previously depressed pattern selection button. This has occurred by virtue of releasing the depressed pattern selection button before the delay of step 260 has been completed. Referring now to step 270, the central processor inquires as to whether or not the current value of the software reference "file number" is equal to zero. It is to be noted that a "file number" of zero is not recognized as a valid file assignment. In this regard, the central processor pursues a "YES" path out of step 270 to common conjunction A in FIG. 4A. This will require the operator to again initiate communication with the automatic sewing machine system. This communication cannot result in an ultimate selection of a displayed pattern file number equal to zero.
Referring again to step 270, it is seen that if the current value of the software reference "file number" is other than zero, the central processor proceeds along the "NO" path to a step 272. The central processor now generates an address of a memory location within the "file value" table corresponding to "2× file index". Referring to FIG. 5, the "file value" table is illustrated in detail. It will be remembered that the addressable memory locations within the "file value" table corresponding to twice the "file index" are the first addressable storage location within each pair of storage locations for a particular pattern selection switch. In this regard, each of the thus addressable storage locations initially are set at zero. The contents of the thus addressed memory location are changed to the current value of the software reference "file number" in a step 274. It is hence to be appreciated that any further addressing of this particular memory location within the "file value" table will result in a reading of the thus stored value of the " file number". Referring to FIG. 4E, the central processor proceeds from the step 274 back to the common junction A in FIG. 4A. Referring to FIG. 4A, it is noted that the central processor will proceed through the steps 204 and 206 so as to check for the "start" button 42 being depressed. This will constitute the communication from the operator that the displayed pattern file number is to be executed by the automatic sewing machine. This is in fact accomplished by the central processor proceeding along a "YES" path from step 206 to a step 276. In this regard, step 276 is an exit from the pattern selection program of FIGS. 4A through 4F. The exiting is to a program which ultimately accesses pattern data from the pattern memory 50. The pattern data which is accessed from the pattern memory is identified by the value of the software reference "file number" which the pattern selection program has provided. This is accomplished by an addressing technique premised on the numerical value of the "file number" which has been provided. It is to be noted that addressing techniques for accessing previously numbered stitch pattern files within randomly addressable memory is well known in the art. In accordance with the invention, the automatic sewing machine will return to the pattern selection program via the path 278. The pattern selection program will now look for a further communication from the operator relative to the next stitch pattern that is to be selected and thereafter sewn.
The central processor will look for the communication from the operator in steps 208, 210 and 216 through 232. In this regard, the central processor will be looking for the depression of a pattern selection button. The particular pattern selection button which is depressed, will result in a setting of the software reference "file index". The setting of the "file index" will allow the central processor to address and read a particular memory location within the "file value" table in steps 214 and 234. In the event that the addressed memory location within the "file value" table is other than zero, the central processor will proceed along a "NO" path to a step 280. It is to be noted that this will be the case when the various addressable memory locations within the "file value" table have been loaded with particular "file values". It will be remembered that the loading of a particular "file value" into a memory location occurs in step 274 following the procedure of selecting a particular "file value". Referring now to step 280, it is seen that the software reference "file number" is set equal to the contents of the addressed memory location containing a previously assigned "file value". The central processor will proceed to write the character generation codes for the word "FILE" into the display memory locations of the interface unit 48 associated with display circuits 96, 98, 100 and 102. This will result in the various letters being displayed on the alpha numeric displays 18, 20, 22 and 24. The central processor will now proceed in a step 284 to write the character generation codes for the decimal equivalent of the value of the software reference "file number". These codes will be written into the display memory locations of the interface unit 48 for an immediate further processing by the display circuits 104 and 106. This will result in an almost instantaneous display of the numerical designation of the stitch pattern on the alpha numeric displays 26 and 28.
The central processor will now introduce a delay of one half second in a step 286. This will allow the operator of the sewing machine time to react to the displayed number. The central processor will now inquire as to whether the previously depressed pattern selection button remains depressed in steps 242 through 248. In the event that the operator agrees with the displayed numerical designation, the pattern selection button will no longer be depressed. This will result in the central processor pursuing the "NO" path out of step 248 and hence through steps 270, 272 and 274 wherein the already read file number will again be stored in the appropriate memory location within the "file value" table. The central processor will now proceed to junction F and await a start authorization in steps 204 and 206. When this occurs, the "YES" path will be pursued to step 276 wherein the stitch pattern data will be accessed from the pattern memory 50.
It is to be appreciated that the operator of the automatic sewing machine may elect to change the displayed pattern file number which has been previously assigned to the particular depressed pattern selection button. This is accomplished by continuing to depress the pattern selection button following the display of the previously selected pattern "file number" in step 284. This will result in the "YES" path being pursued out of step 248 so as to allow the central processor to respond to either the "up" button 38 or the "down" button 40. In this manner, the operator can change the value of the previously displayed pattern file number in steps 250 through 268.
It is to be appreciated that a preferred embodiment of a pattern selection system has been disclosed for an automatic sewing machine system. Portions of this pattern selection system may be changed without departing from the scope of the invention.
|
A pattern selection system having a relatively small number of pattern selection switches is disclosed. Each pattern selection switch is assigned a particular stitch pattern that is stored in a memory. The assigning of the stitch patterns occurs in a series of communications between the operator and the pattern selection system. These communications include the displaying of the stitch pattern assignment that is being made. The pattern selection system thereafter displays the stitch pattern assignment each time the pattern selection switch is activated.
| 3
|
BACKGROUND OF THE INVENTION
The present invention relates to a method for reducing the content of alkali metal in an organo-soluble cellulose ether.
Organosoluble cellulose ethers such as ethyl cellulose and benzyl cellulose are known to be particularly useful in a wide variety of applications including the preparation of molded articles, e.g., extruded films or tubes, and as a component in protective coatings, adhesives, lacquers and ink or binder compositions.
Conventionally, the organosoluble cellulose ethers are generally prepared by the reaction of an alkali cellulose (typically, the reaction product of a cellulose and an alkali metal hydroxide) with an etherifying agent, e.g., ethyl chloride or ethyl oxide, in the presence of a reaction diluent such as toluene. The resulting cellulose ether is conventionally recovered from the reaction medium by desolvating the reaction product, thereby forming solid particles of the cellulose ether, converting any alkali metal hydroxide to salt form and washing the cellulose ether particles several times with water to remove the soluble alkali metal salts and other impurities therefrom. The washed cellulose ether is then dewatered and dried. Unfortunately, to remove the necessary amount of the alkali metal salt by conventional methods requires large amounts of water, e.g., about 5 to 40 times the weight of the cellulose ether, from which water the cellulose ether must be recovered. As such, substantial expenditures of time, energy and apparatus are necessary to effectively produce a purified cellulose ether.
Heretofore, several methods for preparing a cellulose ether having a low alkali metal salt content have been proposed. For example, U.S. Pat. No. 2,744,894 teaches that purified hydroxyalkyl ethers of polysaccharides can be prepared by etherifying the cellulose in a proper reaction diluent, e.g., a solvent mixture of a benzenoid hydrocarbon and a monhydric alcohol, and extracting the alkali metal salts from the polysaccharide ethers prepared therein using a suitable rinse solvent such as a mixture of methanol and acetone. While the disclosed method eliminates the necessity of a water wash, it is undesirable for the reason that large amounts of the rinse solvent mixture are required to obtain a cellulose ether with the desired purity.
Alternatively, as disclosed in U.S. Pat. No. 3,347,847; the alkali metal salts are removed from a conventionally prepared hydroxyethyl cellulose by treating, i.e., cross-linking, the cellulose with glyoxal at an acid pH and subsequently washing the treated cellulose with water at a pH of from about 2 to about 6. Unfortunately, this method stills requires large amounts of wash water, e.g., about 2 to 50 times the weight of the cellulose ether. Improvements to the aforementioned method are disclosed in U.S. Pat. No. 3,903,076 which teaches that following etherification in a proper reaction diluent, the excess alkali metal hydroxide is neutralized and the water and water-soluble hydroxyl containing by-products removed therefrom by azeotropic distillation. The etherified cellulose is then cross-linked and washed with water. Although the azeotropic distillation effectively removes the hydroxyl containing ingredients, e.g., monoethers of glycol, the disclosed method does not substantially improve the prior art methods for reducing the alkali metal salt content in the cellulose ether.
Moreover, none of the disclosed methods are particularly useful in the preparation of purified organo-soluble cellulose ethers.
In view of the stated deficiencies of the prior art, it remains highly desirable to provide a method for effectively reducing the amount of alkali metal, in the form of a hydroxide or salt, from an organosoluble cellulose ether.
SUMMARY OF THE INVENTION
Accordingly, the present invention is a method for reducing the content of alkali metal, in salt or hydroxide form, in an organosoluble cellulose ether. In said method, a solution of the cellulose ether, which cellulose ether contains alkali metal, and an organic solvent is prepared. The alkali metal hydroxide present in the solution is converted to an alkali metal salt and the resulting solution subsequently heated at conditions such that (1) any water present in the solution is removed and (2) the alkali metal salt particles grow larger in size. The enlarged salt particles and the cellulose ether are subsequently separated.
Surprisingly, the particles of the alkali metal salt are enlarged sufficiently by the method of this invention that they are easily removed from the cellulose ether solution by conventional physical separation techniques, e.g., filtration. More importantly, the alkali metal salt content of the cellulose ether treated by the methods of this invention is relatively small. Often, the cellulose ether contains as little as 0.04 weight percent of the alkali metal salt.
In a preferred embodiment, the present invention is an improved method for preparing a cellulose ether, wherein an alkali cellulose and an etherifying agent are contacted at conditions sufficient to form a cellulose ether and the cellulose ether is recovered from the remainder of the reaction medium. The improvement in said method comprises forming a solution of the cellulose ether, which cellulose ether contains alkali metal, in salt or hydroxide form, and an organic solvent at some time prior to the recovery of the cellulose ether. The alkali metal hydroxide in the solution is converted to an alkali metal salt with an acid and the resulting solution heated at conditions sufficient to remove any water present in the solution and enlarge the salt particles. The enlarged salt particles are thereafter separated from the cellulose ether solution.
The cellulose ethers prepared in accordance with the present invention are useful as additives in the preparation of molded articles and as a component in protective coatings, adhesives, binder compositions, ink formulations and lacquers.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the practice of this invention, a solution of an organosoluble cellulose ether and an organic solvent is prepared.
As used herein, the term "organic solvent" refers to a normally liquid organic material in which at least a measurable amount of the cellulose ether is soluble. By "soluble" is meant that the cellulose ether and organic solvent form a true solution, i.e., individual molecules of the cellulose ether are dispersed in the organic solvent. Advantageously, the organic solvent and cellulose ether can form a solution which solution contains at least about 5, preferably at least about 20, weight percent of the cellulose ether based on the total weight of the solution.
Representative of such organic solvents include saturated aliphatic and inertly substituted, saturated aliphatic hydrocarbons, either straight or branched chain, having about 5 or more carbon atoms and advantageously having a boiling point from about 70° to about 150° C. such as hexane, heptane, octane and the like; alicyclic or inertly substituted alicyclic hydrocarbons having 5 or 6 carbon atoms in the ring such as cyclohexane; aromatic and inertly substituted aromatic hydrocarbons, advantageously with a boiling point from about 70° to about 170° C., such as benzene, toluene, ethyl benzene, xylene and the like; ketones such as acetone, methyl ethyl ketone, diethyl ketone, methyl propyl ketone, isobutyl ketone and the like; alcohols such as methanol and isopropyl t-butyl alcohol; and chlorinated solvents such as ethylene dichloride, methylene chloride and benzyl chloride.
Advantageously, the organic solvent employed in this invention can also be employed as a reaction diluent useful in the preparation of the cellulose ether, i.e., the organic solvent is slightly miscible in water and is essentially inert to the reactants, the reaction product and the reactions being conducted. Of such organic solvents; hexane, toluene, benzene, xylene, acetone and ethylene dichloride are preferred; with hexane, toluene and benzene being most preferred.
For the purposes of this invention, the term "organosoluble cellulose ether" is used conventionally and refers to those cellulose ethers which are soluble in one or more organic solvents. In general, those cellulose ethers conventionally characterized as being organosoluble, e.g., ethyl cellulose, ethyl hydroxyethyl cellulose, cyanoethyl cellulose and benzyl cellulose, are advantageously employed in this invention. Typically, such cellulose ethers have a degree of substitution (generally ethoxyl) of equal to or greater than about 2.0. Preferably, in the practice of this invention, the organosoluble cellulose ether is ethyl cellulose or benzyl cellulose, with ethyl cellulose being especially preferred.
Methods for preparing the organosoluble cellulose ethers and the kinds and proportions of the reactants (i.e., the cellulose, the alkali metal hydroxide and the etherifying agent), the reaction diluent, catalysts and the like are well known and reference is made thereto for the purposes of this invention. Illustrative of such methods are U.S. Pat. Nos. 2,163,869; 2,249,673, 2,254,249; 3,903,076 and Cellulose and Cellulose Derivatives, Part II, edited by E. Ott, H. M. Spurlin, and M. W. Grafflin, published in 1954 by Interscience Publishers, Inc. New York, pages 915-920, all of which are hereby incorporated by reference. Generally, in the disclosed methods for preparing cellulose ethers, an alkali cellulose (typically, prepared from a cellulose and an alkali metal hydroxide) is reacted with an etherifying agent to form the desired cellulose ether.
In one conventional method, the preparation of the cellulose ether comprises a two-step process wherein the first step is the preparation of the alkali cellulose. Methods for preparing the alkali cellulose are well known and reference is made thereto for the purpose of this invention. Illustrative of such methods are U.S. Pat. Nos. 2,143,855; 2,143,863, 2,145,862; 2,149,309 and 2,149,310; all of which are hereby incorporated by reference. Generally, in the disclosed methods, the alkali cellulose is prepared by contacting the cellulose material, in sheet or fibrous shred form, with an excess amount of aqueous solution of from about 50 to about 70 weight percent alkali metal hydroxide, at an elevated temperature, e.g., from about 55° to 130° C. Typically, the resulting alkali cellulose is then removed from the alkali metal hydroxide solution using pressure or evaporation.
The desired cellulose ether is then prepared by reacting the resulting alkali cellulose with an etherifying agent in the presence of an alkali metal hydroxide (typically, sodium hydroxide) in an oxygen free atmosphere. Etherifying agents generally employed include alkyl monochlorides such as ethyl chloride and monochloro-propane or -butane; vicinal epoxides such as ethylene oxide, 1,2-propylene oxide and 1,2-butylene oxide; and monochlorocarboxylic acids or alkali metal salts thereof such as monochloro-substituted acetic, propionic or butyric acid. Optionally, a reaction diluent, generally an organic liquid in which the cellulose ether is soluble, is employed. This reactant mixture is thoroughly agitated at elevated temperatures, e.g., 120° to 130° C., until reaction is complete.
In a second conventional method for preparing the cellulose ether, the alkali cellulose and the corresponding cellulose ether are prepared in situ, i.e., both the alkali cellulose and cellulose ether are prepared in a single reaction vessel (a one-stage process) without intermediate product purification between the preparation of the alkali cellulose and the subsequent preparation of the cellulose ether. Typically, in such method, the cellulose, advantageously, in a finely distributed form, is dispersed in a reaction diluent, generally an inert organic liquid in which the cellulose ether is soluble and which is at least partially water miscible. The desired amounts of an aqueous solution of an alkali metal hydroxide, preferably from about 300 to about 400 weight percent alkali metal hydroxide, based on the weight of the cellulose ether is added to the resulting dispersion. After a sufficient time period, an etherifying agent is added to the mixture. Generally, during the entire process, the mixture is maintained in an oxygen-free atmosphere, and at elevated temperatures, e.g., 130° to 135° C., while being thoroughly agitated.
Using either method, following completion of the reaction, the reaction vessel will generally contain a mixture of the cellulose ether, water, a salt of the alkali metal hydroxide, unreacted (1) alkali metal hydroxide and (2) etherifying agent and any by-products formed during the etherification reaction, e.g., the alcohol and ether corresponding to the etherifying agent. The term "reaction medium" will be used herein to describe this mixture.
As noted, the etherification reaction is generally carried out in an organic liquid reaction diluent. In general, the diluent can also be employed as the organic solvent as that term is used herein. As such, the cellulose ether is not normally recovered from the reaction medium prior to being treated by the methods of this invention, i.e., the reaction diluent serves as at least a portion of the organic solvent.
Alternatively, if the cellulose ether is prepared in a reaction diluent which cannot be suitably employed as an organic solvent, the cellulose ether is advantageously recovered therefrom by conventional techniques and the recovered cellulose ether mixed with a suitable organic solvent. Similarly, if the cellulose ether is prepared neat, i.e., no reaction diluent is employed, the cellulose ether must be mixed with a suitable organic solvent prior to being treated by the methods of this invention.
The amounts of the cellulose ether and organic solvent most advantageously employed in the preparation of a solution thereof are dependent on a variety of factors, including the type of cellulose ether, organic solvent and alkali metal hydroxide employed; and the desired alkali metal content of the purified cellulose ether. Advantageosuly, sufficient amounts of the organic solvent are employed to dissolve essentially all the cellulose ether. In general, the desired results are obtained when the organic solvent is employed at from about 5 to about 12, preferably from about 6 to about 8, times the weight of the cellulose ether. In general, the reaction product contains substantial amounts of water, e.g., about 2 to about 4 weight percent based on the weight of the cellulose ether, and, in such case, the organic solvent is preferably employed in an amount which provides an azeotropic composition or constant boiling composition of the organic solvent and the water.
In the practice of this invention, the alkali metal hydroxide is generally converted to an alkali metal salt by contacting the hydroxide with an acid. The acids useful herein are acids which form a salt when contacted with the alkali metal hydroxide, which salt, when subjected to the methods of this invention, grows in size, i.e., the particle size thereof increases. Preferably, such growth is sufficient to allow for the removal of the salt from the remainder of the solution by standard physical separation techniques, e.g., filtration or centrifugation. Representative of such acids are the mineral acids such as hydrochloric acid, sulfuric acid, phosphoric acid and the like, with hydrochloric acid being the most preferred. Advantageously, a highly concentrated form of the acid is employed, with the anhydrous form being most advantageously employed herein.
The acid is advantageously employed in an amount sufficient to convert essentially all the alkali metal hydroxide in the solution of the cellulose ether and organic solvent to an alkali metal salt. Preferably, the acid is employed in an amount in a slight excess, e.g., about 1 to 10 weight percent, of the amount required to convert 100 percent of the alkali metal hydroxide to an alkali metal salt. As an example, when a highly concentrated mineral acid is added to a cellulose ether solution of a reaction product consisting of from about 2 to about 3 weight percent water, sufficient amounts of the acid are advantageously added to adjust the pH of the solution to at least about 6.5, with a pH of at least about 6 being preferred.
Optionally, a flocculant, i.e., a substance which induces the aggregation of suspended solid particles into a larger particle, can be added to the solution of the cellulose ether to facilitate growth of the salt particles. Representative examples of flocculants useful in the practice of this invention include the inorganic flocculants such as lime, alum, ferric chloride and the like; and the organic flocculants including multivalent polyelectrolytes such as polyethylene imine, polyacrylic acid salts, polyacrylamide, copolymers of acrylamide and acrylic acid and the quaternized Mannich derivative of a polyacrylamide, preferably having a low molecular weight, e.g., number average molecular weight from about 1000 to about 10,000. A preferred flocculant is the quaternized Mannich derivative of a low molecular weight polyacrylamide.
The flocculant is advantageously employed in an amount sufficent to increase the particle size of the alkali metal salt when said particle size is compared to the particle size of the alkali metal salt of an identically treated cellulose ether solution which contains no flocculant. The amount of the flocculant most advantageously employed is dependent on many factors including the specific flocculant employed, the composition of the reaction product, and the desired particle size of the alkali metal salt. In general, concentrations from about 0.1 to about 2, preferably from about 0.5 to about 1, weight percent based on the total weight of the reaction product are effectively employed.
In the normal practice of this invention, the alkali metal content of the cellulose ether is reduced by contacting the solution of the cellulose ether which contains the alkali metal, organic solvent and, optionally, the flocculant, with the hereinbefore specified amounts of acid, heating the resulting acidified solution (i.e., the solution of the cellulose ether following the addition of the acid thereto) at conditions sufficient to (1) remove any water present in the solution and (2) promote the growth of the alkali metal salt particles and subsequently recovering the cellulose ether essentially free of the enlarged salt particles. By the term "reduce the content of the alkali metal" it is meant that the alkali metal content (in the form of an alkali metal salt) in a cellulose ether treated in accordance with the method of this invention is reduced by an amount measurable using a conventional test method, e.g., a chloride ion sensitive electrode such as Model No. 94-17 sold by Orion Research, when compared to the alkali metal content of a cellulose ether prepared by an identical method, but which is not subsequently purified, i.e., the cellulose ether reaction product is recovered by simply devolatilizing the reaction product. Advantageously, the alkali metal salt content is measurably less than a similarly prepared cellulose ether which, following preparation, is purified by desolvating the reaction product and washing the desolvated cellulose ether with an amount of water from about 2 to about 20 times its weight. Preferably, the alkali metal salt content is less than about 0.5, more preferably less than 0.1, most preferably less than about 0.05 percent of the total weight of the cellulose ether.
The conditions at which the cellulose ether solution containing the alkali metal salt is most advantageously heated will vary depending on the type and proportion of the cellulose ether, the organic solvent, the reaction by-products and the content of the alkali metal desired in the final cellulose ether. Generally, the solution is advantageously heated to a temperature at which it boils, while allowing the volatile material to escape. Typically, temperatures between about 80° and about 110° C., more typically, between about 83° and about 105° C., are employed to boil the solution. Generally, at such temperatures, any of the alcohol which corresponds to the etherifying agent employed in preparing the cellulose ether is removed with the water. Such removal of alcohol is desirable for the purposes of this invention. In general, the boiling temperatures are maintained for a period of time sufficient to remove essentially all, i.e., at least about 90 weight percent, of the water from the reaction product and to allow the particle size of the alkali metal salt to increase to a size sufficient to provide easy removal of the salt particles from the remainder of the cellulose ether solution using conventional physical separation techniques, e.g., filtration or centrifugation. In general, the size, i.e., primary particle dimension, of the salt particles is advantageously greater than about 0.5 μm, preferably greater than about 0.8 μm, more preferably greater than about 1.0 μm, most preferably greater than about 1.5 μm. This time period will vary depending on a variety of factors such as the original amount of water, the organic solvent employed, the desired size of the salt particles and the like. In general, while the water is generally removed in from about 30 to about 45 minutes, the reaction product is generally maintained at the elevated temperature for a period of from about 1 to about 3, preferably from about 1 to about 2, hours to provide for sufficient growth of the salt particles.
Following the removal of the water from the cellulose ether solution and sufficient growth of the salt particles, the enlarged salt particles are advantageously removed from the reaction product, which has advantageously been previously cooled, by conventional physical separation techniques such as filtration or centrifugation. For example, the enlarged alkali metal salt particles have been found to be effectively removed from the cellulose ether solution by a No. 1 filter paper sold by Whatman Inc., precoated with Filter Cell® to a thickness of about 0.32 cm.
After removal of the alkali metal salt from the solution of the cellulose ether, the cellulose ether is recovered from the remainder of the solution by the devolatilization thereof, advantageously by heating the filtered solution to a temperature from about 40° to about 60° C. until an essentially dry, normally solid cellulose ether is obtained.
The following examples are set forth to illustrate the embodiments of the present invention and should not be construed to limit its scope. In the examples, all parts and percentages are by weight unless otherwise indicated.
EXAMPLE 1
To a 10 1. pressure vessel equipped with an addition funnel, heating and cooling means, thermometer and agitator is added 400 g of ground cellulose and 608 g of an aqueous solution of 73 weight percent sodium hydroxide. The pressure vessel is evacuated and flushed with nitrogen. To the vessel is then added 320 g of toluene which has first been purged with nitrogen to remove any dissolved oxygen. The resulting mixture is mildly agitated and the vessel is heated to a temperature of 120° C. and maintained at this temperature for a one-hour period.
At the end of this period, 2800 g of ethyl chloride is charged to the reactor. The temperature of the vessel is raised to about 135° C. and is maintained at this temperature for a period of about 10 hours. The vessel is cooled to 25° C. at the end of this period and subsequently vented. The reaction product is found to contain about 2 percent sodium hydroxide, using the silver nitrate titration technique.
A 500 g-portion (Sample No. 1) of the reaction medium is transferred to a 3 1. flask equipped with a thermometer, heating and cooling means, agitator and distillation means. To the flask is then added an equal portion, by volume (about 400 ml), of toluene. Subsequent thereto, sufficient anhydrous hydrochloric acid (about 9 g) is added to convert the sodium hydroxide to sodium chloride; the resulting solution having a pH of about 6. The solution is then heated to about 120° C., which causes the solution to boil. Boiling of the solution is maintained for a period sufficient to remove any water from the flask by distillation (about 60 minutes). During this distillation, toluene is added to the flask at a rate sufficient to maintain the initial volume of the flask.
After removal of essentially all the water, the flask is heated at a temperature of 105° C. for an additional 30-minute period. At the end of this period, the flask is cooled to 25° C. and filtered through No. 1 filter paper sold by Whatman Inc., precoated with Filter Cell® to a thickness of 0.32 cm to remove the salt particles. Following filtration, the filtrate is dried by heating to a temperature of 60° C. and maintaining said temperature for 90 minutes. The dried filtrate is ethyl cellulose having a viscosity of 100 centipoises as a 5 weight percent solution in an 80/20 by volume toluene/ethanol mixture as measured by a Ubbelhode viscometer (1.1 mm inside diameter) at 25° C. and an ethoxy degree of substitution of 2.8. It is found to contain 0.04 percent sodium in the chloride salt form.
A second portion (Sample No. C-1) of the reaction medium is treated in a similar manner as Sample No. 1 except that it is not distilled, i.e., the cellulose ether solution is heated but water is not removed therefrom. Upon drying the filtrate, it is found to contain 3.5 percent sodium in the chloride salt form.
Another sample of the cellulose ether solution (Sample No. C-2) is treated in a manner similar to Sample No. C-1 except that the solution is centrifuged at about 1800 revolutions per minute for 2 hours rather than being filtered. The recovered ethyl cellulose is found to contain 3.5 percent sodium in the chloride salt form.
Yet another sample of the ethyl cellulose is recovered using a more conventional technique. The reaction medium is desolvated by heating the reaction product to a temperature of about 105° C. for a period of about 10 minutes. About 10 g of the desolvated material (consisting of ethyl cellulose, sodium hydroxide and sodium chloride) is slurried in about 60 g water and sufficient hydrochloric acid added thereto to convert the sodium hydroxide to sodium chloride, the pH of the resulting slurry being 6.5. The desolvated material is then washed three times with water, each wash consisting of 60 g of water. The washed material is then dried by heating for about 70 minutes at 60° C. The dried ethyl cellulose is found to contain 0.12 percent sodium chloride salt.
As evidenced by this example, the content of the alkali metal in ethyl cellulose is effectively reduced when the cellulose ether is purified by the methods of this invention.
EXAMPLE 2
An ethyl cellulose having a reduced alkali metal salt content is prepared by the method of this invention following the procedure of Example 1 except that 0.75 weight percent, based on the weight of the reaction product, of a flocculant of quaternized Mannich product of a polyacrylamide having a number average molecular weight of 2000 as determined by solution viscosity correlation methods was added to the cellulose ether solution prior to distilling off the water.
Due to the presence of the flocculant, the salt particles grow visibly larger in size than in Example 1. When filtered by a precoated filter paper (0.32 cm Filter Cell®), the resulting ethyl cellulose is found to contain 0.04 percent sodium in the chloride salt form.
|
In the preparation of organosoluble cellulose ethers, the content of alkali metal (hydroxides and the salts thereof) in the resulting cellulose ether is reduced by forming a solution of the cellulose ether and an organic solvent, converting the alkali metal hydroxide therein to an alkali metal salt and heating the resulting solution at conditions sufficient to (1) increase the size of the alkali metal salt particles and (2) remove any water therefrom. Filtering the resulting mixture and drying the filtrate yields a cellulose ether containing a very small percentage of alkali metal salt, e.g., often less than about 500 ppm.
| 2
|
FIELD OF THE INVENTION
The present invention relates to a fishing float, lure, or sinker.
BACKGROUND OF INVENTION
This invention is applicable to surface floats, or bobbers, or to the under water gear at or near the hook, such as sinkers, lures, or floats; said floats being used to overcome the underwater weight of the hook, swivels, or other underwater gear. Such floats are commonly placed adjacent to the hook and have buoyancy approximating the underwater weight of the hook and leader tackle, and are used to lift the hook off the bottom to reduce the propensity of the hook to snag on the bottom of a river, lake, or the sea. Such floats are commonly called corkeys. A corkey may also be shaped and/or decorated to be a lure and/or to have elements such as skids or skirts to shield the hook from underwater weeds and the like.
DESCRIPTION OF THE PRIOR ART
Floats, sinkers, lures, and corkeys all have means to connect them to the fish line. In most cases, the line is cut and the float, sinker or lure is tied to loops provided for that purpose. Corkeys have a central bore which requires the end of the line to be fed through the bore. All of these devices require considerable dexterity to install on the fish line. Fish tend to bite on different color, shape, size, and motion of a lure under different conditions. Since it is very difficult to second guess a fish's appetite, a successful fisherman will try several lures on a fishing trip with the technology that is presently available on the market. To change many types of lures you are required to cut your line and re-tie it in order to change the color, shape or size.
While conventional products are satisfactory in operation, changing them is time consuming, requires changes to, and sometimes waste of, other gear, and requires dexterity often not present in cold-weather fishing or not possessed by a person with disabling physical handicaps including arthritis.
Therefore, what is needed is a lure device with means to receive a fishing line or leader requiring only the dexterity normally found while wearing gloves or with very cold hands.
Various inventions have previously been directed to means for attachment of devices to fishing lines. These include the following U.S. Pat. No. 3,837,783, issued Feb. 25, 1976 to Simpson for QUICK CHANGE FISHING FLOAT; U.S. Pat. No. 3,991,506, issued Nov. 16, 1976 to Wise for FISHING LINE FLOAT; U.S. Pat. No. 4,418,492 issued Dec. 6, 1983 to Rayburn for FISHING FLOAT; U.S. Pat. No. 4,563,831 issued Jan. 14, 1986 to Gibney for a FISHING FLOAT; U.S. Pat. No. 4,827,657, issued May 9, 1989 to Slehofer for FISHING EQUIPMENT; and U.S. Pat. No. 5,112,614 issued May 19, 1992 to Morita.
Floats with in them which are adapted to accept a fishing line are described in several patents; most are for surface type floats commonly described as bobbers. Representative of such devices are those seen in U.S. Pat. Nos. 3,367,683, 3,991,506, 4,418,492, and 4,563,831. However U.S. Pat. Nos. 3,867,783 and 4,418,492 are not integral and have extra pieces, to provide friction against the line U.S. Pat. No. 4,563,831 has a structure adapted to provide a locking function so as to prevent free movement of the fishing line relative to the device.
A helical structure for use in conjunction with a fish hook is shown in U.S. Pat. No. 4,827,657. That structure is designed with specific shape and used as an anchor for non-living bait, or in some cases, by itself as a lure. It requires, contrary to the present invention, that the helix be constructed of flexible material.
Helical structures for use in attachment of bobbers and lures assemblies to a line are shown in U.S. Pat. No. 5,113,614. Helix assemblies are provided at the ends of a wire spreader yoke which is affixed to a surface float device.
Neither of the two just mentioned U.S. Patents address the problem of quick connection of a fishing line to a lure.
SUMMARY OF THE INVENTION
In its simplest form, a fishing accessory is constructed of piece of resilient material with an axial bore to receive the fish line. The accessory is slit from the outer surface to the axial bore. The fishing leader is then snapped through the slit and into the bore. The slit then closes because of the restoration forces present within the resilient material, entrapping the line which may be loose or frictionally attached to the material depending on the relative diameters of the bore and fish line. Such simple embodiments of the present invention usually use a round, egg-shaped, or tapered cylinder shape.
Another embodiment uses a helical slit between the surface and an axial bore through which the fish line is passed as described above. The loops of the helix are cast around the fish line thus enclosing the line. The line is thusly held in the central bore by the geometry of the accessory, thus, permitting the slit to be open, i.e. a slot, permitting the accessory to be constructed of rigid material.
Another embodiment uses a helical slit between the surface and a radial distance short of the axis of the implement. The fish line is passed into the slot as described above, but comes to rest at the inner end of the slot. The loops of the helix and the accompanying fish line are cast around the now solid cylinder. The fish line is thus being held in a helix shape by the helical slot. Considerable friction is developed between the fish line and the helical accessory. Thus, the accessory is held fast to the fish line, yet easily installed or removed by winding or unwinding the fish line through the slot and around the central cylinder. The embodiment works equally well with open slots or closed slits.
Another embodiment uses an irregular or zigzag slit between the surface and axial bore, thus forming interdigitated elements, or fingers, through which slit the fish line is passed as described above. The fingers therefore surround the line. The line is thusly held in the central bore by the geometry of the accessory permitting the accessory to be constructed of rigid material.
Another embodiment uses appendage helixes of wire or similar material for line retainers at either end of a fishing accessory to receive the fishing line as described above, and an open slot through the body of the accessory to pass the fish line through the body, located between the helical line retainers. The slot may be helical or other shape so as to enhance friction between the line and accessory.
OBJECTS, ADVANTAGES, AND FEATURES OF THE INVENTION
My invention has no moving parts yet enables a fisherman to change to a different lure without cutting or re-tieing. My method is not only faster but also require less dexterity and prevents having to shorten the fishing line each time a lure is changed.
Different lures have different fish attraction capabilities and as fishing condition changes are not always obvious to the fisherman, my invention allows the fisherman to change to several different types or styles of lures in a matter of seconds. Varying light conditions for example, often dictate the size or color of lure on which a fish will bite. My invention allows the fisherman to change a lure in seconds giving the fisherman not only the ability to efficiently change size for different times of day, but is also fast enough to be able to change lures quickly enough for temporary light conditions such as a cloud blocking the sun that would pass before a fisherman using the presently available products could respond.
It is assured that a fisherman will have a much better chance of catching fish, if only for the fact that with my lures the fisherman can have his line in the water a greater percentage of the time. A knowledgeable fisherman will have his line in the water with the right lure for the conditions for a greater percentage of time. A less knowledgeable fisherman will be able to learn what fish will probably take much more quickly with my quick change method by trial and error much more quickly than he would using conventional products.
Therefore, it is an object of this invention to provide a fishing accessory such as a corkey, float, lure, sinker, or combination with means to quickly install or remove it from a fishing line even in the presence of gloves, numbness, or other impairment of dexterity.
It is a further object to enhance the luring ability of the accessory with shape, color, motion, and/or scent.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a an axial view of the preferred embodiment of the invention using a straight, self closing slit for entry to the central bore.
FIG. 2 is an equatorial view of the same embodiment.
FIG. 3 is an equatorial view of a second embodiment of the invention utilizing an open helical or spiral slit for entry to the central bore.
FIG. 4 is a side view of a third embodiment using a helical or spiral slit in an essentially cylindrical shaped body.
FIGS. 5A and 5B illustrate interdigitated fingers which are essential elements in several embodiments of the invention.
FIGS. 6, 7, and 8 show helical coil appendages as the elements of the invention.
FIG. 6 is a plan view looking down on the body of an attachment means constructed in accord with the present invention.
FIG. 7 is a side elevational view taken looking at the body of the attachment means first illustrated in FIG. 6.
FIG. 8 is an end view of the attachment means first illustrated in FIGS. 6 and 7 above.
FIGS. 9 and 10 illustrate an embodiment without an axial bore or channel.
FIG. 9 is a side elevational view taken looking at the body one embodiment of the attachment means of the present invention, where the slot is provided extending inward toward, but not reaching, the central axis.
FIG. 10 is a top view of the attachment means first illustrated in FIG. 9 above, showing the slot extending inward toward, but not reaching, the central axis.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, the simplest form of this line attachment means for a float, lure, or sinker is a body of any shape 1, constructed of resilient material and an overall specific gravity suitable to provide the desired amount (if any) of flotation or sinking as required by the application. Body 1 has axial hole 2 thru the body, and a longitudinal slit 3, from the outside of the body extending into the axial hole 2 at the center of the lure, to allow a compression entry path for the fishing line 4, to be easily positioned thru the center of the body 1 for use as any other float, lure, or sinker.
With a small amount of pressure the line 4 can be immediately inserted and the pliability of the lure body 1 material will close the slit 3 to keep the fishing line 4 from disengaging from the axial hole 2 until such time the line 4 is pulled back out the same path with slight pressure without harming the fish line 4. This form of fishing accessory body 1 will work with easily pliable materials such as cork, balsa wood, or synthetic materials without restraining the possibilities of external shapes, designs, or colors of the accessory.
An alternate form of this line attachment means for a float, lure, or sinker is to form the slit 5' or 5" in a helical pattern in body 1 A or 1 B as shown in FIGS. 3 and 4. Since the line 4 is surrounded by the helical pattern, the slot 5' or 5" need not be closed.
FIGS. 5A and 5B show use of a zigzag shaped slit 6 or 6' in body 1 C or 1 D respectively, to form two or more interdigitated fingers 7 and 8 or 7' and 8', respectively, that fit around the fish line 4. Since the line 4 is surrounded by the interdigitated fingers, the slot 6 or 6' need not be closed as required by the shape shown in FIGS. 1 and 2 above. Thus, the slot 6 or 6' may optionally have width adequate to pass a fish line 4. Since resilience is not required, the fishing accessory 1 C or 1 D may be constructed of hard or firm material. Note that a helical slot of less than one revolution is a structure of two interdigitated fingers.
In use, the fishing implement 1 A , 1 B , 1 C , or 1 D is fastened to the fish line 4 by simply holding the body 1 A , 1 B , 1 C , or 1 D in one hand and winding the fish line 4 around the body 1 A , 1 B , 1 C , or 1 D and into the slot, hence into the central bore 2. Removal is simply the reverse process.
FIG. 5B illustrates the invention showing that the slot 6 does not have to be a continuous same-shape throughout its length. In this illustration, the end sections of the slot 6 are essentially straight and may be required to accommodate particular shapes of a fishing implement.
Turning now to FIGS. 6, 7, and 8, another alternate form of this means of attaching a line 4 to a float, lure, or sinker is to form an attachment means 11 at each end of the body 1 E and provide a slot 12 for passage for the fish line 4 between the two attachment means. Metallic or plastic wires embedded in the body 1 E have helical spring attachment means 11 formed at the free ends. Slot 12 is sufficiently wide and deep to freely admit and pass the fish line 4 strung through the helical spring attachment means 11.
In use, the fishing implement 1 E is attached to the fish line 4 by simply holding the body 1 E in one hand and winding the fish line 4 between the coils of the wire helix attachment means 11 with the other hand. The other end is attached to line 4 similarly by either switching hands or turning the body 1 E around. Removal is simply the reverse process. One-handed fishermen can use the invention simply by using some other means to substitute for the holding hand.
Some applications require the float, lure, or sinker to be fixed rather than slide on the fish line 4. Simple variations provide adequate friction to prevent sliding, yet not diminish the easy-on, easy-off properties of the invention. In general, the friction will be provided by causing the line passage way or slot to have curves or corners, i.e., the line 4 will have to pull around friction producing corners in the slot.
FIGS. 9 and 10 illustrate a novel expression of this friction generating concept. Body 1 F is cut with helical slot 13, but the slot 13 is cut only part way into the body 1 F . The locus of the inside end 14 of the slot 13 thusly is a smaller spiral enclosing a solid core 15. The core 15 occupies approximately the same space formerly vacated by the axial bore 2 in FIG. 4, for example. A fish line 4 wound into the slot 13 will come to rest at the bottom or inside end 14 of the helical slot 13 and itself will be formed into a helical shape conforming to the bottom surface or inside end 14 of the slot 13. Tension on the fish line 4 will pull the line 4 against the solid core 15 and result in increased friction. Obviously, insertion and removal of line 4 is unaffected whether the central element is a bore 2 or a solid core 15.
As a lure, a fishing implement as described by bodies 1 through 1 F above colors, patterns, textures, shape, wings or other motion inducing shapes, scents or scent holding pockets, all intended individually or in combination to attract fish.
As a corkey-float or corkey-lure, an implement as described by bodies 1 through 1 F above may be fitted with skirts, skids, or pockets to deflect weeds and otherwise reduce the tendency of a hook to snag objects in the water or on the bottom.
The descriptions and figures represent shapes usually formed by molding or similar processes. There is nothing in the concept precluding manufacture by cutting the individual body pieces from lengths of bulk stock. Helical attachment means 11 may be constructed by winding rod or wire around a mandrel. Further the body shapes 1 through 1 F above represented are generally smooth and symetrical although the same technique can be applied to oblique or odd shape bodies.
It is my view that these concepts illustrated and described fulfill the objectives previously set forth.
The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to exactly as described, and accordingly all suitable modifications and equivalents may be resorted to which fall within the scope of the claims of the invention.
|
A novel design for a fishing lure which makes for easy attachment to and detachment from a fishing line. The lure is preferably made with a resilient material which tends to return to its original closed shape after manual manipulation to insert a fishing line into a slit in the lure. In a second embodiment, a substantially helical slot is provided in the lure for frictional attachment to a fishing line. In another embodiment, a substantially linear slot is provided through the lure for passage therethrough of a fishing line, and the lure is provided with helical spring shaped line guides for encircling and thereby attaching the lure to the fishing line.
| 0
|
BACKGROUND OF THE INVENTION
[0001] This invention relates to a process for chemically modifying textile articles which contain hydrolizable polymers to reduce pilling tendency.
[0002] Hydrolizable polymers, such as polyester, possess many attributes that lead to their use for many items of commerce, such as fibers, films and molded products. Among these attributes are strength and toughness of the products, lack of reactive surface groups that can lead to staining, and various other advantages. However, many of these attributes can become problematic for certain end uses of the polymers. For example, the tenacity and other strength properties of the hydrolizable polymers such as polyester contribute to their outstanding performance as textile fibers and various other applications, such as films. However, this same strength characteristic can result in a phenomenon known as pilling if this fiber is manufactured, for example, into a spun yarn or in the manufacture of certain microdenier yarns.
[0003] Pilling results from fibers being pulled out of the fiber bundle and becoming entangled into a “ball” due to mechanical action, such as rubbing that, for example, fabrics encounter during normal use. Fabrics composed of cellulosic fibers experience similar action, but because the fiber is much weaker, the “pill balls” tend to break off before they become objectionable. These “pill balls” are a detriment to the appearance and comfort of textile articles. Reducing or eliminating the pilling propensity of hydrolizable polymer-containing textile articles would typically extend the useful life of the end-use product, such as a garment, by retaining its original appearance and comfort. Various products introduced by the fiber producers, such as low pill T-351 Trevira® polyester fiber from Hoechst-Celanese, have resulted in some degree of success in reducing pilling tendency. U.S. Pat. No. 3,104,450 to E.I. du Pont de Nemours and Company suggests that by controlling the relative viscosity and the break elongation of polyester fibers, one can reduce the pilling tendency of fabrics containing those spun polyester yarns.
[0004] Two major disadvantages are typically associated with fiber modifications made by the fiber producers in attempting to resolve the pilling issue. First, if the fiber producer lowers the fiber strength to the level required for good resistance to pilling, it becomes difficult for the yarn manufacturer to spin the yarn without excessive breaks and resulting off-quality. This necessitates further treatment to adequately reduce the yarn strength, such as alkaline hydrolysis after fabric formation or in a subsequent laundering step, to provide good resistance to pilling. Second, due to the vast number of fiber options (such as denier, cross-section, staple length, etc.) desired in the market, the fiber producer experiences cost, quality, and capacity issues associated with the spinning of small quantities of specialty fibers.
[0005] Textile manufacturers face a multitude of challenges in attempting to resolve the pilling issue on textile articles containing hydrolizable polymers. For example, textile chemists have applied binders to increase the force required to remove fibers from the fiber bundle; however, this typically results in detrimental changes to the feel of a fabric, and the effect is generally reduced by washing the fabric or end-use product (i.e. a garment). Some effort has been devoted to lowering the fiber strength by various chemical treatments. Hydrolysis with, for instance, sodium hydroxide does indeed lower the fiber strength, but it is difficult to precisely control this process and the resulting fabric also undergoes a significant weight loss. Aminolysis of the ester linkage of the polymer, such as addressed by Farmer in commonly-assigned U.S. Pat. No. 4,103,051, incorporated by reference herein, indeed can achieve the desired properties in many instances, but also can adversely affect the dyeing of the resulting fabric. This disadvantage is addressed by commonly-assigned U.S. Pat. No. 6,113,656 to Kimbrell which discloses a method for improving the dyeing of fabric treated with the Farmer chemistry. In addition, the structure of the amines disclosed by Farmer, especially those preferred by Farmer, can lead to chemical handling issues in textile finishing facilities (as will be discussed further herein) and also to quality issues resulting from attempting to handle such chemicals. Furthermore, it has proven difficult to control the batch to batch variation, within a somewhat narrow range, on certain styles, which in turn, leads to significant treated yardage that is not acceptable, either due to poor pilling performance or excessive strength loss.
[0006] More specifically, Farmer describes in U.S. Pat. No. 4,103,051 that organic amines are a particularly preferred class of compounds for this type of reaction, resulting in generally good control of the degree of pilling improvement obtained. Farmer discloses the use of aliphatic amines containing at least 10 carbon atoms. In addition, Farmer states that fatty diamines such as n-coco-1,3-propanediamine, are the preferred amines for this process.
[0007] It has been found that the use of the above-mentioned fatty diamines can impart detrimental variability to the textiles treated by this process. First these fatty diamines, especially those containing greater than 10 carbon atoms, tend to solidify at or around room temperature. This necessitates special storage and handling requirements in a typical textile dyeing operation such as, for example, drum heaters or other heating equipment to maintain the amine at a temperature above its melting point. Second, these compounds, such as the n-coco-1,3-propanediamine preferred by Farmer, are mixtures of unbranched carbon chains containing from 8 to 18 carbon atoms. This mixture tends to separate according to the size of the carbon chain resulting in unacceptable variations of the chemical composition and the degree of strength reduction obtained by this process. This again leads to special chemical handling requirements to minimize this potential variable, such as the use of drum mixers. Finally such diamines are known to adsorb and react with carbon dioxide from the air, resulting in an insoluble carbamate that does not react with polyester or other hydrolizable polymers. Without special attention to controlling the exposure of these amines to the air, various mixtures of products result. The net result can be less than the necessary amount of active amine being used to obtain the required strength reduction necessary to achieve good pilling performance. All of these potential chemical variations result in a process that can be very difficult to control within acceptable product performance tolerances.
SUMMARY OF THE INVENTION
[0008] In light of the foregoing discussion, it is one object of the current invention to achieve a textile article, which contains hydrolizable polymers that have been chemically modified by branched chain amine treatment, that has consistently good pilling and acceptable strength characteristics. A textile article includes fiber, yarn, fabric, film, etc. or any combination thereof. The textile article may be dyed or undyed. As used herein, a hydrolizable polymer is or includes any polymer that is capable of undergoing a hydrolysis reaction, such as, for instance, polyester. The term hydrolysis is used herein to include any reaction that typically results in the cleavage of the ester linkage in the polymer. Without being bound by theory, it is believed that this cleavage is the mechanism by which the textile article is weakened and improved resistance to pilling is obtained. Hydrolysis can include the addition of water, resulting in the reformation of carboxylic acid and alcohol moieties, and can include a reaction with acids or bases. If amines are utilized, the resulting decomposition products are an alcohol and an amide. Hydrolysis reactions can also occur with polymers such as wool, such that an amide linkage is cleaved. However, this reaction typically requires more robust treatment conditions such as increased temperature, increased amine concentration, etc.
[0009] By good pilling, it is meant that the article achieves a minimum 3.0 rating after 30, 60, or 90 minutes when tested for Random Tumble Pilling according to ASTM test method D 3512-99A and is typically dependent upon the composition of the article being treated, the method of manufacture of the article, the amine used for treatment, etc. The amount of strength that will generally be considered to be “acceptable” is the strength required for the treated article to function within its anticipated end product for a minimum number of use or wear cycles, which will generally also include intermittent cleaning cycles as well. The strength that is considered to be acceptable for a given article will therefore vary depending on the type of treated article, how it will be used in an end product, the type of end product, etc. By way of example, acceptable strength for an article intended for use in knit shirting is achieved with a minimum 50 pound rating when tested for Mullen Burst Strength according to ASTM test method D 3786-87. More specifically, by experience it has been determined that a certain double knit (24 gauge) 100% polyester tuck fabric to be used in knit shirting should have strength of about 50 pounds, but no more than 90 pounds, when tested for Mullen Burst Strength according to ASTM test method D 3786-87, and preferably, between 55-65 pounds. If the Mullen Burst Strength exceeds 65 pounds, unacceptable pilling performance is obtained on this particular style. If the Mullen Burst Strength drops below 50 pounds, the fabric is generally considered to be too weak for apparel applications and holes may be punctured into the garment during normal use conditions.
[0010] As an ASTM test method, Mullen Burst Strength is typically used for determining the strength of knit or non-woven fabrics. If the treated fabric is a woven fabric, or if fibers or yarns are modified by the process of the current invention, other methods for determining the strength of the textile article must generally be used. By way of example, these methods include determining the tear strength of a woven fabric or determining the tensile strength of the fibers or yarns using test methods which are known and available to those skilled in the art.
[0011] Similarly, other standard methods for evaluating the pilling resistance of fabrics or fibers and yarns exist and may be used. By way of example, these methods include Brush and Sponge, Martindale and Elastomeric Pad methods which are known and available to those skilled in the art.
[0012] A second object of the current invention is to achieve a textile article, which contains hydrolizable polymers that have been chemically modified by branched chain amine treatment, that maintains its aesthetic appearance and comfort properties due to its improved resistance to pilling. The formation of “pill balls” leads to an unsightly appearance of the article. In addition, these “pill balls,” when found in a garment, for example, generally result in a loss of garment comfort due to the abrasive nature of these protrusions against the skin. Therefore, reducing or eliminating the formation of “pill balls” allows for the extension of the useful life of textile articles, such as apparel, made from hydrolizable polymer-containing fabric.
[0013] It is also an object of the current invention to achieve a method for modifying textile articles, such as fabrics containing hydrolizable polymer fibers and/or yarns, with branched chain amines to reduce their propensity to pill while at the same time maintaining acceptable strength characteristics. The chemical structure of these amines improves both the process of modifying the hydrolizable polymer-containing textile articles and reduces or eliminates certain quality and cost issues associated with variations in this process. These variations are believed to be caused by the chemical compositions of amines disclosed in the prior art and the chemical handling procedures typical in a textile dyeing and finishing operation. This method also generally reduces the process and product variability associated with the prior art.
[0014] It is another object of the current invention to achieve a substituted hydrolizable polymer wherein the substitute is a branched chain amine. It is generally believed that this polymer is a reaction product that is formed after the textile article has been treated with the branched chain amine.
[0015] Other objects, advantages, and features of the current invention will occur to those skilled in the art. Thus, while the invention will be described and disclosed in connection with certain preferred embodiments and procedures, such embodiments and procedures are not intended to limit the scope of the current invention. Rather, it is intended that all such alternative embodiments, procedures, and modifications are included within the scope and spirit of the disclosed invention and limited only by the appended claims and their equivalents.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1A is a scanned image of an untreated sample of 100% double knit (24 gauge) polyester fabric showing the pill balls observed on the fabric when tested for Random Tumble Pilling according to ASTM test method D 3512-99A for 90 minutes.
[0017] [0017]FIG. 1B is a scanned image of a sample of the same fabric of FIG. 1A, but which was treated with isotridecyloxypropyl-1,3-diaminopropane, a branched chain alkyl amine according to the present invention, showing the lack of pill balls on the surface of the fabric when tested for Random Tumble Pilling according to ASTM test method D 3512-99A for 90 minutes.
DETAILED DESCRIPTION OF THE INVENTION
[0018] A textile article that contains hydrolizable polymer is provided that has been chemically modified to achieve a useful change in certain of its properties. The textile article may be a chemically modified fiber, yarn, fabric, film, etc. or any combination thereof, and the fiber or yarn may be used to manufacture a fabric. The fibers used to manufacture the yarns or fabrics can have any cross-section or any of the deniers commonly used for textile applications. By way of example, this would include round or multi-lobal cross-sections and deniers ranging from about 5 denier to less than 1 denier (namely, microdenier fibers) and can also include splittable (or bi- or multi-component) microfibers. By splittable microfibers, it is meant to include fibers coextruded from two or more polymers that can be separated by chemical and/or mechanical treatment to yield two or more fibers of lower denier than the fiber that was initially extruded. Such chemical treatments may or may not result in the dissolution of some of the initial fiber material (as in the standard islands-in-the-sea type fibers).
[0019] Any hydrolizable polymer can be modified by treatment according to the invention, under the appropriate conditions, with ammonia or organic amines. By way of example, hydrolizable polymers include polyesters such as polyethylene terephthalate, polybutylene terephthalate, polytriphenylene terephthalate, other polyesters, wool, polylactic acid based polymers, and the like, and any combination thereof. As previously discussed, in the example of polyester, aminolysis of the ester linkage is believed to be the mechanism of reducing the polymer strength and thereby improving the resistance to pilling. Such aminolysis generally results in the formation of amide groups within the polymer chain by incorporation of the amine utilized in the reaction. These amide groups may be located on the surface of the fiber or anywhere within the fiber cross-section depending on the reaction conditions employed.
[0020] In addition, hydrolizable polymer-containing articles that have been chemically modified according to the present invention may be dyed using conventional textile dyeing procedures. The resulting dyed article is typically substantially spot-free and generally exhibits evenly distributed dye throughout the article.
[0021] In one practice of the present invention, a fabric containing certain polyester fibers is treated with certain branched chain amines prior to dyeing. Without wishing to be bound by any theory, such amines are believed to reduce the strength of the polyester fibers by aminolysis of the ester linkage of the polymer as previously discussed.
[0022] The fabrics of the current invention may be constructed from 100% spun polyester yarns, 100% microdenier filament polyester yarns, blends of spun and filament polyester yarns (which may be microdenier or non-microdenier filament yarns), and blends containing other fiber types, such as polyester and cotton blend fabrics. Suitable blends may contain, in addition to polyester fibers (which may be filament or staple fibers), other synthetic fibers, such as polyamides, polyolefins, polyacrylics, and regenerated cellulose fibers. Suitable blends may also incorporate other natural fibers, such as cotton, wool, linen, and flax. The fabrics of the current invention may be of any variety, including but not limited to, woven fabrics, knit fabrics, or non-woven fabrics or combinations thereof. They may optionally be colored by a variety of dyeing techniques, such as high temperature jet dyeing with disperse dyes, thermosol dyeing, pad dyeing, transfer printing or any other technique that is common in the art for comparable, equivalent, traditional textile products. If yarns or fibers are treated by the process of the current invention, they may be dyed by suitable methods prior to fabric formation, such as for instance package dyeing, or after fabric formation, or they may be left undyed.
[0023] The present invention discloses the use of certain branched chain amines that will reduce the hydrolizable polymer strength to a level required for acceptable resistance to pilling for textile applications, will reduce or eliminate all of the previously discussed potential chemical variations, and does not necessitate special storage and handling requirements. The amines are preferably chosen from the group consisting of aliphatic amines, alkyl amines, aliphatic substituted cyclic amines (as long as the substituent does not exhibit an electron withdrawing effect that renders the amine less reactive) and diamines or polyamines of the above-mentioned amine classes. The alkyl-amines may be isodecyloxypropyl-1,3-diaminopropane, isododecyloxypropyl-1,3-diaminopropane, or isotridecyloxypropyl-1,3-diaminopropane.
[0024] The amines generally contain from 8 to 14 carbon atoms with a branched chain. Typically, the branch occurs at the third carbon atom. Other branched chain amines can be used, but preferably the substituent is not a mixture of products having a tendency to separate from each other (which can cause the consistency problems). It is preferable that substantially all of the branched chain amines have a molecular weight that varies by less than 42 atomic units both before and after the chemical reaction with the polymer. It is also preferable that the amine is a liquid within the range of temperature found in a typical textile dyeing facility. Substituted amines of this type generally have a substantially lower solidification temperature, such as below room temperature.
[0025] In addition, the branched chain reduces or eliminates the adsorption of carbon dioxide and the resulting carbamate formation. Without being bound by theory, it is believed that the branched chain provides a stearic hindrance to such carbamate formation. Also within this class of amines, one can obtain pure C 8 to C 14 substituents unlike the mixtures obtained with other classes of amines. This property reduces or eliminates the potential for separation of the chemical into its various fractions and also leads to more uniform reaction kinetics. All of these properties result in a chemical that is very consistent, despite day to day variations that can be expected in a textile dyeing facility. Accordingly, a more consistent, modified hydrolizable polymer-containing product is produced that repeatedly achieves good pilling performance and exhibits acceptable strength characteristics for its intended end-use. This is achieved even when the strength requirement for acceptable pilling approaches the minimum strength requirements dictated by the product end-use which, for example, may be an apparel garment that does not contain any holes or is not easily torn.
[0026] The concentration of the amine used to treat textile articles can be varied within a broad range, depending on the amount of degradation required to achieve acceptable pilling performance, and is related to the inherent strength of the textile article to be processed. The chosen amount of amine typically is between about 0.05% and 5% on weight of the article to be treated. Generally, this range is between about 0.10% and 1% on weight of the fabric. In other instances, this range is between about 0.20% and 0.70% on weight of the fabric to be treated. The inherent strength of the fiber, which will ultimately be treated with the amine, generally varies between different manufacturers of the fiber and between fiber types. As a result, this characteristic typically needs to be examined in determining the concentration and amount of amine to be used for a given treatment. As stated previously, the controlling factors that determine the amount of amine necessary are the inherent strength of the fiber, the amount of strength degradation required to achieve acceptable pilling performance for the particular product, and the lower limit of strength acceptable for the end-use of the article.
[0027] In one aspect of the invention, the process of the current invention requires no special equipment; standard textile dyeing and finishing equipment can be employed. By way of example, a textile fabric may be treated either in a batch operation, wherein chemical contact is prolonged, or in a continuous operation, wherein chemical contact with the fabric is shorter. Generally, a predetermined amount of the desired chemical is deposited onto the hydrolizable polymer-containing article, and the treated article is then exposed to a sufficient amount of heat for a predetermined amount of time, as will be discussed further below. The application of the chemical to the hydrolizable polymer-containing article may be accomplished by immersion coating, padding, spraying, foam coating, or by any other technique whereby one can apply a controlled amount of a liquid suspension to an article. Employing one or more of these application techniques may allow the chemical to be applied to a textile article in a uniform manner. As noted above, once the chemical has been applied to the article, the article is subjected to heat to obtain the desired reaction between the chemical and the article. A typical time and temperature relationship follows for this reaction. As the temperature is increased, the reaction time will generally decrease. For example, suitable temperatures for polyethylene terephthalate will generally range from about 180 to about 400 degrees F., and exposure times will typically range from about 1 to about 90 minutes. Heating can be accomplished by any technique typically used in manufacturing operations, such as dry heat from a tenter frame, microwave energy, infrared heating, steam, superheated steam, autoclaving, etc. or any combination thereof.
[0028] One process that has been found acceptable involves placing a textile fabric to be treated into a high temperature jet dyeing machine charged with dye liquor, adding the appropriate amount of a branched chain amine, heating the dye jet to a predetermined temperature, holding the temperature for a certain amount of time, cooling the machine to a lower temperature, dropping the liquor out of the dye jet, and finally rinsing the fabric with water, then acetic acid, and water again to remove any unreacted amine from the fabric surface. While acetic acid is commonly used in textile dyeing operations, other acids of similar nature, such as citric acid or formic acid could be used. In an alternative embodiment of the current invention, a small amount of a strong base, such as sodium hydroxide, is added to the amine treatment. This addition maintains a high pH in the dye liquor and thereby assists in forcing the reaction to proceed to completion, theoretically by decreasing the solubility of the amine in water, which increases the affinity of the amine to the fabric so the chemical reaction can occur. Adding dyes and auxiliary chemicals to the dye machine and dyeing the fabric can follow this treatment by suitable dyeing processes. Alternatively, with the appropriate dye selection, one can amine treat and dye the hydrolizable polymer-containing article in one step, or one could amine treat the article following the dyeing process.
[0029] As mentioned previously, a substituted hydrolizable polymer, wherein the substitute is a branched chain amine, is produced as a result of the chemical reaction that occurs between the hydrolizable polymer contained in the textile article undergoing treatment and the amine. The amine is comprised essentially of hydrogen, nitrogen, and carbon atoms, but it may, in some instances, further comprise oxygen atoms. During the aminolysis reaction that occurs between the polymer and the amine, some of the ester linkages of the hydrolizable polymer are cleaved by the branched chain amine molecule. The product of the reaction is typically an amide and an alcohol. The resulting substituted hydrolizable polymer may be in the form of a textile article such as a fiber, yarn, fabric, film, or any combination thereof. By way of example, a fabric containing this polymer may be incorporated into an article of apparel, bedding, commercial upholstery, residential upholstery, or automotive upholstery.
[0030] The following examples illustrate various embodiments of the present invention but are not intended to restrict the scope thereof. In the examples, all parts and percentages are by weight on the fabric unless otherwise noted.
[0031] Unless otherwise stated, all examples utilize fabric comprised of double knit (24 gauge) 100% polyester tuck construction. The fabric contains 29.16% 36.0/1 T-472 ring spun polyester yarns, 44.31% 27.0/1 T-472 ring spun polyester yarns and 26.53% 1/070/100 56T Danbury microdenier polyester yarns. The staple fiber T-472 is commercially available from Wellman, Inc. of Charlotte, N.C.; the microdenier polyester yarn 56T is commerically available from E.I du Pont de Nemours and Company of Wilmington, Del. The fibers were collectively spun into yarn by Milliken & Company of Spartanburg, S.C. Pilling is determined by ASTM D 3512-99A Method for Testing Random Tumble Pilling. Strength is determined by ASTM D 3786-87 Method for Testing Mullen Burst Strength.
EXAMPLE 1
[0032] The following example shows treatment of the polyester fabric with n-coco-1,3-propanediamine, a fatty diamine.
[0033] A 100 gram piece of fabric was placed into a Werner Mathis laboratory jet dye machine. Two liters of water, containing 0.75 grams of n-coco-1,3-propanediamine (Duomeen® CD from Akzo Nobel Surface Chemistry of Chicago, Ill.) and 0.50 grams of sodium hydroxide was added to the dye vessel. The dye vessel was sealed and heated to 266 degrees F. This temperature was maintained for 30 minutes, then the dye vessel was cooled to 160 degrees F. and emptied. The fabric was then rinsed with water, rinsed a second time with water containing 1.0 gram of acetic acid, and rinsed once more with water. The acetic acid was present to dissolve any residual, unreacted amine from the surface of the treated fabric. The treated fabric was subsequently dyed with a disperse dye, rinsed with water, and then dried and heat set following procedures that are known in the art. The Mullen Burst Strength and Random Tumble Pilling of the fabric was then measured and compared both before and after dyeing. This example was repeated 2 times. The results are shown in Table 1 and FIG. 1A.
EXAMPLE 2
[0034] Example 1 was repeated, except that in place of the n-coco-1,3-propanediamine, isotridecyloxypropyl-1,3-diaminopropane (available from Tomah Products, Inc. of Milton, Wis.), a branched alkyl amine according to the present invention, was used. This example was also repeated 2 times. The results are also shown in Table 1 and FIG. 1B.
TABLE 1 Comparison of n-coco-1,3-propanediamine to isotridecyloxypropyl-1,3-diaminopropane Mullen Burst Strength Randon Tumble Pilling Example (Pounds) 30 min. 60 min. 90 min. 1A 81 3.5 3.0 3.5 1B 90 2.5 3.0 4.0 1C 83 3.0 4.5 4.5 Average 85 +/−5 3.0 3.5 4.0 1A: Dyed 77 4.5 4.5 4.5 1B: Dyed 76 4.5 5.0 5.0 1C: Dyed 77 4.0 4.5 4.5 Average 77 +/−0.7 4.3 4.7 4.7 2A 83 4.0 4.5 4.5 2B 78 3.0 5.0 4.5 20 83 3.0 4.0 4.5 Average 81 +/−3 3.3 4.5 4.5 2A: Dyed 83 4.5 4.5 4.5 2B: Dyed 78 4.0 4.5 4.0 2C: Dyed 76 4.5 4.5 4.0 Average 79 +/−4 4.3 4.5 4.2 Untreated 127 1.0 1.0 1.0
[0035] Two observations could be made regarding the data in Table 1. First, the batch to batch variation of the treatments was lower for the isotridecyloxypropyl-1,3-diaminopropane than for the n-coco-1,3-propanediamine treatments. Second, the amine reaction was essentially complete for the isotridecyloxypropyl-1,3-diaminopropane before the dyeing process. This typically indicates that this amine has been essentially consumed, whereas the n-coco-1,3-propanediamine sample contained residual, unreacted amine when the dye cycle began. This can lead to dye stains on the fabric due to the unreacted amine being exuded from inside the fabric and subsequent complexation with the dyestuff in the aqueous dye liquor. Both factors indicate the obvious benefits of the branched chain amine over the straight amine.
EXAMPLE 3
[0036] The following example shows how exposure to ambient air affects the state of matter for the fatty diamine by changing it from a liquid to a solid due to adsorption of carbon dioxide.
[0037] Approximately 2 grams of n-coco-1,3-propanediamine was exposed for two hours to the airflow under a laboratory hood. Essentially the entire product was changed from a clear liquid to a white waxy solid due to the adsorption of carbon dioxide from the air. When the same chemical was exposed for two hours under a dry nitrogen stream (i.e. a carbon dioxide free environment), it remained unchanged.
[0038] The above experiment was repeated with isodecyloxypropyl-1,3-diaminopropane, an amine of the present invention. No change was observed in the appearance of the chemical in either the air or dry nitrogen environments.
[0039] When the laboratory hood air exposed samples and samples directly from the container of n-coco-1,3-propanediamine were examined by a Hewlett Packard 6890 Gas Chromatography/Mass Spectroscopy machine, the only significant finding was an increase in the peak heights of the laboratory hood samples which generally indicates a greater mass of the chemical being detected. Since it is known that this amine will adsorb carbon dioxide from the air and react to form an insoluble carbamate, it is believed that only the carbamate is being detected. Due to the reaction rate, it is difficult to isolate the pure starting material by this technique. While techniques exist that should allow one to determine the percentage of amine that was converted to carbamate, these techniques were not investigated.
EXAMPLE 4
[0040] The following example shows how exposure of the amine to air affects the strength of the treated fabric.
[0041] Examples 1 and 2 were repeated 2 times each, except the amine in each case was intentionally exposed to the air for 2 hours before the treatment was performed. The results of this exposure to carbon dioxide in the air are shown in Table 2.
TABLE 2 Effect of Chemical Exposure to Air on Fabric Strength Loss Average Mullen Burst Example Sample Strength 1A Duomeen ® CD 83 1B Duomeen ® CD: Exposed to Air 89 2A Isotridecyloxypropyl-1,3- 90 diaminopropane 2B Isotridecyloxypropyl-1,3- 91 diaminopropane: Exposed to Air
[0042] Table 2 shows that exposing Duomeen® CD to the ambient air generally increases the strength of the chemically treated product which, for the purposes of the present invention, adversely affects the pilling tendency of the fabric by making it harder for the pill ball to break away from the fabric. However, the fabric treated with isotridecyloxypropyl-1,3-diaminopropane does not show significant changes in its strength characteristic, and thus, exposure to the carbon dioxide in the ambient air does not detrimentally affect the pilling tendency of the treated fabric. This observed condition can be even more extreme in a production dye facility due to typical seasonal changes in temperature, humidity, airflow rates, and other chemical handling variables.
[0043] The above description and examples show that the present invention provides a novel method for reducing the pilling tendency of hydrolizable polymer-containing textile articles. Accordingly, the invention has many applicable uses for incorporation into articles of apparel, bedding, residential upholstery, commercial upholstery, automotive upholstery, and any other article wherein it is desirable to manufacture a product with reduced pilling tendency.
[0044] These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the scope of the invention described in the appended claims.
|
A hydrolizable polymer-containing textile article and method for producing the same is provided that has been chemically modified by treating the article with certain branched chain amines to reduce the strength of the fibers contained therein, thus rendering the article less prone to the formation of objectionable pill balls, thereby increasing wearer comfort and retaining the desired appearance of the article, and thereby extending the useful life of the article.
| 3
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to carbonless materials. More particularly it relates to pressure sensitive layers on substrates. Many existing compositions exhibit a yellow or brown color cast which is caused by the color of the reactive metal compounds contained therein. This invention uses compositions containing colorless iron salts which are reactable at room temperature to give a visible image.
In commercial applications, pressure sensitive labels are sought which not only provide visible images but which are also capable of being read by optical scanners using near infrared radiation (NIR). The images resulting from reacting the colorless iron salts with chelates having certain substituents exhibit good discrimination both visually and to NIR.
2. Background of the Art
For many years heat and pressure sensitive imaging sheets have been used for copying and labeling. Many of these materials involve the mixing of two or more physically separated reagents to cause a color forming reaction. Several general classes of color forming reactants have been used, of which two common ones are a) leuco lactone or spiropyran compounds reactable with phenolic compounds (e.g. U.S. Pat. No. 3,829,401 and U.S. Pat. No. 3,846,153) and b) heavy metal salts of organic acids reactable with ligands to give colored complexes (e.g. U.S. Pat. No. 2,663,654, U.S. Pat. No. 3,094,620, U.S. Pat. No. 3,293,055, U.S. Pat. No. 3,953,659, U.S. Pat. No. 4,334,015, U.S. Pat. No. 4,513,302, U.S. Pat. No. 4,531,141, U.S. Pat. No. 4,533,930 and U.S. Pat. No. 4,602,264).
Commercial preference for the heavy metal salt class has often resulted from the high stability and near black color of the images produced (U.S. Pat. No. 4,531,141). Of the heavy metals used, iron, nickel, and cobalt are common and ferric iron appears to be preferred U.S. Pat. No. 2,663,654, U.S. Pat. No. 3,953,659, U.S. Pat. No. 4,531,141, U.S Pat. No. 4,533,930 and U.S. Pat. No. 4,602,264)
The objection raised to the ferric salt-phenolic ligand systems is the colored nature of the unreacted ferric salt. This has led to the use of white fillers (U.S. Pat. No. 4,531,141) or other incident light scattering devices (e.g., "blushing" the surface of the layer as in U.S. Pat. No. 3,953,659) to reduce the observed color tint of the coated layer.
Recently, there has been interest in obtaining reactive iron salts which are colorless and which give sharp, high density images when reacted with a colorless ligand. Organophosphates of ferric iron are known in the art to be amongst the few colorless ferric salts (Smythe et al., J. Inorg. Nucl. Chem., 30 1553-1561, (1968)). In U.S. Pat. No. 4,533,930 and U.S. Pat. No. 4,602,264 it is disclosed that such organophosphates, and the equivalent thiophosphates, can react with a variety of ligands under the influence of heat or pressure to give colored results. Ferric salts of organophosphinic acids and organophosphonic acids are included in those disclosures. Some of these organophosphates and many of the thiophosphates have some color cast before reaction which appears to be obscured by the use of white filler in the compositions. In these two patents there are disclosed pressure sensitive manifold papers in which at least one of the two reactants is encapsulated as a solvent solution. When the microcapsules are burst by pressure, the reactants come into contact and immediately react at room temperature to give a colored result. These patents further disclose the use of ferric organophosphates containing organic acid moieties formed by the aqueous reaction of a ferric salt, an alkali metal organophosphate, and an alkali metal salt of an organic acid. These are disclosed as giving the initial material better "color forming properties" an giving better image colors (U.S. Pat. No. 4,533,930, Column 5, lines 38-39 and U.S. Pat. No. 4,602,264, Column 5, lines 7-9) than the simple organophosphates. Excess organic acid salt is disclosed as degrading the white color. It is of significance that the inventors do not consider the choice of the ferric salt used in the preparation to be important. In fact they specifically mention ferric chloride and ferric sulfate (U.S. Pat. No. 4,533,930, Column 6, lines 10-17 and U.S. Pat. No. 4,602,264, Column 6, lines 12-18) and all of their examples use ferric chloride.
SUMMARY OF THE INVENTION
This invention provides pressure sensitive imaging systems comprising reagents which are stable at room temperature but give intense dark colors when mixed together via pressure imaging.
The pressure sensitive imaging systems of the invention may take any of a variety of forms. However, each comprises at least two reactants which are physically separated until pressure is applied, at which point they mix and react with one another at room temperature to form a visible color. Typically the imaging system comprises two substrates arranged in an overlying adjacent relationship to one another with the surface of each substrate facing the other substrate coated with a layer containing a different one of two color-forming coreactants. The reactant containing layers may be solid or liquid and may consist of reactant alone or a solution or dispersion of the reactant. Furthermore, liquid solutions and dispersions of reactant may be encapsulated in pressure-rupturable microcapsules dispersed throughout a layer of film-forming binder material coated on the surface of the substrates. Alternatively, liquid solutions or dispersions of reactant, which may be microencapsulated, may be dispersed or otherwise contained within the substrate in lieu of a surface coating. In carbonless constructions, however, usually one substrate, referred to as a receptor substrate, is coated with a solid reactant containing layer comprising reactant alone or reactant dispersed in microparticulate form in a film-forming binder material; and the other substrate, referred to as a donor substrate, is coated with a layer of film-forming binder material having microcapsules containing a liquid solution or dispersion of the coreactant dispersed throughout.
Additionally, the imaging system may comprise a single substrate having coated thereon or dispersed therein two reacting coreactants, provided at least one of the reactants is microencapsulated as a liquid solution or dispersion to provide the required physical separation. The reactants may be contained in a single layer or in separate overlying adjacent layers coated on one surface of the substrate. Alternatively, the microencapsulated reactant may be dispersed within the substrate and the other reactant coated on the substrate's surface, or both reactants may be dispersed within the substrate. Furthermore, if the substrate is porous, the reactants may even be coated on opposite surfaces of the substrate.
One of the coreactants is a colorless iron containing compound chosen from the class of ferric iron complexes in which the ligand is chosen from organophosphates, organophosphinates and organophosphonates (hereinafter collectively referred to as organophosphates) which react with the second reactant at room temperature. The second reactant is chosen from the class of colored chelating agents having either neutral donors or at least one ionizable hydrogen, or both, and which form dark colored complexes with iron (III). Examples of suitable colored chelates include colored catechols, quinones, azo dyes and macrocyclic chelates.
Iron(III) is the preferred metal for the reaction with chelates since it is capable of oxidizing the chelate, and generating iron complexes that are both black in the visible and strongly absorbing in the near infrared.
The pressure sensitive receptor layers are typically coated or extruded from coating mixes using aqueous or non-aqueous solvents, which solvents enable efficient milling of the ferric organophosphates or chelates.
The pressure sensitive donor layers are typically coated from coating mixes containing microencapsulated coreactant in solution.
The use of colored chelates in the pressure sensitive imaging systems of the present invention provide imaging systems for producing a dark colored image on a colored substrate. These systems are particularly desirable for self-marking paper form sets in which a colorless original and a colored copy is desired. For example, if the donor (or original) substrate bears a coating containing microencapsulated colorless ferric iron compound and the receptor (or copy) substrate bears a coating of the colored chelate, a colorless original and a copy having a dark colored image on a colored background can be obtained upon pressure imaging without the addition of any other dyes or pigments to the paper base stock of the copy substrate.
Definitions:
"ferric organophosphate" compounds of the form
Fe(O.sub.2 P(R).sub.2).sub.3
where R is an organic moiety such as alkyl, alkoxy, aryl, aryloxy, alkaryl, aralkyl, alicyclic groups, etc.
"ferric dialkylphosphate" as above where R is an alkyl moiety.
"chelate" in this case refers to a bidentate or polydentate ligand in which the coordinating groups can bind to the same metal ion.
DETAILED DESCRIPTION OF THE INVENTION
Carbonless transfer papers have come into wide usage over the past several years. Ordinarily, these papers are printed and collated into form sets for producing multiple copies. Impact on the top substrate causing each of the underlying substrates to form a mark thereon corrresponding to the mark applied by machine key or stylus on the top substrate, without carbon paper interleaves or carbon coatings. The top substrate, on which the impact is immediately made, usually has its back surface coated with tiny microscopic capsules containing an active ingredient for mark production. A receptor substrate placed in contact with the back face of the top substrate has its front surface coated with a material having a component reactive with the contents in the capsules. When the capsules are ruptured upon impact by stylus or machine key, the contents of the ruptured capsules react with a coreactant therefor on the receptor substrate forming a mark on the receptor substrate corresponding to the mark impressed by the stylus or machine key. These self-marking impact transfer papers are designated by the terms CB, CFB and CF, which stand respectively for "Coated Back", "Coated Front and Back", and "Coated Front". The CB substrate is usually the top substrate having its back surface coated with the microcapsules, and it is this substrate on which the impact impression is directly made. The CFB substrates are the intermediate substrates which form a mark on the front surface thereof and transmit the contents of ruptured capsules from the back surface thereof to the front of the next succeeding substrate. The CF sheet is the bottom substrate and is only coated on the front surface to form an image thereon, as no further transfer is desired.
As indicated above, carbonless transfer papers comprise two physically separate coreactants which react upon contact to form a dense colored image. Usually, one of the reactants is dissolved in a reaction implementing cosolvent vehicle and encapsulated in substantially pressure-rupturable microcapsules which are coated on the surface of a substrate. A solution or dispersion of the coreactant is coated on a second substrate, the copy sheet, and dried. The substrates containing the coating of microcapsules and the coating of coreactant are then placed in such a relationship to each other that rupture of the capsules will release the entrapped contents and allow the coreactants to react thereby forming a dense colored image. While it is customary to coat the capsules on the back surface of the overlying substrate and coat the coreactant for the encapsulated reactant on the front surface of the substrate upon which the image is to be copied, this procedure could be reversed if desired. Alternatively, both reactants may be encapsulated and located either on adjacent substrates in superimposable relationship or on the same surface of a single substrate. Additionally, the microcapsules are so rugged and impervious to the coreactants that microcapsules containing one reactant may be interspersed with a fluid suspension or solution of the coreactant and applied to a surface as a single coating with little danger of premature image formation.
Furthermore, the capsules need not be applied as layers, but may be subjected to the rigors of paper formation on a paper machine and can be directly incorporated into the paper, the capsules being carried as a filler therewithin. Similarly, the coreactant can be incorporated into a second or copy surface or may be carried adjacent to the capsules in the same web of paper.
Alternatively, a composition comprising a solution or dispersion of one reactant can be carrried by a variety of materials such as woven, non-woven or film transfer ribbons for use in impact marking systems such as typewriters and the like, whereby the reactant is transferred to a coreactive record surface by impact transfer means. Furthermore, a composition comprising a solution or dispersion of one of the reactants could be absorbed in a porous pad for subsequent transfer to a coreactive record surface by a transfer means such as a portion of the human body, e.g., a finger, palm, foot or toe, for providing fingerprints or the like.
As noted above, the color-forming composition of the present invention can be readily microencapsulated by techniques known in the art, such as those described in "Microcapsule Processing and Technology," A. Kodo, Marcel Dekker, Inc. (1979); "Capsule Technology and Micro-encapsulation," M. Gutcho, Noyes Data Corporation and as described in U.S. Pat. No. 3,516,941.
Capsules containing a reactant of the present invention may be formed from any substantially impermeable film-forming material sufficiently strong to withstand necessary handling. A suitable class of film-forming materials are aldehyde condensation polymers, particularly urea-aldehyde condensation polymers, and more particularly urea-formaldehyde condensation polymers. The capsules are preferably in a size range of from 1 to 50 microns and are preferably used in an amount from 5 to about 50 parts by weight dry capsules per 100 parts pulp when incorporated within the body of paper substrates.
The color-forming system of the present invention requires two coreactants, a colored chelate and a colorless iron (III) organophosphate. As used herein, "colorless" is an indication that upon reflective or transmissive observation of the composition (depending upon the nature of the substrate upon which the composition is coated, i.e., opaque or transparent) the human eye observes a "true white" rather than a colored tone. For example, there would be no clear yellow, pink, or blue tones in the observed material. In the transmissive mode this would require that the composition not absorb significantly more strongly in one or more 25-50 nm ranges of the visible portion of the electromagnetic spectrum than in other 25-50 nm ranges within the visible portion of the electromagnetic spectrum. Small percentage variations are of course tolerable so long as the eye does not observe them. This is usually exemplified by having an optical density of less than 0.2 in a 50 nm range in the visible portion of the electromagnetic spectrum. These kind of measurements can readily be taken by densitomiters in reflective or transmissive mode. Some optical brighteners tend to add coloration (in particular blue) at an optical density level of less than 0.05. This is acceptable, but not preferred. Optical densities which vary in any 50 nm range within the visible portion of the electromagnetic spectrum by more than 0.1 are not preferred; it is desirable that any variation be less than 0.05.
It is an important feature of the present invention that the liquid employed as the solvent for the encapsulated reactant may be a solvent for the coreactant but need not be. If the liquid is a solvent for both reactants, then it serves as a reaction implementing medium for the two reactants at the time of rupture of the capsules, and is commonly referred to as a cosolvent. Examples of cosolvents include cyclohexane, tributyl phosphate, diethyl phthalate, toluene, xylene, 3-heptanone and the like. The selection of additional suitable cosolvents will be obvious to those skilled in the art.
U.S. Pat. No. 4,533,930 and U S. 4,602,264 disclose a wide range of ferric salts of organo phosphorus oxyacids and thioacids as useful in pressure sensitive and thermographic reactions with a range of ligands. They are presented as giving much whiter backgrounds than ferric salts previously used in this art. It is clear from the examples, and confirmed from our own investigations, however, that the organothiophosphates are highly colored and dark. Furthermore, many of the examples using organophosphates, disclosed in these patents, record appreciable coloration of the compounds with whiteness levels being achieved by the use of fillers such as zinc oxide, aluminum hydroxide, and calcium carbonate.
This invention defines a preferred narrow range of ferric organophosphates which are entirely colorless. The structural formulae of some of these compounds (I) are encompassed generically by the disclosures of U.S. Pat. No. 4,533,930 and U.S 4,602,264 without any means of providing them as truly colorless species being disclosed. Other structures within this invention are not even generically disclosed (II-IV). These compounds are dialkylphosphates, dialkylphosphinates, and dialkylphosphonates (hereinafter collectively referred to as dialkylphosphates) and have structures chosen from the general formulae: ##STR1## in which each R is selected independently from alkyl or alkoxy groups and substituted alkyl or alkoxy groups bearing substituents such as those selected from alkyl, cycloalkyl, and aryl provided that such substituents do not act as ligands or chelates for ferric ions; and X is a counterion.
Preferably R is selected from the group represented by the formula: ##STR2## where d=0 or 1, b>a, b>c, c is 1 to 10, and 3<a+b<18; and X is selected from F - ,PF 6 - , Ph 4 B - , BF 4 - and NO 3 - (where Ph=phenyl). In our most preferred compounds a=1, b=4, c=2, d=1 and X=NO 3 - .
Dialkylphosphates are the preferred ligand for iron(III) since the resulting complexes are completely colorless. If trialkylphosphates are used as the main ligand, sufficiently stable iron complexes do not form, and if monoalkylphosphates (as well as inorganic phosphates) are used, generally undesirable, extensive crosslinking occurs between metal centers such that the resulting iron organophosphate is too stable to react with the chelate. Previously used iron carboxylates typically are too highly colored and cannot produce colorless backgrounds. Mixed dialkylphosphate/carboxylate iron complexes can be made to be less colored than iron carboxylates, but they still retain undesirable color because of the presence of the carboxylate. The iron complexes of the sulfur analogues of the carboxylates, phosphates, and their mixtures are particularly undesirable since they are highly colored, even black, materials. Aromatic phosphates often provide an iron complex that is less reactive and more colored than the dialkylphosphates.
Ferric propyl(2-ethylhexyl)phosphinate, ferric cyclohexyl(2-ethylhexyl)phosphinate, and ferric dicyclohexylphosphinate have been made and found to be reactive with chelates. The most preferred organophosphate ligands, however, are branched chain dialkylphosphates, especially di-2-ethylhexylphosphate (DEHP). Linear chain dialkylphosphates form colorless iron complexes that give images with chelates but are generally too unreactive (too highly crosslinked) to provide sufficient image density. The branch on the main chain should be sufficiently long and sufficiently close to the metal center that crosslinking between metal centers is inhibited. On the other hand, the branch should not be too long or too close to the phosphorus center since iron that is incompletely reacted with the phosphate may result in a colored iron source. From a practical aspect, the ideal structure is illustrated by DEHP. The range for the side chain length might best be put at about 1-10 carbon atoms, the further from the connection point to the phosphorous the longer the chain. The length of the main chain is best illustrated by DEHP, that is, around 6-10 carbon atoms. Chains as long as 18 carbon atoms are the practical maximum due to the required loading necessary to achieve suitable optical density (i.e., the molecular weight of the non-image contribution of the organic moiety becomes impractically high).
Fe(DEHP) 3 , Fe(DEHP) 3 (NO 3 ), Fe(DEHP) 3 (HDEHP) 3 and Fe(DEHP) 3 (HDEHP) 3 (NO 3 ) are preferred in the iron organophosphate series. These are completely colorless, a major improvement over the iron carboxylates and mixed carboxylate/organophosphate iron complexes. In addition, unlike the general straight chain dialkylphosphate iron complexes, they are very reactive with chelating ligands. The latter three are also soluble in the organic solvents used in the microencapsulation process and can, therefore, be microencapsulated on donor sheets for pressure-sensitive imaging constructions.
We have found that the preparation of the colorless ferric organophosphate compounds of I is not as simple as U.S. Pat. No. 4,533,930 and U.S. Pat. No. 4,602,264 suggests. Their method involves mixing aqueous solutions of an alkali metal salt of the organophosphoric acid and a ferric salt of a strong mineral acid such as hydrochloric and sulfuric acids, which results in a precipitate of the ferric organophosphate. It has been found that ferric chloride (which is preferred by these patents) gives slightly colored precipitate even with dialkylphosphates whereas those from ferric nitrate are completely colorless. The preferred preparation, therefore, uses ferric nitrate to give compounds I-IV.
Ferric dialkylphosphate compounds II where X=fluoride, hexafluorophosphate, tetraphenylborate or tetrafluoroborate may be prepared by mixing required equivalent quantities in aqueous solution of ferric nitrate, alkali metal salt of the dialkylphosphoric acid, and the alkali metal salt of the acid HX. Compounds II then precipitate.
When X=nitrate, however, the nitrate ion is too soluble in water to remain attached to the ferric dialkylphosphate and the result is the compound I again. However, if the ferric nitrate and dialkylphosphoric acid are dissolved in glacial acetic acid, then compound II for X=nitrate is precipitated. This compound and the fluoride may also be prepared using ethyl alcohol as solvent and adding potassium acetate or sodium fluoride to the ferric nitrate and alkali metal phosphate in required equivalent amounts.
Ferric dialkylphosphate compounds III and IV may be prepared by mixing together the required equivalent quantities of an aqueous solution of ferric nitrate and an organic solution of the dialkylphosphoric acid, or its alkali metal salt, and extracting into the organic solution. Alternatively, compounds III and IV may be prepared directly in non-aqueous solution.
The chelate compounds which we select as pressure-activated reactants with these iron compounds are chosen to be colored, to react rapidly with the iron compounds at room temperature and to be easily soluble in organic solvents. These colored chelates are selected from aromatic or alkyl ligands having either neutral donors or at least one ionizable hydrogen, or both, and which react with iron (III) to form colored complexes. Examples of chelates meeting these criteria include the colored catechols, quinones, azo dyes, macrocylic compounds and the like. Furthermore, colored mixtures comprising one or more of these colored chelates and one or more colorless chelates having either neutral donors or at least one ionizable hydrogen, or both, and which react with iron (III) to form colored complexes are useful in the pressure sensitive imaging systems of the present invention. For example, intense dark images displaying good discrimination to NIR can be formed by reacting the colorless iron compound with a mixture comprising one of the colored chelates described above and a colorless substituted catechol bearing electron donating groups. Commonly known electron donating groups (such as alkyl, mono- or di-alkyl substituted amino, alkoxy, etc.) enable the catechol to be oxidized more readily by the iron, which is important for obtaining the infrared absorption properties (at 905 nm in particular) needed for bar code readers.
A carbonless recording donor substrate of the invention can be made in the following manner. The chelate or the organic solvent soluble ferric dialkylphosphates of (II-IV) are dissolved in an organic solvent and encapsulated by methods known in the art. The pressure rupturable microcapsules so formed are dispersed throughout a suitable binder material to form a coating composition. The coating composition is then coated on a suitable substrate and dried.
A carbonless recording receptor substrate of the invention can be prepared as follows. The coreactant for the reactant encapsulated on the donor substrate is dissolved or dispersed in microparticulate form throughout a suitable solvent to form a coating composition. When the encapsulated reactant is the chelate, the coating composition may comprise solid ferric dialkylphosphate (I-II) dispersed throughout or dissolved in a solvent such as water, acetone, methyl ethyl ketone, ethanol, etc. or organic solutions of ferric dialkylphosphates (II-IV). When the encapsulated reactant is one of the organic solvent soluble ferric dialkylphosphates, the coating composition is an aqueous dispersion or solution, or an organic solution of the chelate. The coating composition is coated on a suitable substrate and dried.
Substrates which may be used as carbonless recording substrates are films of transparent, opalescent, or opaque polymers, paper, optionally with white or colored surface coatings, glass, ceramic, etc.
The following are preparative examples for the ferric dialkylphosphates I, II, and IV.
EXAMPLE A
Preparation of Fe(DEHP) 3
1. The method is similar to the literature preparation of L. E. Smythe, T. L. Whateley and R. L. Werner, J. Inorg. Nucl. Chem., 30, 1553 (1968) (but using ferric nitrate instead of ferric sulfate). To 2.0 g KOH in 175.0 ml H 2 O is added 10.0 g DEHP. This solution is added over 5 minutes to 35.0 ml of water containing 4.0 g Fe(NO 3 ) 3 ·9H 2 O with vigorous stirring. The mixture is stirred 10 minutes, filtered, washed in fresh water with stirring, filtered and dried under vacuum at 70° C. to a constant weight. An off-white solid is obtained . The infrared spectrum shows the expected phosphate stretches, as well as small amounts of OH, and the characteristic ethyl group presence at 1466.1 cm -1 .
EXAMPLE B
Preparation of Fe(DEHP) 3 (NO 3 )
Powdered Fe(NO 3 ) 3 ·9H 2 O, 80.8 g, is dissolved in 800 ml glacial acetic acid. As soon as a clear solution is obtained, 193.0 g bis-(2-ethylhexyl) phosphate (DEHP) is added in a rapid dropwise manner with vigorous stirring. Less than a stoichiometric amount of DEHP gives a more colored product; an excess of DEHP is not disadvantageous. The white product is filtered, washed with acetic acid and dried under vacuum. The approximate yield is 84%. The product is found to be rubbery and may be recrystallized by precipitation from cyclohexane by acetone. It is important that FeCl 3 not be used since a clear yellow acetic acid solution results.
Alternative preparation from ethanol: To 40 ml of absolute ethanol is added 2.0 g Fe(NO 3 ) 3 ·9H,0. Upon dissolution, 5.0 g DEHP are added, and the clear solution stirred 5 minutes. An aqueous solution of potassium acetate (0.5 g in 4.5 g H 2 O) is added dropwise. The mixture is stirred 2 minutes, filtered, redispersed in water, stirred an additional 20 minutes, filtered and vacuum dried. The infrared spectrum is identical to that prepared from acetic acid.
Characterization: The infrared spectrum clearly shows the coordinated organophosphate (1000-1200 cm -1 ) and nitrate (1551.0 cm -1 asymmetric stretch, the symmetric stretch is under other peaks), and the absence of Fe-O-Fe stretches. The complex is readily soluble in cyclohexane, and is an excellent film forming material when coated on a substrate (clear, colorless film). Elemental analysis is consistent with the presence of one nitrate, and confirms the 3:1 P:Fe ratio. Magnetic susceptibility determined by the Evan's NMR method (J. Chem. Soc., 2003 (1959)), demonstrates a high spin iron complex. The complex was also found to be conductive in cyclohexane solution.
EXAMPLE C
Preparation of Fe(DEHP) 3 F
1. To 500.0 g H 2 O is added 6.0 g KOH. To a separate 500.0 g H 2 O is added 12.0 g Fe(NO 3 ) 3 ·9H 2 O followed by 0.62 g NaF. To the aqueous base solution is added 32.0 g DEHP, which is then added rapidly to the mechanically stirred iron solution. The pure white iron complex is filtered, washed and vacuum dried.
2. To 300 ml ethanol is added 16.13 g Fe(NO 3 ) 3 ·9H 2 O. Upon dissolution, 40.0 g DEHP is added rapidly dropwise (3 minutes). The clear solution is stirred 5 minutes then 3.2 g NaF in 32 g H 2 O are added dropwise (5 minutes). The white solid is stirred, then diluted with 400 ml H 2 O, stirred 30 minutes and filtered. A colorless solid results. Elemental analysis is consistent with a 3:1:1 P:Fe:F ratio.
EXAMPLE D
Preparation of Fe(DEHP) 3 (tetraphenylborate)
To 1.1 g sodium tetraphenylborate and 1.0 g Fe(NO 3 ) 3 ·9H 2 O in 40 ml H 2 O is added rapidly 3.2 g DEHP and 0.73 g KOH in 80 ml H 2 O. The mixture is filtered, dispersed in water, stirred, filtered and air dried. The infrared spectrum is consistent with the proposed material.
EXAMPLE E
Preparation of ferric n-propyl(2-ethylhexyl)phosphinate
To a solution of 25 g of n-propyldichlorophosphineoxide in 300 ml of petroleum ether, 28 g of diethylamine in 150 ml of petroleum ether was added over 4 hours. The petroleum ether was removed by distillation and the remaining n-propyl(diethylamine) chlorophosphineoxide was distilled off under vacuum.
The Grignard of 1-bromo-2-ethylhexane (31 g) was prepared in ether, and 26.4 g of the n-propyl(diethylamine)chlorophosphineoxide was added to it at room temperature and refluxed for 72 hours. The resulting solution was treated with 5M hydrochloric acid and refluxed overnight. On cooling the n-propyl(2-ethylhexyl)phosphinic acid was extracted with petroleum ether and distilled to give a colorless liquid (B.P.=172-180° C. at 12 mm Hg).
To 1.3 g of Fe(NO 3 ) 3 ·9H 2 O dissolved in 5 g of glacial acetic acid, 2.7 g of the prepared organophosphinic acid was added. This solution was diluted with 9 parts of water rapidly. The ferric n-propyl(2-ethylhexyl)phosphinate appeared as a white solid precipitate which was filtered off, washed with water, and dried in air.
EXAMPLE F
Preparation of ferric dicyclohexylphosphinate
The dicyclohexylphosphinic acid was made by the method disclosed in D. F. Peppard, G. W. Mason, and C. M. Andrijasich, J. Inorg. Nucl. Chem., 27, 697 (1965). Phosphinic acid, 2.35 g, was dissolved in a solution of 0.66 g of KOH in 10 g of water. This solution was diluted with 50 ml of water and added rapidly to a solution of 1.3 g of Fe(NO 3 ) 3 ·9H 2 O in 50 ml of water. A fine yellow precipitate occured which was filtered off, washed with water, and air dried to give the ferric dicyclohexylphosphinate.
EXAMPLE G
Preparation of ferric cyclohexyl(2-ethylhexyl)phosphinate
Using the method described in Example E, 30 g of cyclohexyldichlorophosphineoxide was used in place of the n-propyldichlorophosphineoxide to give a thick colorless oil. The white ferric cyclohexyl (2-ethylhexyl)phosphinate was obtained by the treatment described in Example F.
EXAMPLE H
Preparation of Fe[OOP(OR) 2 ] 3 [HOOP(OR) 2 ] 3 NO 3
To a solution of 4.04 g Fe(NO 3 ) 3 ·9H 2 O in 50 ml of ethanol was added a solution containing 0.56 g KOH and 19.66 g DEHP dissolved in 100 ml ethanol. This will yield a substantially colorless solution species having the formula Fe(DEPH) 3 (HDEPH) 3 ·NO 3
EXAMPLE I
The iron(III)-organophosphate used in the following preparations was prepared according to example B.
1. Encapsulation of Fe(DEHP) 3 (NO 3 ) To 126 g of a 10% solution of Fe(DEHP) 3 (NO 3 ) in xylene was added 27 g of a polyphenylmethylene diisocyanate (commercially available from the Mobay Company under the trade designation Mondur MRS). This solution was then added to a one liter baffled reactor containing a solution of 1 g of a polyvinylpyrrolidone polymer (commercially available from the GAF Company under the trade designation PVP-30) in 500 g of water. The mixture was homogenized at 7000 rpm for 2 minutes with a Tekmar mixture equipped with a G-456 head. After homogenizing, the G-456 head was replaced with a Waring Blender blade and the mixture stirred at 2300 rpm. While the mixture was being stirred at 70° C., 77 ml of a 25% tetraethylenepentamine (TEPA) solution was added to the mixture. The mixture was then stirred for a period of 1 hour. At this point, microscopic investigation demonstrated the presence of microcapsules ranging in size from 2-20 microns.
2. Reaction of Fe(DEHP) 3 (NO 3 ) with colored chelates. The results of breaking the microcapsules prepared in 1 against a paper receptor sheet coated with the following colored chelates was:
______________________________________Chelate Chelate Color Image Color______________________________________1-(2-pyridylazo)-2-naphthol bright orange purple-black1,8-dihydroxy-4,5-dinitro- bright yellow violetanthraquinone1,2-naphthquinone tan-brown grey1-hydroxy- purple blue4-aminoanthraquinoneN,N'-bis(salicylidene)-1,3- yellow redpropanediamine4-nitrocatechol bright yellow grey-black______________________________________
3. Reaction of Fe(DEHP) 3 (NO 3 ) with mixtures of colored and uncolored chelates. The results of breaking the microcapsules prepared in 1 against a paper receptor sheet coated with the following mixtures of colored and colorless chelates was:
______________________________________ Print Color of ContrastChelate Mixture Chelate Mixture Image Color Ratio______________________________________50%A and 50%B bright orange purple-black 0.3250%A and 50%C bright orange black 0.4650%A and 50%D bright orange black 0.6525%A and 75%D bright orange black 0.80______________________________________
wherein:
A was 1-(2-pyridylazo)-2-naphthol (colored),
B was 8-hydroxyquinoline (colorless),
C was 6-t-butyl-3-methyl-catechol (colorless),
D was 3-iso-propyl-6-methyl-catechol (colorless), and
|
Pressure sensitive imaging materials are stable until pressure addressed, but thereafter provide an intense dark image. The materials comprise colorless ferric organophosphate, ferric organophosphinate, or ferric organophosphonate and a colored chelate.
| 8
|
BACKGROUND OF THE INVENTION
The present invention relates to the field of fluid dynamics. More particularly, it relates to mechanisms capable of obstructing, retaining, or transferring fluids such as valves.
The field of fluid mechanics pertains to the transfer of fluids from one location to another, usually for the purpose of accomplishing some work or result. Valves obstruct, retain or allow transfer of a fluid from a first location to a second location. There are a vast quantity of valve designs available in the prior art. Each design is best suited for a specific range of purposes. Gate valves typically serve as flow/no-flow mechanisms, globe valves serve as fluid throttle mechanisms, check valves allow fluid flow in one direction, and pressure relief valves allow fluid pressure release where pressure reaches some undesirably high level. There are other valves which accomplish special or specific functions, but one thing all valves have in common are some form of disc and seat which working in combination serve to prevent or allow fluid flow as the case may be.
One type of valve, the pressure relief valve provides a release mechanism for an excess rise in pressure of a particular control volume. The control volume is usually a vessel, tank, or pipe system used to maintain or transfer fluids under pressure. The need for a pressure relief mechanism arises during instances when the tank is exposed to some undesirable increase in pressure. One application for pressure relief valves is on cryogenic storage tanks. In cryogenic applications such as liquid nitrogen storage, the tank is insulated to minimize heat flux. Pressure relief valves are used to protect against undue pressure created by a breakdown in the tank's insulation. If the insulation were to fail the resulting increase in temperature could cause a rupture in the tank or an explosion.
The design of a pressure relief valve depends on the specifics for a particular application. The desired operating pressure is an important specification in the valve's design. When operating pressure is reached the valve begins to allow the flow of gases out of a vessel. As the gas escapes the tank pressure decreases. An important feature of a pressure relief valve is its self-actuating capability. This capability offers versatile and dependable protection against increases in tank pressure. A tank stored for extended periods of time in a remote location can be protected without supervision or maintenance.
There are two separate sources of force present in a relief valve during operation. One is created by the tank pressure and the other is a sealing load required to balance the tank pressure load. The main difference between valve designs is the way the load is reduced. All pressure relief valves rely upon a sealing mechanism, the aforementioned disc and seat, in order to prevent fluid flow. This sealing mechanism is the primary concern in pressure relief valve design and is usually the cause for poor performance. The sealing mechanism or disc and seat are responsible for maintaining zero fluid flow through the valve while tank pressure is below the valve's rated operating pressure. For high pressure situations the valve must actuate to permit a decrease in pressure. The seat provides the surface which when in contact with the disc creates the actual seal. A washer or O-ring is often integrated into the seat because material deformation is often necessary to achieve a good seal.
In situations of over-pressurization, the fluid in the tank places pressure upon the seat attempting to dislodge the seat from the disc, this force is typically referred to as a point of thrust. When designing a valve, it is generally recommended to locate this point of thrust along or below the seat and disc contact plane. Ignoring this can result in poor valve performance including sealing mechanism vibration, fluttering, and inadequate self alignment characteristics.
Three factors are commonly involved in the design of the seat edge or sealing surface. They are angular orientation to seating plane, concavity, and width. An angled seating contact plane creates reaction forces along the seat perpendicular to the sealing surface. These forces help to correct translational misalignment of the seat and disc. Seat concavity, the second factor of concern may also be used to correct misalignment. A curved surface insures a uniform area of contact if rotation of the sealing member occurs. The third factor involved in the design of the sealing surface is the width. A sealing surface with no measurable width is known as knife edge. A knife edge design will open at a tank pressure closest to the value obtained by the dividing the load of the affected surface area of the seat. As the width is increased the stress along the sealing surface decreases reducing its sealing capability. Therefore, a knife edge is ideal. However, a knife edge design may result in stress levels greater than the materials elastic yield strength. This can crush the seat thereby preventing good performance. The optimum seat edge width will create a stress profile which is conducive to valve sealing.
SUMMARY OF THE INVENTION
In spite of the existence of prior art pressure relief valves there is still a need for a pressure relief valve capable of adequately sealing a pressure vessel. Typical improvements in valve design have focused upon reducing friction between moving parts and improving concentricity of the disc to the seat. The applicant has found that reducing friction between components does not effectively improve the performance of the valve. Improvements to concentricity would provide the desired result. Concentricity can be improved by reducing any translational misalignment of the seat to the disc. However, improving the concentricity of the valve is not a realistic solution to the problem of poor valve performance due to the inability to reduce the misalignment to a satisfactory level without increasing friction between moving parts.
Therefore the present invention seeks to correct the deficiencies in the prior art by changing the way a valve attempts to achieve sealing. Instead of trying to improve the valve's concentricity, it is accepted that perfect concentricity will not be achieved. Rather the present invention seeks to define a maximum degree of misalignment which may occur between the seat and the disc. The sealing mechanism is designed to correct for any degree of misalignment up to the defined maximum. Allowing the sealing mechanism to correct itself will improve the sealing of the valve on a repetitive basis.
The proposed solution to the above-referenced problems are applicable to all types of valves, including but not limited to pressure relief valves. Because precise and repeatable operation of pressure relief valves is critical in cryogenic applications, this invention is particularly suited for use in pressure relief valves designed for use in cryogenic applications.
It is therefore an object of the present invention to provide an improved valve mechanism suitable for use in cryogenic applications.
It is another object of this invention to provide a valve mechanism which seals a fluid properly against undesirable passage of said fluid from one location to another until some predetermined situation occurs.
It is another object of the present invention to provide a valve seat and disc assembly which seals effectively when sealing is desired and opens effectively when flow is desired with minimal valve vibration or fluttering due to the disc and seat assembly design.
It is another object of the present invention to provide an accurate and dependable pressure relief valve mechanism.
It is another object of the present invention to provide a valve seat and disc assembly suitable for use on any type of valve that avoids the problems associated with designing low friction, low misalignment sealing mechanisms.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features considered characteristic of the invention are set forth in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will best be understood from the following description of the specific embodiments when read and understood in connection with the accompanying drawings.
FIG. 1 is an elevation depicting a valve seat and disc assembly constructed in accordance with the present invention and located within a standard pressure relief valve;
FIG. 2 is a partial cutaway view of a valve seat and disc as embodied in FIG. 1; and
FIG. 3 is an oblique view of a valve seat as embodied in FIGS. 1 and 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As stated in the "Summary of the Invention" the present invention is applicable to all valves and devices meant to obstruct, retain or allow transfer of a fluid from a first location to a second location. However, the applicant's preferred embodiment of the invention is for use on pressure relief valves suitable for cryogenic applications. FIG. 1 depicts one preferred embodiment of the present invention. Item 1 refers to a valve base which is typically adapted to be mounted to pressure tanis such as a cryogenic fluid storage tank. Nozzle 2 forms a passage between a first and second environment such as between said tank and atmosphere to which a fluid contained within said tank is discharged. Collar 3 surrounds nozzle 2, the collar and nozzle form part of the base in the present embodiment. However, the collar can be a completely separate element from the base wish no resulting impact to valve operation. A plurality of standoffs 4 are attached to collar 3, said standoffs are preferably rounded and it is preferable that there be three such standoffs located at 120 intervals from each other. Each rounded standoff should be independently adjustable in a vertical direction measured from uppermost surface of the collar.
Disc 5 is constructed with flange 6 located around the outer diameter of disc 5. Flange 6 incorporates the same number of grooves 7 as there are standoffs 4. In the preferred embodiment, three grooves 7 shaped to conform to an inverted "V" correlate in position to the three rounded standoffs 4 on collar 3 of base 1. The interaction of these standoffs and grooves serve as an alignment means to ensure accurate alignment of parts to effectively seal the valve. Disc 5 is accurately positioned with respect to base 1 through alignment of the three rounded standoffs on collar 3 to the three "V" grooves on flange 6. The 120 radial spacing of the grooves and rounded standoffs allows for uniform expansion and contraction of base 1 and disc relative to each other over wide temperature variables while maintaining precise alignment. A preferred material of base 1 and rounded standoffs 4 for cryogenic applications is composite bronze however the materials selected are not a necessary feature of the invention so long as the selected materials have the capability to withstand cryogenic temperatures and applications.
Contact between disc 5 and base 1 should occur at exactly six points in the preferred embodiment. This is more commonly referred to as "kinematic coupling" or the minimum number of contact points in which all motion through "x", "y", and "z" planes can be constrained. In the present invention, each rounded standoff will contact each groove 7 at two points. Contact between three standoffs at two points with each groove equals six contact points. A sealing force is required to hold base 1 and disc 5 in contact with each other, this sealing force is applied by a loading means such as a spring. However, in non-pressure relief valves this sealing force can be provided by fluid pressure or other mechanical engagements. The amount of sealing force applied by the loading means should be adjustable in order to precisely control the conditions under which an over-pressure condition will trigger the pressure relief function. Prior art methods provide an adjustment bolt which can be adjusted to vary the spring tension of the loading means.
Proper alignment of disc 5 to base 1 enabling seat 8 to efficiently seal at nozzle 2 is accomplished by individually adjusting the relative height of each of the three rounded standoffs from the vertical surface of the uppermost surface of collar 3. Proper alignment is accomplished when the contact points between each groove and standoff permit a tight seal between a sealing means such as formed by seat 8 and nozzle 2.
The net downward force applied to disc 5 relative to base 1 by the loading means should be sufficient to allow seat 8 to engagingly seal nozzle 2, and to allow final alignment of rounded standoffs 4 to grooves 7. To better enable seat 8 to engagingly seal nozzle 2, a cryogenic compliant gasket 10 could be located on nozzle 2. Gasket 10 should be capable of deformation so as not to add a substantial contact point thereby detrimentally impacting the kinematic coupling of rounded standoffs 4 to grooves 7. On an over-pressurization event sufficient to trip the valve, the contact between the rounded standoffs and v grooves should break just prior to lifting disc 5 thereby releasing pressure. Collar 3 must allow for an exhaust means to exhaust fluid from the valve during pressure relief periods. To accomplish this, one method is to provide cutouts 9 through collar 3. Such cutouts should not occur directly beneath any of the standoffs since this could weaken the structure at points where the load will be applied.
While the invention has been described and illustrated with reference to a specific embodiment thereof, it is understood that other embodiments may be resorted to without departing from the invention. Therefore the form of the invention set out above should be considered illustrative and not as limiting the scope of the following claims.
|
A fluid sealing mechanism suitable for use in valves. This mechanism is capable of self aligning to ensure precise and repeatable sealing of the valve inlet to outlet. Sealing is accomplished by a plurality of standoffs on one surface which engage a plurality of corresponding grooves on another surface. Each standoff is independently adjustable in its height dimension in order to allow precise field adjustability of the sealing surfaces. This mechanism is suitable for use in pressure relief operations.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a nailing gun, and more particularly to a composite a buffer apparatus of an electrical nailing gun.
2. Description of the Related Art
FIG. 1 shows a conventional nailing gun, comprising a main body 1 , a nail outlet 2 , a nail magazine 3 , a coil 4 , a bar 5 and a spring 6 . The bar 5 passes through the coil 4 and rests a front end thereof in the nail outlet 2 for punching nails (not shown). The bar 5 is provided with a stop flange 5 a at a rear end thereof and the spring 6 is installed on the bar 5 having an end thereof against the stop flange 5 a and the other end thereof against the coil 4 . While adding electricity to the coil 4 will generate magnetic force to drive the bar 5 punching out and make the spring 6 compressed as shown in FIG. 1, and while cut the power off, the magnetic force provided by the coil 4 will be gone and the spring 6 will drive the bar 5 back in the main body 1 as shown in FIG. 2 .
It will cause the nailing gun a large vibration when the punched-out bar 5 is drawn back by the spring 6 and crashes on the sidewall of the main body 1 . It sometime will affect nailing, or damage the sidewall of the main body 1 , or make the bar 5 deviating. Some conventional nailing guns were provided with a buffer block (not shown) therein to absorb the vibration, but the buffer block will loose the absorbing capacity after a long time of use. The buffer block sometime will escape from its original position, at this time, it will affect the bar 5 acting.
In addition, the coil will rise its temperature after a long time use and there still is no perfect solution for this problem.
SUMMARY OF THE INVENTION
The primary objective of the present invention is to provide a buffer apparatus of a nailing gun, which use air flow to provide the buffer capacity.
The secondary objective of the present invention is to provide a buffer apparatus of a nailing gun, which can dissipate the heat of coil.
According to the objectives of the present invention, it provides a buffer apparatus of a nailing gun, wherein the nailing gun comprises a main body, a coil and a bar. The main body has a nail outlet, a chamber therein and a through hole communicating the chamber to outside. The coil is provided in the chamber and the bar is movably provided in the chamber, which passes through the coil and corresponds to the nail outlet. A sealing member, which is a flexible piece, is provided in the chamber of the main body and secured to the bar, wherein the sealing member is against a sidewall of the chamber when extended. A returning member is provided at between the sealing member and the coil, and an adjusting member is provided in the chamber of the main body having a stop face and an aperture, wherein the adjusting member has an end thereof pivoted on the sidewall of the chamber to make the stop face sheltered and unsheltered the through hole and the aperture corresponds to the through hole which has a size smaller than the through hole.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a conventional nailing gun, showing a bar punched out;
FIG. 2 is a schematic view of the conventional nailing gun, showing the bar drawn back;
FIG. 3 an exploded view of a preferred embodiment of the present invention;
FIG. 4 is a sectional view in part of the preferred embodiment of the present invention;
FIG. 5 is an enlarged view in part of FIG. 4; and
FIG. 6 is a sectional view similar to FIG. 5, showing the bar punching a nail.
DETAILED DESCRIPTION OF THE INVENTION
Please refer to FIG. 3 to FIG. 4, the first preferred embodiment of the present invention provides a nailing gun 100 , comprising a main body 10 , a nail outlet 20 , a nail magazine 30 , a coil 40 , a sealing member 50 , a support member 60 , a returning member, e.g. a spring 70 , a bar 80 , an adjusting member 90 and a pressing piece 95 .
The main body 10 consists of a main housing 11 and a rear box 12 . The main housing 11 has a head portion 111 and a handle 112 , wherein the head portion 111 is provided with the nail outlet 20 at a front end thereof and holes 113 at a rear end thereof The rear box 12 , a column-like element, is provided in the head portion 111 of the main housing 11 closing to the rear end thereof, which has a closed end 121 at an end thereof and an opening end 122 at the other end thereof The rear box 12 further has a chamber 13 therein and a through hole 14 at the closed end 121 communicating the chamber 13 with outside.
The coil 40 is mounted in the chamber 13 closing the nail outlet 20 . The coil 40 has a central hole 41 .
The sealing member 50 is made of flexible material, such as rubber, into a disk-like element, which has a masking face 51 , a sealing edge 52 at an edge of the masking face 51 and a through hole 53 at a center of the masking face 51 . The sealing member 50 is installed in the chamber 13 and the sealing edge 52 will be against an interior sidewall of the chamber when the masking face 51 is extended.
The support member 60 is a rigid disk which size is smaller than the sealing member 50 . The support member 60 has a top ring 61 , a concave portion 62 and a through hole 63 , wherein the top ring 61 locates around the concave portion 62 , the concave portion 62 orients the nail outlet 20 and the through hole 63 is provided at the concave portion 62 .
The spring 70 is installed in between the support member 60 and the coil 40 which opposite ends rests against the top ring 61 and the coil 40 respectively, therefore, the top ring 61 is against the masking face 51 and the location of the top ring 61 against the sealing member 60 is at between the sealing edge 52 and the through hole 53 .
The bar 80 has a head end 81 , a punching section 82 , a guiding section 83 and a tail end 84 . The head end 81 passes through the central hole 41 and extended in to the nail outlet 82 for punching nail. The punching section 82 is received in the through holes 41 and the guiding section 83 is extruded out of the coil 40 . Please refer to FIG. 3 and FIG. 5, the guiding section 83 of the bar 80 passes through the spring 70 , the through hole 63 of the support member 60 and the through hole 53 of the support member 50 . The bar 60 is provided with a stop portion 85 (such as a nut) to limited the sealing member 50 escaped form the bar 60 . In addition, the bar 80 will be driven by the magnetic force provided by the coil to move between a stand-by position P 1 , as shown in FIG. 4, and a punching position P 2 , as shown in FIG. 5 . The spring 70 is to drive the bar 80 to the stand-by position P 1 at initial.
The adjusting member 90 is a piece element which has a fixed end 91 , a stop face 92 and an aperture 93 . The adjusting member 90 is received in the rear side of the chamber 13 with the fixed end 91 thereof fixed to the interior sidewall of the main body 10 , such that the stop face 92 will be suspended and shelters the through hole 14 of the main body 10 . The aperture 93 locates at the stop face 91 corresponding to the through hole 14 and the size of the aperture 93 is smaller than the through hole 14 .
The pressing piece 95 is more flexible than the adjusting member 90 having a first end 951 and a second end 952 . The pressing piece 95 fixes the first end 951 thereof to the interior sidewall of the main body 10 and rests the second end 952 against the masking face 92 of the adjusting member 90 to make the sheltering the through hole 14 of the rear box 12 .
FIG. 4 and FIG. 5 show the nailing gun of the present invention in stand-by condition, wherein the bar 80 locates at the stand-by position P 1 , the spring 70 is uncompressed and the pressing piece 95 is pushing the adjusting member 90 to shelter the through hole 14 .
FIG. 6 shows the pushing condition, the coil 40 is electrified and generating magnetic force to drive the bar 80 rapidly moving to the punching position P 2 . In the beginning of the bar 80 moving, a vacuum force will applied to make the pressing piece 95 biasing and unsheltered the through hole 14 . In the mean time, the sealing member 50 will be curved by the top ring 61 of the support member 60 to make the edge of the sealing member 50 not against the sidewall of the chamber 13 anymore, such that air will be sucked into the chamber 13 via the holes 113 and the through hole 14 to make the bar 80 can move without any interference.
In the interval of bar moving back from the punching position P 2 to the stand-by position P 1 , as shown in FIG. 5, the sealing member will be against the sidewall of the chamber 13 and the pressing piece 95 will shelter the through hole 14 again. Air only can escape from the chamber 13 via the aperture 93 , such that the bar is buffered by the air.
The air flow in and out the chamber 13 can buffer the bar 80 when it is moving back from the punching position P 2 to the stand-by position P 1 but no interference will be applied when the bar 80 moves from the stand-by position P 1 to the punching position P 2 , except that the air flow also can convect the heat generating by the coil 14 out of the chamber 13 .
|
A buffer apparatus of a nailing gun, which controls the air flow in and out a chamber of a main body of the nailing gun, reduces the vibration of the nailing gun when nailing. The air will flow in with a larger rate and will flow out with a smaller rate, such that a buffer force will be provided to a bar being punched to reduce the vibration, and more particularly, the air flow also can bring the heat out.
| 1
|
CROSS-REFERENCE TO RELATED U.S. APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
Not applicable.
REFERENCE TO AN APPENDIX SUBMITTED ON COMPACT DISC
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the improvement provided to the rollers which are coated with elastic material, found in the drafting and guiding zone, and used in yarn production techniques, by apron cladding having shift structure and pre-tensioning mechanism.
2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98
Nowadays, in almost all of the yarn production techniques, rollers coated with elastic material are used either for drafting purposes or with the purpose of guiding the yarn to the next stage. The yarn, according to the place it is used either in fibre form or in its final form, contacts these rollers with a certain tension and it is exposed to drafting or guiding process via these rollers.
Material hardness of the rollers coated with elastic material is directly related with the quality of the yarn produced and its function, and the elastic material hardness of the top rollers at the drafting zone is especially important for the quality of the yarn.
It is a known situation that the contact of the fibre or the yarn with the roller coated with elastic material has an abrasive effect. As the application point allows, the machine producers move the fibre or the yarn on the rollers on which they are guided or drafted in order to delay the abrasion of the elastic material and extend its operation period.
Compact ring yarn spinning technique is an important example in which the abrasion in the rollers coated with elastic material is intensive. In the compact spinning technology, yarns are positioned closer to each other by using a compacting zone just after the main drafting zone, and thus the spinning triangle is almost removed. In this way, the improvement of the properties of the yarn, for example increasing its strength, and reducing its hairiness is aimed.
One of the compact ring yarn production techniques is the mechanical compactor mechanism. In FIGS. 1 and 2 , the views of the prior mechanical compactor mechanism is given and the operating principle of this mechanism will be explained below by making references to the reference numbers found in the figures. In FIG. 1 , the side schematic view of the mechanical compactor mechanism used in the prior art for producing compact yarn is given. In FIG. 2 , the detail view showing the positions of the mechanical compactor and the rollers relative to each other is given. As it is seen in the figures, a Delivery drafting roller ( 1 ) initiated by the gearbox, supports the Top roller ( 9 ) and the Front roller ( 10 ) belonging to the compaction zone. The contact point of the compaction zone is between the points A and B shown in FIG. 2 . The mechanical compactor ( 12 ), which is a precision instrument, presses on the Delivery drafting roller ( 1 ) without any gaps. The mechanical compactor ( 12 ) forms a completely closed compaction room together with the Delivery drafting roller ( 1 ), and the Delivery drafting roller ( 1 ) surface moves together with the fibres synchronously in order to guide these fibres to the compactor ( 12 ) precisely. As it is seen in the detail view of the A-B compaction part, a compaction channel ( 12 . 1 ) is found at the inner part of the mechanical compactor ( 12 ), which has a funnel shaped structure narrowing downwardly. The fibres entering through the Delivery drafting roller ( 1 ) and the Top roller ( 9 ) are compacted while they go downwards through the compaction channel ( 12 . 1 ) which is found at the inner part of the mechanical compactor ( 12 ). When the compacted fibres go out of the channel ( 12 . 1 ), they are exposed to winding operation by passing through the Front roller ( 10 ) and the Delivery drafting roller ( 1 ) and they become high durability yarn.
As it is seen in FIG. 1 , mechanical compact yarn production mechanism according to the prior art comprises a Delivery drafting roller ( 1 ), which is made of metal based material and which makes rotational motion by being initiated by the gearbox and a Middle drafting roller ( 2 ), a roving guide ( 11 ) which operates as a guide for providing entrance of large numbers of fibre into the mechanism, a bottom apron ( 8 ) which is placed over a Middle drafting roller ( 2 ) and the Bottom apron guide bar ( 6 ), and a Top apron ( 7 ) which is placed over the Top apron roller ( 5 ) and the Apron cradle ( 4 ). Fibres entering from the roving guide ( 11 ) are compacted by passing through the top and the bottom apron ( 7 , 8 ). Fibres passing through the top and the bottom apron ( 7 , 8 ) reach between the Delivery drafting roller ( 1 ) and the Top roller ( 9 ). Via a pressure arm ( 3 ) of the mechanism, the Top roller ( 9 ) made of rubber material is pressed onto the Delivery drafting roller ( 1 ) with a certain force. The drafted and expanded fibres which passed through the Delivery drafting roller ( 1 ) and the Top roller ( 9 ) are guided to the mechanical compactor ( 12 ). Since the fibres pass through almost at the same place, abrasions occur at the rubber Top roller ( 9 ) surface and these deformations increase when the operation hours extend. Due to the deformations on the rubber surface, problems occur such as frequent grinding or renewal labour for the Top roller ( 9 ), loss of production, and quality differences between spindles. Yarn end brakes per average of 1000 spindles increase with the deformations at the surface, and problems occur due to the abundance of quality error cleaning in winding, which is the next operation, and therefore the expenses of maintenance increase. Moreover, in the prior mechanism, the fibres ( 20 ) which cannot enter the compactor ( 12 ) during spinning ( FIG. 6A ) generate fluffs, and these fluffs causes environment and machine pollution and/or it is added to the yarn structure at the spinning zone in an uncontrolled way. This situation makes negative impact on the yarn quality and operation conditions. Since the position of the clearer roller ( 18 ) shown in FIG. 6A is distant from the fibres ( 20 ) that can not enter the compactor, it is not effective in accumulating fibres on itself.
About the mechanical compact yarn production mechanism, the application with publication number WO 2006005207 is found as the closest document to the mechanism, which is the subject of the invention. However, when this patent document is examined, it can be seen that adequate solution suggestions are not provided in this document for eliminating the above said drawbacks and problems.
As a result, the inadequacy of the prior solutions have necessitated an improvement on the related field, which reduces the abrasion tendency at the rollers coated with elastic material for drafting and guiding purposes in the yarn production techniques, eliminates the said drawbacks and disadvantages in the mechanical ring compact spinning which is especially the basis of operation, improves the yarn parameters, and provides more efficient operation conditions.
3. Disadvantages of the Prior Art:
In the known status of the art, the abrasive impact on the elastic material and the coated surface as a result of the contact between the rollers coated with elastic material and the fibre or the yarn is inevitable after a certain period. Guiding of the fibre or the yarn to the rollers coated with elastic material by continuous moving, use of elastic material developed with different formulas, and choosing the roller dimensions in the smallest diameters and widths that can be used according to the application point are the applications for delaying this abrasion impact.
Despite all these measures, in the spinning techniques in which the fibre or the yarn is guided to the roller coated with elastic material without moving to the left or to the right or with a very little moving distance;
1. Maintenance labours due to abrasion in very short periods
2. Quality problems due to rapid abrasion
3. Great quality deviations between production units, and
4. Negative operating conditions due to abrasion originating impacts such as breaks, laps etc. are observed.
Since the fibres pass through almost at the same place also in the prior mechanical compact ring spinning system, they rapidly cause abrasion at the place that they pass through on the Top roller ( 9 ). As a result of this, deformations occur in the yarn quality parameters and operating conditions. In order to prevent such an undesired condition, the Top roller ( 9 ) has to be grinded and renewed in very short periods. After each grinding, diameter of the Top roller ( 9 ) decreases and due to the decreased rubber amount, the hardness impact of the Top roller ( 9 ) increases. This situation ruins the fibre expanding property between the Top roller ( 9 ) and Delivery drafting roller ( 1 ).
Ineffective Removal of the Fluffs Occurring at the Compactor Zone:
In FIG. 6 a , fibres ( 20 ) that cannot go through the compactor ( 12 ) during the spinning operation in the present system are shown. Perspective view given in FIG. 6 b shows the distance of the clearer roller ( 18 ) to the fibres ( 20 ) coming out in between the top roller ( 9 ) and compactor ( 12 ) in the prior art. This distance is not sufficient for clearer roller ( 18 ) to collect the fibres ( 20 ) that cannot go through the compactor on itself.
The fibres ( 20 ) that can not enter the compactors generate fluffs, and these fluffs causes environment and machine pollution and/or it is added to the yarn structure at the spinning zone in an uncontrolled manner. This situation makes negative impact on the yarn quality and operation conditions.
BRIEF SUMMARY OF THE INVENTION
Purpose of the Invention
The main purpose of the invention is to develop a mechanical compact ring yarn production mechanism which eliminates the deficiencies found in the present mechanical compact yarn mechanism, improves the yarn parameters, and provides more efficient operating conditions.
The purpose of the invention is to provide application of a band called apron on the roller, in order to decrease the short term fibre or yarn originating abrasion impact on the roller made of material coated with elastic material, and comprise techniques which would extend the abrasion period.
In the mechanical compact yarn production mechanism, which is the subject of the invention, the technique of operating apron on the roller is used.
Patent applications are found which disclose various apron applications used in yarn production systems. The patents with publication numbers EP 0635590, WO2005038104 and WO2007101742 can be given as examples to these applications. However, in the invention, the improvements such as:
1. Formation of the apron applied on the roller larger than the perimeter of the roller such that it would be as large as the other equipments allow, and thus the abrasion period can be extended,
2. Obtaining different fibre or yarn path by shifting the apron on the roller by choosing the apron to be used in a narrow size than the roller width, and thus the abrasion period can be extended,
3. Uniform winding of the apron to be used on the roller via a stretching mechanism mounted on the roller bearing component, are provided. In this way, advantages are obtained which can not be provided with the prior apron coating patents on the roller.
Again with the invention;
Winding of the apron over the roller coated with elastic material by stretching the apron via a stretching system, Formation of the apron with large perimeter as large as the space and mechanics at the application point allow (large operation surface, abrasion delay), Formation of the apron in a way that it is narrower than the roller coated with elastic material in order to be able to move the apron to the left or to the right on the roller coated with elastic material, Obtaining new yarn or fibre contact path by moving the apron to the left or to the right on the roller coated with elastic material (extension of the period of usage), Providing the operation of shifting the apron to the left or to the right on the roller coated with elastic material be made manually or automatically even during the progress of the production via the systems which will be developed according to the place of application, Formation of a bearing unit according to the present mechanics in order to provide the apron be mounted to its place of application, Formation of guide arms on this bearing unit, which will guide the apron in order to keep the apron on the roller coated with elastic material, In order to be able to coat the apron on the roller coated with elastic material with a certain tension, formation of a tension system between the bearing unit and the present mechanics (spiral or leaf spring, rubber chock etc), are provided.
With the application of narrow Top roller apron ( 17 ) and soft Top roller ( 9 ) under it, the pressure on the fibre is increased, and thus more effective fibre control is provided. Extension of the abrasion period due to the apron ( 17 ) used in the application being made of a material which is highly durable against abrasion regarding the present Top roller ( 9 ) and having less abrasion because of its structure, and also the perimeter of the apron ( 17 ) being larger than the present Top roller ( 9 ), is the most significant factor in reducing the yarn breaks. Application of narrow Top roller apron ( 17 ) and the effective point of the clearer roller ( 18 ) have also provided improvement in the next operations.
As a result of the above said benefits of the narrow Top roller apron ( 17 ), the defective zones determined in winding have decreased (especially A 1 zone in Classimat). Moreover, it has provided the advantages of reducing maintenance expenses, which are very important for business, reducing laps and yarn end breaks per hour, thus reducing the workload.
In order to achieve the above said purposes, the invention is a method, which comprises the phases of tensioning of the aprons ( 17 ) by application of tension via a tension component ( 22 ) and shifting of the bearing unit ( 15 ) carrying the aprons ( 17 ) in predetermined intervals while the fibre drafting operation continues in order to decrease the abrasion impacts on the said apron ( 17 ) caused just before the winding operation for production of compact yarns by the fibres moving over the aprons ( 17 ), which are covered over the bearing guide arms ( 15 . 2 ) connected to a bearing body ( 15 . 1 ) on a bearing unit ( 15 ) placed on the pressure arm ( 3 ) and the Top rollers ( 9 ) in a way that it would cover these ( 9 , 15 . 2 ) together, and thus since the Top roller ( 9 ) and apron ( 17 ) surfaces are abraded in a longer period, the usage and operation periods are extended.
Again the invention is a fibre drafting mechanism, in which just before the winding operation for the production of compact yarn, the aprons ( 17 ), which are covered over the bearing guide arms ( 15 . 2 ) connected to a bearing body ( 15 . 1 ) on a bearing unit ( 15 ) placed on the pressure arm ( 3 ) and the Top rollers ( 9 ) and can be shifted in horizontal plane if desired, in a way that it would cover these ( 9 , 15 . 2 ) together, and which are stretched by application of a tension.
The structural and characteristic features of the invention and all advantages will be understood better in detailed descriptions with the figures given below and with reference to the figures, and therefore, the assessment should be made taking into account the said figures and detailed explanations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the side schematic view of the mechanical compactor mechanism used in the prior art for producing compact yarn.
FIG. 2 is the detail view showing the positions of the mechanical compactor and the rollers relative to each other.
FIG. 3 a is the side schematic view of the alternative mechanical compactor mechanism, which is the subject of the invention.
FIG. 3 b is the perspective view of and alternative embodiment of the invention.
FIG. 4 a is the detail view showing the crush of the Top roller in the mechanical compact mechanism of an alternative embodiment of the invention.
FIG. 4 b is the detail view showing the crush of the Top roller in the mechanical compact mechanism of the prior art.
FIG. 5 a is the front view of the bearing body according to the alternative embodiment.
FIG. 5 b is the upper view of the bearing body according to the alternative embodiment.
FIG. 5 c is the side view of the bearing body according to the alternative embodiment.
FIG. 6 a is the representative drawing showing the positions of the fibres that do not enter the compactor and the clearer roller in the prior art.
FIG. 6 b is the perspective drawing showing the position of the clearer roller in the prior art.
FIG. 6 c is the representative drawing showing the layout of the clearer roller, which is the subject of the invention and effective removal of the fibres that do not enter the compactor from the environment via the clearer roller.
FIG. 7 is the side mounted view of the bearing unit found in the mechanical compact mechanism, which is the subject of the invention.
FIG. 8 a is the perspective mounted view of the bearing unit in the shift mechanical compact mechanism, which is the subject of the invention.
FIG. 8 b is the demounted perspective view of the bearing unit in the mechanical compact mechanism, which is the subject of the invention.
FIG. 8 c is the view of an alternative embodiment of the bearing unit in the mechanical compact mechanism, which is the subject of the invention.
FIG. 8 d is the front schematic view showing the application of the subject of the invention to the pressure arm and Front roller group of the ring spinning system.
FIG. 8 e is the front view of an alternative embodiment of the invention.
FIG. 9 a is the perspective view showing the contact between the Top roller and the Delivery drafting roller in the prior art.
FIG. 9 b is the schematic view showing the fibre pinch distance and the contact width between the Top roller and the Delivery drafting roller in the prior art.
FIG. 10 a is the perspective view showing the contact between the Top roller apron and the Delivery drafting roller, which is the subject of the invention.
FIG. 10 b is the schematic view showing the fibre pinch distance and the contact width between the Top roller and the Delivery drafting roller, which is the subject of the invention.
FIG. 11 a is the yarn quality error versus time graph according to the prior art.
FIG. 11 b is the yarn quality error versus time graph after the application according to the subject of the invention.
REFERENCE NUMBERS
1 . Delivery drafting roller
2 . Middle drafting roller
3 . Pressure arm
4 . Apron cradle
5 . Top apron roller
6 . Bottom apron guide bar
7 . Top apron
8 . Bottom apron
9 . Top roller
10 . Front roller
11 . Roving guide
12 . Mechanical compactor
12 . 1 Compaction channel
13 . Front roller cage
14 . Compactor centralizer
15 Bearing unit
15 . 1 Bearing body
15 . 2 Guide arms
15 . 2 . 1 Roller bearing
15 . 2 . 2 Limiter
15 . 2 . 3 1st grade cavity
15 . 2 . 4 2nd grade cavity
15 . 3 Housing
15 . 4 Bar housing
15 . 5 Additional roller bearings
15 . 6 Housing base
16 . Clearer roller bearing component
17 . Top roller apron
18 . Clearer roller
19 Fixing component
19 . 1 Adjustment component
19 . 2 Pressure adjustment pin
19 . 3 Retaining ring
20 . Fibre that can not enter the compactor
21 . Front roller pressure spring
22 Tension component
23 Shift components
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to a mechanical compactor fibre yarn production mechanism used in producing compact yarn.
In the yarn production techniques, the rollers coated with elastic material are commonly used at the points where the fibre or the yarn are drafted or at the parts where they are guided to the next step. As examples for the yarn spinning systems, ring spinning, rotor spinning, air jet spinning systems etc. can be given. In all these spinning techniques, the roller coated with elastic material systems with drafting or guiding purposes are used.
In mechanical compact ring spinning yarn production, the required explanations are made regarding the operation of the mechanism and the deficiencies of the known status of the art. In such yarn spinning systems, for modelling the elimination of the deficiencies of the known status of the art, a study is made on the Top roller ( 9 ) coated with elastic material in the mechanical compact ring spinning system and the details of this study are given below.
If the subjects which are the basis of the invention are considered under main headings;
Improvement Obtained by Application of Apron ( 17 ) Over the Top Roller ( 9 ):
The deformations in the yarn quality parameters and the operating conditions by rapid abrasion of the Top roller ( 9 ) in the prior art have been disclosed in the above technical part. In the improvement made, an apron ( 17 ) is placed on the Top roller ( 9 ), which is in narrower dimensions than the Top roller ( 9 ), but which is made of a material having higher abrasion resistance and which has larger perimeter than the Top roller ( 9 ). This apron ( 17 ) is stretched via a bearing unit ( 15 ) mounted on the pressure arm ( 3 ) and a bearing body ( 15 . 1 ) which is connected to this unit ( 15 ), and thus its movement together with the Top roller ( 9 ) over the Delivery drafting roller ( 1 ) is provided.
By choosing the Top roller ( 9 ) as soft as possible and by choosing the apron ( 17 ) as narrow as possible than the Top roller ( 9 ), a higher pressure is applied on the fibre with the present pressure force. In this case, better fibre control and thus improvement in the yarn quality parameters are obtained. The apron ( 17 ) materials being resistant against abrasion and its perimeter being larger than the Top roller ( 9 ), long-lasting usage with constant values are provided. The perimeter of the apron ( 17 ) being larger than the perimeter of the Top roller ( 9 ) is the factor which also increases its expected life.
In FIG. 3 a , the side schematic view of the mechanical compactor mechanism, which is the subject of the invention, and in FIG. 3 b the perspective view of the mechanical compactor mechanism, which is the subject of the invention are given. Mechanical compactor yarn production mechanism; comprises a Delivery drafting roller ( 1 ), which is made of metal based material and which makes rotational motion by being initiated by the gearbox and a Middle drafting roller ( 2 ), a roving guide ( 11 ) which operates as a guide for providing entrance of large numbers of fibre into the mechanism, a bottom apron ( 8 ) which is placed over a Middle drafting roller ( 2 ) and the Bottom apron guide bar ( 6 ), and a Top apron ( 7 ) which is placed over the Top apron roller ( 5 ) and the Apron cradle ( 4 ). Fibres entering from the roving guide ( 11 ) are compacted by passing through the top and the bottom apron ( 7 , 8 ). Fibres passing through the top and the bottom apron ( 7 , 8 ) are compacted by passing through the Delivery drafting roller ( 1 ) and the Top roller ( 9 ) and through the compaction channel ( 12 . 1 ) (See FIG. 2 A-B detail) at the inner part of the mechanical compactor ( 12 ), and finally they are made into yarns after the winding operation made at the outlet of the Front roller ( 10 ) and the Delivery drafting roller ( 1 ), and they are wound on the bobbins found on spindles.
Via a pressure arm ( 3 ) of the mechanical compactor mechanism, the Top roller ( 9 ) made of rubber material is pressed on the Delivery drafting roller ( 1 ) with a certain force. The fibres passing through the Delivery drafting roller ( 1 ) and the Top roller ( 9 ) are expanded and guided to the mechanical compactor ( 12 ).
As it is seen in FIG. 2 , a Delivery drafting roller ( 1 ) initiated by the gearbox belonging to the mechanical compact yarn production mechanism, supports the Top roller ( 9 ) and the Front roller ( 10 ) belonging to the compaction zone. The contact point of the compaction zone is from the point A to point B. The mechanical compactor ( 12 ), which is a precision instrument, presses on the Delivery drafting roller ( 1 ) without any gaps. The mechanical compactor ( 12 ) forms a completely closed compaction room together with the Delivery drafting roller ( 1 ), and the Delivery drafting roller ( 1 ) surface moves together with the fibres synchronously in order to guide these fibres to the compactor ( 12 ) precisely. As it is seen in the detail view of the A-B compaction part, a compaction channel ( 12 . 1 ) is found at the inner part of the mechanical compactor ( 12 ), which has a funnel shaped structure narrowing downwardly. The fibres entering through the Delivery drafting roller ( 1 ) and the Top roller ( 9 ) are compacted while they proceed downwards through the compaction channel ( 12 . 1 ) which is found at the inner part of the mechanical compactor ( 12 ) and when the compacted fibres come out of the channel ( 12 . 1 ), they are exposed to winding operation by passing through the Front roller ( 10 ) and the Delivery drafting roller ( 1 ) and they become high durability yarn.
However, since the fibres pass through almost at the same place between the Delivery drafting roller ( 1 ) and the Top roller ( 9 ), abrasions occur in a short while at the rubber Top roller ( 9 ) surface. The Top rollers ( 9 ) grinded after short periods of usage are removed and grinded or they are replaced with a new Top roller ( 9 ). In both situations, very high labour force losses and additional processing (grinding etc.) and material costs occur.
As it is also said above, in order to prevent the abrasion formed on the Top roller ( 9 ) made of rubber material, different from the mechanical compact yarn mechanisms of the prior art, apron ( 17 ) application is made on the Top roller ( 9 ). The Top roller apron ( 17 ) operates on the Top roller ( 9 ) on which the abrasions occur and guides the fibres to the mechanical compactor ( 12 ). Moreover, since the width of the apron ( 17 ) used is narrower than the Top roller ( 9 ) width the force impact formed on the fibre by the pressure arm ( 3 ) increases and thus better fibre control is provided. With the application of narrow Top roller apron ( 17 ) and soft Top roller ( 9 ) under it, the pressure on the fibre is increased, and thus more effective fibre control is provided. Extension of the abrasion period due to the apron ( 17 ) used in the application being made of a material which is highly durable against abrasion regarding the present Top roller ( 9 ) and having less abrasion because of its structure, and also the perimeter of the apron ( 17 ) being larger than the present Top roller ( 9 ) provided extending the abrasion period. This situation is one of the most significant factors in reducing the yarn breaks.
In FIGS. 2 and 3 a , the exit drafting zone in the ring spinning system is given as side view. The fibres guided from the rear part are drafted through the Top roller ( 9 ) coated with elastic material mounted on the pressure arm ( 3 ) and the Delivery drafting roller ( 1 ) found below it, and they are guided to the spinning system at the outlet of the rollers ( 1 , 9 ).
During guidance of the fibres, the Top roller ( 9 ) coated with elastic material is abraded with time. On the Top roller ( 9 ) coated with elastic material on which abrasion occurs, it is essential to clad an apron ( 17 ) under tension in a narrower dimension and larger diameter than the Top roller ( 9 ) coated with elastic material, which would be shifted to the left or to the right when required. In order to provide bearing of the apron ( 17 ), a bearing unit ( 15 ) is mounted on the pressure arm ( 3 ). The guide arms ( 15 . 2 ) fitted on the bearing unit ( 15 ) is used in order to provide the bearing of the apron ( 17 ) to be able to rotate with the initiation of the Delivery drafting roller ( 1 ) on the Top roller ( 9 ) coated with elastic material.
In FIGS. 5 a , 5 b and 5 c , a bearing body ( 15 . 1 ) belonging to the said alternative embodiment is shown. As it is seen in FIG. 5 , the bearing unit ( 15 ) mounted on the pressure arm ( 3 ); comprises a bearing body ( 15 . 1 ) having a convenient cavity with the form of the pressure arm ( 3 ) in a way that the pressure arm ( 3 ) would be mounted on it, preferably two guide arms ( 15 . 2 ) formed integrally at the side parts of the bearing body ( 15 . 1 ), and roller bearings ( 15 . 2 . 1 ) formed on the guide arms ( 15 . 2 ) in order to provide the apron ( 17 ) fully fit. The roller bearings ( 15 . 2 . 1 ) allow the apron ( 17 ) make rotating motion together with the Top roller ( 9 ) on the guide arms ( 15 . 2 ) without shifting to the left or to the right. As an alternative to the guide arms ( 15 . 2 ) having fixed structure, the pulleys and couplings having rotating structure which allow rotating motion of the apron ( 17 ) can also be used as the bearing component.
In FIG. 3 b , the perspective view of and alternative embodiment of the invention is given. According to the figure, the Top roller apron ( 17 ) makes rotational motion in a way that, on one hand while it is in contact with the Top roller ( 9 ) surface, on the other hand it is in contact with the roller bearing ( 15 . 2 . 1 ) surface formed on the guide arms ( 15 . 2 ) belonging to the bearing body ( 15 . 1 ) mounted on the pressure arm ( 3 ).
Again as it is clearly seen in FIG. 5 a , 5 b , 5 c , a housing is formed at the upper surface of the bearing body ( 15 . 1 ). The bearing body ( 15 . 1 ) is mounted on the pressure arm ( 3 ) via a fixing component ( 19 ) passing through the housing ( 15 . 3 ). By providing mounting of the bearing unit ( 15 ) and the bearing body ( 15 . 1 ) on the pressure arm ( 3 ) via the housing ( 15 . 3 ), the distance setting between the guide arm ( 15 . 2 ) and the Top roller ( 9 ) and therefore the tension of the apron ( 17 ) can be adjusted.
In order to provide bearing of the apron ( 17 ), a bearing unit ( 15 ) is mounted on the pressure arm ( 3 ). The guide arms ( 15 . 2 ) fitted on the bearing unit ( 15 ) is used in order to provide the apron ( 17 ) with the bearing that it would rotate on the Top roller ( 9 ) coated with elastic material with the initiation of the Delivery drafting roller ( 1 ). The tension component ( 22 ) between the pressure arm ( 3 ) and the bearing unit ( 15 ) provides the apron ( 17 ) to be wound over the Top roller ( 9 ) coated with elastic material with a certain tension. Tension component ( 22 ) can be formed in various different forms, such as leaf spring, spiral spring, bending chock etc.
Again as it is seen in FIG. 3 a , 3 b (alternative) and in FIG. 8 a , the tension adjustment of the bearing unit ( 15 ) and the bearing body ( 15 . 1 ) pushed upwards via a tension component ( 22 ) is provided with the help of a fixing component ( 19 ), which preferably a screw. Moreover, in order to make distance adjustment between the said bearing unit ( 15 ) and the bearing body ( 15 . 1 ) and the pressure arm ( 3 ), an adjustment component ( 19 . 1 ) is placed on the bearing body ( 15 . 1 ). In the said placement operation, the adjustment component ( 19 . 1 ) is fixed on the pressure arm ( 3 ) found below in a vertical form, from the hole/housing opened on the bearing body ( 15 . 1 ). The adjustment component ( 19 . 1 ) is preferably in a screw form and it keeps the bearing unit ( 15 ) and the bearing body ( 15 . 1 ) and the pressure arm ( 3 ) in a certain distance if adjustment is not made. At the same time, it also limits the tension component. This component ( 19 . 1 ), by being rotated to the left or right, provides an adjustment operation by increasing or decreasing the distance between the bearing unit ( 15 ) and the bearing body ( 15 . 1 ) and the pressure arm ( 3 ).
Via the said tension component ( 22 ), rotation of the Top roller apron ( 17 ) is provided with a tension, or in other words, its free rotation is prevented. When a little pressure is applied from above on the said bearing unit ( 15 ) and the bearing body ( 15 . 1 ), the bearing unit ( 15 ) and the roller bearings ( 15 . 2 . 1 ) which are mounted together with the guide arms ( 15 . 2 ) integrally shown in FIG. 3 a , 3 b (alternative) and FIG. 8 a , move downwards and the Top roller aprons ( 17 ) can have a more free form.
Moreover, an adjustment component ( 19 . 1 ) is used between the said pressure arm ( 3 ) and the bearing unit ( 15 ) in order to determine the tension limit point. The fixing component ( 19 ) is used for fitting the tension component ( 22 ) to the bearing unit ( 15 ). Again, in order to provide the said bearing unit ( 15 ) be fit to the pressure arm ( 3 ) in a way that it would be able to move, pin ( 19 . 2 ) is used. The pin ( 19 . 2 ) connects the pressure arm ( 3 ) and the bearing unit ( 15 ) via retaining rings in a way that it would not prevent upwards and downwards motion of the bearing unit ( 15 ). In this way, the bearing unit ( 15 ) mounted on the pressure arm ( 3 ) via the pin ( 19 . 2 ) stretches the apron ( 17 ) rotating between the Top roller ( 9 ) coated with elastic material and the guide arms ( 15 . 2 ) as much as the adjustment component ( 19 . 1 ) allows via the tension component ( 22 ) fitted into its inner part.
In order to adjust the pressure distribution of the said Top rollers ( 9 ) the pin ( 19 . 2 ) is placed on the pressure arm ( 3 ). While the structural function of the said pin ( 19 . 2 ) remains same, bearing of the pin ( 19 . 2 ) is provided by addition of retaining rings ( 19 . 3 ) to the bearing body ( 15 . 1 ). Mounting of the tension component ( 22 ) to the bearing body ( 15 . 1 ) is provided via the fixing component ( 19 ) and the holes which are projections of the housings ( 15 . 3 ) formed on the bearing body ( 15 . 1 ). While the said tension component ( 22 ) is mounted on the bearing unit ( 15 ) and the bearing body ( 15 . 1 ) to be adjusted by the fixing component ( 19 ), it is also in contact with the pressure arm ( 3 ) in order to bend and make pressure on the pressure arm ( 3 ). In this way, a bend between the pressure arm ( 3 ) and the bearing unit ( 15 ) and the bearing body ( 15 . 1 ) is provided. Therefore, with this bend provided by the pressure arm ( 3 ), a tension load is provided on the guide arms ( 15 . 2 ) connected to the bearing body ( 15 . 1 ) seen in the FIG. 3 a , 3 b (alternative) and the FIG. 8 a , and the aprons ( 17 ) in bearing position on the roller bearings ( 15 . 2 . 1 ).
In the said invention; the guide arms ( 15 . 2 ) can be fitted on the guide arm (bar) housing ( 15 . 4 ) on the bearing unit ( 15 ) via the grade cavities ( 15 . 2 . 3 , 15 . 2 . 4 ) in a way that it is shifted to the left or right. As an alternative to this embodiment, the guide arms ( 15 . 2 ) can be mounted to the pressure arm ( 3 ) as a screw. Guide arms ( 15 . 2 ) can be shifted to the left or right on the pressure arm ( 3 ) with a screw motion.
In both embodiments or in all shifting techniques which can be alternative, the purpose is to provide the guide arms ( 15 . 2 ) be shiftable to the right or left on the bearing unit ( 15 ). Thus, the apron ( 17 ) which is narrower than the width of the Top roller ( 9 ) coated with elastic material can be shifted on the Top roller ( 9 ) coated with elastic material. The purpose is to obtain a new operating surface on the apron ( 17 ), which is not abraded by the fibre or yarn coming from the systems at the backside. Thanks to this operation, the expected life of the apron ( 17 ) increases twice or more.
In FIG. 7 , the side mounted view of the mechanical compactor mechanism, which is the subject of the invention is given. According to the figure, the bearing unit ( 15 ) and the bearing body ( 15 . 1 ) are seen which are placed on the said pressure arm ( 3 ) in contact with each other via the tension component ( 22 ) and the adjustment component ( 19 . 1 ). At the front part of the bearing unit ( 15 ), a guide arm ( 15 . 2 ) is placed. The said guide arm ( 15 . 2 ) is in a modular structure and it provides bearing of the apron ( 17 ). The apron ( 17 ) seen in the figure can have a longer perimeter through the guide arms ( 15 . 2 ) which would be added on the bearing unit ( 15 ). This can be made until the most available apron ( 17 ) perimeter is obtained at all places that the application will be made. The purpose is to obtain the largest apron ( 17 ) perimeter which can be applied according to the perimeter of the perimeter of the Top roller ( 9 ) coated with elastic material, and thus extend the abrasion period said in the known status of the art.
In FIG. 9 a , the perspective view showing the contact between the Top roller ( 9 ) and the Delivery drafting roller ( 1 ) in the prior art is given. In FIG. 10 a , the perspective view showing the contact between the Top roller apron ( 17 ) and the Delivery drafting roller ( 1 ), which is the subject of the invention, is given. The width of the Top roller apron ( 17 ) used is preferably the half of the width of the Top roller ( 9 ) width.
In FIG. 9 b , the fibre pinch distance (A 1 ) and the contact width (B 1 ) between the Top roller ( 9 ) and the Delivery drafting roller ( 1 ) in the prior art is given.
In FIG. 10 b , the fibre pinch distance (A 2 ) and the contact width (B 2 ) between the Top roller apron ( 17 ) and the Delivery drafting roller ( 1 ), which is the subject of the invention, is given. A 1 and A 2 pinch distances are given in the side views in the FIGS. 4 a and 4 b.
As it is again seen in FIG. 7 , while the said apron ( 17 ) can be wound only between the Top roller ( 9 ) and the guide arms ( 15 . 2 ), it can also make ring over the additional roller bearings ( 15 . 5 ) which are formed on the bearing unit ( 15 ) and/or the bearing body ( 15 . 1 ).
In FIG. 8 a , the mounted perspective view of the bearing unit ( 15 ) in the mechanical compact mechanism, which is the subject of the invention, is given. As it is seen in the figure, the said guide arm ( 15 . 2 ) is placed at the lower part of the bearing body ( 15 . 1 ). At the lower part of the bearing unit ( 15 ), which has a demounted perspective view in FIG. 8 b , a bar housing ( 15 . 4 ) is formed for placement of the said guide arm ( 15 . 2 ). Again as it is seen in FIG. 8 b , grade cavities ( 15 . 2 . 3 , 15 . 2 . 4 ) are formed at the lower part of the bar ( 23 ). Via these grade cavities ( 15 . 2 . 3 , 15 . 2 . 4 ) the guide arm ( 15 . 2 ) can be fixed on the bar housing ( 15 . 4 ) by fitting on it. In the fitting operation the 1st grade cavities ( 15 . 2 . 3 ) or the 2nd grade cavities ( 15 . 2 . 4 ) are arbitrarily fitted on the housing base ( 15 . 6 ) in the bar housing ( 15 . 4 ).
For example, the guide arm ( 15 . 2 ), which is fitted on the 1st grade cavity ( 15 . 2 . 3 ) in the first usage, would form an abrasion zone by the yarn on the apron ( 17 ) which makes rings in a bearing form. After a certain time, when the abrasion increases, the said guide arm ( 15 . 2 ) is lifted upwards by being hold through the apron limiters ( 15 . 2 . 2 ) and thus it is removed from the bearing body ( 15 . 1 ). Afterwards, the guide arm ( 15 . 2 ) is shifted in the “−x axis” and the said guide arm ( 15 . 2 ) is again fixed on the bearing body ( 15 . 1 ) in a way that it would fit on the 2nd grade cavity ( 15 . 2 . 4 ) housing base ( 15 . 6 ) belonging to the guide arm ( 15 . 2 ). After this operation, the yarn will pass through another zone on the apron ( 17 ) which is not abraded. This operation is the method of usage of the un-abraded other surface of the apron ( 17 ), on which the used zone is abraded after usage. In this way, profitable usage of the apron ( 17 ) surface is provided. The adjustment operations said here are made without stopping the machine. This is a very important property. Because, stopping the machine for each adjustment operation causes serious losses in production. All the adjustments in the prior are made by stopping the machine. The known status of the art is exceeded by using the apron ( 17 ) in a profitable manner without stopping the production, and far exceeding the grinding or renewal life of the Top roller ( 9 ) used in the prior art.
As it is seen in the figures, via the Top roller apron ( 17 ), which is the subject of the invention, the contact width (B 2 ) decreases and the fibre pinch distance (A 2 ) increases regarding the prior art. Thanks to the increasing fibre pinch distance (A 2 ), the fibres are caught better and their compaction is provided under higher pressure. In this way, control of fibre is provided in a much easier manner and the quality of the yarn increases.
For the mathematical explanation of the FIGS. 9 b and 10 b , the below given conditions have to be met:
a) F 1 =F 2 ,
b) The materials of the Top roller ( 9 ) in FIG. 9 a and the Top roller ( 9 ) in FIG. 10 a would have elastic properties and their hardness would be equal,
c) The Top roller apron ( 17 ) width (B 2 ) would be smaller than the prior Top roller ( 9 ) width (B 1 ), In this case;
A2>A1
would be obtained. Since the F 1 and F 2 forces found in the figures have impact on a circular surface;
B 1/ B 2> A 2/ A 1
is obtained. In this case, the inequality could be expressed as;
A 1× B 1> A 2× B 2
According to these data the P 1 pressure impacting on the fibres in the prior art in FIG. 9 a is;
P 1=( F 1/2)/( A 1× B 1)
Whereas, the P 2 pressure impacting on the fibres in the mechanism, which is the subject of the invention is;
P 2=( F 2/2)/( A 2× B 2)
According to the above given information, since F 1 =F 2 and A 1 ×B 1 >A 2 ×B 2 ;
P2 22 P1
is obtained. In other words, under a constant F force, the pressure force applied on the fibre on a unit area is increased via the Top roller apron ( 17 ) used in the mechanism, which is the subject of the invention. In this way, the fibre is caught better, its control is provided in a better manner, and the quality of the yarn increases.
Effective Cleaning Obtained with the New Position of the Clearer Roller ( 18 ):
Since the clearer roller ( 18 ), with its new position, effectively catches the fibres ( 20 ) that cannot enter the mechanical compactor ( 12 ), and accumulates these on itself, their entrance into the yarn structure is prevented and the working environment is kept cleaner.
As it is seen in FIGS. 6 a and 6 b , in the prior art, the clearer roller ( 18 ) in cylindrical structure is far away from the zone where the fibres ( 20 ) that cannot enter the mechanical compactor ( 12 ) generate fluffs, its cleaning effect is quite small. As it is seen in FIGS. 5 and 6 c , the clearer roller ( 18 ) is placed at a zone much nearer to these fibres generating fluffs via the clearer roller bearing component ( 16 ), which is the subject of the invention. In this way, the fluffs formed between the Top roller apron ( 17 ) and the mechanical compactor ( 12 ) is effectively taken onto the clearer roller ( 18 ). The clearer roller ( 18 ) is in contact with the Top roller apron ( 17 ) and makes rotating motion via the motion it takes from the apron ( 17 ), and thus gathers the fibre fluffs on itself and increases the yarn quality by preventing these fly be added into the yarn structure.
The length of the apron ( 17 ) used in FIG. 8 a is longer than the one in FIG. 3 b . In this way, the expected life of the apron ( 17 ) is longer. The said guide arm ( 15 . 2 ) seen in this structure can be gradually shifted to the right and to the left on the “x” plane. In this way, two different yarn paths can be obtained on the apron ( 17 ), which provides the increase of the expected of the apron ( 17 ) twice.
Whereas in FIG. 7 , the length of the apron ( 17 ) is increased much more, which is used by forming additional roller bearings ( 15 . 5 ) on the said bearing body ( 15 . 1 ) (the apron ( 17 ) shown in dotted form in FIG. 7 ). In this way, the expected life of the apron ( 17 ) increased much more because of its increased length and also the guide arm ( 15 . 2 ) being gradually shiftable on the “x” plane.
FIG. 8 c is the view of another alternative embodiment of the bearing unit in the mechanical compact mechanism. For profitable use of the said apron ( 17 ), other alternative embodiments can also be formed in which the apron ( 17 ) is moved. In another alternative embodiment, the said guide arm ( 15 . 2 ) is again placed on the bearing body ( 15 . 1 ), whereas it makes its movement to the left or right not in a gradual manner, and in infinite screw etc. embodiments by being a shifting component ( 23 ). In FIGS. 8 d and 8 e , an alternative embodiment is seen. In the figures, an alternative embodiment is seen, in which the guide arms ( 15 . 2 ) are separate from the bearing body ( 15 . 1 ). In this structure, at the parts where the guide arms ( 15 . 2 ) would be connected to the bearing body ( 15 . 1 ), screw paths/gears are formed. In this way, the shifting of the guide arms ( 15 . 2 ) on the bearing unit ( 15 ) by being moved back and forth via the geared form and their re-positioning and profitable usage of the apron ( 17 ) by making the guide arm ( 15 . 2 ) and apron ( 17 ) left-right movement is provided. In this context, all the structures comprising the shifting of the apron ( 17 ) with the guide arm ( 15 . 2 ) on which it is carried are within the context of this invention, and thus, they would not comprise novelty.
As a result of all of these improvements, the expected grinding or renewal life of the Top rollers ( 9 ) in the prior art are far exceeded and thus the known status of the art is exceeded. In this way the inventive step criterion is exceeded.
The above provided improvement is not only used in ring spinning systems, but also it can be used in all other yarn production techniques. Therefore, the invention cannot be limited to the representative applications given in this section. In the light of the basic elements and methods stated in the claims, any alternative embodiment which can be developed by the people skilled in the related art would mean violation of the invention.
|
The purpose of the invention is to reduce the abrasive impact of the fiber or the yarn on the rollers coated with elastic material, which are used for drafting and guiding purposes in yarn production techniques, and thus keep the operating conditions and yarn quality parameters constant. The fiber on the top rollers coated with elastic material especially in the mechanical ring compact yarn production among the yarn production techniques, is an apron cladding method, over the top roller and the bearing guide arms connected to a bearing body found on the bearing unit placed on the pressure arm, in a way that it would cover these together. The method includes the operation steps of stretching the aprons by application of tension via a tension component and, while the fiber drafting operation continues, the bearing unit carrying the aprons being shifted in the horizontal plane in certain intervals.
| 3
|
RELATED APPLICATION
This application claims the benefit of U.S. Patent Provisional Application No. 61/119,156 filed on Dec. 2, 2008. The provisional application is incorporated by reference.
BACKGROUND OF THE INVENTION
Music and other recorded sound often plays in public and private spaces where there is little or no identifying information about that music. For example, a song could be playing in a bar or restaurant, on a car radio or at a gathering, where there is often no easy way to determine the artist and/or title information about the song to facilitate finding it again. In such situations, it is desirable to have a way to identify the song or sound using only the sound of the audio being played.
SUMMARY OF THE INVENTION
We disclose useful components of a method and system that allow identification of music from the song or sound using only the sound of the audio being played. A system built using the method and device components disclosed processes inputs sent from a mobile phone over a telephone or data connection, though inputs might be sent through any variety of computers, communications equipment, or consumer audio devices over any of their associated audio or data networks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts the various sources of noise.
FIG. 2 depicts these filterbank center frequencies.
FIG. 3 depicts module inputs and outputs.
FIG. 4 depicts the method of producing a characteristic matrix by processing of the same data from the filterbanks.
FIG. 5 illustrates a filterbank masking curve for sounds that are expected to be preserved by perceptual encoding codecs.
FIG. 6 illustrates how a system allows the loudness in a particular filterbank of a given frame to affect the time mask for a zone of several frames after.
FIG. 7 depicts the method for computing a score.
DETAILED DESCRIPTION
The assignee of this application builds and distributes the popular Midomi app and software. Users of Midomi can hold their cell phone up to a car speaker, for instance, capture a brief sample of the play back, and have the song that they are listening to identified with useful links for previewing or buying the artist's music. Doing this presents a wide variety of technical challenges. This disclosure describes several of the challenges and technology that is useful for building components of Midomi-like systems and other sound recognition applications.
The following detailed description is made with reference to the figures. Preferred embodiments are described to illustrate the present invention, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a variety of equivalent variations on the description that follows. We have used the term “characteristic matrix” in place of “fingerprint” to avoid confusion related to inconsistent use of the term fingerprint in the field of art. Fingerprint is used to refer to many things, but not to the sort of frame-by-frame, filter bank-by-filter bank characteristic matrix that we disclose.
Module to Obtain a Filterbank Representation
One component disclosed is useful to obtain a representation that allows reliable identification of matches between queries and references. By choosing the correct representation, we can ensure that the system will be robust to the types of additive noise and nonlinear distortions that affect the query audio data. We may consider the references to be fairly high quality audio, but the queries will be subject to at least five sources of distortion. Specifically, it is important to capture features that will survive such distortions as background noise, distortions due to the hardware of the collection device, distortions due to noise cancellation algorithms, distortions due to codecs and quantization and transmission errors.
It is preferred that these five types of distortion do not too strongly affect characteristic matrices of the query or references. If the characteristic matrices are distorted, it will be difficult to make meaningful comparisons between a query and a matching reference. The goal, then, is to build a characteristic matrix 117 based on information that is resilient to distortion, including some or all of these five types of distortion. FIG. 1 depicts the various sources of noise. The five types of distortion are identified and described below:
Background Noise
Background noise is noise that occurs in the same physical environment as the desired audio itself. This includes people talking 101 , clinking glasses, transportation sounds like traffic, rumbling and honking 121 , and sounds from nature such as those made by wind or animals. Generally, background noise is temporally limited and can be treated that way, when a system successfully separates background noise from the sound that is playing.
When there is background noise, the loudest parts of a signal, which preferably is the desired music, will still be passed. There is little that can be done if the background noise is drowning out the desired music signal at all times and frequencies, but it is desirable for a characteristic matrix to capture the desired music at times and frequencies that are less noisy. It is more desirable to process the signal at times and frequencies where it is present than to ignores larger time segments or frequency ranges.
Distortions Due to the Hardware of the Collection Device
The microphone 113 used on the phone or other device often has a bias in frequency, such as to accurately record only frequencies in which voice data tends to occur. The technology that we disclose accommodates such distortions.
Though the microphone may have a nonuniform frequency response, it can generally be counted on to pass information over the frequency range that encodes most speech sounds, specifically from about 100 Hz to about 4 kHz. Therefore, a characteristic matrix should rely primarily on frequency content inside this range. Also, the microphone may have a frequency response that reflects a bias towards lower or higher frequencies. Therefore, a characteristic matrix should not rely exclusively on the relative strengths of frequencies. A better solution is to determine which frequencies are loudest.
Distortions Due to Noise Cancellation Algorithms
Phones and other audio devices 111 often have noise cancellation algorithms 113 that seek to eliminate background sounds other than a particular desired input sound such as voice. These algorithms may seek to suppress or eliminate background music, which may be the very query audio our system wants to hear and identify. These algorithms can be linear or nonlinear, meaning that a linear or convolutive model for their behavior will not always suffice.
Noise cancellation algorithms may seek to remove any non-speech sounds. Specifically, if sound seems to come from multiple pitches (which few speaking humans can produce), the noise-cancellation algorithm might eliminate sounds that appear to be derived from the weaker pitch. Therefore, the characteristic matrix algorithm should not rely too heavily on identifying weaker harmonics that could be noise cancelled out.
Distortions Due to Codecs and Quantization
Audio is often transmitted in compressed form to reduce the cost or increase the speed of transmission, or purely by convention. The codec that compresses the audio may use psychoacoustic encoding, as in MP3 and similar algorithms, in which some audio quality is lost, but not in a way that specifically hurts music or speech. The codec might also be a speech codec designed to pass only sounds that can be well parameterized as speech. Speech codes may introduce significant nonlinear distortions to music audio, removing components that cannot be identified as speech-like, while including and even amplifying other spurious components that the codec considers to be speech-like. Depending on the type of quantization used in the codec, there may be distortions in the magnitude of frequency components, an addition of white noise, or both.
If a speech codec is used in the system, it will try to pass only information that is necessary to understand speech. Specifically, the phonetic and prosodic information that characterizes what human listeners recognize as speech tends to be encoded via rapidly updated spectral contour and pitch information. This can only be reliably passed as harmonic signals with approximately correct spectral shape. Therefore, the loudest harmonic peaks and their relative strengths should survive the codec distortion, and a characteristic matrix that captures this information will be more robust. Also, fricatives such as “f” and “sh” will typically be encoded as a stochastic component with much energy at the upper end of the above-noted frequency range.
Transmission Errors.
Telephony and data networks 115 do not have perfectly consistent connectivity or data rates, and as a result the transmitted signal may include gaps or lower quality segments.
Transmission errors may provide particularly challenging. At the very least a characteristic matrix should not break down over a larger time period than any unintended silences in the query audio. Also, the characteristic matrix should degrade gracefully, so that if a lower bitrate is temporarily used, at least the information passed will still be something the characteristic matrix can use.
A characteristic matrix should reliably detect short term frequency peaks (in a representation such as the hopped, windowed FFT.) It should be able to tell which of those peaks are loud enough to be considered important and audible (though not fall victim to peaks' relative loudness changing somewhat.) It should detect these peaks in the typically used speech frequency band, it may benefit from using energy information at the upper end of this band. And, it should not be affected over an excessive time or frequency range by background noise or transmission errors. The filterbank and characteristic matrix representations described below address these requirements.
Alignment of Query and Reference Sounds
Before moving on, we describe a particular challenge which may be viewed as less than one of the distortions of the query audio, and rather one of how the query interacts with the fingerprinting. In the characteristic matrix system described herein, we will break up audio into chunks that last about a tenth of a second at a time, and update those chunks every one twentieth of a second. This leads to the question: what if the query is processed so that the first chunk of audio we take is exactly 50% off of the chunks in the matching query? For example, consider if the lead vocal in a reference begins right at the start of a chunk at 10.1 sec. If the query starts its first chunk just before that, so that the vocal comes in half way through the chunk, then this chunk and all subsequent ones will not line up. In this case, none of the chunks will appear to match, because none of them will line up. We have developed at least three ways to deal with this issue.
First, various offsets are used by choosing offsets for the first frame when creating a characteristic matrix for the query. For example, make a first characteristic matrix so that the first frame starts at the first sample in the recording. But also make a second version of the characteristic matrix whose first frame begins one half of the characteristic matrix hopsize into the recording. Note also that we could use various divisions of the hopsize, and that we need not initially search all offset versions of the query characteristic matrix initially; we could save these versions for refining scores or a final matching stage.
Second, sufficiently long chunks (frames) are chosen. This mitigates the extent to which a very short time event can dominate a single frame, because the rest of the frame will contain other events. By ensuring sufficiently long frames, we are likely to have fewer frames that are substantially different when they do not line up exactly.
Third, “wide” frequency peaks are allowed. When identifying peaks in the FFT, it is preferred to allow some leeway when describing peak frequency. This may not be intuitive, because peaks in the FFT generally indicate the detection of a stable frequency. In practice, however, the strongest harmonics often come from voice signals, which often smoothly change frequency versus time during pitch transitions and vibrato, which leads to wider peaks and different peak frequencies at different times. Therefore, if we ascribe some minimum width to detected frequency peaks, we can actually allow slightly misaligned frames to show similar or identical peak frequencies.
We combine these approaches to varying degrees in the characteristic matrices described below. The last of these three, allowing some flexibility in peak detection, is something facilitated by our choice of filterbank spacing. We next consider that aspect of the characteristic matrix.
Filterbank Module
In many applications, filterbanks are used to capture general spectral shape, as that encodes such information as instrumental timbre or speech phoneme. For our disclosure, we capture individual spectral peaks, without excessive frequency precision.
FIG. 2 depicts these filterbank center frequencies 201 . The plot shows, on the horizontal axis, the center frequencies 221 used. On the vertical axis, the corresponding midi value 211 for a pitch at the center frequency specified is depicted.
There are certain practical issues about spectral peaks. For instance, at higher frequencies, due to pitch variation, peaks often appear wider in the FFT. Therefore, it can be difficult or impossible to capture peak information at higher frequencies. At the same time, higher frequencies contain other general energy information that tends to pass a speech codec that could be useful in identifying musical sounds such as percussion. Therefore, we have chosen more widely spaced filterbank center frequencies at higher frequencies. At the lower frequencies, uniform spacing of filters may be used, because FFT peak widths are influenced more by the window transform (the spectral shape that an ideal sinusoidal peak forms based on the FFT windowing function) rather than pitch variation. Pitch variation will have less bearing on peak detection. For these reasons, one filterbank that we apply (with standard triangular filters) has the following center frequencies (in Hz):
396.5 418.0 439.5 460.9 482.4 503.9 525.4 546.9 568.4 589.8 611.3 632.8 654.3 675.8 697.3 718.8 740.2 761.7 783.2 804.7 826.2 847.7 869.1 890.6 912.1 933.6 955.1 976.6 998.0 1019.5 1041.0 1062.5 1084.4 1105.5 1127.0 1148.4 1169.9 1191.4 1212.9 1234.4 1255.9 1277.3 1298.8 1320.3 1341.8 1363.3 1384.8 1406.3 1428.1 1458.6 1498.5 1548.3 1609.1 1681.9 1768.3 1869.8 1988.6 2127.2 2288.7 2476.6 2695.6 2950.9 3249.1 3598.1
The filterbank module takes as input an audio signal x representing either a query or a reference. We will generally assume that this signal is a waveform with values between −1 and 1, or can readily be converted to such a signal.
It creates as an output a special perceptual filterbank representation of the input audio.
Module Operation:
FIG. 3 depicts module inputs and outputs. The module begins by forming a hopped, windowed FFT 301 representation of the input audio signal. We call this representation X(k,l) where k is the frequency bin and l is the frame number versus time. The window length used is 100 ms, though lengths as short as 50 ms or as long as 200 ms could be advised. The hopsize used is generally 50% of the window length, though 25% or 100% could be used.
Once the spectrogram representation has been created, the magnitudes |X(k,l)| will have a maximum value of 1.0. This maximum reflects that x ranged in value from −1 to 1 and that by convention normalized FFT windows are used. We next convert the magnitude spectrogram values to dB 311 as follows:
X dB =20·log 10 (| X ( k,l )|+ε)
where ε is a very small numeric value included to prevent taking the log of zero. Given that the maximum value of the FFT was 1, the maximum value of the dB representation is 0, and the minimum is a negative number limited by ε.
Next, to facilitate conversion to a perceptual scale, we add 110 to existing X dB values:
X dB =X dB +110
which generally brings them into a positive range. This is done to simulate dB SPL (sound pressure level), a representation of how loud sound is in the real, physical world. The quantity dB SPL measures the magnitude of sound pressure waves at a sensor, and at a frequency of 1000 Hz, sound at 100 dB SPL or more is considered very loud to a human listener. Adding 110 dB to the previous representation causes the loudest possible value to be 110 dB (simulated SPL), though this value is rarely reached in practice. The maximum value is only reached when the input x is at a maximum or minimum value for a certain period of time. Furthermore, mechanisms are typically used when making audio signals to prevent hitting the maximum input values, because doing so increases the risk of overloading the available input range, a phenomena known as clipping. On the other hand, audio signals can sometimes be very quiet, meaning that all information has a dB SPL value far below the maximum of 110 dB. This is also limited by the SNR of an analog system and the SNR and quantization of a digital system. If the audio signal has 16 bit quantization (which is a typical value), then there is no useful information more than 96 dB down from the maximum. (This is obtained by taking 20*log 10(2^16)=96.33 dB.)
In practice, a human listening to a reproduced signal will adjust the volume into a range which is easy to hear, but not so loud as to be uncomfortable. Therefore, even though we have converted the FFT to have a maximum magnitude value of 110 dB simulated SPL, we do not necessarily consider FFTs with an average peak value of 30 dB simulated SPL to be different from those with an average peak value of 70 dB simulated SPL, because a human listener might adjust the volume to be more like 50 dB SPL for either case.
This has practical implications when developing a perceptual model of the input audio. We use a curve to change the magnitudes of the input FFT to reflect phons 321 , which are values that model how loud human listeners perceive sounds at various frequencies. By definition, phons values and dB SPL values are identical at 1000 Hz, but generally vary at other frequencies. For example, at the frequency 1000 Hz, a 50 dB SPL sound is said to have a level of 50 phons. But at 440 Hz, a 50 dB SPL sound is said to have a level of about 46.2 phons. Though phons curves have different shapes at different dB SPL values, we choose to always use the weighting for a dB SPL input value of 50 dB as a “happy medium” because we assume that a human listener would adjust the volume of the recording up or down to be at a comfortable level of about 50 dB. In general, then, to convert a dB SPL value to phons, we require two things in addition to the dB SPL value: the frequency at which this value occurred, and a chart derived from human listening tests that maps such values to phons. In our implementation, we assume that all inputs are at a level of 50 dB SPL. To convert to phons in our implementation then, the following steps are followed. First, the phons bonus curve is created. To do so, consider the phons values versus frequency when the input is 50 dB SPL. Some of the output values will be greater than 50 phons, and some less. We subtract 50 from these phons values to get a “phons bonus” p(k), which is positive when the phons value is larger and negative when the phons value is smaller. These values vary versus frequency bin k. For example, we may have a phons bonus of −2.01 phons at 554.7 Hz and a phons bonus of 2.99 phons at 2500 Hz. Thus, we have an individual phons bonus value for every frequency bin in the FFT. Second, the phons bonus values are added to all of the dB SPL values recorded, using the phons bonus corresponding to the appropriate FFT bin frequency. For any and all frames l, we may write:
X ( k,l ) phons =X ( k,l ) dB,SPL +p ( k )
This is a “best mode” implementation in the sense that no judgment need be made about the input level (loud versus quiet recordings), that any frame of the input FFT sequence may be processed without seeing past or future frames, and that table lookup of individual phons bonus values versus dB SPL input need never be performed. However, it is also possible to consider the actual individual dB SPL values of the input when choosing the phons bonus. This may be done if computation cost is not an issue, if we have an input whose level is known to be in some way a true indicator of perceived volume, and/or if we have no latency requirement and can determine a good normalization value to apply to some or all of the simulated dB SPL values before adding the phons bonus.
Finally, adding the phons bonus is optional, as we may simply use simulated dB SPL values.
Before moving on to the final step of applying the filterbank, we convert from phons or simulated dB SPL values back to squared magnitude values:
X ( k,l ) sq.mag. =10^( X ( k,l ) phons /10)
or
X ( k,l ) sq.mag. =10^( X ( k,l ) dB,SPL /10).
This is done by convention; the application of the filterbank may be viewed as taking a weighted sum of values in the FFT. When adding magnitudes from different frequencies, to achieve a perceptually meaningful quantity, it is generally advised to do so in the squared magnitude domain rather than a logarithmic domain such as decibels or phons.
The last step is to apply the filterbank channels 331 . This may be performed as a matrix multiplication if we have all the frames, or on an individual frame level. To state this as a matrix multiplication, we may describe the filterbank as a matrix F(c,k), which has a total of C channels, each of which has values for each frequency bin k out of a total of K. To obtain the filterbank representation, then, we perform:
X ( c,l ) filterbank =F ( c,k ) X ( k,l ) sq.mag. .
which is the multiplication of a C×K matrix by a K×L matrix to generate a C×L matrix. To apply the filterbank one frame at a time we may consider L to be 1, in which case we multiply a C×K matrix by a K×l vector to generate a C×l vector.
Module to Create Characteristic Matrices from Filterbank Data
Module Inputs and Outputs:
This module uses as input the special perceptual filterbank representation of the input audio described above.
It produces a binary array of the same dimensionality as the filterbank representation. Roughly speaking, a one in this representation represents a value that is louder than its neighbors in time and/or frequency.
Module Operation:
FIG. 4 depicts the method of producing a binary array of the same dimensionality as the filterbank representation. This module proceeds with seven operations, pre-processing 403 , processing a single frame at a time to see relative frequency loudness 413 , processing a single filter's data at a time to see relative time loudness 423 , post-processing of the single frame at a time data 433 , post-processing of the single filter at a time data 443 , combining information from the above two types of processing 453 , and post-processing the combined characteristic matrix 463 .
(1) Pre-Processing
The module begins by converting the squared magnitude of the filterbank representation to dB. This may be written as:
X ( c,l ) dB-filterbank =10·log 10 ( X ( c,l ) filterbank )
Next, we smooth the filterbank representation versus time to help remove bias from the FFT, for instance when frequency components collide due to chosen window types and lengths. (This bias produces misleading and inconsistent values for the frequencies and magnitudes of peaks in the FFT. As noted above, the peaks are useful in our representation, so we wish to reduce the bias. Above, we created a filterbank representation, which itself performed smoothing versus frequency, helping to compensate for bias in the FFT. Similarly, we reduce bias by smoothing versus time.) In our system using 100 ms frames with 50 ms hopsize, the smoother used is [0.15 1.0 0.15] (which is divided by 1.3 to normalize the smoothing). This smoother is applied to the data at each frequency value in the filterbank, and represents smoothing over three time frames whose central values are a total of 100 ms apart. Useful smoothing could smooth over a time range of 50 to 200 ms; any variety of standard windows such as Blackman, Kaiser, or Hamming could be used.
(2) Processing One Frame at a Time
This part of the processing considers one frame of the filterbank data at a time. If there are 64 filters in the filterbank, and 1000 frames of the filterbank data, then this part of the system considers 64 values at a time, and does so 1000 times.
For each frame, the system creates a version of a masking curve, such as has been described in advanced codecs. However, in this case the goal is not to identify sounds which might not be perceived by a human so much as sounds that are most likely to survive processing by psychoacoustic and noise cancelling codecs. For sound matching, the otherwise useful functions of the codec introduce distortion and noise to channels that a query is likely to pass on its way to a matching engine. The issues of human perception and codec behavior are, of course, related. It would be difficult to catalog codecs and discern what information they eliminate when they process sound, because different codecs may place different emphasis on sound quality or bit rate, or may be tailored to specific input such as voice. Therefore, we address the sound information preserved by the codecs rather than the information eliminated. We expect that the loudest, most human-perceptible sounds will be preserved by a generic codec.
FIG. 5 illustrates a filterbank masking curve 523 for sounds 503 that are expected to be preserved by codecs. We consider the data in filterbank channels 553 , rather than FFT bins. For each channel, we effectively draw diagonal lines down and away from the data value, starting at some fixed point below that value, a so-called masking margin 513 . For example, say there is a value of 51.0 dB in filterbank channel 10 . In one implementation, the fixed value down from the data is 15 dB and we use a diagonal slope down of 1.0 dB per filterbank channel. In that case, the 64 values for the masking curve based on the value of 51.0 dB in filterbank channel 10 would be:
28 29 30 31 32 33 34 35 36 35 34 33 32 31 30 29 28 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 8 7 6 5 4 3 2 1 0 −1 −2 −3 −4 −5 −6 −7 −8 −9 −10 −11 −12 −13 −14 −15 −16 −17 −18
In this case, some of the numbers are negative, though we will see that this is of no consequence. We create similar curves based on every one of the 64 data points. Once all 64 curves are obtained, we take a max function M F (c,l) of the 64 curve values at all 64 filter frequencies. For example, at the 10th frequency value, the above data shows the curve to be at 36 dB. However, there are 63 other curve values at bin 10 . If there was a very loud filterbank value at filter 20 , of say 70 dB, then at bin 10 its curve would show a value of 45.0 (which we obtain as 70−15−1.0*10=45.0). Therefore, when we take a max function, the value at bin 10 would be at least 45.0, depending on the other 62 curve values. We call the values of this max function the combined mask 525 . We depict a combined mask with three controlling peaks, on of which is at channel 10 . For clarity, we have offset this combined mask just above the individual filterbank mask for channel 10 .
Once the combined mask has been calculated, we may calculate how far above this mask the actual filterbank data is, if it is above the combined mask value at all. We may write this distance above the combined frequency mask:
A F ( c,l )= X ( c,l ) dB-filterbank −M F ( c,l )
It should be clear that the maximum channel dB value above the combined mask is 15.0 dB 527 , because each point in the combined masking curve is only 15.0 dB below channel dB value. Generally speaking, music and voice tend to have peaks in their FFT (and in this filterbank) representations, meaning that some spectral values will be much higher than others. Therefore, A F (c, l) will often be negative. In FIG. 5 , sounds with magnitudes above and below the combined mask are indicated by a triangle 515 and circle 535 , respectively.
(3) Processing One Channel at a Time
The system performs a similar processing versus time, in which a combined time mask is created. In this case, the system considers each filterbank channel separately, and considers a zone of several frames at a time within that channel for each time frame. Above, when creating frequency masks, we considered any one of the 64 filterbank channels to affect all of the 64 channels. In the current case of data versus time, however, the analogue is not practical or desired, because it would require that data at a given time instant create a mask that affects all other time instances: past, present, and future. Therefore, we define a zone of time before and after any given point within which the current point may affect the time mask.
Otherwise, the idea behind the time mask is the same as behind the frequency mask: we wish to reflect that some data is much louder than other data, and therefore more likely to be passed by the various noise and processing described above.
FIG. 6 illustrates how a system allows the loudness in a particular filterbank 611 of a given frame to affect the time mask 625 for a zone of several frames. In one implementation, a masking sound 607 affects only about 10 frames following the current frame. In this case, the mask value is 25 dB below that of the current frame.
To illustrate, consider the 1st through 15th frames in a filterbank channel to have the following dB values and time mask contributions:
60
55
54
55
55
55
56
56
58
59
59
60
62
62
63
35
35
35
35
35
35
35
35
35
35
35
0
0
0
0
0
30
30
30
30
30
30
30
30
30
30
30
0
0
0
0
0
29
29
29
29
29
29
29
29
29
29
29
0
0
0
0
0
30
30
30
30
30
30
30
30
30
30
30
0
0
0
0
0
30
30
30
30
30
30
30
30
30
30
30
0
0
0
0
0
30
30
30
30
30
30
30
30
30
30
0
0
0
0
0
0
31
31
31
31
31
31
31
31
31
0
0
0
0
0
0
0
31
31
31
31
31
31
31
31
0
0
0
0
0
0
0
0
33
33
33
33
33
33
33
0
0
0
0
0
0
0
0
0
34
34
34
34
34
34
0
0
0
0
0
0
0
0
0
0
34
34
34
34
34
0
0
0
0
0
0
0
0
0
0
0
35
35
35
35
0
0
0
0
0
0
0
0
0
0
0
0
37
37
37
0
0
0
0
0
0
0
0
0
0
0
0
0
37
37
0
0
0
0
0
0
0
0
0
0
0
0
0
0
38
As before, to obtain the combined time mask, which we call M T (c,l), we take a max function of the contributing masks. In this case, based on data points, our combined time mask for frames 1 through 15 would be
35
35
35
35
35
35
35
35
35
35
35
35
37
37
38
This process is repeated for all frames in the file. It should be clear that in this system, once we have processed a given frame, the combined mask for all frames before that frame is then known. (Note that in implementations where the time mask is influenced by frames in the future this does not hold; in that case, the combined mask is not known until after all frames influencing the current frame have been processed.)
As before, once the combined mask has been calculated, we may calculate how far above this mask the actual filterbank data is, if it is above the combined mask value at all. We may write this distance above the combined time mask:
A T ( c,l )= X ( c,l ) dB-filterbank −M T ( c,l )
It should be clear that the maximum value above the combined mask in our setup is 25.0 dB, because the masking curve generated by any given point is only that far below the point itself Generally speaking, music and voice occasionally have loud, percussive events versus time. Therefore, after loud events, A T (c,l) will often be negative. In the figure, sounds with magnitudes above and below the combined time mask are indicated by a triangle 627 and circle 637 , respectively.
(4) Post-Processing Versus Frequency
After processing one frame at a time and one filter at a time, we have two sets of data in A F (c,l) and A T (c,l) that respectively tell us how far above the masks M F (c,l) and M T (c,l) the dB filterbank data is. We next revisit the data in the combined frequency mask, M F (c,l).
Again, we process the data frame by frame, considering all frequencies in a frame l 0 together. This time, the goal is to identify peaks in the mask itself (rather than the filterbank data), and to see how close to the frame's maximum M F (c,l 0 ) value they were. The logic here is that weaker peaks in the filterbank data will fall below the combined mask curve, and therefore not be peaks in the combined frequency mask. The system first detects all peaks in the frequency mask for the frame, with this simple definition: a peak occurs if the value is greater than the left neighbor (one frequency filter to the left) and greater than or equal to the value of the right neighbor (one frequency filter to the right). After peaks have been identified this way, a peak flags array O(c,l 0 ) is created that labels peaks as occurring at the filter of the peak, as well as one filter to the left and one to the right. That is, if there is a peak at filter 13 in frame 100 , we have O(13,100)=1, and also O(12,100)=1 and O(14,100)=1. The idea here is that FFT bias, as well as misalignment of frames, can lead to peaks being slightly off in frequency for two recordings of the same audio. By allowing the peak to be identified over three filters, these problems are mitigated.
The next step is to label these peaks as loud, intermediate, or quiet based on how loud they were compared to the maximum M F (c,l) value in the frame. For coding purposes, we also assign a code to each situation. The table below shows thresholds and what we call “frequency codes”:
O(c, l 0 ) Frequency Peak Flag Level of M F (c, l 0 ) Code 1 at least max(M F (c, l 0 )) - 15.0 1 1 below (max(M F (c, l 0 )) - 15.0) and at least 2 (max(M F (c, l 0 )) - 32.0) 1 below (max(M F (c, l 0 )) - 32.0) 4 0 at least max(M F (c, l 0 )) - 15.0 3 0 below (max(M F (c, l 0 )) - 15.0) and at least 3 (max(M F (c, l 0 )) - 32.0) 0 below (max(M F (c, l 0 )) - 32.0) 4
In FIG. 5 , the highest peak would be coded 1,1, for its peak flag and frequency code 517 . The other two peaks, both above the 15 dB threshold, would be coded 1,2. The triangle sound might be coded 1,2 and the circle coded 0,3, depending on the values of left and right neighbors that are not illustrated in the figure.
We note that other values than 15.0 and 32.0 547 for the thresholds below the maximum could be used. These are values that generally work well, though values from 5 to 20 dB for the first parameter, and 25 to 40 for the second parameter would also be reasonable.
(5) Post-Processing Versus Time
The system next processes the data in A T (c,l) that tells us how far above the mask M T (c,l) the dB filterbank data is. Again, the idea is to reflect how far below the combined time mask the filterbank data is. We assign “time codes” as follows:
Level of A T (c, l) Time Code At least 24.0 1 Above 6.5 and below 24.0 2 At most 6.5 3
In FIG. 6 , the masking sounds would be coded 1. The triangle and circle sounds would be coded 2 and 3, respectively.
(6) Combining the Two Types of Data Above
We can now generate the first version of the output characteristic matrix based on the time and frequency codes used in the tables above.
Characteristic matrix
Frequency Code
Time Code
value
1, 2, or 3
1
1
1 or 2
2
1
All other combinations
0
(7) Post-Processing to Deal with Silence
At this point, the main processing is done. We observe that because the system identifies significant sounds as those louder than neighbors in time and frequency, that silence presents a special case. In silence, time and frequency maxima lose meaning, and all points qualify as “loud,” leading to characteristic matrices that are all ones for most of the silent frames. One way to address this circumstance is to apply a post-processing rule: if any three consecutive frames have characteristic matrices of all ones, set the first such frame to be all zeros. In practice, we found that requiring anywhere from three to ten frames to pass this test is reasonable. Also, in some situations, it is useful to deactivate this post-processing.
Module to Score a Query Against a Reference
This module compares a query and a reference, computing a score which, casually speaking, represents “how nearly the query matches the reference”. The scores are not necessarily meaningful on an absolute scale (that is, they are not necessarily meaningful outside the context of a particular query). However, when such scores are computed by comparing a particular query to many or all of the references in the database, the resulting scores can be used to decide which reference(s) most likely match the query.
Module Inputs and Outputs:
This module accepts several inputs, including: a set of characteristic matrices for the query (as produced by the preceding module), a characteristic matrix (as produced by the preceding module) for a given reference in the database of searchable content or an enumeration of query-to-reference alignments to consider. If the last input is not given, it is assumed that “all possible” alignments should be considered.
It outputs a score that represents “how well the query/reference match each other”. Various other numeric values are computed in the process of computing the final score, and these values can also be useful outside the context of the present module.
Module Operation:
Few examples of exemplary characteristic matrices query and reference are included. We will use a characteristic matrix dimensionality of only 8, though this value would generally be much higher in practice, for instance 64. In this simplified example, the characteristic matrices represent values from only 8 filterbands. In this example, we use a query characteristic matrix of four frames and a reference characteristic matrix of 10 frames.
In the following characteristic matrices, each column represents a new frame (time progresses from left to right) and each row represents a different frequency. Thus, when we refer to “frame 3 ” we mean “the eight values in column number 3 ”. We refer to these columns/frames in a 0-indexed form (counting 0, 1, 2 . . . ), so “frame 3 ” is in the “fourth column”.
Example Reference Characteristic Matrix (R1):
0 0 0 0 1 0 0 1 1 0 0 0 0 0 1 0 0 0 1 0 0 0 0 0 1 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 1 1 0 0 1 1 1 0 0 0 0 1 1 1 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0
Example Query Characteristic Matrix (Q1):
0
0
0
0
0
0
1
0
0
0
1
0
0
1
1
0
0
0
1
1
0
0
1
1
0
0
0
0
0
0
0
1
FIG. 7 depicts the method for computing a score. The overall module operation includes the following phases. Create an alignment score 705 for every available alignment. In the simplest case, one alignment is specified, so only one alignment score is created. Another option is to compute additional possible scores for the top-score alignments, using queries with different framing 715 of the input sound. Return the maximum computed alignment score 725 as the overall match score between this query and reference.
Phase (1)
Let's assume the given alignment is A=1. This represents a hypothesis that frame 0 in the query corresponds to frame 1 in the reference, that frame 1 in the query corresponds to frame 2 in the reference, etc. (that in general frame N in the query corresponds to frame N+A in the reference).
This means that we have four (query-frame, reference-frame) pairs that correspond for this alignment. We will proceed to compute a frame score for each pair, and we will then average these scores to create an overall score for this alignment.
The frame score can be computed in a number of ways which are all roughly equivalent. In each case, the first step is to compare each Boolean value in the query frame one-by-one with its corresponding Boolean value in the reference frame. Since there are two Boolean values involved in each such comparison, there are four possible outcomes, which by convention we label as follows:
If the query value is 1 and reference value is 1, we call this a “white_hit”.
If the query value is 0 and the reference value is 0, we call this a “black_hit”.
If the query value is 1 and the reference value is 0, we call this a “white_miss”.
If the query value is 0 and the reference value is 1, we call this a “black_miss”.
For our current example, then, the 8 values for frame 0 of the query are “00000000” while the 8 values for frame 1 of the reference are “00000010” (that is reading the values from the second column of the reference from top to bottom). This means that there are 0 white_hits, 7 black_hits, 0 white_misses, and 1 black_miss. Similarly, for the final frame of the query (frame 3), the query values are “00001101” and for the corresponding reference frame (frame 4), the reference values are “11111100” so for this comparison there are 2 white_hits, 1 black_hit, 1 white_miss, and 4 black_misses.
The next step is to derive a frame score from some subset of these four counts. In general, white_hits and black_hits are “good” (that is, they suggest a match), while white_misses and black_misses are “bad” (that is, they suggest a non-match). So a naïve approach would be to simply add the number of white_hits and black_hits, which would yield a score between 0 and 8 for every frame.
It is often advantageous, however, to use a more involved linear combination such as 1.16*white_hit_count+black_hit_count, which rewards white_hits more than black_hits. Note that this particular formula would yield a frame score between 0 and F_max for each frame where F_max is the maximum possible score for that frame and depends on the query characteristic matrix (ranging, for instance between 8 when the query frame is all 0's to 8*1.16=9.28 when the query is all 1's).
Another option would be to extend the formula above such that the frame score is defined as F_max−(1.16*white_hit_count+black_hit_count). With this approach the maximum frame score is always 0 and the score becomes progressively more negative with every miss that is present. This formula is equivalent, then, to the following simplified formula: −1.16*white_miss_count−black_miss_count. This approach (where zero is the best possible frame score for every frame) is essentially equivalent to the proceeding approach but is, in our opinion, preferable for it's intuitive (ie, human-readable) characteristics.
Returning to our example, then, and using the formula above, the frame score for frame 0 is −1.16*0−1=−1. The frame score for the final frame (frame 3) is −1.16*1−4=−5.16. Completing this scoring for the other two frames in this alignment (A=1) gives us the following four frame scores: −1 (based on “00000000” vs. “00000010”), −1.16 (based on “00010000” vs. “00000000”), −3.48 (based on “01111100” vs. “00011000”), and −5.16 (based on “00001101” vs. “11111100”). Thus, the overall alignment score (average of the four frame scores) is: (−1−1.16−3.48−5.16)/4=−2.7.
We then proceed to calculate alignment scores for the remaining alignments. For instance, for alignment A=2 (meaning frame 0 of the query corresponds to frame 2 of the reference) the frame scores are much better: 0 (based on “00000000” vs. “00000000”), −1 (based on “00010000” vs. “00011000”), −1 (based on “01111100” vs. “11111100”), and −1.16 (based on “00001101” vs. “00000101”). Thus, for the alignment A=2 the overall alignment score is (0−1−1−1.16)/4=−0.79.
As noted previously, this module takes as optional input an enumeration of alignments to consider. If, for example, such an enumeration was given and contained only the two alignment analyzed above (A=1, A=2) then we would now be done with phase (1) of the module operation, and the optimal score thus far would be the score from alignment A=2.
If instead the optional enumeration of alignments was not given, we would proceed to calculate alignment scores using the method above for “all remaining alignments”. For alignments (A=0, A=3, A=4, A=5, and A=6) the process is identical to the process given above for alignments (A=1 and A=2). However, alignment A=7 presents an edge case we have not yet considered: with this alignment, frame 0 in the query corresponds to frame 7 in the reference, etc, however frame 3 in the query “should” correspond to frame 10 in the reference but no such frame exists as frame 9 is the final frame. We call this edge case an “alignment with overhang”. For such edge cases, we simply compute and average frame scores for the available frames: in this case that means averaging the frame scores from the three query frames which do have corresponding reference frames. This is, in fact, the primary reason we average the frame scores in the first place. Care must be taken when doing this sort of averaged scoring over alignments with “too much overhang”. For instance, the score for alignment A=9 would consist of the scores from only one frame, which may be quite noisy and not particularly meaningful. As a result, it is necessary to set a limit on “how much overhang is allowed”. For a query for N frames, it would reasonable, for instance, to allow at most N/4 frames of overhang. Applying this logic in the current example, alignment A=7 would be allowed but alignment A>7 would not be allowed. Finally, it is worth noting that a similar overhanging edge case exists for alignments with negative values such as A=−1. We treat this second edge case the same way as the first, thus with the N/4 rule, alignment A=−1 would be valid since there would be three frames of corresponding data to analyze, which alignments A<−2 would not be valid. Thus, in this example, the set of all valid alignments would be (A=[−1,7]) and in each case we would have either 3 or 4 frame scores which would be averaged to create the respective alignment scores.
Phase (2)
In this optional phase, we take into account any other versions of the query characteristic matrix that are available to us. For instance, as described in earlier modules, it is desirable to create multiple query characteristic matrices by processing the audio data at varying start points. This, while our example above provided query Q1, we may also have been given additional characteristic matrices Q2, Q3, and Q4. In most cases these additional characteristic matrices will be very similar to the first, and thus the corresponding alignment scores will be generally similar.
In phase (1) we computed the “top alignments” based on alignment score. Let's assume the top alignments were A=2 and A=6, and that we have configured phase (2) to analyze the top 2 alignments from phase (1). We would then compute an alignment score using Q2, R, and alignment A=2 following the same approach as in phase (1)—the only difference being the use of Q2 instead of Q1. If the resulting alignment score is better, we would update our maximum alignment score accordingly.
Note, when executing phase (2) it may be necessary to subtract 1 from the alignments used for certain versions of the query. For instance, let's imagine Q1 was created by processing the query data starting from “frame 0”, while Q2 was created by processing the data starting from “frame 0.25” (this is, starting the first frame of Q2 from what would have be 25% of the way through the first frame in Q1), etc, such that Q4 was created by starting from “frame 0.75”. When, based on calculations from Q1, we know the best alignments are A=2 and A=6, we then want, when considering another version of the query Qn, to use the two alignments that “are most similar to using A=2, A=6 for Q1”. Thus, when considering Q2, if we use A=2, this is equivalent to “using Q1 with an alignment of A=2.25” which is clearly our best option. However, when considering Q4, if we use A=2, this is equivalent to “using Q1 with an alignment of A=2.75” where it would be better to use Q4 with an alignment of A=1, as this is equivalent to “using Q1 with an alignment of A=1.75” which is most similar to using Q1 with alignment A=2.
Phase (3)
In phase (3) we simply select the maximum available alignment score (compute either in phase (1) or phase (2)). It may also be useful to return the alignment value, A, that corresponds to the best alignment, as well as which version of the query, Qn, yielded the best alignment (this value can be thought of as a ‘micro-alignment’).
Using Returned Match Data to Align Queries with Temporally Rich Media
In the proposed system, a returned result includes an identifier of a song or sound and an indication of the best alignment within the matched reference. The identifier can include, implicitly or explicitly, title, artist, or album data. For example, a code of A123456 might encode the song “Dance Love Baby” by “Joe Blow” on the album “Love Dances.”
The indication of the best alignment within the matched reference can be termed as the alignment offset. As a matter of convention, we will indicate the match as how many frames into the reference the beginning of the query appears to be. For example, the best match might occur such that beginning of the query best aligns with the 1400th frame of the reference. At 20 frames per second, this would be 70 seconds in to the reference.
By combining the above two pieces of information, we may synchronize time-labeled streamed media with the query. For example, if particular lyrics are known to occur 1400 frames into the example reference just above, we would know that those lyrics should match the lyrics in the query. It would be a satisfying user experience to see those lyrics displayed in synchronization with the query. Lyrics are one of many examples of temporally rich media. Lyrics occur at specific time points in a song. The exact times for each lyric may be known either from human annotation or machine detection. Another example can be videos. As opposed to lyrics, videos are continuously streamed. If an audio version of a song corresponds to audio for a video, a video might be shown to the user in synchrony with the query audio. Additional copies of the same song are also temporally rich media where a user might wish to play a copy of a queried song from his or her querying device or local environment. For example, a user could play a streamed or locally stored copy of “Dance Love Baby” directly from his or her mobile phone. This might be used to increase the volume of a queried song. Remixes of the same song are similar to the additional copies of the same song in concept, but with the user giving the musical environment a different feel through using a slightly different but still time-synchronized version of the song. Similarly, songs similar to the queried song are also temporally rich media when a song that complements the query song rather than an original copy or remix is used.
Any music or audio that can be synchronized in terms of melody, harmony, or rhythm with the queried audio. Existing audio systems allow music to be identified as similar based on melody (Melodis sing search, as on existing Melodis patents), harmony (as in Sapp, Craig Stuart, “Visual Hierarchical Key Analysis”, ACM Computers in Enterntainment, Vol. 4, No. 4, October 2005, Article 3D, or rhythm (as in Vercoe, Barry L., et al., “CiteSeerx Music-Listening Systems”, PhD Thesis, MIT Cambridge, Mass. USA2000, and could be used to align similar music in a pleasing or interesting way to an audience. Preprogrammed lighting that matches a particular song or category of songs could be synchronized with the query.
In order for the system to succeed a number of steps occur. First, the matching reference and best matched alignment offset X is identified.
Second, we determine the total time elapsed from the beginning of the query to the time that the temporally rich media could be synchronized. This includes the duration D of the query itself, plus the time P required for processing, plus the latency L required for the network to receive and transmit information. Call this total quantity Y. That is Y=D+P+L.
Third, we have the querying device (or the environment of the agent performing the query) display or otherwise deliver the temporally rich media to arrive at time X+Y. That way, the temporally rich media (such as lyrics) will occur in synchrony with the query audio. Note that the temporally rich media may be stored on the querying device (such as in the case of querying a song the user already owns, or lyrics the user already has downloaded), or may be streamed to the device (such as in the case of lyrics the user does not yet have). Also, buffered combinations of the two models could also be used.
Due to the repetitive nature of music and other audio, the alignment offset estimate may be ambiguous. For example, if the query audio occurs during a chorus that is repeated in the reference (and possibly the query, for that matter), then each similar occurrence would be a strong candidate for a match. In such instances, one solution is to use the first matching occurrence, as this ensures that the aligned media does not stop before the end of the query. However, in situations where this would be worse than the aligned media stopping, the opposite solution could be used: choose the last matching occurrence versus time.
Network latency L may also be challenging to estimate in some situations. It is assumed that best practices to mitigate estimation difficulty would be used, such as combining multiple estimates of upload and download time to obtain the best offset for synchrony.
Module to Decide if the Top Reference is a Correct Match:
As noted earlier, the above systems create one score per reference for “the top references” however these scores are not necessarily meaningful on an absolute scale (that is, they are not necessarily meaningful outside the context of a particular query). This means that while the scores tell us which reference(s) is/are most likely a match, they don't tell us if this reference(s) is/are indeed a match.
Module Inputs and Outputs
Input includes a single score associated with each of the “top scoring references” in the database.
The output produced is a decision about whether the top reference “IS” or “IS NOT” a correct match. That is, a decision about whether we think the correct reference was indeed found in the database.
Module Operation
The operation of this module is relatively simple. If we can safely assume that the audio associated with each reference is unique (that is, each reference occurs exactly once in the database), then the following approach is sufficient:
Compare the value of the maximum score with the value of the next highest score, computing their difference. If the difference is low this suggests that two references match about as well as each other to the query and thus, since we assume they are unique, neither is likely to match the query. If, however, the difference is large, this suggests that the reference with the maximum score is a significantly better match than everything else in the database and is thus highly likely to be the correct match, especially if the database is sufficiently large. As such, it sufficient in this case to base this module's decision of whether the difference is greater than or equal to a fixed constant. For instance, we may say that if the difference is greater than 0.5 (which is units of average score per frame of the optimal alignment) we decide the top reference “IS” a match and that otherwise it “IS NOT” a match.
If it is possible for the same audio content to exist in the database multiple times, for instance passages of a well-known cover performed by multiple performers, then we must extend this approach because it is possible that the difference between the maximum and next high scores is very low and they are both the correct match. In this case, it is sufficient to decide the top reference “IS” a match whenever the difference between the Nth and (N+1)th reference scores is greater than a certain constant. We should only examine differences where N is small (such as N<5) which corresponds to an assumption that a particular reference occurs no more than N times in the database.
If no such assumption can be made about whether a reference occurs multiple times, it is then necessary for this module to perform more intelligent calculations. In such cases, creating a vector of features containing the various differences mentioned above as well as the absolute scores of the top references, plus other values mentioned throughout this document, can be a useful approach. We can then gather such data for a large number of labeled use cases (where the correct response is known) and use standard machine learning techniques to accurately map this vector of values to one of the top output states as can be done by someone familiar with the art.
Some Particular Embodiments
The technology disclosed is computer-based, whether the computer is a CPU, FPGA, digital signal processor or other processor. The technology may be embodied in a method, a device, system or article of manufacture. It is useful for processing reference sounds, query sounds or both. In some implementations, it is particularly useful for matching a query sound to one or more stored reference sounds. The query sound typically is a short sample that is matched against a longer reference.
One embodiment of the technology disclosed includes a method of creating a resilient characteristic matrix of a reference sound or a query sound. A sample processor 453 is used to repeatedly characterize the loudness of sound components grouped in filter banks 521 of sample frames. Grouping into filter banks includes a process such as described above of combining multiple bins of an FFT, for instance, that are in a particular filter band that defines the filter bank. The sample frames reside in a computer readable memory. The filter banks have a narrower frequency range and have closer mid-frequency spacing, on average, in frequencies between about 750 Hz and 1450 Hz than above 1500 Hz or below 500 Hz. The loudness peaks among the filter banks that are above cross-frequency and time thresholds in the sample frames are flagged. The cross-frequency masking threshold for a particular frame is set relative to filter band characterizations of one or more masking sounds 503 . The time masking threshold for successive frames is also set relative to the filter band characterizations of the masking sounds. The masking margins 513 between masking sounds and masking thresholds 527 , 547 may differ and typically will differ between the cross-frequency and time masks. The flagged peaks are coded in relation to the cross-frequency and time masking thresholds to create a frame-by-frame, filter bank-by-filter bank characteristic matrix.
In one implementation, flagging the loudness peaks above the cross-frequency and time masking thresholds avoids the inclusion in the frame-by-frame, filter bank-by-filter bank characteristic matrix of particular sound components that are likely to be eliminated from a frame sample by an auditory perception codec. Optionally, the flagged loudness peaks may be limited to filter banks in which the loudness exceeds the thresholds 527 , 547 . Or, flags may be applied both to peaks in filter banks in which the loudness is above the thresholds and to adjoining filter banks.
One or more filter banks can be flagged that are adjoining to a particular filter bank at which a loudness peak was flagged. Three or more peaks that are centered at about the particular filter bank can also be flagged. Similarly, five or more peaks that are centered at about the particular filter bank can be flagged. Flagging loudness peaks and adjoining filter banks effectively broadens frequency widths of the loudness peaks.
The scoring optionally may include first coding the flagged loudness peaks within the particular frame against the cross-frequency masking threshold by first bands of relative loudness. (By first coding and first bands, we mean to distinguish from second coding and second bands, without implying any order, hierarchy or relationship between firsts and seconds.) The method also includes second coding the flagged loudness peaks within the particular frame against the time masking threshold by second bands of relative loudness. The first and second coding are combined to set filter bank-by-filter bank values in the characteristic matrix. The first and second coding are repeated numerous times for the sample frames the sound. The numerous repetitions are expected to include at least 40 sample frames representing at least two seconds of a query sound and more sample frames of a reference sound, which typically will last longer than a query sound.
Characteristic matching between the query and reference characteristic matrices 117 can apply the following method, which may either extend the methods, aspects and implementations described above or which may stand on its own. In this method, reference characteristic matrices are created for numerous reference sounds and for at least one query sound. Various alignments of the query characteristic matrix are compared to at least some of the reference characteristic matrices. The comparing includes identifying filter bank-by-filter bank positive peak matches, negative peak matches, peak in query but not in reference mismatches, and peak in reference but not in query mismatches. Composite scores are derived frame-by-frame, across filter banks. The composite scores distinctly weight and also combine the positive peak matches, the negative peak matches, the peak in query characteristic matrix but not in reference characteristic matrix mismatches and peak in reference characteristic matrix but not in query characteristic matrix mismatches. The frame-by-frame composite scores are combined, for instance by summing and, optionally, normalizing, into query scores for the alignments 705 . One or more best alignments of the query characteristic matrix to the reference characteristic matrices are selected. The composite scores for the best alignments are organized to identify likely query-to-reference characteristic matrix matches.
When this scoring method stands on its own, it should be understood that the characteristic matrices are created for numerous reference sounds and for at least one query sound includes creating frame-by-frame, filter bank-by-filter bank characteristic matrices for the numerous reference sounds and the query sound.
Any of the processes described can be repeated for multiple versions of the query sound and corresponding version of the query characteristic matrix. As described above, sampling of the query sound can start at various times offset from one another so that sample frames have a variety of alignments to the query sound.
Any of the methods described above can be extended to include comparing the composite scores for the best alignments and identifying a true match where one of the composite scores is significantly better than any others of the composite scores. Optionally, a best match can be reported only if it has a composite score that is significantly better than the other composite scores. Similarly, multiple best matches can be identified as identical true matches when a plurality of the composite scores match each other and are significantly better than the others of the composite scores. Again, the multiple best matches optionally can be reported only if they have a composite score that is significantly better than the other composite scores.
The methods described have corresponding devices. One device embodiment is a system that creates a resilient characteristic matrix for a reference sound or a query sound. This system includes at least a sample processor and memory coupled to the sample processor. The sample processor repeatedly characterizes loudness of sound sample frames that reside in the computer readable memory. The loudness is characterized for sound components grouped in filter banks of sample frames. Grouping into filter banks is described above. The filter banks applied by the sample processor have a narrower frequency range and have closer mid-frequency spacing, on average, in frequencies between about 750 hz and 1450 hz than above 1500 hz or below 500 hz. The processor flags loudness peaks among the filter banks that are above cross-frequency and time thresholds in the sample frames. The processor sets the cross-frequency masking threshold for a particular frame relative to filter band characterizations of one or more masking sounds. Similarly, it sets the time masking threshold for successive frames relative to the filter band characterizations of the masking sounds. The masking margins between masking sounds and masking thresholds may differ and typically will differ between the cross-frequency and time masks. The processor codes the flagged peaks in relation to the cross-frequency and time masking thresholds to create a frame-by-frame, filter bank-by-filter bank characteristic matrix data structure in the computer readable memory.
In one implementation, the sample processor avoids the inclusion in the frame-by-frame, filter bank-by-filter bank characteristic matrix of particular sound components that are likely to be eliminated from a frame sample by an auditory perception codec by flagging the loudness peaks above the cross-frequency and time masking thresholds. Optionally, the flagged loudness peaks may be limited to filter banks in which the loudness exceeds the thresholds. Or, flags may be applied both to peaks in filter banks in which the loudness is above the thresholds and to adjoining filter banks.
The processor may flag one or more filter banks that are adjoining to a particular filter bank at which a loudness peak was flagged. Three or more peaks that are centered at about the particular filter bank can be flagged. Similarly, five or more peaks that are centered at about the particular filter bank also can be flagged. Having the sample processor flag loudness peaks and adjoining filter banks effectively broadens frequency widths of the loudness peaks.
The sample processor optionally may score the peaks by first coding the flagged loudness peaks within the particular frame against the cross-frequency masking threshold by first bands of relative loudness. (By first coding and first bands, we mean to distinguish from second coding and second bands, without implying any order, hierarchy or relationship between firsts and seconds.) The processor also second codes the flagged loudness peaks within the particular frame against the time masking threshold by second bands of relative loudness. The sample processor combines the first and second coding results and uses those results to set filter bank-by-filter bank values in the characteristic matrix. The sample processor repeats first and second coding numerous times for the sample frames of the sound. The numerous repetitions are expected to include at least 40 sample frames representing at least two seconds of a query sound and more sample frames of a reference sound, which typically will last longer than a query sound.
A match processor performs characteristic matching between the query and reference characteristic matrices, either in cooperation with the sample processor or standing on its own. This match processor is coupled to a memory. It creates numerous characteristic matrices for numerous reference sounds and at least one query sound. The reference characteristic matrices typically, but not necessarily, are persisted in non-volatile memory for repeated use. The match processor processes various alignments of the query characteristic matrix against at least some of the reference characteristic matrices. The match processor identifies on a filter bank-by-filter bank basis: positive peak matches; negative peak matches; peak in query but not in reference mismatches; and peak in reference but not in query mismatches. The match processor derives composite scores on a frame-by-frame basis, across filter banks. The composite scores distinctly weight and also combine the positive peak matches, the negative peak matches, the peak in query characteristic but not in reference mismatches and peak in reference but not in query mismatches. The match processor combines the frame-by-frame composite scores, for instance by summing them and, optionally, normalizes the combined scores into query scores for the alignments. The match processor selects one or more best alignments of the query characteristic matrix to the reference characteristic matrices. It organizes the composite scores for the best alignments to identify likely query-to-reference characteristic matrix matches.
When the match processor stands on its own, it should be understood that the characteristic matrices that it creates for numerous reference sounds and for at least one query sound include frame-by-frame, filter bank-by-filter bank characteristic matrices for the numerous reference sounds and the query sound.
The match processor optionally may repeat the processing described above for multiple versions of the query sound and corresponding versions of the query characteristic matrix. As described above, processing of the query sound by a sampler into sample frames can start at various times offset from one another so that sample frames have a variety of alignments to the query sound.
Any of the devices described above can be extended by a verification processor. The verification processor compares the composite scores for the best alignments and identifies a true match where one of the composite scores is significantly better than any others of the composite scores. Optionally, the verification processor can report a best match only if it has a composite score that is significantly better than the other composite scores. Similarly, the verification processor can identify multiple best matches as identical true matches when a plurality of the composite scores match each other and are significantly better than the others of the composite scores. Again, the verification processor optionally can report multiple best matches only if they have a composite score that is significantly better than the other composite scores.
Hardware for the sample processor, the match processor and the verification processor can be shared, such as in as single FPGA or a multi-core processor or a system including multiple processors. Memory also can be shared.
The methods described above can further be embodied in computer instructions stored in a computer readable storage medium. The computer instructions can enable a processor to carry out any of the methods, embodiments, implementations, features, aspects described above. Alternatively, the computer instructions can be stored in a computer readable transport medium.
Another article of manufacture embodying the technology disclosed is a computer readable storage medium that includes computer instructions that can be used to build a system that includes one or more processors to carry out any of the methods, embodiments, implementations, features, aspects described above or to build one or more of the device embodiments disclosed. Alternatively, these computer instructions can be stored in a computer readable transport medium.
|
Components of a method and system that allow identification of music from the song or sound using only the sound of the audio being played. A system built using the method and device components disclosed processes inputs sent from a mobile phone over a telephone or data connection, though inputs might be sent through any variety of computers, communications equipment, or consumer audio devices over any of their associated audio or data networks.
| 0
|
1. FIELD OF THE INVENTION
[0001] This invention relates to a tool for opening a locked vehicle door and to the method of making the tool.
2. DESCRIPTION OF THE PRIOR ART
[0002] Tools for opening locked vehicle doors are well known and have been in use for a long time. They run the range from a simple bent coat hanger to highly specialized tools such as those formed for a specific vehicle type and model year. The most often experience is the use of a tools designed for insertion into the door of the vehicle and interface with the internal locking mechanism to unlock the door. While some hand tools are intended to be inserted into the vehicle door interior, others are intended to be used inside the vehicle to operate the door latch from the passenger's compartment, as would the passenger have.
3. SUMMARY OF THE INVENTION
[0003] A rod, most commonly with a circular, oval, elliptical, or polygon, cross section, used to open a locked door must be strong enough to be inserted in a narrow opening made between the vehicle door and the vehicle door jam and engage a locking mechanism and deliver sufficient force to unlock the door. Depending upon the type of locking mechanism, the force may be exerted left, right, up, or down, or in or out, relative to the vehicle door. This usually requires the rod to be of a material, such as steel, that can withstand such forces and to be of a sufficient thickness so as not to permanently deform in use. At the same time, the tool must be flexible to allow flexure of the tool and responsive movement of the operative tip of the tool about a radius sufficient to maneuver the tool in the enclosed and limited space of the vehicle interior.
[0004] Optimum use of the tool in the hands of a human operator, requires an ergonomic grip, that permits the operator to grip the tool and comfortably maneuver the tip toward and away from the door latch controls, exerting pushing or pulling forces, and to turn or rotate the operative tip, about the axis of the tool, as may be necessary to rotate the vehicle door latch.
[0005] At the opposite end from the handle, the tip of the tool may be shaped in a right angle bend forming a hook. To enhance the frictional grip of the tool on a door latch handle, and prevent the tool tip from slipping from the door latch or damaging the door latch when force is applied, a covering may be applied to the hook at the tool tip.
[0006] In a preferred embodiment, the invention is directed to a tool for use in unlocking a vehicle door. The tool is formed from a rod with an off center angle bend, a tip formed into a hooking mechanism a handle used to hold and manipulate the tool.
[0007] As shown for a preferred embodiment, the tool is a made from a unitary rod with a electrostatically applied coating, fixed by heat curing, as would be known to those skilled in the art.
[0008] As disclosed in a preferred embodiment, at a first end, the rod is bent or shaped into a handle with a space for hand insertion and gripping. At a second end opposite to the first end, the rod tip is bent or made in the shape of a hook. To achieve the best ergonomic positioning of the hook, the plane of the handle opening is made facing the hook at the tip second end of the tool and perpendicular to the plane passing through the angle bend, as described below, and the axis of the rod.
[0009] The rod is constructed with an angle bend at a distance displaced from its midpoint, as measured proximately from the handle at the first end to the tip at the second end and with the angle bend located between the angle bend and the handle at the first end.
[0010] What is disclosed is a hand tool for opening a locked vehicle from a position outside the vehicle, comprising, a rod including a first end and a second end; said rod including an axis and a midpoint on said axis and spaced proximately equally from said first end and said second end; said rod including an angle bend disposed on said axis between said midpoint and said first end and dividing said rod into a first part and a second part; d. said first end on said first part, including a handle and said second end on said second part including a tip.
[0011] Disclosed is the hand tool wherein, e. said handle includes an opening; f. said handle opening defining a plane lying substantially perpendicular to a plane intersecting said axis and said angle bend.
[0012] Disclosed is the hand tool, wherein, g. said tip includes a door latch tool, and wherein, h. said door latch tool is a hook; and wherein, h. said hook has a first part aligned with said axis and said hook has a second part extending from said axis at an angle to said axis.
[0013] Disclosed is the hand tool, wherein, j. said hook angle and said hook second part, is substantially in said plane intersecting said axis and said angle bend; including k. a hook cover; and l. said cover is mounted on said hook first part and said hook second part and extends to a point on said first part displaced from said hook angle.
[0014] Disclosed is the hand tool, wherein, m. said cover is frictionally engaged with said rod and said cover has a soft surface, relative to said rod surface. wherein,
[0015] said rod is wire rod approximately between 0.20 and 0.22; wherein said angle bend is substantially between 15 and 30 degrees; and wherein the ratio of the length of said first part to the length of said second part is between 3:4 to 1:3.
[0016] Disclosed is a method of making a hand tool for opening a locked vehicle from a position outside the vehicle, comprising the steps of, a. at a location displaced from a rod midpoint, making an angle bend, separating said rod into a first part and a second part and with said second part length longer relative to the length of said first part; b. at a first end of said first part opposite said angle bend, forming a handle with the plane of said handle perpendicular to a plane passing through said angle bend and the longitudinal axis of said first part and said second part.
[0017] Disclosed is the method of making a hand tool including the steps of c. at a second end of said second part, forming a hook in said rod; and the step of placing a cover over said hook; d. at a second end of said second part, forming a hook in said rod; e. forming a cover from an elastomer material; and f. inserting said hook into said cover to cover said hook and at least a part of said second part.
[0018] Disclosed is the method of making a hand tool including the step of coating said rod.
[0019] Disclosed is the method of making a hand tool wherein said step of separating said rod into a first part and a second part includes the step of separating into a first part with a length relative to said second part length by an ratio in a range of 1:3 to 3:4; wherein said step of making an angle bend includes the step of making said angle bend in a range between 15 degrees to 30 degrees; and wherein said step of making an angle bend includes the step of making said angle bend in a range between 15 degrees to 30 degrees.
[0020] These, and other features of the invention are described in the following and in Detailed Description of the Invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a perspective schematic view of the Vehicle Door Opening Tool.
[0022] FIG. 2 is a detailed schematic view of the tool tip at the end of the tool opposite to the handle.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The vehicle door opening tool is shown generally in FIG. 1 by numeral 11 . In a preferred embodiment, its body 13 is a metal wire rod stock between 0.210 and 0.220, as would be known by those skilled in the art, and substantially in a circular cross section, As would be apparent to those skilled in the art, the cross section of the tool 11 may be varied or it may be made from material other than a rod, without departing from the disclosed principles of the invention.
[0024] As shown in FIG. 1 , the tool body 13 has a first part 17 and a second part 15 , separated by an angle bend 19 . A first longitudinal axis 38 is partially shown for the second part 15 , terminating at angle bend 19 . A second longitudinal axis 42 is partially shown for the first part 17 , terminating at angle bend 19 . The angle bend 19 is shown by arc 39 extending between longitudinal axis 38 on second part 15 and longitudinal axis 42 on first part 17 . Opposite the angle bend 19 , and at a first end 18 , of the first part 17 of the tool body 13 , a handle 21 is formed. The handle 21 is made with its plane 23 substantially perpendicular with a plane 37 , intersecting the longitudinal axis 38 , the angle bend 19 and the longitudinal axis 41 of the tool body 13 . Arc 39 lies in the plane 37 .
[0025] The angle bend 19 , as shown for a preferred embodiment, is in a range of an included angel 39 , as shown in FIG. 1 , of 15 to 30 degrees. The location of the angle bend 19 along the length of the rod may vary from a point displaced from the rod 13 mid point 16 with the first part 17 shorter than said second part 15 by a ratio in a range from approximately 1:2 to about 3:4, and which may be varied about without departing from the disclosed inventive principles, as would be apparent to those skilled in the art. In a preferred embodiment, the ratio of first part 17 to second part 15 , is approximately 2:3 and the angle bend is approximately 30 degrees.
[0026] Opposite the angle bend 19 , at second end 25 of the second part 15 , is tool tip 27 . The tool tip is in the shape of a hook 29 , shown in phantom inside too tip cover 31 .
[0027] A detail of the hook 29 at the second end 25 of the tool 13 , as shown in FIG. 2 , with a partial view of second part 15 . The hook 29 at the second end 25 , is shown in phantom inside the tool tip cover 31 . The material of the cover 31 , may be an elastomer material, into which the tool tip end 32 may be inserted and the tool tip end slipped over the hook 29 to the full length of its internal cavity of the tool tip cover 31 , as shown in FIG. 2 .
[0028] The elastomer material of the tip cover 31 , when stretched, exerts a counter force directed against the tool hook 29 , holding it in place against any forces directed against it when the tool is in use and serves to hold the tip cover 31 , in place. The elastomer material of the cover 31 is made softer or with a surface hardness less than the hardness of the rod, 13 preventing any damage caused to the door latch controls, by the harder surfaces of the rod material of the tool 13 . At the same time, the relatively softer cover tip cover 31 , provides a higher coefficient of friction, a larger surface area than the surface of area of the rod used to form the tool body 13 , and relatively improved frictional contact with the door latch.
[0029] The vehicle door opening tool 13 , in a preferred embodiment, may be bent into the desired shape as shown and described herein, and coated with an electrostatically applied coated which is cured in place, for example by heat treatment.
[0030] The positioning of the handle 21 shown with the plane 23 of the handle perpendicular to plane 37 , permits a tool operator to grip the tool, with better control over the movement of the tip 27 and hook 29 , in three axes of rotation. In use, as would be known to those skilled in the art a wedge or block may be inserted between the vehicle door frame and the door, preferably close to the top of the door and toward the side opposite the door hinge. In this way the greater flexibility of the door may be used to advantage. The hand tool is inserted tip down into the interior of the locked vehicle and proximate the door latch handles or controls, on the driver or passenger side.
[0031] An advantage of the invention as shown in a preferred embodiment, is the length of the radial arm formed in the hand tool between the tip 25 at the second end 25 of the tool 13 and the angle bend 19 , relative to the radial arm formed in the hand tool between the angle bend 19 and the handle 23 . As would be apparent to those skilled in the art, movement of the handle in a radial direction about a point proximate the angle bend 19 , will be amplified by a larger movement of the tip 27 at the second end 25 , proportionately, with respect to the ratio of the length of the first part and second part, as described above.
[0032] As would be apparent to those skilled in the art, the material of the tool body 13 and its cross section may be varied, without departing from the disclosed inventive principles. The coating of the tool body 13 may be varied, without departing from the disclosed inventive principles. The shape of the tip 27 may be varied, as may be useful for any configuration of door latch handles. The tip cover 31 may varied by varying the elastic quality or its length or the length of its internal cavity shown in phantom in FIG. 2 , without departing from the disclosed inventive principles.
|
A vehicle door opening tool used to unlock a vehicle door from outside the vehicle. It is made from a rod with an angle bend off center toward the handle. The handle is made with its plane perpendicular to a plane passing through the angle bend and the axis of the rod. A hock is formed at an end opposite the handle for use with the inside door latch to open the vehicle door.
| 4
|
This application is a continuation of applicant's earlier filed patent application Ser. No. 07/521,326, filed May 9, 1990, now U.S. Pat. No. 5,139,559.
BACKGROUND OF THE INVENTION
In the art of glass container manufacture, it is typical standard practice to utilize an individual section machine in which a number of machine sections are mounted side-by-side on a single machine bed to operate in synchronization with each other while being independently adjustable. In the utilization of a press and blow method of glass container production in an individual section machine, discrete molten glass gobs are fed into an upwardly-open blank mold after which the mold is closed at the top by a baffle. Although a single gob mold may be utilized, it is more common to have a plurality of molds in a section, such as double gob or triple gob arrangements. Then, separate molten glass gobs are fed simultaneously to each mold in the section.
For each mold, a vertically-elongated pressing plunger is driven upwardly to press the molten glass into the blank mold and into an adjacent neck ring mold, forming a parison from the glass gob. The plunger is then downwardly retracted and the blank mold and the baffle are temporarily removed so that the parison can be removed and inverted by the neck ring mold from the blank to a laterally adjacent blow mold station where the final formation of the glass container occurs by a blowing operation.
For each blank mold, there is a separate mechanism for supporting and driving a pressing plunger for initially forming the parison in cooperation with the mold, and this mechanism includes a vertically-elongated cylinder mounted to support an axially-oriented piston rod within the cylinder's longitudinal bore. The pressing plunger is removably mounted by means of an adapter to the upper end of the piston rod whereby the plunger can be cycled through its pressing operation.
The piston and piston rod are an integral structure driven to cycle linearly by pressurized air fed into the cylinder's chamber. The plunger is cooled during its gob pressing operation by a relatively high-pressure air flow directed through the cylinder's bottom end structure and upwardly through a rigid air tube on which the hollow piston vertically slides. The air stream directed upwardly through the air tube and into the piston bore enters an elongated distributor projecting internally within the hollow plunger. The air flow is dispersed by the distributor within the plunger and returned downwardly through an array of exhaust passages or ports circumferentially arranged, usually in the bottom flange of the distributor. The exhaust air then passes through communicating openings in component structure of the adapter utilized to retain the plunger in its operative position on the piston rod.
The upper end of the cylinder casing serves as a collecting chamber for the exhaust air which may then be emitted outwardly through a laterally mounted exhaust manifold. The exhaust manifold in a plural gob section may be a unitary structure extending across a bank of aligned cylinders with a sidewall opening in each upper cylinder casing in sealed air flow communication with the exhaust manifold. Vertically-extending exhaust conduits may be utilized to direct the exhaust air flow downwardly for emission into the section box beneath the cylinders.
In the type of glass container forming machine heretofore generally described, a continuing problem is the control of machine performance to obtain consistent quality in the glass containers produced at a high production rate. Variance of conditions associated with the machine's operation will significantly affect the finished product. The failure to hold within a proper range such parameters as gob temperature, plunger dwell, rate of heat removal from the plunger by the cooling air flow, air pressure within the cylinder, and gob size or weight can result in the formation of rejected or inferior containers.
There have been many approaches to controlling one or more of the conditions associated with the machine's operation, none of which have been entirely satisfactory. One common method involves the operator of the machine making manual adjustments to various controls in accordance with his prior experience and the results of his visual inspection of the quality of glass containers delivered from the machine, the object being to correct, through trial and error, those conditions contributing to the noticed defects whereby subsequently produced containers will be of higher quality. Another method utilized, particularly addressing the control of gob weight for the purpose of having each gob contain sufficient glass to form an acceptable container, has been to weigh the finished product and utilize this after-attained information to adjust incoming gob weight in accordance with the findings in the weighing operation.
A recent development and significant advancement in controlling gob weight recognizes the direct relationship between the extent of advancement of the plunger into the gob and the size of the gob being pressed. This requires knowing the position of the plunger and the extent of its penetration into the gob as it occurs, whereby plunger position can be correlated with gob weight and gob weight can be continuously adjusted through the use of appropriate control station means of interpreting the received data and automatically controlling the timing of gob shearing, etc. To accomplish the foregoing, a proximity sensor has been mounted on the cylinder of a plunger mechanism to detect vertical movement of an angled surface on the plunger assembly and, by the variance in proximity of the angled surface, the position of the plunger has been extrapolated.
The foregoing method, while a significant move toward a worth objective, fails to take into account other parameters or conditions subject to fluctuation within the equipment during its operation which, unless they are also monitored and controlled, prevent accurate control of gob weight by simply monitoring plunger position at full penetration.
SUMMARY OF THE INVENTION
This invention pertains generally to quality control of containers produced in a glass container forming machine and more particularly pertains to a method and apparatus for collecting critical data directly from within the gob pressing mechanism as the mechanism is functioning.
The present invention comprehends the provision of a method of collecting data to indicate, continuously and simultaneously during the press and blow operation of a glass container forming machine, the temperature and variance of the cooling air flow within the plunger cycling mechanism, the pressure of the cooling air flow, and the linear position of the plunger, whereby the data collected during the actual gob pressing function can be interpreted at a remote operating location and utilized for adjustment and control of conditions affecting initial formation of glass containers without interrupting the continuing operation of the machine.
The invention further comprehends the provision of apparatus constituting a combination of certain devices for efficiently accomplishing the data collection under dynamic operating conditions.
Inasmuch as the method and apparatus of the present invention has the capability to separately collect data and thereby monitor the performance of the parison forming equipment associated with each cylinder of a plural-gob section, it is believed most appropriate to refer to the method and apparatus herein disclosed as a Cylinder Performance Monitoring System.
The system includes a method of collecting data to indicate performance in a glass container forming machine adapted to perform a press and blow operation in the formation of glass containers. The basic practice of the method involves providing position-reactive means, on the machine, for sensing, during the gob-to-parison pressing operation, the linear position of the plunger; and, providing pressure-reactive means on the machine for sensing the pressure of the incoming cooling air to the plunger and, providing a temperature-reactive means on the machine for sensing the temperature of the exhaust air flow at the same time the linear position of the plunger and the air pressure are being sensed; and, further, providing means for transmitting the sensed information to a remote location for comparative interpretation and use in controlling and adjusting machine performance to obtain high quality containers.
The apparatus for practicing the method of the invention includes a novel arrangement of structural elements for accomplishing the objectives of the method, particularly with respect to the means of sensing the linear position of the plunger.
A primary objective of the invention is to facilitate practice of the method by mounting the plural sensing means at critical points within the structure of the glass container forming machine in an arrangement that permits rapid manual withdrawal and replacement, as a unit, of each cylinder in the machine.
Details, features, and advantages of the Cylinder Performance Monitoring System herein disclosed will be best understood and appreciated from the ensuing detailed description of the preferred embodiment of the invention, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in vertical section illustrating a plunger cycling mechanism of a glass container forming machine, in accordance with the present invention;
FIG. 2 is a view in vertical section of the same plunger cycling mechanism shown in FIG. 1, but with less detail, illustrating the retraction or maximum-down position of a piston rod and associated structure first shown in the maximum-down position in FIG. 1;
FIG. 3 is a side elevational view of an air tube component first shown in FIG. 1;
FIG. 4 is a side elevational view, partially cut away in vertical section, of a component of the structure first shown in FIG. 1;
FIG. 5 is a bottom plan view of the structure illustrated in FIG. 4;
FIG. 6 is a top plan view of the structure illustrated in FIG. 4;
FIG. 7 is a horizontal sectional view taken along Line 7--7 of FIG. 1;
FIG. 8 is a side elevational view of an air tube component first shown in FIG. 1;
FIG. 9 is a side elevational view of a connector element first shown in FIG. 1;
FIG. 10 is a top plan view of the connector element shown in FIG. 9; and
FIG. 11 is a fragmentary side elevational view of an alternate double-gob arrangement of plunger cycling mechanisms in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a plunger cycling mechanism 10 for an individual section glass container forming machine, having a cylinder or casing 12 defining a chamber 14. The cylinder base or bottom is an end cap 16, and the upper end of the cylinder is defined by an intermediate cap 18. Extending axially upwardly through the chamber 14 is a piston rod 20 having a lower end radially outwardly flanged portion 22 which constitutes a piston formed integrally with the rod 20. The piston rod 20 and the piston 22 are adapted for air-driven linear vertical movement to cycle a plunger (not shown) in a press and blow operation. A circular casing 24 is disposed above the cylinder 12 and serves to contain certain plunger positioning elements (not shown). Also not shown in FIG. 1 are the seals and bearings which would be supported by the intermediate cap, about the piston rod 20, to facilitate its reciprocal operation. For a more detailed understanding of the structure and operation of an individual section machine generally, reference should be made to the Ingle U.S. Pat. No. 1,911,119 or certain patents issued to G. E. Rowe, particularly U.S. Pat. Nos. 2,508,890; 2,702,444; and 2,755,597.
Beginning at the upper end 28 of the piston rod 20, a central circular full-length bore 30 is provided within the piston rod 20. Within the bore 30 is an annular shoulder 32 separating a narrowed short bore segment 34 from the major wider bore portion therebeow which extends the remainder of the length of the piston 20 and is of uniform diameter.
Also shown in FIG. 1 and 2 is air tube structure including a first tube or tubular member 38, the upper end of which is secured within the upper end of the piston rod 20 by a connecting member 40. Between the inside wall surface of the piston rod 20 and the tube 38 is an annular space 42, and extending within the annular space 42 is the upper end of a second tube or tubular member 44 which projects upwardly from the inward surface of the end cap 16. Securably press-fit into the second tubular member 44 is a tube liner 46 having an upper tubular portion 47 and a lower end solid base portion 48 (see FIG. 4) secured in a socket 50 in the end cap 16.
The first tubular member 38 is shown as it appears removed from the mechanism 10, in FIG. 8, and details of the tube base connector 40 are shown in FIGS. 9 and 10. FIG. 3 shows the second tubular member 44 as it appears removed from the mechanism, and FIG. 4 shows the tube liner 46. The tubular members 38 and 44 are of rigid relatively thin-walled construction. The liner 46 is also rigid, and its upper portion 47 is tightly press-fit into the tube 44. The tube 38 has an upper end 52 which is designed to be sealably threaded into a socket end 54 of the connector 40, and the narrow end 56 of the connector 40 is sealably threaded into sealed securement within the lower end of the bore segment 34 in the piston rod 20, as shown in FIG. 1.
The second tubular member 44 is held in its fixed operative position, projecting upwardly from the end cap 16, by means of the tube liner 46. The lower end of the tubular member 44 abuts an annular ledge 62 of the liner 46. The lower solid end or base portion 48 of the liner 46 has annular shoulders 64 and 66 which compress against O-rings resting on complementary shoulders 68 and 70 in the socket 50 of the end cap 16, as shown in FIG. 1. The base portion 48 (FIG. 6) also has an integral annular ridge 72 with an annular recess 74 to accommodate a seal ring 76 (FIG. 1). A circular snap-ring 78 fits into an accommodating annular groove at the upper end of socket 50 of the end cap 16 and projects outwardly over the upper surface of the ledge 72 to retain the liner 46 in secured fixed mounted position on the end cap 16. The liner 46 has an angled transitional opening 80 which is in sealed air flow communication with a cooling air opening or port 82 entering laterally through the body of the end cap 16.
The bore 30 of the piston rod 20, at its lower end, is widened to accommodate an annular bearing 86 and an annular seal 90 which are fixed to the piston rod 20 to slide against the outer sidewall surface of the second tubular member 44. Within the second tubular member 44, beginning at the upper end of the liner 46, an annular bearing 92 and an upwardly-successive annular seal 94 are fixed to the inside surface of the tubular member 44 to slide against the sidewall outer surface of the tubular member 38. The internal groove 58 in the upper end of tube 44 (FIG. 5) accommodates a snap-ring to retain the bearing 92 and seal 94 in position against the outer end of the liner 46.
In the function of the mechanism 10 shown in FIGS. 1 and 7, pressurized air to drive the piston 22 and the rod 20 is delivered to the chamber 14 through an air inlet port 98 and into an annular piston recess 100 to move the piston and rod 20 from the maximum down position shown in FIG. 1 to the maximum up position shown in FIG. 7. By other means (not shown), the rod 20 is held in the intermediate blank-loading position during operation of the mechanism. Incoming cooling air flow moves from the port 82, through the transition 80 and upwardly through the lower coaxial tube arrangement 44 and 46. The air flow then moves through the upper tube 38, through the rod bore segment 34 and into the central air passage of the plunger.
The structure and function of the sliding tube-in-a-tube arrangement for directing cooling air flow to the piston 20, as heretofore described, is specifically disclosed as a distinct and separate invention in a separate patent application filed concurrently herewith. A feature of the present invention, however, is the adaptation and modification of the air tube structure to obtain a position reactive means of sensing the linear position of the piston rod, and sense the plunger, in the form of a linear transducer, identified in FIG. 1 by the number 102, which is hereinafter explained in greater detail.
FIG. 1 illustrates a saddle plate 104 having affixed to the upper surface thereof separate port blocks 106 and 108. The saddle plate and port blocks serve as a supporting cradle for the cylinder 10. The cylinder 10 is adapted to be manually withdrawn through an intermediate ring-like positioning plate (not shown) when it is necessary to remove and replace the cylinder. The port blocks 106 and 108 define respective air inlet passages 110 and 112 communicating, respectively, with end cap ports 82 and 98. The passage 110 terminates inwardly on the inward face of the block 106 with a flexible seal 114, and the passage 112 terminates inwardly on its support block with a flexible seal 116. When the cylinder 10 is installed into its operative position on the saddle plate 104, the seals 114 and 116 compressibly complete sealed air flow communication whereby a pressurized flow of cooling air directed inwardly through the passage 110 will move through the port 82 and thence upwardly through the central sir tube structure, and a separate air flow directed inwardly through the passage 112 will move through the port 98 and into the chamber 14 for imparting a driving force to the piston 22.
FIG. 1 also illustrates an exhaust manifold 120 mounted laterally on the cylinder structure and having an inner passage 122 in flow communication with an opening 124 for receiving exhaust air flow from within the positioner mount 24. Insertably mounted upwardly through an opening 126 in manifold 120 is a thermocouple device 128 having a sensing tip 130 projecting into the passage 122.
The linear transducer assembly 102, shown in FIGS. 1 and 2, comprises a wound wire coil 140 secured within the second tubular member 44 at the upper termination of the liner 46. Extending from the coil 140 and downwardly through the tube structure are insulated electrical conductors 142, which lead downwardly to a separable connector 144. As shown in FIG. 7, the liner 46 is provided with a longitudinal service groove 148 which provides a passage for the conductors 142 along the inside wall of tubular member 44. At the lower end of tubular member 44, where the annular ridge 72 of the liner 46 projects radially outwardly, the groove 148 merges with a small opening 150 (see FIG. 6) which angles downwardly through the liner base 48 and merges with a socket opening 152 in the base 48 (see FIG. 4). The lowermost ends of the conductors 142 project through the opening 150 and to the separable connector 144, as shown in FIGS. 1 and 2. The connector 144 comprises a female receptacle 156 locked into the socket 152 by means of a groove and snap-ring arrangement 158 (FIG. 4). The connector 144 further comprises a male plug 160 firmly cemented into an accommodating opening in a bracket 162 which is removably attached to the underside of the saddle plate 104 in alignment with an accommodating central opening through a box 164 integral to the end cap 16.
The transducer 102 further comprises the tubular member 38, the lower end of which (as shown in FIG. 1) will move linearly within the coil 140 when the piston 20 nears its maximum linear extension from a cylinder 10. The operation of the linear transducer 102 is effected by inducing a low-voltage electrical current to the coil 140. This is accomplished by directing the electrical current from a remote electrical potential source through a coaxial cable 170 and through the connector 144 and the conductors 142. For the purpose of attaining the linear position function of the transducer 102, the tube 38 must be formed from aluminum or some other non-ferrous material. Energization of the coil 140 creates a magnetic field which, when interrupted by the presence of the lower end of the tube 38 within the coil, directly affects the voltage of the current passing through the coil. The voltage will vary as a function of the vertical position of the end of the tube 38 within the coil 140, and the voltage of the current in the coil can be determined at any point in time by appropriate instrumentation, at a remote operator location, appropriately connected to the coil by means of the coaxial cable 170.
The performance control monitoring device of the present invention comprises utilization of means of sensing certain critical conditions occuring in a plunger cycling mechanism, particularly conditions occuring in the operation of the mechanism's cylinder, to simultaneously collect and report data which can be interpreted and used to adjust controllable functions such as timing and air flow input, and correlating these functions to obtain improved quality in the glass containers being produced. The system preferably includes a position-reactive means within the cylinder for sensing, during the pressing operation, the linear position of the plunder, pressure-reactive means for sensing the pressure of the air stream provided to impart linear pressing motion to the plunger, and temperature-reactive means for sensing the temperature of cooling air being directed to the plunger and to sense the heated exhaust air moving out of the plunger, and further including means to continuously transmit the sensed conditions to a remote operator location for processing and correlation whereby adjustments can be continuously performed, as required, either manually or by computerized control means, to maintain optimum operating conditions with the mechanism.
The position-reactive means is preferably the linear transducer 102 shown in FIG. 1, including an electrical field coil installed within an air tube of the machine as heretofore described. The pressure-reactive means is preferably a pressure transducer device, such as the device 132 shown in FIG. 1, installed to continuously sense pressure of the air flow moving through the passage which communicates with the port providing air to the chamber 14 of the piston 10. The temperature-sensing means preferably includes a thermocouple mounted somewhere on the incoming air line to the cylinder (not shown) and a device, such as thermocouple 128, mounted directly in the exhaust air stream of the mechanism. With respect to the means of sensing the incoming air pressure, it is preferred, in a multiple-gob section, to have the thermocouple located to sense the temperature of the air flow before it divides into separate conduits to each cylinder of the section whereby only one thermocouple needs to be used for this purpose on a double-gob or triple-gob section, etc. It is also of significant importance that the sensing devices be appropriately located and installed to perform their function without interference with removal and replacement of the cylinder 10 relative to the saddle plate 104 and port blocks 106 and 108. Accordingly, the thermocouple 128 is placed in the exhaust manifold which, like the port block 108 on which the pressure transducer 132 is mounted, remains in place during change of the cylinder. In this regard, it should be noted that the coil 140 is a constituent part of the air tube structure assembly which "comes with" and remains within each cylinder assembly as a constituent part thereof, and that the separable connector 144 is adapted to separate as a function of the removal of the cylinder from its mounted position and to automatically rejoin and complete the circuit to the coil as a function of replacement of the cylinder into its mounted position.
In the cylinder performance monitoring system of the present invention, the importance of obtaining comparative data on the cooling and exhaust air flow and the pressure of the piston-impelling air flow, along with the linear position of the plunger during the gob-pressing operation. The plunger-impelling air flow can be interpreted to determine the speed at which the plunger moves to its maximum position. Measuring the temperature of incoming air and then comparing it to the exhaust temperature provides a means of calculating and then controlling the temperature, and, hence, the rate at which heat is extracted from the parison during the parison-forming operation. Knowing the linear position of the plunger at its uppermost dwell point and the distance the plunger travels before it is stopped by the pressure of the glass in the mold can be interpreted to determine the volume of glass in the blank. The sensing and collecting of such data, simultaneously and continuously during the parison-forming operation, enables continuous process control never before attained.
Because the plunger which is pressed into the glass gob to form the parison is metal, the intense heat of the glass transfers to the highly conductive metal and causes physical expansion whereby the plunger actually increases in length and direct proportion to the amount of heat it absorbs. Hence, the actual distance of penetration of the plunger into the glass is function of temperature within the plunger. The temperature data received by the monitoring system herein described can be utilized to more closely maintain an ideal operating temperature whereby more accurate linear positioning of the plunger can be determined at the critical dwell point.
The pressure of the air within the cylinder which advances the piston and, hence, the plunger in its pressing operation, goes from zero and gradually to maximum pressure in response to the resistance of the glass gob which finally halts the upward movement of the plunger. When the glass stops the upward penetration of the plunger, air is still being applied to the piston, and since the air in the cylinder chamber is compressible, the viscosity of the glass in the mold will determine the final stopping point of the plunger at which point the maximum air pressure can be determined by the pressure transducer 132.
By virtue of the system herein disclosed, the temperature can be maintained at a desired parameter whereby the plunger is not being overheated or underheated. At this known temperature, the performance of the cylinder can be determined by ascertaining how quickly the pressure being delivered to the cylinder moves the plunger to the position of full penetration, and the distance of travel of the plunger can be utilized, in view of its direct relationship to gob weight, to control gob weight and vary it as necessary. By monitoring the temperature of the air flow through the plunger, the air pressure against the piston, and the linear advancement of the plunger, the quality of glass containers being formed can be known without ever examining a finished container delivered from the machine.
The cylinder performance monitoring system of the present invention enables separate monitoring of each cylinder in a plural-gob section, as illustrated in FIG. 11. Each cylinder would have, as shown in FIG. 11, its own linear transducer to monitor the up position of the plunger, and separate thermocouples 128 and pressure transducers 132 would be utilized to respectively separately monitor the temperature and pressure conditions in the separate cylinders 10.
The present invention has been described and illustrated in connection with a presently preferred embodiment, however, it is to be understood that other modifications and variations may be resorted to without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the invention and the appended claims.
|
A method of collecting data to indicate certain internal conditions during the function of a glass container forming machine, and apparatus for the practice of the method including sensing devices within a plunger cycling mechanism of the machine for transmitting information from the mechanism during the operation of the machine.
| 8
|
BACKGROUND OF THE INVENTION
It is well known in the art to clarify raw turbid waters containing kaolin or other finely divided suspended solids with various inorganic compounds and water soluble organic positively charged polymeric coagulants which are used independently of one another. In general, for high turbidity waters containing, for example 200 parts per million (ppm) kaolin, such organic coagulants are effective in reducing turbidity. In low turbidity waters, for example, those containing 20 ppm kaolin, the organic coagulants alone are not as effective. Cost effectiveness is also a problem in water clarification.
U.S. Pat. No. 4,450,092 teaches the use of polydiallyl dimethylammonium chloride polymer or dimethylamine epichlorohydrin ethylene diamine polymer used in conjunction with either aluminum chloride, aluminum sulfate, ferric chloride, or ferric sulfate. This combination of polymeric coagulant having an average molecular weight of at least 2000 and inorganic water soluble salt specified above has been shown to be useful for coagulating finely divided solids in turbid water.
It is desirable to provide a new and improved products which is effective in clarifying water and at the same time are cost effective.
BRIEF SUMMARY OF THE INVENTION
In accordance with the invention compositions are provided which are useful for coagulating finely divided solids in turbid waters. These are prepared by mixing or blending together with calcium chloride a water soluble organic positively charged polymeric coagulant such as polydiallyl dimethylammonium chloride polymer or dimethylamine epichlorohydrin-ethylenediamine polymer. The compositions are especially useful for treating low turbidity waters, for example, waters having a turbidity of less than 20 NTU (nephelometric turbidity units). More particularly, these compositions are useful for reducing the heavy metal (Zn, Pb, Cr, Mn) of water.
These compositions provide a dosing advantage over the compositions of the U.S. Pat. No. 4,450,092.
DETAILED DESCRIPTION OF THE INVENTION
Calcium chloride is available commercially as a solid and can be dissolved in water to form an aqueous solution.
Usually, for the purpose of the invention, it is preferable to employ the inorganic component of the composition as an 18-40% by weight aqueous solution, preferably 18-25% by weight.
The preferred high molecular weight polydiallyl dimethylammonium chloride polymer has an intrinsic viscosity of 0.8 and a molecular weight of approximately 100,000. The preferred dimethylamine epichlorohydrin-ethylenediamine polymer is available commercially as a 47% by weight polymer in aqueous solution. The high molecular weight polydiallyl dimethylammonium chloride polymer is available commercially as a 20% by weight polymer in aqueous solution. These polymers are positively charged. Other polymers of a similar type with intrinsic viscosities usually within the range of 0.08 to 1.0 can be employed for the practice of the invention.
Since the compositions employed for the purpose of the invention are used in very small dosages measured in terms of parts per million (ppm) of the water being treated, it is desirable from the standpoint of application to prepare the compositions in the form of aqueous solutions. In preparing these solutions it is preferable to prepare the inorganic component separately as a aqueous solution having 18-25% by weight solids concentration, although the solids concentration may go as high as 40% by weight, and to mix or blend this solution and the water soluble organic positively charged polymeric coagulant component, which has also been previously dissolved or occurs commercially, in aqueous solution.
In general, the weight ratio of the inorganic component of the compositions prepared in accordance with the invention and utilized to clarify turbid waters is within the range of 0.75:1 to about 4:1 and the water present in the solutions containing said components will vary from about 30% by weight to about 57% by weight.
For turbidity removal a pH greater than 5 is desired. To maximize heavy metal ion removal a pH greater than 8 is desired.
EXAMPLES
The invention will be further illustrated but is not limited by the following example in which the quantities are by weight unless otherwise indicated.
The following Tables provide Product Compositions used, Jar Test results using those compositions or water from an actual existing automotive plant, and Influent, Effluent and Sludge cake analyses from an actual automotive plant.
The standard jar test described in The Nalco Water Handbook, 808 to 822, McGraw Hill Book Company, 1979 was used. A 500 ml sample of turbid water was dosed at 100 rpm. The clarity at 3 minutes was noted.
TABLE I______________________________________PRODUCT COMPOSITION______________________________________A 15 wt % Dimethylamine epichlorohydrin-ethylene diamine polymer 85 wt % Aluminum Chloride Solution (23 wt % AlCl.sub.3)B 19.2 wt % CaCl.sub.2 20.0 wt % Polydiallyl dimethylammonium chloride polymer, iv = 0.12-0.18; Mw = 50,000; 20 wt % polymer 60.8 wt % Naperville Tap Water (NTW)C 19.2 wt % CaCl.sub.2 20.0 wt % Polydiallyl dimethylammonium chloride polymer, iv = 0.25; Mw = 50,000; 20 wt % polymer 60.8 wt % NTWD 19.2 wt % CaCl.sub.2 20.8 wt % Dimethylamine epichlorohydrin-ethylene diamine polymer, iv = 0.12-0.18; Mw = 50,000; 47 wt % polymer 60.8 wt % NTWE 19.2 wt % CaCl.sub.2 20.3 wt % Dimethylamine epichlorohydrin-ethylene diamine polymer, iv = 0.08; Mw = 20,000 50 wt % polymer 60.8 wt % NTWF 5.0 wt % Dimethylamine epichlorohydrin-ethylene diamine polymer, iv = 0.25; Mw = 50,000; 20 wt % polymer 95.0 wt % Ferric Chloride Solution (14.1% FeCl.sub.3)______________________________________
TABLE II______________________________________Jar Testing ResultsFor the Product CompositionsProduct Dosage (PPM) Clarity______________________________________10% Lime 150 GoodA 50 GoodB 25 GoodC 50 GoodD 50 GoodE No Activity HazyF 50 Good______________________________________
TABLE III______________________________________Influent AWATER ANALYSIS______________________________________ *FILTERABLE* TOTALCATIONS: PPM PPM______________________________________Calcium (CaCO3) 380. 720.Magnesium (CaCO3) 56. 850.Sodium (CaCO3) 1600. 1600.Nickel (Ni) 0.3 47.Potassium (K) 27. 27.Cadmium (Cd) 0.02Chromium (Cr) 29.Copper (Cu) 0.39Iron (Fe) 0.06 34.Manganese (Mn) 0.44Strontium (Sr) 0.19 0.34Titanium (Ti) 0.23Zinc (Zn) 0.01 11.Aluminum (Al) 2.0Lead (Pb) 0.05 0.05ANIONS: PPM PPMBoron (B) 5.9Phosphorus (P) 1.7 54.Silica (SiO2) 36.Sulfur (S) 180. 180.OTHERS: PPM PPMTotal Suspended Solids at 105 C. 1600.*Passes through a 0.45 micron filter*The following elements were 0.1 ppm:Ba Mo SbThe following elements were 0.01 ppm:Co V Zr______________________________________
TABLE IV______________________________________Effluent AWATER ANALYSIS______________________________________ *FILTERABLE* TOTALCATIONS PPM PPM______________________________________Calcium (CaCO3) 340. 340.Magnesium (CaCO3) 68. 72.Sodium (CaCO3) 1200. 1200.Barium (Ba) 0.4 0.4Nickel (Ni) 0.3 0.7Potassium (K) 31. 31.Chromium (Cr) 0.5 0.29Copper (Cu) 0.02 0.02Iron (Fe) 0.10 0.39Strontium (Sr) 0.19 0.20Titanium (Ti) 0.03Vanadium (V) 0.01 0.01Zinc (Zn) 0.01 0.01Zirconium (Zr) 0.01 0.01Aluminum (Al) 0.1Lead (Pb) 0.05 0.05ANIONS: PPM PPMBoron (B) 6.7Phosphorus (P) 1.8 2.2Silica (SiO2) 46.OTHERS: PPM PPMTotal Suspended Solids at 105 C.*Passes through a 0.45 micron filter*The following elements were 0.1 ppm:Mo SbThe following elements were 0.01 ppm:Cd Co Mn______________________________________
TABLE V______________________________________Sludge Cake for AASH ANALYSIS(WEIGHT PERCENT OF ASH)______________________________________Magnesium (MgO) 35Calcium (CaO) 17Silicon (SiO2) 14Phosphorus (P2O5) 10Chromium (Cr2O3) 8Nickel (NiO) 5Iron (Fe2O3) 4Sulfur (SO3) 3Sodium (Na2O) 1Zinc (ZnO) 1Loss at 800 C. (%) 37.4Loss at 105 C. (%) 63.8Elements Not Detected in the Ash:Al Cl K Ti V Mn Co Cu SrMo Sn Ba Pb______________________________________
TABLE VI______________________________________Influent BWATER ANALYSIS______________________________________ *FILTERABLE* TOTALCATIONS PPM PPM______________________________________Calcium (CaCO3) 120. 150.Magnesium (CaCO3) 110. 150.Sodium (CaCO3) 780. 780.Nickel (Ni) 6.1 45.Potassium (K) 29. 29.Cadmium (Cd) 0.01Chromium (Cr) 0.02 33.Copper (Cu) 0.28Iron (Fe) 0.02 9.3Manganese (Mn) 0.01 0.15Strontium (Sr) 0.15 0.21Titanium (Ti) 0.08Zinc (Zn) 0.04 3.7Aluminum (Al) 0.4Lead (Pb) 0.05 0.05ANIONS: PPM PPMBoron (B) 7.3Phosphorus (P) 6.9 27.Silica (SiO2) 44.Sulfur (S) 170. 170.OTHERS: PPM PPMTotal Suspended Solids at 105 C. 410.*Passes through a 0.45 micron filter*The following elements were 0.1 ppm:Ba Mo SbThe following elements were 0.01 ppm:COo V Zr______________________________________
TABLE VII______________________________________EFFLUENT BWATER ANALYSIS______________________________________ *FILTERABLE* TOTALCATIONS: PPM PPM______________________________________Calcium (CaCO3) 130. 140.Magnesium (CaCO3) 70. 73.Sodium (CaCO3) 1100. 1100.Barium (Ba) 0.1 0.1Nickel (Ni) 0.3 0.4Potassium (K) 19. 19.Chromium (Cr) 0.05 0.14Copper (Cu) 0.01 0.02Iron (Fe) 0.06 0.12Strontium (Sr) 0.14 0.15Titanium (Ti) 0.03Zinc (Zn) 0.05 0.05Zirconium (Zr) 0.01Aluminum (Al) 0.01Lead (Pb) 0.05 0.05ANIONS: PPM PPMBoron (B) 8.0Phosphorus (P) 2.0 2.4Silica (SiO2) 36.OTHERS: PPM PPMTotal Suspended Solids at 105 C. 5.*Passes through a 0.45 micron filter*The following elements were 0.1 ppm:Mo SbThe following elements were 0.01 ppm:Cd Co Mn V______________________________________
TABLE VIII______________________________________Sludge Case For BASH ANALYSIS(WEIGHT PERCENT OF ASH)______________________________________Chromium (Cr2O3) 24Magnesium (MgO) 18Phosphorus (P2O5) 13Nickel (NiO) 13Silicon (SiO2) 12Calcium (CaO) 10Iron (Fe2O3) 4Sulfur (SO.sub.3) 2Sodium (Na2O) 1Zinc (ZnO) 1Loss at 800 C. (%) 40.4Loss at 105 C. (%) 65.1Elements Not Detected In The Ash:Al Cl K Ti V Mn Co Cu SrMo Sn Ba Pb______________________________________
While the blends produced in accordance with the invention are useful in reducing water turbidity levels in both high turbidity water and low turbidity water they are especially useful in low turbidity water clarification applications in which most organic coagulants do not reduce water turbidity levels to the desired range. In the past, alum and other inorganic coagulants have been used for this type of application. However, the alum sludge and other inorganic sludges are often too bulky and too fine for handling. Blends of the inorganic and organic coagulants alleviate this problem.
As shown by the data, these compositions significantly reduce the amount of the heavy metal found in the water to be clarified. A reduction of greater than 50% is achieveable.
|
A process for reducing turbidity in turbid waters which comprises adding to said waters a composition consisting essentially of an aqueous solution of:
(a) calcium chloride and
(b) a water soluble organic positively charged polymeric coagulant having an average molecular weight of at least 2000 selected from the group consisting of polydiallyl dimethylammonium chloride polymer and dimethylamine epichlorohydrin ethylenediamine
the weight of (a) to (b) being within the range of 0.75:1 to 4:1.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to removable stanchions for supporting life lines and more particularly to a novel stanchion adapted to terminate mountings on a variety of building structures and which includes a detachable portion adaptable for removal when not required.
2. Brief Description of the Prior Art
In the past, stanchions have been combined so as to cooperatively support a life line or a pair of life lines which are trained around the perimeter of a predetermined area. Such an area may be the gunwale of a boat or the edge of a building on a roof. In the latter instance, the life line is intended for temporary use while workmen are in the process of construction or repair activities on the roof. Once the construction or repairs have taken place, the life line is removed. However, upon the need for workment to go along at subsequent times, a new life line system must be established. Installation at this time is extremely hazardous to personnel, time consuming and it may structurally damage the building fixtures upon which the life line system is being reestablished.
Such prior art systems can be found in disclosures of U.S. Pat. Nos. 2,379,572 and 3,268,193. Although the prior stanchions and line supports are useful for their intended purposes, they do not reflect a detachable or removable construction and do not provide means for reusable supports in the event establishment of a safety line system is needed after initial installation.
Therefore, a long standing need is present to provide a stanchion for life line support that may be readily installed and removed leaving a base portion secured to the building construction for future reestablishment for a life line system.
SUMMARY OF THE INVENTION
Accordingly, the above problems and difficulties are obviated by the present invention which provides a novel stanchion and life line system wherein each stanchion includes an anchor base or support which is form fitting to the structure on which it is attached. The anchor or base support further includes a tube section or portion which is fixedly carried on the anchor plate or base and is supported thereon by means of an angular gusset. The tubular portion on the support insertably receives one end of an elongated post, rod or tube which extends upwardly and includes a plurality of eyelets intended to slidably receive a length of life line. Means are provided for releasably or detachably coupling a selected end of the post, rod or tube to the tubular support base or anchor and other means are provided for indexing the elongated rod, post or tube to the base so that the eyelets project from a selected side of the base. Such an arrangement would provide a means for cooperating with life line extension from adjacent ones of other stanchions arranged about the perimeter of an area to be protected.
Therefore, it is among the primary objects of the present invention to provide a novel life line stanchion system wherein installation may be initially reformed followed by subsequent removal of the stanchion whereby the base would remain for future reestablishment of the system.
Another object of the present invention is to provide a novel life line stanchion having a permanently secured base portion fastened to a building structure and a removable portion which supports a life line system.
Another object of the present invention is to provide novel life line system wherein each stanchion includes an anchor support form fitted to a variety of structures.
A further object of the present invention is to provide a novel life line stanchion having a fixed portion for anchoring the stanchion on to a roof of a building and having a removable portion carried thereon by means of indexing and releasable fastening devices so that the base or anchor portion need not be removed when the need for life line support is no longer present and the removable portion has been disassembled.
Still a further object of the present invention is to provide a novel life line stanchion having a fixed portion and a removable portion secured together by releasable means which is inexpensive to manufacture and which is easily maintained and installed.
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 present invention, both as to its organization and manner of operation, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings in which:
FIG. 1 is a perspective view of the novel life line stanchion system incorporating a plurality of stanchions for cooperatively supporting a pair of life lines;
FIG. 2 is an enlarged longitudinal cross sectional view of a novel stanchion used in the system of the present invention;
FIG. 3 is a transverse cross sectional view of a modified base for the novel stanchion so that the stanchion may be supported on a roof wall;
FIG. 4 is a side elevational view of another system for securing the base on to a roof;
FIG. 5 is another modification of the anchor or support base illustrated for installation on an inclined or angular roof surface; and
FIGS. 6 and 7 are other embodiments.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the roof of a building is illustrated and represented by numeral 10 which includes a roof 11 having a edge 12 joining with the sides of the building to define the outer limits of the roof. In order to protect personnel, such as workmen and others, while engaging in construction or repair of the roof, a life line support system is incorporated on the roof and is shown in the general direction of arrow 13. The life line support system includes a plurality of upright stanchions, such as stanchion 14, which cooperate with adjacent stanchions for supporting a pair of life lines 15 and 16 which are trained through eyelets 17 and 18 on each of the stanchions. A feature of the present invention resides in the fact that each of the stanchions includes a support base 20 which is fixedly secured onto the surface of the base 11, a tubular portion 21 which is attached to the base or anchor 20 and serve to support a removable portion 22. The eyelets 17 and 18 are carried on a removable portion 22. By this means, the life line system may be erected while workmen are performing the repairs or construction on a roof and when this work has been completed, the removable portions 22 may be separated from the fixed portion. Therefore, the fixed portion can remain on a roof ready for installation of the removable portion and establishment of a life line system.
It can be seen that the anchor or base 20 is rigidly attached to support members 23 and 24 of the roof construction by means of bolts or screws 25. The anchor or base 20 includes a tubular portion 26 which is made rigid by means of a gusset plate 27. Tube 21 may be a part of the tube 26 and in any event, upwardly projects from the support base 20 so as to terminate at an open free end 28. A selected end of removable tube or rod 22 is inserably received through the open end 28 and removable securement is effected by means of a detachable fastening means such as a pin 30 which passes through aligned holes provided in tubes 21 and 22 respectively. Unused holes in tubes 22 are illustrated by numeral 31. By this means, the height of the stanchion above the surface of the roof may be adjusted as desired.
Referring now in general to the embodiment shown in FIG. 3, modification of the anchor plate is made so that the stanchion may be installed on the edge of a wall 35 carried on the roof 11. The base 20 is modified so as to provide downwardly extending legs 36 and 37 which are separated by sufficient space to accommodate the thickness of the wall 35. Inasmuch as the thickness of walls sometimes is different from one building to another, an adjustment means is provided wherein the plate 20 is divided into a pair of L-shaped sections which are joined together by adjustment screws 38 and 39. It can be seen that the L-shaped plate 36 may be moved with respect to the L-shaped plate 37 since the fasteners 38 and 39 pass through a slot through one end of the plate 36 as indicated by numeral 40. Once proper separation has been established, the screws or bolts may be tightened so there is no further relative movement between the two L-shaped parts. In a similar fashion to the previously described embodiment, gusset plates 41 and 42 are provided for added strength and the upright post or rod 22 is removable from the support tube 21.
With respect to FIG. 4, a modification is shown wherein the anchor support 20 includes a downwardly depending tube 43 which is buried or imbedded within a beam 44 of the roof structure. The tube 43 includes a receptacle into which the upright post or rod 22 is seated. The receptacle 43 is a downwardly depending extension from the upper tube 21 which removably receives the selected end of an upright tube or rod 22. A removable pin 30 is employed for detachably securing the tubes 21 and 22 together.
In FIG. 5, another modification is illustrated so that the base plate 20 may be carried on a slanting or inclined roof 11'. In this latter instance, the plate 20 angularly disposed with respect to the elongated center line or longitudinal axis of the tube 21.
Referring to FIGS. 5 and 6, additional versions or modifications of the present invention are illustrated wherein a portable life line stanchion is shown that does not require as substantial and anchoring fixture as previously described. For example, the stanchion shown in FIG. 6 includes a base anchor or plate 50 which is fixedly secured to the surface of the roof 51 by any suitable means such as screws, bolts or the like. The remainder of the stanchion is detachably connected or releasably secured to a lug 52 carried on the plate 50 by means of a wing nut attachment 53. The stanchion itself includes a post portion 52 which carries an L-shaped member 55 on one end and a lug 56 on its opposite end. Between the lug 52 and the lug 56 and extendable or expandable brace 57 is attached at its opposite end by pivot means. The extendable member 57 includes a plurality of holes or apertures, such as aperture 58, which may be readily aligned with a pin insertably carried on a slide member 59. The pin is identified by numeral 60 and may be slid or inserted through a hole in the slider 59 when it is in registry with a selected one of the holes in the member 57. A brace 61 is pivotally connected at its opposite ends between an intermediate lug 62 carried on the post 54 midway between its opposite ends and a lug 63 carried on the slider 59. By this construction, the height of the post may be accommodated depending upon the distance between the corner of the roof and the placement of the blade 50. Also, the L-shaped member 55 form fits about the corner or the edge of the roof 50.
Referring now in detail to FIG. 7, it is noted that the stanchion apparatus is substantially similar to that shown in FIG. 6 with the exception that the brace 65 is fixed between the post 54 and expandable member 57. In this instance, member 57 is composed of a pair of links having a slot formed in one with a wing nut tying the two together. Therefore, when it is desired to extend the length of member 57, the pair of links are pulled apart when the wing nut is released and when the stanchion post 54 is properly seated on the roof, the wing nut can be tightened to prevent slippage between the two links. Suitable eyelets and life lines may be carried on the exterior surface of the respective posts.
In the modification shown in FIGS. 5 and 6, when it is desired to remove the stanchion, all that is necessary is removal of the wing nut 53 so that the entire post and expandable member 57, including brace 55, can be removed.
Accordingly, it can be seen that the novel stanchion system of the present invention provides a plurality of stanchions wherein each stanchion has a removable portion which may be detached from a base portion when it is desired to take the life line system away from the installed installation. The anchor portion is permanently mounted to the roof and is ready for use at a subsequent time to receive the removed portion to re-establish the life line system. A plurality of different shaped base plates are provided so that a variety of different shaped roof supports may be accommodated. The anchor support may be placed on the edges of walls, slopes or inclined roofs, flat roofs or carried into buried receptacles.
While particular embodiments of the present 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 this invention in its broader aspects and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of this invention.
|
A stanchion is disclosed herein for supporting a life line around the perimeter of an elevated area such as a building roof. The stanchion includes a base secured to a building support and includes a tubular receptacle carried on the base and supported thereon by an angular gusset. The tubular receptacle insertably receives one end of an elongated rod or tube which projects upwardly and terminates in a free end. Midway along the length of the upright tube and the support tube, a plurality of eyelets are provided through which the life line may be trained. Removable fastening means as well as indexing devices are employed for detachably securing the upright tube or rod to the support tube.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority to U.S. Provisional Application No. 61/460,417 filed on Jan. 3, 2011, all of which application is incorporated herein by reference in its entirety for all purposes.
TECHNICAL FIELD
The present invention relates generally to structural wall assemblies and, more particularly, to metal framing structural wall components, support members, and related assemblies configured to sealingly connect together opposing edges of adjacent pieces of wallboard positioned on a wall assembly.
BACKGROUND OF THE INVENTION
In the building construction industry metal framing assemblies are commonly used to construct commercial and residential buildings. Such metal framing assemblies are generally constructed from a plurality of metal framing members including studs, joist, trusses, and other metal posts and beams formed from sheet metal and frequently fabricated to have the same general cross-sectional dimensions as standard wood members used for similar purposes. Metal framing members are typically constructed by roll-forming 12 to 24 gauge galvanized sheet steel. Although many cross-sectional shapes are available, the primary shapes used in building construction are C-shaped studs and U-shaped tracks.
In the building construction trade, a head-of-wall joint (also sometimes referred to as a top-of-wall joint) refers to the linear junction or interface existing between a top section of a framing/wallboard wall assembly and the ceiling (where the ceiling may be a next-level floor or corrugated pan roof deck, for example). In common practice, a wall to ceiling connection of many newly constructed buildings consists essentially of an inverted U-shaped elongated steel channel (or track) configured to receive steel studs between the legs (also sometimes referred to as sidewalls or flanges) of the shaped channel. A wallboard is generally attached to at least one side of the studs. The studs and wallboard are in many instances spaced apart from the ceiling a short gap distance in order to allow for ceiling deflections caused by seismic activity or moving overhead loads. Similarly, wallboard is also commonly horizontally spaced apart as short gap distance from an immediately adjacent piece of wallboard (to thereby allow for thermal expansion and/or contraction of the wallboard without visible wall cracking). Exemplary steel stud wall constructions may be found in U.S. Pat. Nos. 4,854,096 and 4,805,364 both to Smolik, and U.S. Pat. No. 5,127,203 to Paquette. Exemplary dynamic head-of-wall systems having steel stud wall constructions may be found in U.S. Pat. No. 5,127,760 to Brady, and U.S. Pat. No. 6,748,705 to Orszulak et al.
In order to contain the spread of smoke and fire, a fire resistant material such as, for example, mineral wool is often times stuffed into the gaps between the ceiling and wallboard. For example, mineral wool is often stuffed between a steel header beam (e.g., an elongated U-shaped channel) and a corrugated steel roof deck (used in many types of steel and concrete building constructions); a fire resistant and generally elastomeric spray coating is then applied onto the exposed mineral wool to thereby form a fire resistant joint seal. In certain situations where the ceiling to wallboard gap is relatively small, a fire resistant and elastomeric caulk is commonly applied so as to fill any small gaps.
Intumescent materials have been used to seal certain types of construction gaps such as, for example, conduit through-holes. In this regard, intumescent and fire barrier materials (often referred to as firestop materials or fire retardant materials) have been used to reduce or eliminate the passage of smoke and fire through openings between walls and floors and the openings caused by through-penetrations (i.e., an opening in a floor or wall which passes all the way through from one room to another) in buildings, such as the voids left by burning or melting cable insulation resulting from a fire in a modern office building. Characteristics of fire barrier materials suitable for typical commercial fire protection use include flexibility prior to exposure to heat, the ability to insulate and/or expand, and the ability to harden in place upon exposure to fire (i.e., to char sufficiently to deter the passage of heat, smoke, flames, and/or gases). Although many such materials are available, the industry has long sought better and more effective uses of these materials and novel approaches for better fire protection, especially in the context of wall construction joints and gaps.
Among the few products and methods available for effectively and efficiently sealing head-of-wall construction joints and gaps (to thereby significantly enhance the ability of such joints and gaps to withstand smoke and fire penetration) are those sold under the tradename BLAZEFRAME, which products are protected under U.S. Pat. No. 7,681,365, U.S. Pat. No. 7,814,718, U.S. Pat. No. 7,866,108, and U.S. Pat. No. 8,056,293 all to Klein. In particular, the BlazeFrame line of technology addresses the need for adequate fire protection of dynamic head-of-wall systems associated with steel stud wall constructions.
Although advances have been made with respect to fire protection of structural wall assemblies, there is still a need in the art for new and improved structural wall assemblies and related components, especially in terms of products that allow for expansion and/or contraction of opposing pieces of wallboard fastened onto a wall assembly, while at the same time allowing for adequate fire protection. The present invention fulfills these needs and provides for further related advantages.
SUMMARY OF THE INVENTION
In brief, the present invention in one embodiment is directed to a wall assembly comprising first and second pieces of wallboard positioned adjacent to each other. The first and second pieces of wallboard are positioned apart from each other a short gap distance to thereby allow for thermal expansion and/or contraction of the wallboard without visible wall cracking.
These and other aspects of the present invention will become more evident upon reference to the following detailed description and attached drawings. It is to be understood, however, that various changes, alterations, and substitutions may be made to the specific embodiments disclosed herein without departing from their essential spirit and scope.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an offset view of an embodiment of the profile described in provisional claim 2 having slots located in what will become the vertical leg once the profile is installed.
FIG. 2 is an offset view of an embodiment of the profile described in provisional claim having pre-punched alignment holes located in what will become the vertical leg once the profile is installed.
FIG. 3 is an end view of a wall assembly having a profile of provisional claims affixed to wall framing studs with the top sheet of the wall assembly on both sides in contact with the horizontal leg of the profile.
FIG. 4 is a frontal view showing the profile of provisional claim affixed to and bracing wall framing studs through pre-punched slots with the top sheet (cut away view) of a wall assembly in contact with the horizontal leg of the profile and a bottom sheet located below.
FIG. 5 is an end view of an embodiment of the invention of provisional claim with a flat strap and intumescent located in the center of the outside surface of the strap.
FIG. 6 is an end view of an embodiment of the invention of provisional claim with a flat strap having a minimum of one corrugation in the flat strap in the direction of the affixed intumescent.
FIG. 7 is an end view of an embodiment of the invention of provisional claim with a flat strap having a minimum of one hemmed edge on the flat strap and affixed intumescent.
FIG. 8 is an end view of an embodiment of the invention of provisional claim having a profile with a minimum of one additional flange that extends outward in a perpendicular fashion from the base “flat strap” in the direction of the affixed intumescent.
FIG. 9 is an end view of an embodiment of the invention having an angle profile of the base material (two flanges connected in perpendicular fashion) with an intumescent affixed to the outer surface of one flange.
FIG. 10 is an assembly detail drawing showing the invention located on the “cavity” side of installed wall sheathing behind a gap between opposing wall board sheets.
FIG. 11 is an assembly detail drawing showing the invention located on the “cavity” side of installed wall sheathing behind a gap between opposing wall board sheets having a control or reveal joint installed in and over the gap from the “finished” side.
FIG. 12 is an assembly detail drawing showing prior art approach of installing a second layer of drywall behind the finish layer containing the control joint materials to maintain a 1 hour fire rating.
FIG. 13 is an assembly detail drawing showing prior art approach of installing mineral wool in the wall cavity behind the finish layer containing the control joint materials to maintain a 1 hour fire rating.
FIG. 14 is an end view of three possible embodiments of the invention in provisional claim.
A—Single corrugation (pyramid shaped corrugation option) B—Extra flanges at body ends (square shaped corrugation option) C—Extra return flanges at end of flanges (rounded shaped corrugation option) D—Extra return flange at one end and corrugation at opposing end of body.
FIG. 15 is an end view of three possible embodiments of the invention with an affixed cured intumescent.
D—Single corrugation E—Extra flanges at body ends F—Extra return flanges at end of flanges G—Extra return flanges at one end and corrugation at opposite end of body.
FIG. 16 is an offset view of three possible embodiments of the invention with an affixed cured intumescent (on exemplary item B and D only)
A—Single corrugation B—Extra flanges at body ends C—Extra return flanges at end of flanges D—Extra return flange at one end and corrugation at opposite end of body
FIG. 17 is a top view of current methods of installation of control joints. Displayed are the 2 extra studs needed for drywall backing that span the wall cavity and either drywall rips or mineral wool “stuff” required to provide fire rating at control joint break in gypsum wall sheathing.
FIG. 18 is a top view showing use of the invention to support drywall edges and fire retardant materials behind the defined control joint on both sides.
FIG. 19 is a top view showing use of the invention on one side of the wall with a “horizontal wall cavity obstruction” (i.e. pipe or wire conduit) located in the wall cavity. The invention provides support of the gypsum board edges, fire stop material and doesn't become a wall cavity obstruction. Being formed to flex horizontally and of a size creating little intrusion allows invention installation during wall board installation post cavity obstructions. A control joint can also extend into the gap without encumbrance from any fire stopping materials in the joint.
FIG. 20 is a top view showing use of an embodiment located on and attached to the “hard side” of a wall framing stud member.
FIG. 21 is a top view showing the use of an embodiment with the corrugation located on the “soft side” of a wall framing stud member attached to the hard side via a flange of the profile.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings as appropriate, the present invention is directed to an angle support profile cooperative with walls and partitions of a building providing bracing of wall framing studs, vertical support of wall sheathing, a horizontal ledge to support the weight of wall sheathing material resting upon the ledge with the ledge having a distance shorter that the thickness of the wall sheathing.
The inventive profile may have a minimum of one horizontal slot in the vertical leg that allows for attachment of a fastener through to secure a wall framing “stud” and which the slot is wide and long enough to allow for the fastener attaching the stud to slide horizontally.
The inventive profile may have a minimum of one pre-punched hole in the vertical leg that allows for attachment of a fastener through to secure a wall framing “stud”.
A wall assembly utilizing any of the above-described profiles with the profile attached through the vertical leg to a minimum of one wall stud and having a minimum of one of the “top sheets” of the wall assembly in contact with a portion of the horizontal “ledger” leg of the profile.
A metal/intumescent composite formed from a “flat stock” piece of metal having an inner surface and outer surface with an intumescent material affixed to a portion of the outer surface area and having a minimum of one corrugation in the flat stock directed outward from the outer surface and/or having a minimum of one of the edges of the flat stock hemmed outward towards the affixed intumescent material and/or having the affixed intumescent located in a manner which exposes a portion of the metal material on both sides of the intumescent creating “free and open” ends.
An angle profile having two flanges connected in a perpendicular fashion and an intumescent material composite where the intumescent is attached to the outside surface of one flange at the intersection of both flanges.
The inventive profile may be located on the “cavity” side of installed wall or behind the outer surface layer of wall sheathing with the affixed intumescent on the outer surface of the embodiment directed outward from the wall framing materials and inward towards a gap between two opposed wall sheathing members or substrates.
The inventive profile may be located on the “cavity” side of installed wall sheathing with the affixed intumescent on the outer surface directed outward from the wall framing materials and inward towards a gap between two opposed wall sheathing members with a metal, vinyl, aluminum, or steel based control joint or reveal molding installed in and or over the defined joint from the “finished” side of the installed wall sheathing.
Stated somewhat differently, the present invention is directed to a wall assembly that comprises: a plurality of studs having upper and lower ends, the studs being vertically positioned relative to the ceiling and floor such that the uppers ends are engaged within a header track and the lower ends are engaged within a footer track; first and second pieces of wallboard attached to the plurality of studs, the first and second pieces of wallboard being adjacent to each other and separated apart from each other so as to define a control gap between them; a first strip of a sheet-metal material positioned within the wall and connecting the first and second pieces of wallboard together along the length of the control gap, the first material strip having a flexible first central portion that runs the length of the control gap and allows for expansion and contraction of the first and second pieces of wallboard without cracking; and a second strip of a sheet-metal material positioned on the wall and connecting the first and second pieces of wallboard together along the control gap, the first material strip having a flexible second central portion that runs the length of the control gap and allows for expansion and contraction of the first and second pieces of wallboard without cracking, and wherein the first and second strips seal the control gap from the interior and exterior wall spaces. As shown, an intumescent material strip positioned along the first central portion of the first material strip, the second central portion of the second material strip, or both.
While the present invention has been described in the context of the embodiments illustrated and described herein, the invention may be embodied in other specific ways or in other specific forms without departing from its spirit or essential characteristics. Therefore, the described embodiments are to be considered in all respects as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
|
The present invention is directed to a profile used to support fire retardant and or wall sheathing behind opposing wall sheathing edges, horizontally at head of walls, and behind control/reveal joint profiles. The profiles are shaped to support wall sheathing, intumescent stopping, and fire rated “rips” of wall sheathing and work in a manner that allows protection or support of intersecting opposing drywall edges.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a National Stage Application of International Patent Application No. PCT/CN 2004/000983, with an international filing date of Aug. 25, 2004, which is based on Chinese Patent Application No. 03135662.1, filed Aug. 25, 2003.The contents of both of these specifications are incorporated herein by reference.
TECHNICAL FIELD
The invention relates to an overpass, and especially an interchange overpass suitable for city roads and highways.
BACKGROUND
In order to solve traffic jams at city intersections many types of overpasses have been employed. Generally, triple level and higher grade overpass intersections are built for channeling motor and non-motor vehicles and for enabling transfer without impact and interference. Such high grade overpasses with their extra long ramps inconvenience drivers and occupy too much space. Especially in cities where much repositioning has to be done, the compensation cost for relocation of residents may be high. Providing clover-type overpasses will cause traffic jams in case of increased vehicle flow due to entanglement between the turning vehicles and the circling vehicles.
SUMMARY OF THE INVENTION
The invention provides a single-level interchange overpass having simple construction and full functionality, and occupying less space.
The technical solution of the invention is as follows: a single-level interchange overpass according to this invention comprises a main road and an intersected road, wherein a U-shaped circle road is provided on the horizontal level at both ends of the main road, a inner semicircle road and a outer semicircle road are provided at an exit of the said U-shaped circle road, a common road is provided between the inner semicircle road and the outer semicircle road, the common road is connected to an on-ramp of the intersected road through the outer semicircle road, and an off-ramp of the intersected road is connected to the on-ramp of the main road through the inner semicircle road.
In the above-described technical solution, an arched separated bridge is provided on the main road of the single layer interchange overpass, semi-ramped overhead bridge stages are provided on the intersected road on both sides of the arched separated bridge, the said semi-ramped overhead bridges stages are connected with the arched separated bridge through a connection platform, U-shaped circle roads are provided on the horizontal level at both ends of the arched separated bridge, the arcuate end of the outer semicircle road and the inner semicircle road is connected to the U-shaped circle road, the other end of the outer semicircle road and inner semicircle road of the U-shaped circle road is connected to the connection platform, a branch common road is provided on the off-ramp of the arched separated bridge of the main road, the other end of the common road is connected to the connection platform, a right turn road is provided at the entrance of the upper and lower U-shaped circle roads, and the other end of the right turn road is connected to the on-ramp of the arched separated bridge.
In the technical solution of this invention, in the single layer interchange overpass, the main road can be a leveled driveway, and the intersected road can be an overhead bridge, the U-shaped circle road comprises the inner semicircle road and the outer semicircle road, the common road is connected with the entrance of the outer semicircle road of the U-shaped circle road on other side of the overhead bridge after passing through under the overhead bridge, and the inner semicircle road is connected to the on-ramp of the main road through the left turn driveway.
The effects of the invention are as follows:
Reduction of the traditional 3 or 4 layer overpass to a single layer overpass allowing for transfer of vehicles from different directions and for separation of the motor and non-motor vehicles without inference. Pedestrians can walk on the original road eliminating the need to pass through tunnels or pedestrian overpasses. Reduction of the number of layers in the structures leads to an economic benefit.
The ramp of the overpass is slow which provides significant advantages of energy saving, noise reduction and wasteful exhaust reduction.
The compact construction occupies less space, producing high efficiency ramps, while low height of the construction facilities reduction in costs, environmental protection, and improved aesthetic sense.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view and directional scheme of one embodiment of the invention;
FIG. 2 is a cross-sectional view along the line A-A of FIG. 1 ;
FIG. 3 is a plan view and directional scheme of another embodiment of the invention;
FIG. 4 . is a plan view and directional scheme of yet another embodiment of the invention.
In the FIGS: 1 —main road, 2 —arched separated bridge, 3 —intersected road, 4 —inner semi-circular road, 5 —outer semi-circular road, 6 —underpass tunnel, 7 —common road, 8 —semi-ramped overhead bridge, 9 —right on-ramp, 11 —bidirectional median, 12 —non-motor vehicle road, 13 —secondary road, 14 —left turning circle road, 17 —convergent secondary road, 18 —U-shaped circle road entrance, 19 —ventilating window, 23 —connection platform, 24 —U-shaped circle road, 25 —arcuate end, 26 —U-turn median, 27 —straight transition road, 28 —U-turn road, 29 —overhead bridge, 30 —left turn branch lane, 31 —right turn branch lane, 32 —right turn road, 33 —outer pass way.
DETAILED DESCRIPTION
Conventional circle-type intersections are associated with traffic jams caused by the entanglement and interference between vehicles making turns and vehicles circling on the overpasses. In order to solve this problem, in the overpass of the invention an outer semicircle road 5 and an inner semicircle road 4 are provided on the U-shaped circle road 24 on the upper side of the main road 1 to channel the turning vehicles and the straight-going vehicles. At the same time a common road 7 is provided between the outer semicircle road 5 and the inner semicircle road 4 to prevent the vehicles on the U-shaped circle road 24 from interfering.
The invention will now be described in detail in accordance with the drawings. In the embodiments the terms “left” and “right” refer to the travel direction of the vehicles, and the terms “upper” “lower” “left” and “right” refer to the orientation of the overpasses. With the overpass forming a base for an off-ramp and an on-ramp, the road entering the overpass is the off-ramp and the road exiting the overpass is the on-ramp.
EXAMPLE 1
As shown is FIG. 1 , an overpass is provided at an intersection. The intersection is divided into the upper, lower, left, and right roads in which the main road 1 accommodates vehicle flow in the upper and lower direction, and the intersected road 3 accommodates vehicle flow in the left and right direction. The four roads of the overpass are leveled with the driveway's surface and are connected therewith. The straight main road 1 on the overpass is the arched separated bridge 2 which has the highest height at a position where the main road 1 intersects the intersected road 3 . There is a ramp extending from the highest point of the arched separated bridge 2 down the upper and lower direction to connect it in the direction of the main road 1 . The semi-ramped overhead bridge stages 8 are provided at the left and the right of the intersected road 3 at both sides of the arched separated bridge 2 . One end of the semi-ramped overhead bridge stage 8 is connected with the arched separated bridge 2 at the same level and forms a connection platform 23 , and the other end is connected with the driveway in left and right directions, i.e., in the direction of the intersected road 3 . The arched separated bridge 2 and the semi-ramped overhead bridge stage 8 are provided with bidirectional driveways having off-ramps and on-ramps. The U-shaped circle road 24 which is leveled with the connection platform 23 is provided at a height of the upper and lower direction ramps of the arched separated bridge 2 . The U-shaped circle road 24 comprises entrances 18 and exits connected with the left connection platform 23 and the right connection platform 23 , respectively, and also the arcuate end 25 between the entrance 18 and the exit. The exit comprise an inner semi-circle road 4 in proximity to the interior of the main road 1 and an outer semi-circle road 5 positioned on the outer side of the main road 1 . The arcuate end 25 of the U-shaped circle road 24 is higher with respect to the ramp of the arched separated bridge 2 . The other end of the entrance 18 and the exit of the U-shaped circle road 24 are connected with the connection platform 23 of the left and right semi-ramped overhead bridge stage 8 , respectively. A closed-circle road is formed after connecting the upper and lower U-shaped circle roads through the connection platform 23 . The shape of the circle road is similar to that of the racetrack in a stadium. The unidirectional driveway running anticlockwise is used in the above-referenced circle road.
On the inner side of the outer semicircle road 5 of the upper and lower U-shaped circle road 24 , i.e., between the arched bridges 2 and the outer semicircle road 5 , an inner semicircle road 4 is provided. One end of the inner semicircle road 4 is connected with the arcuate end 25 of the U-shaped circle road and the other end is connected with the connection platform 23 of the arched separated bridge 2 .
A branch common road 7 is provided as the off-ramp of the arched separated bridge 2 of the main road 1 . The above-referenced common road 7 connects the road surface of the main road 1 with the connection platform 23 or the ramp of the arched separated bridge 2 after passing vertically under the accurate end 25 of the U-shaped circle road 24 . The connector of the common road 7 and the connection platform 23 is located between the connectors of the inner semicircle road 4 and the outer semicircle road 5 and the connection platform 23 , respectively. The inclusion of common road 7 effectively ensures the traveling of vehicles on the connection platform 23 and the U-shaped circle road 24 without interference.
The right on-ramp 9 is provided at the entrance 18 of the upper and lower U-shaped circle road 24 i.e. the right side of the upper U-shaped circle road 24 and the left side of the lower U-shaped circle road 24 . The other end of the right on-ramp 9 is connected with the on-ramp of the arched separated bridge 2 .
As shown in FIG. 1 , due to the design of overhead arched separated bridge 2 and the semi-ramped overhead bridge stage 8 , the non-motor vehicle road 12 for bicycles and pedestrians is provided under the overpass. The non-inference with motor vehicles in the areas of the existing intersections fully satisfies the condition of transfer of the pedestrians and bicycles. Therefore the inconvenience that would be caused by construction of the underground passage way is eliminated. In order to improve the illumination under the overpass, ventilation windows 19 passing through the surface of the overpass are formed at the connection platform 23 of the overpass.
Below the traveling directions of the vehicles on the overpass are explained with reference to arrows indicating the traveling directions in FIG. 1 . (1) Straight ahead from lower to upper side: vehicles pass over the overpass along the right entrance of the bidirectional driveway in the lower main road 1 through the arched separated bridge 2 straight ahead from the lower side under the arcuate part 25 of the U-shaped circle road 24 through to the on-ramp of the upper main road 1 . (2) Straight ahead from left to right: vehicles travel to the left connection platform 23 after entering the left semi-ramped overhead bridge stage 8 from the on-ramp of the bidirectional driveway in the left intersected road 3 , and then enter the connection platform 23 , turn right entering the entrance 18 of the outer U-shaped circle road 24 , again enter the right connection platform 23 from outer semi-circle or road 5 of the lower U-shaped circle road 24 along the arcuate part 25 of the lower U-shaped circle road 24 ; then turn right and travel across the overpass entering the right off-ramp of the intersected roads from the right semi-ramped over head bridge stage 8 , completing the straight way on the intersected roads via a zigzag manner instead of straight manner. (3) Turn from the lower main road 1 onto the right interested road 3 : vehicles enter the right common road 7 through the entrance of the bidirectional driveway along the lower main road 1 , and from the common road 7 enter the right connection platform 23 , and then turn right entering the right semi-ramped over head bridge stage 8 continuing onto the on-ramp of the right intersected road 3 and passing through the overpass. (4) Turn from the lower main road 1 onto the left intersected road 3 : vehicles enter the right common road 7 through the entrance of the bidirectional driveway along the lower main road 1 , and from the common road 7 enter the right connection platform 23 , and then continue straight up to the upper U-shaped circle road 24 , turning around into the left connection platform 23 along the upper outer semicircle road 5 , and then turn right entering the right semi-ramped over head bridge stage 8 continuing onto the on-ramp of the left intersected road 3 and passing through the overpass.(5) Turn from the left intersected road 3 into the lower main road 1 : after entering the semi-ramped overhead bridge stage 8 from the entrance of the bidirectional driveway in the left intersected road 3 vehicles enter the connection platform 23 , and then turn right into the lower U-shaped circle road 24 , enter the on-ramp of the lower main road of the right on-ramp 9 which is connected with the lower U-shaped circle road 24 , and so pass through the overpass. (6) Turn from the left intersected road 3 onto the upper main road 1 : after entering the semi-ramped overhead bridge stage 8 through the entrance of the bidirectional driveway in the left intersected road 3 the vehicles enter the connection platform 23 , turn right into the lower U-shaped circle road 24 , and then enter the right connection platform 23 from the inner semi-circular road 4 of the lower U-shaped circle road 24 along the arcuate part 25 of the lower U-shaped circle road 24 , and enter the on-ramp of the upper arched separated bridge 2 by merging left on the right connection platform 23 , and then pass through the overpass from the on-ramp of the upper arched separated bridge 2 accomplishing the convergence into the main road without interference with the convergent secondary road 17 , and pass through the overpass from the on-ramp of the upper arched separated bridge 2 . (7) Return to the lower main road 1 from the lower main road 1 : The vehicles enter the right common road 7 along the entrance of the bidirectional driveway in the lower main road 1 , and enter the right connection platform 23 from the common road 7 , straightway to the upper U-shaped circle road 24 , then enter the left connection platform 23 passing around the inner semicircle road 4 of the upper U-shaped circle road 24 along the upper U-shaped circle road 24 , and then enter the left connection platform 23 into the on-ramp of the lower arched separated bridge 2 by merging left off of the left connection platform 23 , turning back to the on-ramp of the lower main road 1 from the on-ramp of the lower arched separated bridge 2 . (8) Return to the left intersected road 3 from the left intersected road 3 : after entering the semi-ramped overhead bridge stage 8 from the entrance of the bidirectional driveway in the left intersected road 3 the vehicles enter the connection platform 23 and turn right into the lower part of connection platform 23 , then turn around into the inner semi circle road 4 of the lower U-shaped circle road 24 along the lower U-shaped circle road 24 , and then enter the right connection platform 23 , and then enter the upper U-shaped circle road 24 by bearing right on the right connection platform 23 , then enter the left connection platform 23 from the outer semi circle road 5 of the upper U-shaped circle road 24 , along the arcuate part 25 of the upper U-shaped circle road 24 , then turn right to enter the right on-ramp of the left intersected road 3 from the left semi-ramped overhead bridge stage 8 , thus accomplishing the turnaround.
From the foregoing it is clear that that the height of the overpass of the invention is reduced compared with the typical multilayer overpass, and also the occupied ground area and ramp size have been reduced. Compared with the clover-like overpass there is no interference on the main roads which facilities turning of the vehicles on the overpass in left and right direction and turning back.
Because the overpass of the invention is of single layer, not including the ground, therefore the height from the ground is limited only by the U-shaped circle road and generally is about 5 meters of clearance.
In order to increase the driving safety, the double solid line or the bidirectional median 11 between the bidirectional driveways is used to separate the driveways in two directions. In the case of driving to the on-ramp of the arched separated bridge 2 from the inner semicircle road 4 through the connection platform 23 , a convergent secondary road 17 is provided at the right side of the on-ramp of the arched separated bridge 2 for avoiding accidents caused by the abrupt entering of vehicles.
In this embodiment, vehicles are assumed to drive on the right side of the road; for other countries or regions where vehicles travel on the left side of the road, arrangement of the driveways on the overpass can be changed accordingly, and this is also contemplated by the invention.
EXAMPLE 2
The U-shaped circle road 24 is relatively long because the ramp length of the arched separated bridge 2 must satisfy the regulation of the ramp of the driveway and ensure clearance between the arcuate part 25 of the U-shaped circle road 24 and the arched separated bridge 2 . As shown in FIG. 2 , in order to shorten the length of the U-shaped circle road 24 , construction of the embodiment 1 is partially modified by allowing the height of the arcuate part 25 of the U-shaped circle road 24 to exceed the height of the connection platform 23 , so that the combination of the upper and lower U-shaped circle roads 24 has a saddle-like shape. Thus, in order to shorten the length of the U-shaped circle road 24 , vehicles will enter an up-ramp when traveling from the connection platform 23 onto the U-shaped circle road 24 , and will enter a down-ramp when traveling from the U-shaped circle road 24 onto the connection platform 23 .
Because vehicles enter an up-ramp after entering the entrance 18 of the U-shaped circle road 24 , the speed of the vehicles is automatically reduced and the margin for safely turning the vehicle on the arcuate end 25 increased.
If there is no need to provide non-motor vehicle and pedestrian ways under the overpass then the arched separated bridge 2 can be constructed as a flat driveway, and accordingly the connection platform 23 can be provided on the ground, thereby avoiding the need for vehicles to enter the connection platform 23 and the ramp of the arched separated bridge 2 . Raising the arcuate part 25 of the U-shaped circle road 24 to a certain height will ensure that the vehicles on the main road 1 pass under the arcuate part 25 of the U-shaped circle road thus allowing for a large reduction in the overall height of the overpass.
EXAMPLE 3
As shown in FIG. 3 in order to reduce the driving distance of vehicles turning around on the intersected road 3 in embodiments 1 and 2, medians 26 for turning around are provided on the left and right connection platforms 23 , respectively. The median 26 for turning around separates the connection platform 23 into the straight transit driveway 27 between the upper and lower U-shaped circle roads 24 and the U-turn driveway 28 , which not only ensures a straight-way driving between the upper and lower U-shaped circle roads 24 , but also allows vehicles turning around on the intersected road 3 to enter the on-ramp through the U-turn driveway 28 directly after entering the connection platform 23 from the off-ramp, thus decreasing the turnaround distance on the U-shaped circle road 24 .
If the topographic condition permits or if there is a need to expand capacity, an underpass tunnel 6 in the direction of the left and right intersected road 3 can be added beneath the walking way surface extending through the main road 1 . By doing so, the straight-driving vehicle from left to right or vice versa don't need to travel around the connection platform 23 and the U-shaped circle road 24 , and as a result vehicles can be driven faster and more conveniently, to meet the larger traffic flow. If there is no need to consider the pedestrian and non-motor vehicle ways under the overpass, such as in the highways and suburbs, then the underpass tunnel 6 can be constructed as a semi-sinking underpass tunnel passing the arched separated bridge 2 resulting in a reduction of construction costs and improvement in ventilation and in water-removal from the tunnel. Alternatively, it is also possible to provide the overhead bridge passing through the upper side of the connection platform 23 and the arched separated bridge 2 between the left and right intersected roads 3 . Therefore the vehicles on the intersected road 3 can travel straight-though, thus enabling the overpass to be constructed by several periods and added with one more layer of single span bridge to form another main road.
EXAMPLE 4
As shown in FIG. 4 , the overpass of the embodiment is suitable for use in highways and expressways. A level driveway is provided between the upper and lower sides of the main road 1 while at both sides of the main road 1 a secondary road 13 parallel with the main road 1 is provided. The outer pass way 33 connects the main road 1 and the secondary road 13 . The overhead bridge 29 passing above across the main road 1 is provided between the left and right sides of the intersected road 3 .
The U-shaped circle roads 24 are provided at the horizontal level at both the upper and lower sides of the main road 1 . The U-shaped circle roads 24 include the inner semicircle roads 4 and the outer semi circle roads 5 . The branch common road 7 is provided on the secondary road 13 connected with the off-ramp of the main road 1 . The lower common road 7 is connected with the entrance of the outer semicircle road 5 of the upper U-shaped circle road 24 after passing through under the overhead bridge 29 , while the upper common road 7 is connected with the entrance of the outer semicircle road 5 of the lower U-shaped circle road 24 after passing through under the overhead bridge 29 . The outer semicircle road 5 is connected with the on-ramp of the overhead bridge 29 after passing across the arcuate end 25 of the main road. The left turn branch lane 30 is connected with the on-ramp of the inner semicircle road 4 from the off-ramp of the overhead bridge 29 on the intersected road 3 while the inner semi circle road 4 is connected with the on-ramp of the secondary road 13 through the left turn driveway 14 after passing across under the arcuate end 25 of the main road.
The right turn branch lane 31 is provided between the overhead bridge 29 and the secondary road 13 connected with the on-ramp of the main road. The right turn branch lane 31 is connected with the secondary road 13 through the lower ramp. The right turn road 32 is provided on the secondary road 13 connected with the off-ramp of the main road 1 . The right turn road 32 is connected with the on-ramp of the overhead bridge 29 through the upper ramp. The pavement and non-motor vehicle way 12 are provided on the outer side of the secondary road 13 .
Below the driving directions of the vehicles on the overpass will be described with connection to the arrows in FIG. 4 indicating the driving direction of the vehicles. (1) Straight through from the lower side to the upper side: the vehicles travel straight-ahead to the upper part of the road along the lower part of the main road 1 . (2) Straight through from the left to right: the vehicles travel straight to the right part of the road from the left part of the road of the overhead bridge 29 on the intersected road 3 . (3) Turn from the lower main road 1 onto the right intersected road 3 : the vehicles enter the secondary road 13 through the outer pass way 33 from the off-ramp of the main road 1 , and then from the right turn road 32 connected with the secondary road 13 turn right by the upper ramp entering the on-ramp of the overhead bridge 29 of the intersected road 3 . (4) Turn from the lower main road 1 onto the left intersected road 3 : the vehicles enter the secondary road 13 through the outer pass way 33 from the off-ramp of the main road 1 , and then from the common road 7 connected with the secondary road 13 enter the on-ramp of the U-shaped circle road 24 after passing under through the overhead bridge 29 , then after entering the outer semicircle road 5 through the arcuate end 25 enter the on-ramp of the overhead bridge 29 . (5) Turn from the left intersected road 3 onto the lower main road 1 : the vehicles enter the on-ramp of the main road via the lower ramp of the right turn branch lane 31 of the over head bridge 29 . (6) Turn from the left intersected road 3 onto the upper main road 1 : the vehicles enter from the off-ramp of the overhead bridge 29 on the intersected road 3 onto the on-ramp of the inner semicircle road 4 through the left turn branch lane 30 , and then enter the secondary road 13 after passing through the left turn road 14 by the lower ramp of the arcuate end 25 , then enter the on-ramp of the main road 1 through the outer pass way 33 .
Since the height of the overpass of the embodiment is the height of the overhead bridge 29 or the arcuate end 25 of the U-shaped circle road 24 , the overpass belongs to a single laver type. The transfer of the vehicles on the overpass will not cause any inference.
It should be noted that while the foregoing description is aimed to illustrate the principle of the invention, those skilled in the art will appreciate that certain variations and modifications of the basic embodiments are possible.
Therefore, the invention is not limited by any particular construction of the embodiments, and all of the modifications are within the scope of the invention.
|
This invention discloses a single layer interchange overpass. The overpass comprises a main road ( 1 ) and an intersected road ( 3 ), a U-shaped circle road ( 24 ) is disposed at a predetermined level above both ends of the main road ( 1 ), an inner circle road ( 4 ) and an outer circle road ( 5 ) are disposed at the exit of each U-shaped circle road ( 24 ), a common ramp ( 7 ) is located between the inner and the outer circle roads ( 4, 5 ), the common ramp ( 7 ) is joined with an on-ramp of the intersected road ( 3 ) via the outer circle road ( 5 ); and an off-ramp of the intersected road ( 3 ) is joined with an on-ramp of the main road ( 1 ) via the inner circle road ( 4 ).
| 4
|
FIELD OF THE PRESENT INVENTION
The present invention relates to a thermoelectric cooling device and a thermoelectric semiconductor ceramic composition, and more particularly to a composition which is low in toxicity and has excellent characteristics.
BACKGROUND OF THE INVENTION
There is recently a growing demand for electronic components for use in thermoelectric cooling. Many of these components make use of the Peltier effect. However, this requires the use of chlorofluorocarbons which adversely effects the earths atmosphere. These compound are also regulated which impacts the requirements for local cooling or dehumidifying of electronic appliances and others in small-sized cooling devices.
Among the electronic components which are used for thermoelectric cooling, those using Bi-Te singlecrystalline or polycrystalline solidified matter as a thermoelectric semiconductor substance are known. The thermoelectric semiconductor element is manufactered by electric series bonding of an n-type element and a p-type element, and in the Bi-Te compound element, Se is added to the n-type conductive element in order to adjust the characteristics.
The toxicity of Se used as additive to these elements is high, and the Bi-Te composition itself as the main ingredient is expensive. Accordingly, the range of use of the element has been limited.
The performance of a thermoelectric semiconductor device for thermoelectric cooling is expressed as the performance index Z=s×s×σ/k(s 2 σ/k), with the Seebeck coefficient as s, the electric conductivity as σ, and the thermal conductivity as k. The larger the value of Z in the temperature range around the room temperature, the greater the absorption heat per unit power consumption in thermoelectric cooling or the temperature difference from the cooling side.
As the technology relating to the invention, the thermoelectric characteristic of strontium titanate is described beginning at page A44 of Physical Review Vol. 134, 2A (1964). Barium titanatte is described begining at page 358 and after in Physical Review No. 157, 2 (1967).
The idea of using a copper oxide semiconductor for thermoelectric cooling is disclosed begining at page 111 of Materials Science and Engineering Vol. B7 (1990).
In the Japanese Laid-open Patent HEI. 1-231383, barium titanate semiconductor materials are disclosed as the materials suited to application of the Seebeck thermoelectromotive force in a heat sensor.
Aside from these, various semiconductor materials have been studied, but, except for Bi-Te compounds, no practical materials have been known hitherto for use in thermoelectric cooling.
SUMMARY OF THE INVENTION
In the light of the above problems, it is hence a primary object of the invention to present a thermoelectric cooling device using a semiconductor substance which is high in safety, inexpensive, and excellent in performance, having an n-type semiconductor, and a thermoelectric semiconductor ceramic composition for use therein.
To achieve the above object, the thermoelectric cooling device comprising at least two separate electrodes, an n-type semiconductor to a p-type semiconductor mounted on the two separate electrodes, and a bridge electrode for coupling the n-type semiconductor and p-type semiconductor and for generating absorption heat in the bridge electrode when a current flows from the n-type semiconductor to the p-type semiconductor, wherein the n-type semiconductor is an oxide semiconductor mainly composed of a complex oxide containing strontium and titanium, and possessing an oxygen deficiency showing a weight increase by high temperature oxidation in oxygen.
It is preferable in this invention that the n-type semiconductor is a complex oxide comprising at least one element selected from group A consisting of strontium, barium, calcium, potassium, sodium, lithium, cesium, rubidium, scandium, yttrium and lanthanide, and titanium or at least one element selected from group B consisting of titanium, zirconium, hafnium, tin, niobium, tantalum, tungsten, molybdenum, manganese, iron, cobalt, nickel, copper, zinc, indium, magnesium and antimony, and possessing an oxygen deficiency in a range of 0.06≦e≦0.55 where e is the wt. % oxygen deficiency after complete high temperature oxidation.
It is preferable in this invention that the surface of the n-type semiconductor contacting the electrode is electroplated.
Another object of the invention is provide a thermoelectric cooling device comprising at least two separate electrodes, an n-type semiconductor and a p-type semiconductor mounted on the two separate electrodes, and a bridge electrode for coupling the n-type semiconductor to p-type semiconductor and for generating absorption heat in the bridge electrode when a current flows from the n-type semiconductor to the p-type semiconductor, wherein an oxide semiconductor possessing a porous structure of 30% or more porosity in which particles of a complex oxide comprising strontium and titanium are sintered together with the n-type semiconductor.
It is preferable in this invention that the n-type semiconductor comprises a complex oxide of strontium and titanium, and possesses an oxygen deficiency, in which the molar ratio of Ti or Sr is in a range of 1.005≦a≦1.120 where a is the molar of Ti to Sr in the complex oxide, and oxigen deficiency after complete high temperature oxidation is in a range of 0.06≦b≦0.55 where b is the wt. %.
It is preferable in this invention that the n-type semiconductor comprises a complex oxide comprising strontium, barium and titanium, and possesses an oxygen deficiency in a range of 0.45≦c<1.00, 1.005≦d≦1.120 where c is the molar ratio of Sr to the total molar number of Sr and Ba in the complex oxide composition, and d is the molar ratio of titanium to the total molar number of Sr and Ba, and in a range of 0.06≦e≦0.55 where e is the wt. % oxygen deficiency after complete high temperature oxidation.
It is preferable in this invention that the surface of the n-type semiconductor contacting the electrode is electroplated.
As the composition of the thermoelectric cooling device, a complex oxide composed of strontium and titanium is used as the main ingredient, and an oxide semiconductor possessing oxygen deficiency is used in the n-type semiconductor. As the thermoelectric semiconductor ceramic composition suited to such applications, a composition of a complex oxide mainly composed of strontium and titanium in a specific composition range and possessing oxygen deficiency is used.
According to the invention, the thermoelectric cooling device using an oxide semiconductor mainly composed of a complex oxide comprising strontium and titanium, in an n-type semiconductor which possesses oxygen deficiency, has a cooling characteristic equally comparable with that of the device using a Bi-Te compound. Moreover, since it does not contain Se or other harmful metals, and it can be manufactured by the conventional ceramic process technology, the manufacturing cost can be reduced, which is useful industrially.
By the composition of the invention, the toxicity of the n-type semiconductor, which was a serious problem, is lowered, and a thermoelectric semiconductor element which is inexpensive and excellent in performance is obtained.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram of a thermoelectric semiconductor element in one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, a thermoelectric cooling device in one embodiment of the invention is described in detail below.
The surface of each semiconductor element was polished and processed into a cubic sample of 4 mm on one side, and the top and bottom ends were electroplated with nickel to a thickness of about 0.7 μm. Then, at an element gap of 2 mm as shown in FIG. 1, a bridge metal copper plate 13 of 0.7 mm in thickness was soldered to the top end. An n-type element 11 and a p-type element 12 were electrically coupled, and base metal copper plates 14, 15 of 2 mm at a thickness of 20 mm square were soldered to the bottom end, thereby fabricating a single pair of thermoelectric elements.
The base metal copper plates 14, 15 at the bottom end of each element were respectively fixed to metal copper blocks of 150 mm 3 , which were electrically isolated from each other with screws. Through these metal copper blocks, the n-type element was electrically coupled to a DC power supply positive pole, and the p-type element to the DC power supply negative pole.
These elements were put in a vacuum container, and the inside was deaerated to 1 Pa, and DC current was applied. The temperature of the bridge metal copper plate 13 at the junction of the p-type element and n-type element was measured by a thermocouple. Referring to FIG. 1, the Peltier cooling effect takes place as follows: when the current flows from the base electrode 14 into the n-type semiconductor 11, heat is generated. When the current flows from the n-type semiconductor 11 into the bridge electrode 13 and from the bridge electrode 13 into the p-type semiconductor 12, heat is absorbed at the interface of bridge electrode 13 and n-type, p-type semiconductor. That is, the bridge electrode 13 is the cooling part. Furthermore, heat is generated between the p-type semiconductor 12 and base electrode 15.
Some of the preferred embodiments of the invention are described in detail below.
EXAMPLE 1
The compositions listed in Table 1 were evaluated for the thermoelectric cooling device combining an n-type semiconductor element and a p-type semiconductor element.
TABLE 1______________________________________n-type semiconductor Oxygen n-type semiconductorNo. element deficiency element______________________________________1 SrTiO.sub.3 sinter (in air) 0.18 wt. % (BiSb).sub.2 Te.sub.3Reduction treatment in sponge titanium2 Sr.sub.0.97 La.sub.0.02 TiO.sub.3 0.12 wt. % Bi.sub.2 Te.sub.3Reducing atmosphere sinterReduction treatment in titanium metal powder3 SrTi.sub.0.99 Nb.sub.0.01 O.sub.3 0.14 wt. % Bi.sub.2 Te.sub.3Reducing atmosphere sinterReduction treatment in sponge titanium 4* SrTi.sub.0.99 Nb.sub.0.01 O.sub.3 0.00 wt. % Bi.sub.2 Te.sub.3Sinter in air 5* Bi.sub.2 (Te.sub.2.4 Se.sub.0.6) -- Bi.sub.2 Te.sub.3______________________________________ [*Comparison examples out of scope of the invention.
The n-type semiconductor element of sample No. 1 was prepared by reduction treatment, starting from sintering in air. The element had a molar ratio of Sr to Ti of 1:1, a cubic shape of about 6 mm on one side, a relative density of about 95%, and a fine structure with a mean particle size of about 5 μm.
For reduction treatment, an alumina ceramic container was filled with sponge titanium metal, packed with the sinter sample, and heated in an electric oven in an argon atmosphere at 1450° C. for 16 hours.
To determine the oxygen deficiency of the sample, the ceramic portion of the measured sample was ground to a particle size of about 100 μm, and heated in 1500° C. oxygen. The weight change was measured, and oxygen deficiency was calculated when the weight increase stopped during heating.
In this sample, when the total treatment time in 1500° C. atmosphere reached 28 hours, the weight increase was stopped, and the re-oxidation was completely terminated.
The N-type semiconductor elements of sample Nos. 2 and 3 were prepared by reduction treatment, starting from a sinter by baking the captioned compositions in nitrogen containing 3% hydrogen, possessing a cubic shape of about 6 mm on one side, with a relative density of about 95%, and a fine structure with a mean particle size of about 2 μm.
For reduction treatment, an alumina ceramic container was filled with a titanium metal powder of about 100 mesh pass and the sintered sample, and heated in an electric furnace in an argon atmosphere at 1400° C. for 8 hours.
The oxygen deficiency of the sample was measured in the same manner as in sample No. 1.
In all samples, when the total treatment time in 1500° C. oxygen reached 12 hours, the weight increase stopped, and the reoxidation was completely terminated.
The n-type semiconductor element of sample No. 4 was a sintered by baking the captioned composition in air. The element was in a cubic shape of about 6 mm in one side, having a relative density of about 95%, and a fine structure with a mean particle size of about 2 μm, which was changed to a blue color indicative of a semiconductor state.
The oxygen deficiency of the sample could not be detected although measured in the same manner as in sample No. 1.
The n-type semiconductor element of sample No. 5 was a monocrystalline sample of Bi 2 (Te 2 .4 Se 0 .6) conventionally used in thermoelectric cooling.
The p-type semiconductor elements of the samples were Bi-Te monocrystals in the captioned composition hitherto used in thermoelectric cooling.
From these n-type semiconductor substances and p-type semiconductor substances, a single pair of thermoelectric elements was fabricated as in FIG. 1. The minimum temperature reached at the np junction was measured in the same manner.
The current to be applied was tested at 0.5 A increments, and the current at which the temperature hit the bottom was determined.
Table 2 shows the DC value, lapse of time, and temperature reached when the temperature of the metal copper plate junction of each sample reached the lowest point.
TABLE 2______________________________________No. DC value Lapse of time Temperature reached______________________________________1 2.0 A 6 min 00 sec -18.6° C.2 1.5 A 8 min 20 sec -9.2° C.3 1.5 A 4 min 45 sec -10.6° C. 4* 1.5 A 2 min 25 sec 3.6° C. 5* 2.0 A 4 min 20 sec -23.3° C.______________________________________ [*Comparison examples out of scope of the invention.
As is clear from the foregoing embodiment, the thermoelectric cooling device using an oxide semiconductor was mainly composed of a complex oxide comprising strontium and titanium, in the n-type semiconductor type, which possesses oxygen deficiency, and had a cooling characteristic equally comparable with that of the device using Bi-Te compound in the n-type element part. Since the device does not contain Se or other harmful metals, and can be manufactured using existing ceramic process technology, the manufacturing cost can be reduced, which is useful industrially.
On the other hand, the n-type semiconductor element made semiconductive by valence control is not lowered in resistivity, and Joule's heat generation is large, which is not preferable for thermoelectric cooling device.
EXAMPLE 2
As the starting material of the n-type semiconductor substance, a composition mainly composed of a complex oxide comprising Sr and Ti was used, and Bi 2 Te 3 was used as the p-type semiconductor substance.
The n-type semiconductor substance was prepared by reduction treatment, starting from sintering the composition in 1500° C. air for 48 hours. The substance had a cubic shape of about 6 mm on one side, a relative density of about 94 to 98%, and a fine structure with a mean particle size of about 1.4 to 5 μm.
For reduction treatment, an aluminum ceramic container was filled with titanium metal powder of about 100 mesh pass, packed with the sinter sample, and heated in an electric oven in an argon atmosphere at 1400° C. for 8 hours.
Table 3 shows the molar ratio of the component oxide mixture of the n-type semiconductor substance, and the oxygen deficiency in wt. % after reduction treatment.
After reduction treatment the sample was polished on the surface and was processed into a cube of 4 mm on one side.
TABLE 3______________________________________No. Composition Oxygen deficiency______________________________________ 6 SrO; 0.98, TiO.sub.2 ; 1.0 0.23 wt. % 7 SrO; 0.7, BaO; 0.3, TiO.sub.2 ; 1.0 0.16 wt. % 8 SrO; 0.9, CaO; 0.08, TiO.sub.2 ; 1.0 0.31 wt. % 9 SrO; 0.97, Sm.sub.2 O.sub.3 ; 0.01, TiO.sub.2 ; 1.0 0.48 wt. %10 SrO; 0.95, K.sub.2 O; 0.025, TiO.sub.2 ; 1.0 0.26 wt. %11 SrO; 0.99, Na.sub.2 O; 0.005, ZrO.sub.2 ; 0.10 0.16 wt. %12 SrO; 0.97, Y.sub.2 O.sub.3 ; 0.01, TiO.sub.2 ; 1.0 0.55 wt. %13 SrO; 0.97, Sc.sub.2 O.sub.3 ; 0.01, TiO.sub.2 ; 1.0 0.48 wt. %14 SrO; 0.99, Rb.sub.2 O; 0.005, ZrO.sub.2 ; 0.10 0.16 wt. %15 SrO; 0.98, Li.sub.2 O; 0.005, TiO.sub.2 ; 1.0 0.26 wt. %16 SrO; 0.99, CeO.sub.2 ; 0.005, TiO.sub.2 ; 0.99 0.06 wt. %17 SrO; 0.99, TiO.sub.2 ; 0.99, Nb.sub.2 O.sub.5 ; 0.005 0.48 wt. %18 SrO; 0.99, TiO.sub.2 ; 0.99, Ta.sub.2 O.sub.5 ; 0.005 0.42 wt. %19 SrO; 0.99, TiO.sub.2 ; 0.99, HfO.sub.2 ; 0.01 0.12 wt. %20 SrO; 0.9, BaO; 0.1, TiO.sub.2 ; 0.99, SnO.sub.2 ; 0.19 wt. %0.0121 SrO; 1.0, TiO.sub.2 ; 0.94, CoO; 0.02, Nb.sub.2 O.sub.5 ; 0.06 wt. %0.0222 SrO; 1.0, TiO.sub.2 ; 0.94, NiO; 0.02, Nb.sub.2 O.sub.5 ; 0.38 wt. %0.0223 SrO; 1.0, TiO.sub.2 ; 0.94, CuO; 0.02, Ta.sub.2 O.sub.5 ; 0.21 wt. %0.0224 SrO; 1.0, TiO.sub.2 ; 0.94, ZnO; 0.02, Sb.sub.2 O.sub.5 ; 0.36 wt. %0.0225 SrO; 1.0, TiO.sub.2 ; 0.94, MnO; 0.03, WO.sub.3 ; 0.03 0.08 wt. %26 SrO; 1.0, TiO.sub.2 ; 0.94, FeO; 0.03, WO.sub.3 ; 0.03 0.08 wt. %27 SrO; 0.98, TiO.sub.2 ; 0.99, MoO; 0.01 0.48 wt. %28 SrO; 0.98, TiO.sub.2 ; 0.99, In.sub.2 O.sub.3 ; 0.005 0.52 wt. %29 SrO; 0.8, Ba; 0.02, TiO.sub.2 ; 0.7, MgO; 0.1, 0.09 wt. %Ta.sub.2 O.sub.5 ; 0.1 30* Bi.sub.2 Te.sub.3 sinter --______________________________________ [*Comparison example out of scope of the invention.
The p-type semiconductor substance was a polycrystalline solidified compound in the composition of Bi 2 Te 3 in a 4 mm cube. This element had a Seebeck coefficient of 200 μV/deg., an electric conductivity of 740ohm-cm, a thermal conductivity of 0.018 W/cm-deg., and a performance index of 0.00164/deg.
From these n-type semiconductor substances and p-type semiconductor substances, a single pair of thermoelectric elements was fabricated as in Example 1. The minimum temperature reached at the np junction was measured in the same manner.
As a comparison example, the hitherto used polycrystalline solidified sample of Bi 2 Te 3 was used in the n-type semiconductor part.
This n-type element had a Seebeck coefficient of 147 μV/deg., an electric conductivity of 1420 /ohm-cm, a thermal conductivity of 0.021 W/cm-deg., and a performance index of 0.00148/deg.
The base metal copper plates at the bottom end of each element were fixed to metal copper blocks of 150 mm 3 . The plates were electrically isolated with screws. Through these metal copper blocks, the n-type element was electrically coupled to a DC power supply positive pole and the p-type element to the DC power supply negative pole.
These elements were put in a vacuum container, and the inside was deaerated to 1 Pa. DC current was applied, and the temperature of the bridge metal copper plate at the junction of the p-type element and n-type element was measured by means of a thermocouple.
The applied current was tested at 0.5 A increments, and the current at which the temperature hit the bottom was determined.
Table 4 shows the current at which the lowest temperature at the junction of the fabricated single thermoelectric element was reached, lapse of time, and the lowest temperature reached.
TABLE 4______________________________________No. I (A) Lapse of time Temperature reached______________________________________ 6 1.0 A 4 min 20 sec -14.8° C. 7 1.0 A 5 min 15 sec -11.6° C. 8 1.5 A 3 min 20 sec -9.9° C. 9 2.0 A 6 min 35 sec -9.7° C.10 1.5 A 8 min 15 sec -12.2° C.11 2.0 A 4 min 20 sec -11.2° C.12 2.0 A 3 min 50 sec -9.2° C.13 1.5 A 7 min 15 sec -9.2° C.14 2.0 A 6 min 55 sec -10.6° C.15 2.0 A 5 min 50 sec -9.8° C.16 1.5 A 5 min 10 sec -10.2° C.17 1.0 A 9 min 20 sec -12.2° C.18 1.0 A 5 min 05 sec -8.9° C.19 1.5 A 3 min 20 sec -10.6° C.20 1.5 A 3 min 05 sec -12.2° C.21 2.0 A 8 min 20 sec -9.2° C.22 1.0 A 6 min 05 sec -8.8° C.23 1.5 A 6 min 35 sec -14.2° C.24 2.0 A 3 min 50 sec -10.6° C.25 1.5 A 4 min 00 sec -12.2° C.26 2.0 A 2 min 55 sec -14.1° C.27 1.5 A 3 min 25 sec -10.0° C.28 1.5 A 5 min 10 sec -11.5° C.29 2.0 A 4 min 55 sec -8.9° C. 30* 2.5 A 3 min 00 sec -16.8° C.______________________________________ [*Comparison example out of scope of the invention.
In all measurements, the temperature of the metal copper block parts was 24° C.
As shown from the preceding embodiment, it was found that the thermoelectric cooling device comprising an n-type semiconductor element is a complex oxide comprising at least one element selected from group A consisting of strontium, barium, calcium, potassium, sodium, lithium, cesium, rubidium, scandium, yttrium and lanthanide, and titanium or at least one element selected from group B consisting of titanium, zirconium, hafnium, tin, niobium, tantalum, tungsten, molybdenum, manganese, iron, cobalt, nickel, copper, zinc, indium, magnesium and antimony, and possessing an oxygen deficiency in a range of 0.06≦e≦0.55 where e is the wt. % oxygen deficiency after complete high temperature oxidation of the semiconductor device possesses, as compared with an element using a Bi-Te compound in the n-type element, a nearly equal cooling characteristic, does not contain Se and other harmful metals, and can be manufactured by existing ceramic process technology, so that the manufacturing cost may be lowered, which is useful industrially.
EXAMPLE 3
Using a complex oxide of strontium and titanium as the n-type oxide semiconductor ceramic material, a thermoelectric semiconductor element was fabricated.
Using SrCO 3 and TiO 2 as the starting materials for oxide semiconductor ceramic, a complex oxide powder was prepared using a conventional ceramic process.
This complex oxide powder was placed in 1200° C. air for 1 hour by mixing with 30 to 70 vol. % of an organic binder and a proper amount of water, and the organic binder was burned away.
The sample after burning away the organic binder was a porous specimen having a relative density of between 21% and 65%.
This sample was put in a ceramic capsule to be buried in sponge titanium particles, placed in a tubular oven, and was reduced at 1200° C. for 4 hours while passing 20% hydrogen-argon gas.
By the reduction treatment, the relative density of the sample was hardly changed.
The n-type semiconductor element of sample No. 35 as a comparison example was an oxide semiconductor of strontium titanate reduced in the same manner as in Example 1, after densely sintering to a relative density of 98% by using the material of sample No. 31.
The n-type semiconductor element of sample No. 36 was a monocrystalline sample of Bi 2 (Te 2 .4 Se 0 .6) hitherto used for thermoelectric cooling.
The p-type semiconductor elements of the samples were single crystals of Bi-Te compounds hitherto used for thermoelectric cooling.
The p-type semiconductor element was polished on the surface, and processed into a rectangular parallelopiped of 10 mm×2 mm on the top and bottom, and 10 mm in height. The n-type element was processed into a cube of 10 mm on one side, and the top and bottom ends were electroplated with nickel to about 0.7 μm in thickness and at a gap of 2 mm as shown in FIG. 1. A metal copper plate of 0.7 mm in thickness was soldered to the top end, and the n-type and p-type elements were electrically coupled. A metal copper plate of 20 mm square and 2 mm in thickness was soldered to the bottom end, thereby fabricating a single pair of thermoelectric elements.
The metal copper plates at the bottom end of each element were fixed to metal copper blocks of 150 mm 3 and electrically isolated with screws. Through these metal copper blocks the n-type element was electrically coupled to a DC power supply positive pole, and the p-type element to the DC power supply negative pole.
These elements were put in a vacuum container, and the inside was deaerated to 1 Pa. DC current was applied, and the temperature of the metal copper plate at the junction of the p-type element and n-type element was measured by a thermocouple.
The applied current was tested at 0.5 A increments, and the current at which the temperature hit the bottom was determined.
Table 5 shows the DC current for reaching the minimum temperature of the metal copper plate junction of each sample, together with the lapse of time and the minimum temperature reached.
TABLE 5______________________________________Compositionofn-type semi- Por- TemperatureNo. conductor osity I (A) Lapse time reached______________________________________31 SrTiO.sub.3 65% 2.5 A 1 min 20 sec -18.8° C.porous32 SrTiO.sub.3 44% 2.5 A 1 min 48 sec -20.8° C.porous33 SrTiO.sub.3 30% 2.0 A 2 min 15 sec -17.2° C.porous34 SrTiO.sub.3 21% 2.5 A 5 min 30 sec -15.0° C.porous35 SrTiO.sub.3 2% 3.5 A 5 min 20 sec -15.2° C.sinter 36* Bi--Te 0% 3.0 A 5 min 10 sec -21.3° C.single crystal______________________________________ [*Comparison example out of scope of the invention
It is clear from Table 5 that the thermoelectric cooling device using an oxide semiconductor possessing a porous structure composed of a complex oxide comprising strontium and titanium, in the n-type semiconductor element, is capable of reaching a lower temperature, faster and in a shorter time, than the one using a dense semiconductor element at the cooling surface. The final temperature is equally comparable with that the one using a Bi-Te compound, and the improvement in cooling rate is significant especially when the porosity is 30% or more.
This thermoelectric cooling device does not contain Te, Se and other harmful metals, and the material cost is low. It is possible to manufacture using conventional ceramic process technology, and hence the manufacturing cost is reduced, which is very useful industrially.
EXAMPLE 4
As an n-type oxide semiconductor ceramic material, a complex oxide of strontium and titanium in specific composition ratio was used, and a thermoelectric semiconductor element was fabricated.
Using SrCO 3 and TiO 2 as the starting materials for the oxide semiconductor ceramic, a complex oxide powder was prepared by the conventional ceramic process.
This complex oxide powder was formed by mixing with 30 to 50 vol. % of an organic binder and a proper amount of water. The organic binder was burned away by baking in 1350° C. air for 1 hour.
The sample after burning away the organic binder was a porous specimen having a relative density of 40 to 50%.
This specimen was put in a ceramic capsule to be buried in sponge titanium particles, placed in a tubular oven, and reduced for 4 hours at 1200° C. while passing 20% hydrogen-argon gas.
By the reduction treatment, the relative density of the sample was hardly changed.
The oxygen deficiency of the sample was determined by pulverizing the ceramic portion of the sample after measurement to a particle size of about 100 μm, and heating in 1500° C. oxygen to determine the weight change. Oxygen deficiency was calculated when the weight increase stopped during heating.
The p-type semiconductor elements of the samples were single crystals of Bi-Te hitherto used for thermoelectric cooling.
The p-type semiconductor element was polished on the surface, processed into a rectangular parallelopiped of 10 mm×2 mm on the top and bottom, and was 10 mm in height. The n-type element was processed into a cube of 10 mm on one side, and the top end and bottom ends were electroplated with nickel to about 0.7 μm in thickness, at a gap of 2 mm. A metal copper plate of 0.7 mm in thickness was soldered to the top end, and the n-type and p-type elements were electrically coupled. A metal copper plate of 20 mm square and 2 mm in thickness was soldered to the bottom end, thereby fabricating a single pair of thermoelectric elements.
The metal copper plates at the bottom end of each element were fixed to metal copper blocks of 150 mm 3 and were electrically isolated with screws. Through these metal copper blocks the n-type element was electrically coupled to a DC power supply positive pole, and the p-type element to the DC power supply negative pole.
These elements were put in a vacuum container, and the inside was deaerated to 1 Pa. DC current was applied, and the temperature of the metal copper plate at the junction of the p-type element and n-type element was measured by a thermocouple.
The applied current was tested at 0.5 A increments, and the current at which the temperature hit the bottom was determined.
Table 6 shows the molar ratio a of Sr to Ti in the n-type semiconductor element in each sample, the oxygen deficiency amount b in wt. %, the porosity v in vol. %, the DC current at which the minimum temperature of the metal copper plate junction was reached, the lapse of time, and the minimum temperature reached.
TABLE 6__________________________________________________________________________ b v TemperatureNo. a (wt. %) (vol. %) DC current Lapse of time reached__________________________________________________________________________37 0.990 0.22 39.4 3.0 A 1 min 02 sec +3.2° C.38 0.990 0.48 42.9 3.0 A 1 min 46 sec -2.6 °C.39 1.005 0.16 45.8 3.0 A 1 min 56 sec -15.6° C.40 1.005 0.35 33.6 3.0 A 1 min 24 sec -10.8° C.41 1.005 0.79 52.6 2.0 A 1 min 36 sec -0.6° C.42 1.014 0.03 46.8 2.5 A 1 min 16 sec -3.1° C.43 1.014 0.06 41.1 3.0 A 1 min 29 sec -12.2° C.44 1.014 0.25 52.6 3.5 A 0 min 52 sec -14.3° C.45 1.025 0.03 35.7 2.0 A 1 min 20 sec +2.3° C.46 1.025 0.06 33.1 2.0 A 1 min 30 sec -8.6° C.47 1.025 0.22 36.9 2.0 A 1 min 45 sec -15.2° C.48 1.025 0.55 46.2 2.0 A 2 min 06 sec -12.5° C.49 1.025 0.75 40.3 2.5 A 1 min 30 sec -2.3° C.50 1.120 0.09 47.9 2.0 A 1 min 26 sec -12.1° C.51 1.120 0.16 46.3 2.5 A 1 min 15 sec -13.6° C.52 1.120 0.36 32.5 2.0 A 2 min 03 sec -15.8° C.53 1.125 0.22 33.9 1.5 A 2 min 23 sec -2.6° C. 54* Bi(TeSe) -- 6.0 A 6 min 35 sec -21.3° C.__________________________________________________________________________ [*Comparison example out of scope of the invention
As shown from the foregoing embodiment, the thermoelectric cooling device of which an n-type semiconductor element was mainly composed of a complex oxide comprising strontium and titanium, and possessed an oxygen deficiency in a range of 1.005≦a≦1.120 where a is the molar ratio of Ti to Sr in the complex oxide composition, and in a range of 0.06≦b≦0.55 where b is the value of the oxygen deficiency after complete high temperature oxidation of the element expressed in wt. % is, in particular when the semiconductor element is composed of a porous matter with a porosity of 30% or more, small in the loss of electric conduction between particles and small in the factor for disturbing the thermoelectric cooling effect by Joule's heat, and therefore especially the lowest temperature reached is nearly equal to that obtained by using the Bi-Te thermoelectric element, and the time to reach is shorter.
If the composition ratio or oxygen deficiency amount exceeds the specified range, although the time to reach the lowest temperature may be shortened by making use of the advantage of the porous structure, because of the loss of electric conduction between particles and the presence of many semiconductor substances low in characteristics in the heat conduction route, the generation of Joule's heat disturbing the thermoelectric cooling effect increases, and hence the minimum temperature reached is not affected.
EXAMPLE 5
As the n-type oxide semiconductor ceramic material, a complex oxide of strontium, barium and titanium in a specific composition ratio was used, and a thermoelectric semiconductor element was fabricated.
Using SrCO 3 , BaCO 3 and TiO 2 as starting materials for an oxide semiconductor ceramic, the complex oxide powder was prepared using a conventional ceramic process. This complex oxide powder was formed by mixing with 30 to 50 vol. % of an organic binder and a proper amount of water. The organic binder was burned away by baking in 1400° C. air for 1 hour. The sample after burning away the organic binder was a porous specimen having a relative density of 40 to 50%.
This specimen was put in a ceramic capsule to be buried in sponge titanium particles, placed in a tubular oven, and reduced for 4 hours at 1250° C. while passing 20% hydrogen-argon gas.
By the reduction treatment, the relative density of the sample was hardly changed. The oxygen deficiency of the sample was determined by pulverizing the ceramic portion of the sample to a particle size of about 100 μm, heating in 1500° C. oxygen to determine the weight change. Oxygen deficiency was calculated when the weight increase stopped during heating.
Thereafter, a thermoelectric cooling device in the same composition as in Example 4 was fabricated and evaluated.
Table 7 shows the molar ratio c of Ba to the total molar number of Sr and Ba in the n-type semiconductor element in each sample, the molar ratio a of Ti to the total molar number of Sr and Ba, the oxygen deficiency amount b in wt. %, the porosity v in vol. %, the DC current when the minimum temperature of the metal copper plate junction was reached, lapse of time and the temperature reached.
TABLE 7__________________________________________________________________________ b v TemperatureNo. c a (wt. %) (vol. %) DC current Lapse of time reached__________________________________________________________________________55 0.30 0.990 0.22 39.4 3.0 A 1 min 02 sec +3.2° C.56 0.30 0.990 0.48 43.7 2.5 A 1 min 46 sec -2.6 °C.57 0.45 1.025 0.03 41.6 2.5 A 1 min 56 sec -0.6° C.58 0.45 1.025 0.06 46.3 3.0 A 1 min 24 sec -10.8° C.59 0.45 1.025 0.92 46.9 2.0 A 1 min 36 sec -0.6° C.60 0.45 1.014 0.03 40.3 2.5 A 1 min 16 sec -3.1° C.61 0.70 0.990 0.06 46.3 3.0 A 1 min 29 sec -12.2° C.62 0.70 1.025 0.25 46.9 3.5 A 0 min 52 sec -14.3° C.63 0.70 1.025 0.03 39.7 2.0 A 1 min 20 sec +2.3° C.64 0.70 1.025 0.06 33.1 1.5 A 1 min 30 sec -8.6° C.65 0.70 1.120 0.22 31.6 2.0 A 1 min 45 sec -15.2° C.66 0.70 1.120 0.55 33.9 2.5 A 2 min 06 sec -12.5° C.67 0.70 1.120 0.75 39.8 2.0 A 1 min 30 sec -2.3° C.68 0.70 1.150 0.09 50.6 1.5 A 1 min 26 sec -12.1° C.69 0.90 1.025 0.25 42.9 1.5 A 1 min 15 sec -13.1° C.70 0.90 1.025 0.50 39.8 2.5 A 2 min 03 sec -12.7° C.71 0.90 1.025 0.89 30.6 1.5 A 2 min 23 sec -0.6° C. 54* Bi(TeSe) -- 6.0 A 6 min 35 sec -21.3° C.__________________________________________________________________________ [*Comparison example out of scope of the invention
As clear from the foregoing embodiment, the thermoelectric cooling device of which an n-type semiconductor element was mainly composed of a complex oxide comprising strontium, barium and titanium, and possessed an oxygen deficiency in a range of 0.45≦c<1.00, 1.005≦d≦1.120 where c is the molar ratio of Sr to the total molar number of Sr and Ba in the complex oxide composition, and d is the molar ratio of titanium to the total molar number of Sr and Ba, and in a range of 0.06≦e≦0.55 where e is the oxygen deficiency after complete high temperature oxidation of the element expressed in wt. % is, in particular when the semiconductor element is composed of a porous matter with a porosity of 30% or more, small in the loss of electric conduction between particles and small in the factor for disturbing the thermoelectric cooling effect by Joule's heat, and therefore especially the lowest temperature reached is nearly equal to that obtained by using the Bi-Te thermoelectric element, and the time to reached is shorter.
If the composition ratio or oxygen deficiency amount exceeds the specified range, although the time to reach the lowest temperature may be shortened by making use of the advantage of the porous structure, because of the loss of electric conduction between particles and the presence of many semiconductor substances low in characteristics in the heat conduction route, the generation of Joule's heat disturbing the thermoelectric cooling effect increases, and hence the minimum temperature reached is not affected.
With the thermoelectric semiconductor element of the invention, characteristics nearly equal to those of the conventional Bi-Te material are obtained, and the materials are free of the problem of toxicity, and it is possible to manufacture easily using a conventional ceramic process, and the cost is reduced comprehensively, among other features, and hence it is advantageous industrially.
As has been shown, the invention is greatly beneficial to industry.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiment is to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
|
A thermoelectric semiconductor element is disclosed which is particularly low in toxicity and inexpensive. The element is mainly composed of a complex oxide comprising strontium and titanium. An oxide semiconductor possessing oxygen deficiency is used as the n-type element. According to the invention, as compared with a thermoelectric semiconductor element for thermoelectric cooling using a conventional Bi-Te thermoelectric semiconductor which is particularly toxic due to addition of Se or the like, the toxicity of the n-type semiconductor element part is lowered, and a thermoelectric semiconductor element excellent in performance is obtained.
| 7
|
FIELD OF THE INVENTION
[0001] The present invention relates generally to fuel storage and distribution and, more particularly, to a system, apparatus and method for the cold-weather storage and distribution of gaseous fuels.
BACKGROUND OF THE INVENTION
[0002] As gasoline prices have soared and concerns over harmful emissions have mounted in recent years, vehicles that run on alternative fuel sources are becoming increasingly important. For example, the use of compressed natural gas (“CNG”) as an alternative fuel for motor vehicles is becoming increasingly popular throughout the world because it is relatively inexpensive, burns cleanly, is relatively abundant and is adaptable to existing technologies.
[0003] Natural-gas vehicles use the same basic principles as gasoline-powered vehicles. In other words, the fuel (natural gas) is mixed with air in the cylinder of, e.g., a four-stroke engine, and then ignited by a spark plug to move a piston up and down. Although there are some differences between natural gas and gasoline in terms of flammability and ignition temperatures, natural-gas vehicles themselves operate on the same fundamental concepts as gasoline-powered vehicles. Accordingly, existing gasoline-powered vehicles may be converted to run on CNG, thereby easing the transition between gasoline and CNG in markets where gasoline-powered vehicles are dominant. In addition, an increasing number of vehicles worldwide are being originally manufactured to run on CNG.
[0004] Advantageously, CNG-fueled vehicles have lower maintenance costs when compared with other fuel-powered vehicles. In addition, CNG emits significantly fewer pollutants such as carbon dioxide, hydrocarbons, carbon monoxide, nitrogen oxides, sulfur oxides and particulate matter compared to petrol.
[0005] Despite the advantages of compressed natural gas as a motive fuel, the use of natural gas vehicles faces several logistical concerns, including fuel storage and infrastructure available for delivery and distribution at fueling stations. Natural gas suitable for vehicle use is customarily stored in small capacity tank, at 3,600 psi at 70° F., and is distributed from storage tanks to an on-vehicle receiving tank by “cascade filling.” Cascade filling is accomplished by starting out with the storage tank at a higher pressure than the receiving tank and then allowing this pressure to force the gas (or liquid) into the receiving tank. In so doing, natural gas is transferred, and the pressure in the storage tank drops to the point where the pressures of the two tanks become equal and nothing more is transferred.
[0006] The storage and distribution of CNG is severely affected, however, at low temperatures, and particularly when the temperature drops below 40° F. At low temperatures, the pressure in the storage tank drops, thereby resulting in less of a difference in pressure between the receiving tank and the storage tank, ultimately resulting in inefficiencies in gaseous fuel transfer (i.e., less gaseous fuel being transferred to the receiving tank on board the compatible vehicle, and longer filling times).
[0007] Moreover, the storage of CNG in large capacity tanks at high pressures is also problematic. In particular, storing CNG in tanks at 3,000-3,600 psi requires that the tank's walls be cast from thick steel or other suitable metal in order to withstand the enormous stresses caused by the compressed gas. As will be readily appreciated, large capacity CNG storage tanks would therefore be undesirably heavy and inefficient and expensive to manufacture and transport. As a result, transportation and storage of CNG is customarily effectuated by using numerous smaller, tube-shaped cylinders, which themselves are extremely heavy.
[0008] With the forgoing problems and concerns in mind, it is the general object of the present invention to provide a system and method for the cold-weather storage and distribution of gaseous fuels, which utilizes large capacity tanks that are insulative and have a reduced weight.
SUMMARY OF THE INVENTION
[0009] With the forgoing concerns and needs in mind, it is a general object of the present invention to provide a system and method for the cold-weather storage and distribution of gaseous fuels.
[0010] It is another object of the present invention to provide a system and method for the cold-weather storage and distribution of compressed natural gas.
[0011] It is another object of the present invention to provide a system and method for the cold-weather storage and distribution of gaseous fuels that compresses the fuels to a predetermined storage pressure.
[0012] It is another object of the present invention to provide a system and method for the cold-weather storage and distribution of gaseous fuels that maintains the gaseous fuel at a desired storage temperature.
[0013] It is another object of the present invention to provide a system and method for the cold-weather storage and distribution of gaseous fuels having a tank that has a greater storage capacity and is lighter than existing storage tanks.
[0014] These and other objectives of the present invention, and their preferred embodiments, shall become clear by consideration of the specification, claims and drawings taken as a whole.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
[0016] The present invention will be better understood from reading the following description of non-limiting embodiments, with reference to the attached drawings, wherein below:
[0017] FIG. 1 is a schematic view of a system for the cold-weather storage of gaseous fuels in accordance with one embodiment of the present invention.
[0018] FIG. 2 is a side elevational view of a gaseous fuel storage tank for use with the system of FIG. 1 .
[0019] FIG. 3 is a cross-sectional view of the gaseous fuel storage tank for use in connection with the system of FIG. 1 , taken along line A-A of FIG. 2 .
[0020] FIG. 4 is a diagram illustrating the stresses in the walls of the storage tank of FIG. 2 at an internal pressure of 3,600 psi.
[0021] FIG. 5 is a diagram illustrating the stresses in the wall of a single-walled storage tank at an internal pressure of 3,600 psi.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] An embodiment of the system of the present invention is indicated in general at 10 in FIG. 1 . As shown therein, the system includes a slow fill compressor 12 , a heat exchange apparatus 14 , a plurality of gaseous fuel storage tanks 16 , a manifold 18 and a plurality of fast fill dispensers 20 .
[0023] As described in greater detail below, gaseous fuel, e.g., natural gas, is transferred from a low-pressure source to the slow fill compressor 12 . As used herein, “low pressure” is intended to mean the pressure at which the particular gas is originally introduced to the system 10 . In the preferred embodiment, the low-pressure source is a low pressure gas line 22 extending from a gas main, wherein the low pressure is the line pressure of the gas main. Alternatively, however, the low-pressure source may be a low-pressure gas tank 24 that is fluidly connected to the slow fill compressor 12 by a pipeline 26 . In this embodiment, the natural gas may be delivered by a tanker truck, unloaded from the truck via a loading pipeline 28 , and stored in the low-pressure gas tank 24 for use on demand. In any event, the low pressure gas line 22 and/or the low pressure gas tank 24 provide an on-demand supply of gaseous fuel for compression, storage and distribution by the system 10 , as described in detail hereinafter.
[0024] Returning to FIG. 1 , the slow fill compressor 12 includes an inlet and an outlet and may be of the type known in the art, but in any event has a relatively low flow rate. The slow fill compressor 12 is in electrical communication with a power supply 30 for powering the compressor 12 . The power supply 30 may be an electrical outlet hooked up to the power grid. In alternative embodiments, the power supply 30 may be a generator, one or more batteries, or an alternative power generation device such as a solar panel or the like, without departing from the broader aspects of the present invention. In operation, the slow fill 12 compressor intakes and compresses the low-pressure gaseous fuel from the low-pressure source 22 or 24 . The compressed gas is then routed through a direct fill line 32 to the storage tanks 16 , from which it can then be dispensed to compatible vehicles through one or more fast fill dispensers 20 .
[0025] As alluded to above, gaseous fuel storage and distribution and, in particular CNG storage and distribution are greatly affected when temperatures drop below 40° F. It is therefore crucial for efficient storage and distribution that the CNG in the storage tanks is maintained at roughly 70° F. at 3,600 psi, as is standard in the industry. Importantly, the system 10 further includes a means of maintaining the temperature of the gaseous fuel in the storage tanks at a desired level, even when ambient air temperature drops, as discussed below.
[0026] In cold weather, especially below 40° F., the temperature of the gaseous fuel in the storage tanks begins to drop, as does the pressure within the storage tanks. As gaseous fuel stored in the tanks 16 is distributed to compatible vehicles, the slow fill compressor 12 is actuated to intake and compress source gas to replenish the gaseous fuel and pressure in the tanks 16 . As the low-pressure source gas is compressed by the slow fill compressor 12 , its temperature, as well as pressure, rises. This heated, compressed gas is then routed along the direct fill pipeline 32 to the storage tanks 16 for storage. The warmer compressed gas enters the tanks 16 so as to allow the incoming, warmer compressed gas to mix with the gaseous fuel already present in the tanks 16 so as to raise its temperature to a desired and optimum point, namely, approximately 70° F.
[0027] In this manner, compression of low-pressure source gas generates heat, which is then transferred to the gaseous fuel inside the storage tanks 16 to maintain the temperature thereof. As will be readily appreciated, fuel distribution to compatible vehicles triggers an almost continuous, slow pumping and compression of source gas, thereby providing the storage tanks 16 with an almost continuous supply of heat. As a result, cost savings can be realized because stand-alone heaters do not need to be utilized to maintain the temperature of the gaseous fuel within the tanks.
[0028] As further shown in FIG. 1 , each of the storage tanks 16 includes a temperature sensor 34 connected to a thermostat 36 , each of which are set to maintain a desirable temperature of gaseous fuel inside each tank 16 . When the desired or setpoint temperature is reached within the tanks 16 , the thermostat 36 sends a signal to a solenoid valve 38 which changes the direction of the compressed gas exiting the slow fill compressor 12 . In particular, a solenoid valve 38 adjacent the exit of the slow fill compressor 12 is actuated such that the compressed gas exiting the slow fill compressor 12 is not routed directly into the storage tanks 16 via the direct fill line, but is instead directed along a heat exchange loop 40 having a heat exchange apparatus 14 . The heat exchange apparatus 14 effectively cools the compressed gas, i.e., heat from the gas is transferred to the heat exchange apparatus 14 , before the gas is directed back to the storage tanks 16 . Once cooling is effectuated, the compressed gas exits the heat exchange loop 40 and is fed into to a downstream portion of the direct fill line 32 and, ultimately, into the storage tanks 16 .
[0029] In the event that the tanks 16 are full, for instance when no dispensing is occurring, no compression is taking place and thus no heat from the compression of source gas is available to maintain the temperature of the gaseous fuel inside the storage tanks 16 . Accordingly, in order to maintain the temperature of the gaseous fuel in cold weather during times of little or no replenishing of the tanks (i.e., when fuel dispensing is low), the storage tanks 16 are additionally provided with an auxiliary electric heater 42 located in the main body of each of the tanks, discussed in more detail below. In the preferred embodiment, the power supply 30 that powers the slow fill compressor 12 also powers each electric heater 42 , although a separate power supply may also be used without departing from the broader aspects of the present invention.
[0030] Importantly, as discussed above, the temperature sensor 34 positioned within each storage tank 16 monitors a temperature of the gaseous fuel within each tank 16 . As shown in FIG. 1 , each temperature sensor 34 is connected to a thermostat 36 that is set to maintain a desired temperature within each tank 16 . In the preferred embodiment, the desired temperature is approximately 70° F., although the thermostat 36 can be configured to maintain any desired setpoint temperature. When the heat generated from compression of the low pressure source gas is not is not available to maintain the temperature of the gaseous fuel within the tanks 16 , or when compression generated heat cannot keep up with temperature demand, the temperature sensor 34 will detect declining temperatures or a temperature below the setpoint temperature of the thermostat 36 . In response, the auxiliary heater 42 will be activated by the thermostat 36 to provide auxiliary heat to each fuel tank 16 to maintain or raise the temperature inside each tank 16 . Once the temperature of the gaseous fuel within the storage tanks 16 again reaches the setpoint temperature of the thermostat 36 , the auxiliary electric heater 42 is automatically switched off.
[0031] Preferably, the electric heater 42 is envisioned as a “blanket” which surrounds at least a portion of the tanks 16 , although other configurations and positioning of the electric heater 42 are also contemplated in the present invention.
[0032] As further shown in FIG. 1 , valves 44 control the flow of low pressure gas from the loading truck into the low pressure tank 24 , from the low pressure tank 24 into the slow fill compressor 12 , and from the low pressure gas line 22 into the slow fill compressor 12 . Other valves 46 control the flow of pressurized gas from the heat exchange apparatus 14 into the storage tanks 16 . The output pipeline 48 of each storage tank 16 is also configured with a valve 50 to control the flow of compressed gaseous fuel from the tanks 16 to the manifold 18 . Finally, valves 52 control the flow of gaseous fuel from the manifold 18 to each fuel dispenser 20 .
[0033] Check valves 54 are positioned downstream from the solenoid valve along the direct fill line 32 and downstream the heat exchange apparatus 14 along the heat exchange loop 40 . The check valves 54 desirably control the direction of flow through the heat exchange loop 40 and the direct fill line 32 toward the storage tanks 16 , and prevent undesirable flow reversals that might otherwise occur due to unexpected pressure changes, leaks, equipment failures, or the like. Check valves 56 are also positioned along the output pipelines to control the direction of flow therethrough and to prevent similar flow reversals.
[0034] Importantly, the system 10 of the present invention is, broadly speaking, applicable to CNG storage tank assemblies of any size, both small and large capacity. The large capacity tank concept complements this system in the preferred embodiment, but it is not required.
[0035] In connection with the above, the configuration of the gaseous fuel storage tanks 16 is another important aspect of the present invention. In the preferred embodiment, each tank 16 is a large capacity tank, capable of storing a large quantity of gaseous fuel, in contrast to known small-volume tanks. Where the gaseous fuel is compressed natural gas, stored at approximately 70° F. and 3,600 psi, each tank 16 has a storage capacity large enough fill 500-700 compatible vehicles with CNG. Moreover, each storage tank is specially designed to withstand the pressures of the gaseous fuel inside the tank 16 and to insulate the gaseous fuel inside the tank from outside, ambient air, while having a lower weight profile than has heretofore been known.
[0036] FIGS. 2 and 3 show the configuration of a large-capacity storage tank 16 . As shown therein, each tank 16 is generally cylindrical in cross-section and includes an inner tank wall 60 and an outer tank wall 62 defining an annular space 64 therebetween, the inner and outer walls 60 , 62 being generally concentric. Within the annular space 64 , the auxiliary electric heater 42 is preferably disposed. The auxiliary electric heater 42 comprises a fiber carbon or metal electric mesh, through which electrical current is provided to produce heat. The mesh auxiliary heater 42 is preferably wrapped around the outer peripheral surface of the inner wall 60 of the tank 16 and preferably extends the length of the inner wall 60 .
[0037] As further shown therein, a polymer based resin 66 fills the remainder of the annular space 64 . Importantly, this resin 66 functions as an insulation layer to insulate the interior of the tank from the outside, ambient air (and potential low temperature thereof), as well as functioning as a mechanical reinforcement layer that effectively bonds the inner wall 60 to the outer wall 62 , and as a shock absorber for absorbing stress on the walls of the inner wall 60 . In this manner, the inner wall 60 and outer wall 62 are essentially joined together as a single unit. As will be readily appreciated, this increases the ability of the tank 16 to withstand the high pressures of gaseous fuel stored therein, as discussed below. In addition, the use of two walls bonded together with a polymer resin 66 decreases the weight of the tank 16 as compared to a single-walled tank of equal volume.
[0038] In the preferred embodiment, each wall is manufactured from steel, although other metals or materials known in the art may also be used without departing from the broader aspects of the present invention. Preferably, the walls of each wall 60 , 62 are approximately 1″ thick in embodiments where steel is utilized. In contrast to the present invention, known single-wall storage tanks not having the structure of the tanks 16 shown in FIGS. 2 and 3 would have to be manufactured with walls that are 3″ thick to safely withstand the pressures, approximately 3,600 psi, inside the tank. As will be readily appreciated, providing a tank with inch-thick walls is advantageous because the tanks can be manufactured by rolling, whereas a tank with 3″ thick walls cannot be rolled using known methods and devices, but instead must be cast and, of course, would exhibit a much higher weight profile.
[0039] Through testing, it has been shown that the greatest stresses in cylindrical storage tanks oriented in the horizontal direction are concentrated along the top of the tank. Advantageously, as discussed above, the polymer based resin 66 disposed in the annular space 64 functions as a shock absorber to absorb the stresses upon the inner wall 60 of the tank, such that the outer wall 62 is subject to little stress, thereby allowing the walls 60 , 62 to be manufactured from steel or other metals of a lesser thickness. As compared to a single-walled storage tank having the same capacity and suitable to withstand gaseous fuel at a pressure of 3,600 psi at 70° F., the tank 16 of the present invention provides for an approximately 50% reduction in weight. In addition, significant weight savings are also realized in comparison to utilizing a large number of smaller storage tanks to store the same volume of gas, as more tanks equate more weight.
[0040] Referring now to FIG. 4 , a finite element analysis evidences the advantages provided by the large capacity, double-walled tank of the present invention. In particular, as shown in FIG. 3 , at 3,600 psi, the large capacity of the tank 16 of the present invention, having a 40″ diameter inner chamber defined by an inner wall 60 that is 1″ thick, a 44″ diameter outer chamber defined by an outer wall 62 that is 1″ thick, and a 1″ thick resin 66 disposed in the annular space 64 between the walls 60 , 62 results in a maximum von mises stress of 38,454 psi in the top of the inner wall 60 , within material limits (see top half of tank in FIG. 4 ). In addition, the outer wall (bottom half of tank in FIG. 4 ) exhibits a stress of 33,966 psi, also within material limits. The weight of the tank having these parameters is approximately 10 tons.
[0041] In contrast, finite element analysis of a single walled tank having a 44″ diameter and a 1″ thick wall has shown that the tank would yield to internal pressures prior to reaching the optimum internal pressure of 3,600 psi. As shown in FIG. 5 , the von mises stress is 72,757 psi in the sidewall, well above material limits. Accordingly, in order to withstand pressurization at 3,600 psi, the walls of a single walled tank having a 44″ diameter would need to be 3″ thick, as discussed above, which would translate to a gross tank weight of approximately 15 tons. As will be readily appreciated, in these examples, the double-walled tank 16 of the present invention allows for a weight savings of 5 tons over a single-walled tank. In addition to the weight savings, in contrast to the 3″ thick single-wall tank, the tank 16 of the present invention can be rolled, rather than cast, thereby decreasing manufacturing time and cost.
[0042] It is therefore another important aspect of the present invention that the gaseous fuel storage tank 16 of the system of the present invention is capable of withstanding much higher pressures than known single-walled tanks of similar wall thickness. As a result, significant savings in weight, materials, cost, and ease of manufacture are realized, as discussed above. In view of the above, the present invention therefore provides a much lighter tank with the added ability to more precisely control the temperature of pressurized gaseous fuel stored within the tank. Indeed, by utilizing the compression of source gas to maintain the temperature within the storage tanks, significantly less energy is expended than would be the case if a stand-alone heater were utilized. Importantly, the temperature sensor and thermostat allow the temperature within the tanks to be more precisely controlled. Moreover, when the tanks are full and no compression is needed to fill the tanks, the temperature sensor and thermostat are arranged so as to control the auxiliary electric heater located in the main body of the tank to further maintain an optimum temperature of the CNG stored therein.
[0043] As discussed in detail above, the system 10 of the present invention utilizes the heat generated by gaseous compression of the fuel as a way to maintain the proper temperature and pressure regiment within the CNG storage tanks. In addition, the present invention provides a novel construction for large capacity CNG storage tanks that can be manufactured economically and at a much reduced weight profile. It will therefore be readily appreciated that a combination of the system 10 shown in FIG. 1 , with the large capacity tanks 16 shown in FIGS. 2 and 3 , results in a compressed gaseous fuel dispensing assembly that is more economical and efficient than has heretofore been known in the art.
[0044] Although this invention has been shown and described with respect to the detailed embodiments thereof, it will be understood by those of skill in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed in the above detailed description, but that the invention will include all embodiments falling within the scope of this disclosure.
|
A system for the cold-weather storage of gaseous fuels includes a gas source having an inlet pressure, a compressor having an inlet and an outlet, the inlet selectively communicating with the gas source and the outlet having a discharge pressure greater than the inlet pressure, a heat exchange apparatus having an inlet and an outlet, the inlet selectively communicating with the compressor so as to receive pressurized gas therefrom, a high-pressure storage tank having an inlet and an outlet, the inlet selectively communicating with the compressor so as to receive pressurized gas therefrom, and a valve assembly for selectively directing the pressurized gas to the heat exchange apparatus and the high-pressure storage tank in dependence upon a temperature within the storage tank.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of application Ser. No. 13/653,352, filed Oct. 16, 2012 and entitled VAPOR DEPOSITION SYSTEM AND METHOD, which application is incorporated by reference herein in its entirety and claims the benefit of U.S. provisional patent application No. 61/613,366, filed Mar. 20, 2012 and entitled VAPOR DEPOSITION SYSTEM AND METHOD, which application is incorporated by reference herein in its entirety; and this application is a continuation in part of U.S. Ser. No. 13/030,091, filed on Feb. 17, 2011 entitled “VAPOR DEPOSITION SYSTEM AND METHOD, which in turn claims the benefit of U.S. provisional application No. 61/338,949, filed Feb. 26, 2010 and entitled “FIXTURE TO SUSPEND OPHTHALMIC LENSES FOR CONCAVE AND CONVEX SIDE APPLICATIONS; U.S. provisional application No. 61/338,951, filed Feb. 26, 2010 and entitled “FIXTURE DEVICE FOR THE APPLICATION OF VAPOR DEPOSITION ON THE CONCAVE AND CONVEX SIDES OF AN OPHTHALMIC LENS WHILE ROTATING”; U.S. provisional application No. 61/343,668, filed May 3, 2010 and entitled “GRAVITY FED TRANSFER MECHANISM”; U.S. provisional application No. 61/343,669, filed May 3, 2010 and entitled “HYDROPHOBIC, OLEOPHOBIC OR SUPER HYDROPHOBIC APPLICATOR”; and U.S. provisional application No. 61/343,672, filed May 3, 2010 and entitled “FULLY AUTOMATED, IN-LINE, HIGH THROUGHPUT, LOW VOLUME, SIMULTANEOUS AND NON-SIMULTANEOUS PROCESS, HIGH AND LOW VACUUM, PHYSICAL VAPOR DEPOSITION SYSTEM, each of which applications is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The disclosure generally relates to coatings for optical lenses and other substrates. More particularly, the disclosure relates to a physical or chemical vapor, corona method, or thermal evaporation deposition system and method which facilitate sequential application of coatings to an optical lens or other substrate by gravity-actuated transfer of the substrates between successive deposition chambers.
BACKGROUND OF THE INVENTION
[0003] Optical lenses of eyewear such as eyeglasses and sunglasses may include one or more optical coatings which impart a desired appearance or optical characteristic to the lenses. An optical coating includes one or multiple layers of material which are deposited on one or both sides of an optical lens and affects the manner in which the lens reflects and transmits light. Antireflective coatings and high-reflective coatings are examples of optical coatings which may be applied to an optical lens.
[0004] A common method of applying an optical coating to an optical lens includes dipping the lens in a solution which adheres to one or both surfaces of the lens upon removal of the lens from the solution and then curing the solution to form the coating. Another method of applying an optical coating to an optical lens involves applying the coating to one or both surfaces of the lens using a physical vapor deposition (PVD) process.
[0005] In some applications, it may be necessary or desirable to sequentially apply multiple layered coatings to one or both surfaces of an optical lens. For example, application of optical coatings to one or both surfaces of optical lenses for eyewear may include application of metallic, dielectric, dichroic, hydrophobic, oleophobic or super hydrophobic coatings to the lenses in a sequential manner. One challenge, which is inherent in the serial application of coatings to optical lenses, is the transfer of each lens among multiple deposition chambers in a manner which is both efficient and does not risk physical contact or contamination of the freshly-applied coatings on the lens.
[0006] Therefore, a physical vapor deposition (PVD) system which facilitates sequential application of coatings to an optical lens or other substrate by gravity-actuated transfer of the substrates between successive PVD chambers is needed.
SUMMARY OF THE INVENTION
[0007] The disclosure is generally directed to a physical vapor deposition system. An illustrative embodiment of the system includes a system housing having a housing interior, a fixture transfer assembly having a generally sloped fixture transfer rail extending through the housing interior, a plurality of processing chambers connected by the fixture transfer rail, a controller interfacing with the processing chambers and at least one fixture carrier assembly carried by the fixture transfer rail and adapted to contain one substrate. The fixture carrier assembly travels along the fixture transfer rail under influence of gravity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The disclosure will now be made, by way of example, with reference to the accompanying drawings, in which:
[0009] FIG. 1 is a left side front perspective view of an illustrative embodiment of the vapor deposition system, with the system housing in an open configuration;
[0010] FIG. 2 is a right side front perspective view of an illustrative embodiment of the vapor deposition system, with the system housing in an open configuration;
[0011] FIG. 3 is a perspective view of an illustrative embodiment of the vapor deposition system, with the system housing in a closed configuration;
[0012] FIG. 4 is a perspective view of a film application system of an illustrative embodiment of the vapor deposition system;
[0013] FIG. 5 is a block diagram which illustrates interconnection of the various subsystem components of the physical vapor deposition system; and
[0014] FIG. 6 is a flow diagram of an illustrative embodiment of a physical vapor deposition method.
DETAILED DESCRIPTION
[0015] The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to practice the disclosure and are not intended to limit the scope of the appended claims. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.
[0016] Referring initially to FIGS. 1-4 of the drawings, an illustrative embodiment of the physical vapor deposition system, hereinafter system, is generally indicated by reference numeral 100 . As will be hereinafter further described, the system 100 is adapted to sequentially apply one or more coatings (not illustrated) on one or both surfaces (not illustrated) of a substrate (not illustrated) using a physical vapor deposition (PVD) process. In some applications, the substrate may be an optical lens of eyewear such as eyeglasses or sunglasses, for example and without limitation. The coating(s) which is/are applied to the substrate may be hydrophobic, oleophobic or super hydrophobic coatings, for example and without limitation, which may serve as antireflective coatings, high-reflector coatings or other optical coatings known in the art. The PVD processes which are used to apply the coatings to the substrate may be sequentially carried out in a series of multiple processing chambers 185 ( FIG. 4 ). Each substrate may be transferred from one processing chamber 185 to the next processing chamber 185 in the deposition process via gravity, as will be hereinafter further described.
[0017] The system 100 may include a system housing 122 . In some embodiments, the system housing 122 may include a pair of side housing panels 123 , a top housing panel 127 and a rear housing panel 128 which define a housing interior 124 . The housing interior 124 may be divided into a lower subsystem compartment 125 and an upper chamber compartment 126 . The subsystem compartment 125 may contain various subsystem components of the system 100 which will be hereinafter described. The chamber compartment 126 may contain a film application system 184 having multiple processing chambers 185 . In operation of the system 100 , which will be hereinafter described, the processing chambers 185 implement etching and physical vapor deposition functions in the processing of substrates.
[0018] As illustrated in FIGS. 1-4 , the system housing 122 may include at least one front subsystem compartment door 130 provided on the system frame 101 . In some embodiments, the system housing 122 may have multiple, adjacent front subsystem compartment doors 130 . The front subsystem compartment doors 130 may be selectively opened to expose the subsystem compartment 125 at the front portion of the housing interior 124 , as illustrated in FIGS. 1 and 2 , or selectively closed to conceal the subsystem compartment 125 at the front portion of the housing interior 124 , as illustrated in FIG. 3 .
[0019] In some embodiments, the system housing 122 may further include at least one rear subsystem compartment door (not illustrated) provided on the system housing 122 . The rear subsystem compartment door may be selectively opened to expose the subsystem compartment 125 at the rear portion of the housing interior 124 or selectively closed to conceal the subsystem compartment 125 at the rear portion of the housing interior 124 .
[0020] The system housing 122 may include at least one front chamber compartment door 132 to selectively expose and conceal the chamber compartment 126 at the front portion of the housing interior 124 . At least one of the front chamber compartment doors 132 may have at least one window 133 . In some embodiments, the front chamber compartment door 132 may be pivotally attached to a side housing panel 123 of the system housing 122 via door hinges 137 ( FIGS. 1 and 2 ). At least one door latch (not illustrated) may be provided on each front chamber compartment door 132 . The door latch or latches may be adapted to selectively lock the front chamber compartment door or doors 132 in the closed position of FIG. 3 or selectively unlock the front chamber compartment door or doors 132 for opening as illustrated in FIGS. 1 and 2 . In some embodiments, at least one door extension cylinder (not illustrated) may be attached to the system housing 122 . A door extension piston (not illustrated) may be extendable from the door extension cylinder. The door extension piston may be attached to an interior surface of the front chamber compartment door 132 . Accordingly, when the front chamber compartment door 132 is closed and the door latch (not illustrated) is latched, the door extension piston is retracted into the door extension cylinder. When the front chamber compartment door 132 is open, the door extension piston extends from the door extension cylinder and maintains the front chamber compartment door 132 in the open position.
[0021] In some embodiments, the system housing 122 may further include a rear chamber compartment door (not illustrated) to selectively expose and conceal the chamber compartment 126 at the rear portion of the housing interior 124 . The rear chamber compartment door may have a design and attachment which are as were heretofore described with respect to the front chamber compartment door or doors 132 .
[0022] As further illustrated in FIGS. 1-9 , the system 100 may include a fixture transfer assembly 146 . The fixture transfer assembly 146 may include a generally elongated fixture transfer rail 147 which extends transversely through the chamber compartment 126 of the housing interior 124 in the system housing 122 . The fixture transfer rail 147 may have a fixture loading end 148 and a fixture unloading end 149 . A lower loading ramp segment 153 and an upper loading ramp segment 153 a , and a lower unloading ramp segment 154 and an upper unloading ramp segment 154 a , of the fixture transfer rail 147 may protrude beyond the respective loading and unloading ends, respectively, of the system housing 122 . The fixture transfer rail 147 may generally slope downwardly from the fixture loading end 148 to the fixture unloading end 149 .
[0023] The fixture transfer rail 147 of the fixture transfer assembly 146 may be mounted in the chamber compartment 126 of the housing interior 124 according to any suitable technique which is known by those skilled in the art. In some embodiments, the fixture transfer assembly 146 may include a generally elongated chamber support member (not illustrated) which extends through the chamber compartment 126 in generally transverse relationship to the longitudinal axis of the system housing 122 . The chamber support member may be attached to any structural component of the system housing 122 using welding, fasteners and/or other suitable attachment technique. The fixture transfer rail 147 may be sloped with respect to the horizontal at a slope angle of about 91.50 degrees.
[0024] As illustrated in FIGS. 1-3 , the fixture transfer assembly 146 may further include at least one fixture carrier assembly 156 . In some embodiments, the fixture transfer assembly 146 may include multiple fixture carrier assemblies 156 , as illustrated. Each fixture carrier assembly 156 may include an annular assembly frame 157 having a frame opening 158 . A fixture mount plate (not illustrated) having a fixture opening may be provided in the frame opening 158 . The fixture opening is sized and configured to receive and secure a single substrate (not illustrated) typically in the conventional manner.
[0025] As illustrated in FIGS. 1 and 2 of the drawings, a film application system 184 having multiple processing chambers 185 ( FIG. 4 ) is provided in the chamber compartment 126 of the housing interior 124 . The processing chambers 185 have physical vapor deposition capabilities according to the knowledge of those skilled in the art. At least one of the processing chambers 185 may have substrate etching capabilities. As illustrated in FIG. 5 , in some embodiments, the processing chambers 185 may include a first processing chamber 185 a , a second processing chamber 185 b and a third processing chamber 185 c which are sequentially ordered between the lower and upper loading ramp segments 153 , 153 a on one side and the lower and upper unloading ramp segments 154 , 154 a on the other side of the system housing 122 . Therefore, the processing chambers 185 may assume the sloped or angled orientation of the fixture transfer rail 147 .
[0026] Each processing chamber 185 is adapted to receive by gravity and contain a fixture carrier assembly 156 having a substrate (not illustrated) retained therein for processing of the substrate. As illustrated in FIG. 4 , a fixture entry valve 188 may be disposed in fluid communication with each processing chamber 185 at an inlet side of the processing chamber 185 . A fixture outlet valve 189 may be disposed in fluid communication with the processing chamber 185 at an outlet side of the processing chamber 185 . The fixture entry valves 188 and the fixture outlet valves 189 may couple the first processing chamber 185 a to the second processing chamber 185 b and the second processing chamber 185 b to the third processing chamber 185 c with a vacuum-tight seal in the chamber compartment 126 of the housing interior 124 . In operation of the system 100 , which will be hereinafter further described, the fixture entry valve 188 and the fixture outlet valve 189 may facilitate sequential transfer of each of multiple fixture carrier assemblies 156 into and out of, respectively, each processing chamber 185 .
[0027] As further illustrated in FIG. 4 , the film applicator system 184 may include a roughing pump 190 which is disposed in fluid communication with each processing chamber 185 through a roughing pump conduit 191 . Multiple water-cooled evaporation sources (not illustrated) may be provided in each processing chamber 185 . A water chiller (not illustrated) may be connected to the water-cooled evaporation sources through a pair of water hoses. An evaporation power supply (not illustrated) may be electrically connected to the water-cooled evaporation sources through a pair of power cables.
[0028] At least one liquid delivery injection arm (not illustrated) may be disposed in fluid communication with each processing chamber 185 . In some embodiments, a pair of front and rear liquid delivery injection arms may be disposed in fluid communication with each processing chamber 185 . An arm internalization mechanism (not illustrated) may engage each liquid delivery injection arm for internalization of the liquid delivery injection arms through respective front and back side liquid delivery ports (not illustrated) into the processing chamber 185 in operation of the system 100 . When in the internalized configuration, the liquid delivery injection arms may be positioned on opposite front and back sides of the fixture carrier assembly 156 . A deposition liquid delivery system (not illustrated) may be disposed in fluid communication with the liquid delivery injector arms through liquid delivery lines.
[0029] A turbomolecular pump (not illustrated) may be disposed in fluid communication with each processing chamber 185 . Each processing chamber 185 may include a fixture rotation mechanism (not illustrated) which facilitates rotation of the fixture carrier assembly 156 in the processing chamber 185 . The fixture rotation mechanism may include a movement sensor (not illustrated) which senses movement of the fixture carrier assembly 156 in the processing chamber 185 . A vacuum valve (not illustrated) may be disposed in fluid communication with the processing chamber 185 in communication with the turbomolecular pump.
[0030] It will be recognized and understood that the foregoing description of each processing chamber 185 is a general description and it will be recognized and understood that processing chambers of various design which are known by those skilled in the art may be suitable for the purpose of etching and depositing coatings on substrates using physical vapor deposition techniques in operation of the system 100 . Some processing chambers 185 which are suitable for implementation of the system 100 may depart in at least some design details from the foregoing description of the processing chamber 185 which was set forth herein above with respect to FIG. 4 . At least one of the processing chambers 185 may have any etching chamber design with necessary hardware which is suitable for etching and cleaning of the substrates preparatory to deposition of coatings on the substrates by operation of the processing chambers 185 . Etching chamber designs are well-known by those skilled in the art; therefore, the hardware and design of the etching chamber 198 need not be set forth herein in detail. Generally, the etching chamber may include a fixture entry valve 188 and a fixture outlet valve 189 which facilitate entry and exit of individual fixture carrier assemblies 156 into and out of, respectively, the etching chamber, as was heretofore described with respect to the processing chambers 185 in FIG. 4 .
[0031] Referring next to FIG. 5 of the drawings, a block diagram of a control system 216 which is suitable for implementation of the physical vapor deposition system 100 is illustrated. The control system 216 may include a programmable logic controller (PLC) 222 . A human-machine interface (HMI) 224 may interface with the PLC 222 . The HMI 224 may include a keyboard, mouse and/or other elements which may be used to program the PLC 222 to operate the multiple functions of the system 100 . An electrical distribution panel 220 may interface with the PLC 222 . The various functional components of the system 100 may be electrically connected to the electrical distribution panel 220 . Accordingly, the PLC 222 may be adapted to operate the various subsystems of the system 200 through the electrical distribution panel 220 .
[0032] Some of the subsystems of the system 100 may include a roughing pump 190 , water-cooled evaporation sources 194 , a deposition liquid delivery system 204 , a fixture rotation mechanism 211 , a fixture entry valve 188 , a fixture outlet valve 189 and a turbomolecular pump 210 , each of which is disposed inside or interfaces with the processing chamber 185 . The evaporation power supply 200 may be electrically connected to the electrical distribution panel 220 and the water-cooled evaporation sources 194 in the processing chamber 185 . The water chiller 195 may be electrically connected to the electrical distribution panel 220 and disposed in fluid communication with the water-cooled evaporation sources 194 . In some embodiments, an entry position sensor 192 may be connected to the electrical distribution panel 220 and disposed at the entry position of the processing chamber 185 adjacent to the fixture entry valve 188 . The entry position sensor 192 may be adapted to sense the fixture carrier assembly 156 at the entry position of the processing chamber 185 and enable the PLC 222 to open the fixture entry valve 188 of the processing chamber 185 for entry of the fixture carrier assembly 156 into the processing chamber 185 , as will be hereinafter described. As further illustrated in FIG. 5 , in some embodiments, a chamber cooling system 236 may interface with each processing chamber 185 and the electrical distribution panel 220 for the purpose of cooling the interior of the processing chamber 185 .
[0033] Some of the subsystems of the system 100 may be contained in the subsystem compartment 125 ( FIGS. 1 and 2 ) of the housing interior 124 . In some embodiments, the roughing pumps 190 , the water chiller 195 and the evaporation power supply 200 may be contained in the subsystem compartment 125 in the front portion of the housing interior 124 . The electrical distribution panel 220 and the PLC 222 may be contained in the subsystem compartment 125 in the rear portion of the housing interior 124 . The subsystems can be selectively exposed and accessed for repair, replacement and/or maintenance purposes by opening the front subsystem compartment doors 130 ( FIG. 1 ) and the rear subsystem compartment door (not illustrated). Likewise, the PVD chambers 185 can be selectively exposed and accessed for repair, replacement and/or maintenance purposes by opening the front chamber compartment door 132 and the rear chamber compartment door (not illustrated).
[0034] In exemplary application, the system 100 is operated to apply one or multiple coatings (not illustrated) to one or both sides of a substrate (not illustrated) in a sequential manner using a physical vapor deposition (PVD) process. In some applications, the substrate may be an optical lens which will be used in the assembly of eyewear such as eyeglasses or sunglasses, for example and without limitation. For example and without limitation, in some applications, the system 100 may be operated to plasma etch the front and backsides of an optic lens; apply a mirror coating to the front of the lens; and apply an oleophobic/hydrophobic coating to the front and backside of the lens. In other applications, the substrate may be any type of substrate to which one or more coatings is to be applied using a PVD process.
[0035] A substrate is secured in each of multiple fixture carrier assemblies 156 ( FIGS. 1-3 ). As will be hereinafter further described, each fixture carrier assembly 156 serves as a vehicle for transport of the substrate between and within the sequential processing chambers 185 . Accordingly, each substrate may initially be secured in the frame opening 158 of a corresponding fixture carrier assembly 156 .
[0036] As illustrated in FIGS. 2 and 3 , at least one fixture carrier assembly 156 (each containing a substrate 182 held therein) is initially placed on the lower loading ramp segment 153 of the fixture transfer rail 147 . In some embodiments, multiple fixture carrier assemblies 156 may be placed in series on the lower loading ramp segment 153 of the fixture transfer rail 147 , as illustrated. Each fixture carrier assembly 156 may be inserted in place between the lower loading ramp segment 153 and the upper loading ramp segment 153 a such that a circumferential rail groove (not illustrated) in the assembly frame 157 of the fixture carrier assembly 156 receives the lower loading ramp segment 153 and the upper loading ramp segment 153 a of the fixture transfer rail 147 . Therefore, each fixture carrier assembly 156 is self-standing between the lower loading ramp segment 153 and the upper loading ramp segment 153 a.
[0037] Due to the angled or sloped configuration of the lower loading ramp segment 153 and the upper loading ramp segment 153 a , each fixture carrier assembly 156 has a tendency to roll under influence of gravity on the fixture transfer rail 147 from the fixture loading end 148 toward the fixture unloading end 149 thereof. Accordingly, the fixture carrier assembly 156 which is first in the series of multiple fixture carrier assemblies 156 on the loading ramp segment 153 rolls to a “ready” position adjacent to a fixture entry valve 188 at the inlet of the first processing chamber 185 a . A second fixture carrier assembly 156 rolls into the space which was previously occupied by the first fixture carrier assembly 156 , and the remaining fixture carrier assemblies 156 roll into the spaces previously occupied by the preceding fixture carrier assemblies 156 , respectively.
[0038] The system 100 is initialized and enters a standby condition as the PLC 222 ( FIG. 5 ) is turned on. The operational parameters (temperature, pressure, etc.) for the etching process which is to be carried out and for each of the deposition processes which are to be sequentially carried out in the processing chambers 185 may be programmed into the PLC 222 ( FIG. 5 ) through the HMI 224 . An entry position sensor (not illustrated) at the “ready” position adjacent to the fixture entry valve 188 of the first processing chamber 185 a senses the location of the first fixture carrier assembly 156 at the “ready” position and transmits a signal to the PLC 222 . In response, the PLC 222 opens the fixture entry valve 188 of the first processing chamber 185 a and the first fixture carrier assembly 156 rolls into the first processing chamber 185 a . The PLC 222 then closes the fixture entry valve 188 of the first processing chamber 185 a and establishes the programmed pressure in the first processing chamber 185 a . The next fixture carrier assembly 156 in line on the unloading ramp segment 154 rolls on the fixture transfer rail 147 under the influence of gravity into the “ready” position next to the fixture entry valve 188 of the first processing chamber 185 .
[0039] After the PLC 222 establishes the etching temperature, pressure and other operational parameters which were preprogrammed into the PLC 222 , the first processing chamber 185 a , under control by the PLC 222 , may operate to etch and clean both surfaces of each substrate which is held in the first fixture carrier assembly 156 . After etching and cleaning of the substrates in the first fixture carrier assembly 156 is completed, the PLC 222 opens a fixture outlet valve 189 of the first processing chamber 185 and the first fixture carrier assembly 156 rolls from the first processing chamber 185 into the entry position of the second processing chamber 185 b . The entry position sensor 192 ( FIG. 5 ) senses that the first fixture carrier assembly 156 is at the entry position of the second processing chamber 185 b and transmits a signal to the PLC 222 indicating the entry position of the first fixture carrier assembly 156 . In response, the PLC 222 vents the first processing chamber 185 a to atmosphere and then opens the fixture entry valve 188 of the second processing chamber 185 b . Simultaneously, the front and back side liquid delivery ports (not illustrated) of the second processing chamber 185 b are opened and the front and rear liquid delivery injector arms (not illustrated), under actuation by the arm internalization mechanisms (not illustrated), descend into the second processing chamber 185 b . The first fixture carrier assembly 156 rolls into place in the second processing chamber 185 b . The PLC 222 then closes the fixture entry valve 188 . The PLC 222 , responsive to input from the entry sensor (not illustrated) at the “ready” position of the first processing chamber 185 a , opens the fixture entry valve (not illustrated) of the first processing chamber 185 a and the fixture carrier assembly 156 which was next in line behind the first fixture carrier assembly 156 rolls on the fixture transfer rail 147 into the first processing chamber 185 a.
[0040] The deposition liquid (not illustrated) which will form the coatings on one or both surfaces of each substrate in the first fixture carrier assembly 156 is dispensed from the deposition liquid delivery system 204 ( FIG. 5 ) through the respective liquid delivery lines (not illustrated) to the liquid delivery injector arms (not illustrated). The liquid delivery injector arms dispense the deposition liquid into the water-cooled evaporation sources 194 ( FIG. 5 ) in the second processing chamber 185 b . Once the deposition liquid is fully dispensed into the evaporation sources 194 , the liquid delivery injector arms are retracted from the second processing chamber 185 b and the liquid delivery ports (not illustrated) are closed. Next, the fixture rotation mechanism 211 ( FIG. 5 ) may rotate the first fixture carrier assembly 156 in the second processing chamber 185 b and the PLC 222 pulls vacuum on the second processing chamber 185 b via the roughing pump 190 and the turbomolecular pump. Once the correct level of vacuum pressure in the second processing chamber 185 b has been achieved, the deposition liquid in the evaporation sources 194 is evaporated into the second processing chamber 185 b , coating the substrate in the first fixture carrier assembly 156 . After it determines that a predetermined period of time has elapsed to ensure thorough coating of the substrates, the PLC 222 vents the second processing chamber 185 b to atmosphere. The PLC 222 then opens the fixture outlet valve 189 of the second processing chamber 185 b such that the first fixture carrier assembly 156 rolls under influence of gravity the second processing chamber 185 b to the fixture entry position of the third processing chamber 185 c . The same PVD and transfer process is then carried out on the substrates of the first fixture carrier assembly 156 in the third processing chamber 185 d until the desired coatings have been sequentially applied to the surfaces of each substrate. As the PVD process is carried out in the second processing chamber 185 b , the substrates held in the fixture carrier assembly 156 which was next in line behind the first fixture carrier assembly 156 may be etched in the first processing chamber 185 a . The substrates in that next-in-line fixture carrier assembly 156 may then be subjected to the PVD processes in the second processing chamber 185 b and the third processing chamber 185 c in the same manner as the substrates in the first fixture carrier assembly 156 .
[0041] After the PVD processes in the third processing chamber 185 c are completed, the fixture carrier assemblies 156 sequentially roll from the third processing chamber 185 c onto the unloading ramp segment 154 of the fixture transfer rail 147 . The fixture carrier assemblies 156 are removed from the unloading ramp segment 154 and the substrates are removed from the frame openings 158 in the fixture carrier assemblies 156 for further processing. Between uses of the system 100 , the PLC 222 may periodically operate the chamber cooling system 236 ( FIG. 5 ) to clean the interior of each processing chamber 185 as deemed necessary.
[0042] It will be appreciated by those skilled in the art that the physical vapor deposition system 100 is capable of processing substrates in multiple fixture carrier assemblies 156 at the same time by simultaneous operation of the processing chambers 185 . This expedient facilitates high-speed, low-volume and high-throughput production of thin film-coated substrates using physical vapor deposition processes. Moreover, transfer of the fixture carrier assemblies 156 between the processing chambers 185 by gravity eliminates the need for mechanical structure and related power supply which would otherwise be required for the transfer operation. The system 100 may be designed such that the chamber functions and capabilities are flexible and can be adapted for various types of physical vapor deposition applications on different types of substrates. Examples include but are not limited to ophthalmic mirror coatings, ophthalmic anti-reflective coatings, protective coatings, cosmetic coatings, compact disc manufacturing and medical device manufacturing. The construction methods and materials for the system 100 may be tailored according to the particular thin films which are to be applied to the substrates. The system 100 may be constructed in any of various sizes depending on the desired application. Various alternative designs for the subsystems, assemblies and components may be used in various embodiments of the system 100 . The system 100 may be fabricated using a variety of fabrication techniques including but not limited to welding, brazing, connectors, terminal blocks, screws, bolts, nuts and clamps.
[0043] It will be further appreciated by those skilled in the art that each processing chamber 185 may contain multiple water-cooled evaporation sources 194 ( FIG. 5 ) to enhance the flexibility of the physical vapor deposition system 100 . Thus, multiple types of physical vapor deposition by evaporation processes can be carried out in each processing chamber 185 . The system housing 122 may be fabricated with a small footprint to facilitate ease and space efficiency in placement of the physical vapor deposition system 100 in retail locations.
[0044] Various structural provisions instead of or in addition to those which were heretofore described with respect to the drawings may be made for the functioning and distribution of the vacuum subsystem, pneumatic subsystem, electrical subsystem and/or any other subsystems or components which may be deemed necessary for operation of the processing chambers 185 or any other operational component or subsystem of the system 100 . For example and without limitation, vacuum system conduits (not illustrated) may be routed throughout the housing interior 124 to provide connection between the roughing pumps 190 , turbomolecular pumps and/or other pumps and the processing chambers 185 . Pneumatic system conduits (not illustrated) may provide connection between vacuum subsystem components or pneumatic subsystem components and the processing chambers 185 . Pneumatic system ports (not illustrated) may be provided in the fixture transfer rail 147 and/or other structural components of the system 100 for functioning of the pneumatic subsystem. Other structural provisions may include whichever supports, wiring and plumbing may be necessary to interconnect all components and subsystems.
[0045] The film applicator system 184 ( FIG. 17 ) of the system 100 may be designed as a stand-alone unit, as part of an in-line physical vapor deposition system or as part of a larger, more complex system. The film applicator system 184 can coat one side or two sides of a substrate and a two-sided coating applied to the substrate may be performed individually or simultaneously at high speeds and high throughput. The film applicator system 184 may be operated manually, semi-automatically or fully automatically via a computer or the PLC 222 and HMI 224 ( FIG. 5 ).
[0046] The fixture carrier assemblies 156 may be constructed of various materials depending on the particular application. The fixture carrier assemblies 156 may be constructed for single-side application and may be fabricated in various sizes. Alternative methods of holding the substrate in the frame opening 158 of each fixture carrier assembly 156 may be used. Moreover, the design of each fixture carrier assembly 156 , as well as each processing chamber 185 as described and illustrated herein, may facilitate uniform coating of either or both surfaces of each substrate depending on the desired application.
[0047] Referring next to FIG. 6 of the drawings, a flow diagram 2300 of an illustrative embodiment of a physical vapor deposition method is illustrated. In block 2302 , a sloped gradient is provided. In block 2304 , processing chambers are placed along the sloped gradient. In some applications, the processing chambers may include an etching chamber and at least one physical vapor deposition (PVD) chamber. In some embodiments, the processing chambers may include an etching chamber and multiple sequentially-ordered PVD chambers. In block 2306 , at least one fixture carrier assembly is provided. In block 2308 , a substrate is placed in the fixture carrier assembly. In block 2310 , the fixture carrier assemblies are transported into and between the processing chambers along the sloped gradient under the influence of gravity. The design of each PVD chamber and each fixture carrier assembly may facilitate uniform deposition of one or more coatings on either or both surfaces of each substrate.
[0048] While various illustrative embodiments of the disclosure have been described above, it will be recognized and understood that various modifications can be made in the disclosure and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the embodiments of the disclosure.
|
A deposition system includes a system housing having a housing interior, a fixture transfer assembly having a generally sloped fixture transfer rail extending through the housing interior, a plurality of processing chambers connected by the fixture transfer rail, a controller interfacing with the processing chambers and at least one fixture carrier assembly carried by the fixture transfer rail and adapted to contain one substrate. The fixture carrier assembly travels along the fixture transfer rail under influence of gravity. A deposition method is also disclosed.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a U.S. National Stage Application of International Application No. PCT/JP2013/052135 filed on Jan. 31, 2013, and published in Japanese as WO 2014/002520 A1 on Jan. 3, 2014. This application claims priority to Japanese Application No. 2012-146843 filed on Jun. 29, 2012. The entire disclosures of the above applications are incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to an apparatus and a method for forming an anodic oxide coating on part of a profile that is formed of a light alloy such as an aluminum alloy or a magnesium alloy.
BACKGROUND ART
A profile (e.g., extruded profile) formed of aluminum or an alloy thereof (hereinafter referred to as “aluminum alloy”) and having an irregular cross-sectional shape has been used in a wide variety of fields (e.g., building materials, vehicular parts, and daily commodities).
A profile formed of an aluminum alloy or the like is normally anodized in order to improve surface properties such as corrosion resistance and hardness.
However, since it may be unnecessary to form an anodic oxide coating over the entire surface of the profile, a method that forms an anodic oxide coating on part of the surface of the profile has been proposed.
For example, the Applicant of the present application proposed a method that quickly forms an anodic oxide coating on an aluminum alloy extruded profile having an irregular cross-sectional shape only within a specific range in the longitudinal direction (see JP-A-2005-68458).
On the other hand, the present invention was conceived to form an anodic oxide coating on part of the outer surface of a profile in a cross direction.
JP-A-5-25693 and JP-A-11-117092 and the like disclose a method that forms an anodic oxide coating only on the inner side of a hollow aluminum product. However, an apparatus and the like that partially anodize the outer surface of a profile having an irregular cross-sectional shape have not been proposed.
SUMMARY OF THE INVENTION
Technical Problem
An object of the invention is to provide an apparatus and a method that form an anodic oxide coating on part of the outer surface of a profile having an irregular cross-sectional shape.
Solution to Problem
According to one aspect of the invention, there is provided a partial anodizing method that partially anodizes a profile having an irregular cross-sectional shape using an electrolytic bath that includes a first partial bath and a second partial bath, the first partial bath having an approximately box-like shape, and being formed of an insulating material, a cathode being disposed on an inner side of the first partial bath, and the second partial bath having an approximately plate-like shape, and being formed of an insulating material, the method comprising:
disposing first part of the profile that does not form a design surface on the second partial bath through a seal member;
joining the first partial bath and the second partial bath to hold the profile so that second part of the profile is situated outside the electrolytic bath, an electrolysis chamber having inlets and outlets for an electrolyte solution being formed by joining the first partial bath and the second partial bath; and
discharging the electrolyte solution through the inlets.
The term “irregular cross-sectional shape” used herein refers to a shape other than a simple axisymmetrical cross-sectional shape (e.g., plate or cylinder).
The term “profile” used herein refers to a wrought product other than that having a circular cross-sectional shape.
Since the electrolytic bath is divided into the first partial bath and the second partial bath, and the end of the first partial bath and the end of the second partial bath can be joined (connected) either directly or through the profile to hold the profile and form the electrolysis chamber, the electrolytic bath can be formed so that the surface of part of the profile faces the electrolysis chamber.
Therefore, part of the profile for which an anodic oxide coating is unnecessary can be positioned outside the electrolytic bath.
When joining two or more partial baths into which the electrolytic bath is divided, a seal member (seal section) may be provided to at least one partial bath so that the electrolyte solution does not reach part of the profile that is not anodized. In this case, the anodizing range can be limited to the desired part (e.g., design surface) of the profile.
When anodizing the profile in the electrolysis chamber that is formed as described above, the profile that is formed of an aluminum alloy or the like is used as an anode, and a cathode that is situated opposite to the anode is provided in the electrolysis chamber. A voltage is applied between the anode and the cathode so that an electrolytic current flows through the electrolysis chamber to form an anodic oxide coating on the surface of part of the profile.
Since heat is generated during anodizing, it is necessary to cool the electrolyte solution.
In order to efficiently cool the electrolyte solution, and prevent a situation in which local burning occurs on the anodizing target surface of the profile, it is preferable that the electrolysis chamber have inlets and outlets for the electrolyte solution, and be provided with an electrolyte solution circulation device that collects the electrolyte solution drained through the outlets, and discharges the collected electrolyte solution through the inlets.
According to this configuration, the electrolyte solution can be collected when placing or removing the profile by separating the electrolytic bath into the partial baths, and it is possible to prevent a situation in which the electrolyte solution stagnates in part of the electrolysis chamber and local burning occurs on the anodizing target surface of the profile, by providing the inlets and the outlets at equal intervals.
In the partial anodizing method,
the profile is preferably anodized so that 22SJ<30V is satisfied, S being a treatment area (dm 2 ) in which the profile is partially anodized, J being an electrolysis current density (A/dm 2 ), and V being a flow rate (1/min) of the electrolyte solution that is circulated through the electrolysis chamber.
Since the flow rate of the electrolyte solution affects removal of heat generated during electrolysis, the flow rate of the electrolyte solution that is circulated through the electrolysis chamber is controlled.
Advantageous Effects of the Invention
The outer surface of the profile can be partially anodized while providing an excellent design surface by utilizing the partial anodizing apparatus according to the invention.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1A to 1C illustrate an example of the structure of an electrolytic bath according to one embodiment of the invention, wherein FIG. 1A is a cross-sectional view, FIG. 1B is a view A, and FIG. 1C is a view B.
FIG. 2A illustrates a state in which two partial baths are separated, FIG. 2B illustrates a state in which an electrolysis chamber is formed so that a profile is placed therein, and FIG. 2C illustrates a state in which a partially anodized profile has been removed.
FIG. 3A is a cross-sectional view illustrating a state before an electrolytic bath is assembled, FIG. 3B illustrates a state after an electrolytic bath has been assembled, and
FIG. 3C illustrates a state in which an electrolysis chamber is filled with an electrolyte solution.
FIG. 4A illustrates a state in which a profile is anodized, FIG. 4B illustrates a state in which an electrolyte solution 20 a is drained after anodizing, and FIG. 4C illustrates a state in which a profile has been removed.
FIG. 5 shows evaluation sample preparation conditions and evaluation results.
DESCRIPTION OF EMBODIMENTS
FIGS. 1A and 4C illustrate an example of the structure of a partial anodizing apparatus according to one embodiment of the invention.
An electrolytic bath 10 can be divided into a first partial bath 11 and a second partial bath 12 , the first partial bath 11 having an approximately box-like shape, and being formed of an insulating material, a cathode 13 being disposed on the inner side of the first partial bath 11 , and the second partial bath 12 having an approximately plate-like shape, and being formed of an insulating material.
In one embodiment of the invention, a profile 1 is held between one end 11 a of the first partial bath 11 and the second partial bath 12 . Seal members 11 c and 12 a are provided to come in contact with the profile 1 .
An end 11 b of the first partial bath 11 is situated opposite to the second partial bath 12 through the seal member 12 a.
Part of the profile 1 that does not form a design surface (i.e., a part 1 a for which an anodic oxide coating is unnecessary) is sealed with the second partial bath 12 .
An electrolyte solution is introduced into an electrolysis chamber 20 through an inlet 21 , and drained through an outlet 22 .
The electrolyte solution drained through the outlet 22 is cooled using a cooler or the like, and re-introduced into the electrolysis chamber 20 through the inlet 21 using a circulation device such as a pump.
A plurality of inlets 21 are provided at equal intervals so that the electrolyte solution is uniformly discharged toward the profile 1 . A plurality of outlets 22 are provided at equal intervals between the corner of the electrolysis chamber and the inlet 21 so that the electrolyte solution does not remain at the corner of the electrolysis chamber 20 .
Anodizing, corrosion resistance, and the like were evaluated as described below using the electrolytic bath.
An aluminum alloy extruded profile was degreased, and subjected to an etching pretreatment according to a normal method. The extruded profile was then anodized in an electrolysis chamber having a given volume using a 200 g/l sulfuric acid aqueous solution as the electrolyte solution for a given time at a given current density.
The temperature of the electrolyte solution is preferably set to 15 to 25° C. so that a hard anodic oxide coating is not formed from the viewpoint of design.
As illustrated in FIG. 2A , the profile 1 was positioned between the first partial bath 11 and the second partial bath 12 so that part of the profile 1 was situated outside the electrolytic bath, and the first partial bath 11 and the second partial bath 12 were assembled as illustrated in FIG. 2B (see also FIGS. 3A and 3B ).
FIG. 3C illustrates a state in which the electrolytic bath was filled with the electrolyte solution 20 a.
The electrolyte solution that was drained through each outlet 22 was discharged toward the profile 1 through each inlet 21 using a circulation device (not illustrated in the drawings) (see the arrows in FIGS. 1B and 1C ).
The electrolysis chamber and the circulation device were connected through a pipe or the like (not illustrated in the drawings).
As illustrated in FIG. 4A , a voltage was applied between the profile 1 (anode) and the cathode 13 to effect electrolysis.
Either direct-current electrolysis or alternating-current electrolysis may be employed. In the examples, direct current was applied.
As illustrated in FIG. 4C , the electrolytic bath 10 was divided into two section after completion of electrolysis, and the profile 1 was removed.
An anodic oxide coating lb had been formed on part of the profile 1 .
The profile 1 was then washed with water, and subjected to a boiling water sealing treatment for 20 minutes.
FIG. 5 shows the results of a Corrodkote test performed in accordance with JIS H 8502 (“Methods of corrosion resistance test for metallic coatings”).
In Examples 1 and 2, a profile having a length of 250 mm was used. In Example 1, the volume of the electrolysis chamber was 0.4 l, the circulation flow rate of the electrolyte solution was 40 l/min, and the profile was anodized for 4 minutes at a current density of 10 A/dm 2 .
In Example 2, the profile was anodized in the same manner as in Example 1, except that the current density was set to 8 A/dm 2 .
In Example 3, the volume of the electrolysis chamber was 1.3 l, and a profile having the same cross-sectional shape as that of the profile used in Examples 1 and 2, and having a length of 800 mm was used.
The treatment conditions are shown in FIG. 5 .
In Comparative Example 1, the outlets 22 a and 22 b were closed. In Comparative Example 2, the flow rate of the electrolyte solution was reduced.
In Examples 1 to 3, the profile had an excellent surface, and the corrosion ratio determined by the Corrodkote test was 10% or less.
In Comparative Example 1, the electrolyte solution stagnated, and local burning occurred. In Comparative Example 2, the value 30V (V: flow rate (1/min)) was smaller than the value 22SJ (S: treatment area (dm 2 ), J: current density (A/dm 2 )), and burning occurred.
INDUSTRIAL APPLICABILITY
The invention is suitable for forming an anodic oxide coating on part of an extruded profile formed of a light alloy, and various products can be produced using an extruded profile obtained by such a treatment.
|
An apparatus and a method are disclosed that form an anodic oxide coating on part of the outer surface of a profile having an irregular cross-sectional shape. A partial anodizing apparatus that is used to partially anodize a profile having an irregular cross-sectional shape includes an electrolytic bath that is divided into two or more partial baths. The profile is held using the two or more partial baths so that part of the profile is situated outside the electrolytic bath to form a sealed electrolysis chamber.
| 2
|
[0001] The present invention relates to a method of estimating the optimum service rate at a specified quality of service for the transmission of packets of data of different characteristics through a switch node comprising a buffer having a defined size. The invention is also directed towards a system for carrying out such a method.
[0002] Traffic in a data network is essentially composed of individual transactions or flows from a source. The source generates a stream of bits grouped into packets. A complete description of the statistics of the source would be very complex. If the goal is the provisioning of sufficient resources at a router or switch in order to limit packet loss and delay at that router, then a more compact encapsulation of the statistics of traffic arriving at the router can be sufficient. We refer to any such encapsulation as a traffic descriptor. One such traffic descriptor has been described in the US Patent Specification No. 6580691 (Bjoerkman et al), namely a polygonal approximation to a scaled cumulant generating function (sCGF). This US Patent Specification discloses a method and system for estimating the sCGF on-line in real time and storing it as a compact traffic descriptor.
[0003] The terminology of this specification is that which is used in High-Performance Communication Networks [Jean Wairand and Pravin Varaiya (Second Edition) Academic Press 2000], unless clearly otherwise.
[0004] A communication network is a collection of network elements interconnected so as to support the transfer of information from a user at one network node to a user at another. The principal network elements are links and switches. A link transfers a stream of bits from one end to another at a specified rate with a given bit error rate and a fixed propagation time. In this specification, we refer to the rate in bits per second at which a buffer is served as the service capacity. Other terms often used interchangeable with service capacity are link-rate and bandwidth. Links are unidirectional. The most important links are:
[0005] optical fibre;
[0006] copper twisted pair;
[0007] ethernet.
[0008] Several incoming and outgoing links meet at a switch, a device that transfers bits from its incoming links to its outgoing links. The name “switch” is used in telephony, while in computer communications, the device that performs routing is called a router, the terms are used interchangeably in this specification. When the rate of incoming bits exceeds that of outgoing bits, the excess bits are queued in a buffer at the switch. The receiver of each incoming link writes a packet of bits into its input buffer, the transmitter of each outgoing link reads from its output buffer. The switch transports packets from an input buffer to the appropriate output buffer.
[0009] The quality of a communications network service, as perceived by a user, varies greatly with the state of the network. To make packet-switched networks economically viable, it is necessary to be able to guarantee quality while reducing capital investment and operating expenses.
[0010] Degradation in the perceived quality of a service can often be traced back to loss or delay of data packets at a node or switch in the network. User satisfaction can be guaranteed by managing loss and delay of packets at those nodes where congestion can occur.
[0011] Typically, users transmit bits in bursts: active periods are interspersed with periods of inactivity. The peak rate of transmission cannot exceed the link rate. The mean rate of transmission, by definition, cannot exceed the peak rate. The ratio:
( peak rate ) - ( mean rate ) ( mean rate )
is a measure of the burstiness of the source.
[0012] Loss and delay of data packets at a node in the network arise from the queuing of packets in the buffers of switches or routers. Buffers are required to cope with fluctuations in the bit-rate on incoming links. However, if the buffers are too small, packets will be lost as a result of buffer overflow; if the buffers are too large, some packets will experience unacceptable delays. For a given buffer-size, loss and delay can be reduced by increasing the capacity of the outgoing link.
[0013] To eliminate packet loss entirely, it would be necessary to increase the capacity of the outgoing link to equal the sum of the capacities of the incoming links. This is prohibitively expensive. Nevertheless, it is a strategy employed sometimes by network operators who take a conservative view on assuring network quality of service.
[0014] There is a better way. It is unnecessary to eliminate packet loss and unacceptable packet delay in order to give satisfactory perceived quality. It is enough to keep their frequency within predetermined bounds. These bounds are referred to as Quality of Service (QoS) targets.
[0015] The optimal way to ensure satisfactory perceived quality is to provide the minimum capacity that will guarantee the QoS targets. This minimum capacity is referred to as the Bandwidth Requirement (BWR) of the bit-stream. It lies somewhere between mean rate and the peak-rate requirement
[0016] The existence of a BWR and its value can be demonstrated experimentally with a router by observing the change in the frequency with which a target queuing delay in an output buffer is exceeded when the capacity of the outgoing link is varied.
[0017] The mean-rate and the peak-rate doe not depend on the QoS targets. For bursty traffic, the peak-rate can be many multiples of the mean-rate. As the QoS target changes, the BWR varies between them.
[0018] For a given QoS target, the BWR depends strongly on the nature of the traffic. There is no universal multiplier than can be applied to the mean-rate or peak-rate to give the BWR for a given QoS target. The present applicants have provided various ways of measuring BWR on line in real time such as described in US Patent Specification No. 6580691 (Bjoerkman et al).
[0019] This opens the way for many applications: monitoring network quality levels, QoS-sensitive service provisioning, IP call admission control, traffic-based billing and capacity planning.
[0020] Essentially, therefore, given the buffer size b and the QoS target Q, the BWR of the communications system can be calculated from the traffic descriptor D. It will be appreciated that the traffic descriptor, which is essentially the statistical properties of the data, is all important. That descriptor must contain sufficient statistical information to allow computation of the bandwidth requirement. Thus, it is vital to choose the correct Descriptor format, definition or methodology to describe the statistical properties of the traffic. Essentially, the traffic descriptor D describes the characteristics of the particular traffic.
[0021] There are circumstances in which the nature of the source is such that the statistics of the packet stream are independent of the service capacity available at the router in question. This is the case, for example, where the output of the source is voice traffic—digitised speech. Here, the statistics depend on the behaviour of the speaker and on the codec used to digitise the audio signals, but not on the available service capacity. In general, we refer to packet streams from sources whose statistics are independent of the available service capacity as inelastic traffic.
[0022] However, there are circumstances in which the nature of the source is such that it cannot be assumed that the statistics of the traffic stream is independent of the service capacity at the router. A feedback mechanism causes the statistics of the source to depend on the service capacity S available to its packet-stream at the buffer. One example of this is web-browsing; here the rate at which the user requests web-pages can depend on the rate at which they are received. In general, we refer to packet streams from sources whose statistics depend on the available service-capacity as elastic traffic.
[0023] US Patent Specification No. 6,266,322 B1 (AT&T Corp) which is specifically referenced in totality herein describes in some detail how elastic data traffic is handled.
[0024] Indeed this US patent specification discloses a method of dimensioning link bandwidth for elastic data traffic for a link in a communications network. However, this US patent does not disclose a method of accurately determining the minimum service rate to maintain quality of service requirements within the network. Further it does not address the problem of selecting an optimum service rate. It could be suggested that it is not as important for elastic traffic as inelastic traffic, since the former operates by feedback control to adapt to time-varying available bandwidth.
[0025] PCT Publication No. WO 01/13557 (Fujitsu Network Communications, Inc.) discloses 10 a system for supporting multiple application traffic types over a connection network, for example, elastic and inelastic traffic. Further examples of patents in the area of handling elastic traffic in data networks are disclosed by U.S. Pat. No. 6,115,359 (Nortel Networks Corporabon) and PCT Publication No. WO 01/28167 (Telefonakfiebolaget LM Ericsson). However, this patent does not teach how to address, in a fundamental way, the problems of inelastic traffic. It relates more to committing some bandwidth to the inelastic traffic by mapping the inelastic traffic to components or switches which provide bandwidth commitments. These commitments enable the data to be transferred through the switch without exceeding a predetermined delay. However, it could be suggested that it is still not accurately estimating the bandwidth requirement. It is more a question of allocating sufficient bandwidth having regard to what it has believed the traffic to be.
[0026] The fundamental problem in providing quality of service in a data network is to determine accurately the optimum service rate which is in effect the minimum service rate at which packets of data are removed from a buffer in a switch, whilst maintaining quality of service in the data network and optimising the available bandwidth in the network. Methods devised for determining this optimum service rate for inelastic traffic do not work without modification for elastic traffic because the statistical character of the traffic changes in respect to changes in the available service. In practice, data network operators use trial and error methods in setting the service rate to achieve the desired response time for delivering elastic traffic. This is costly and time consuming as it requires network operators to continually monitor the response time and reconfigure the service rate.
[0027] The present invention is directed towards providing a method of estimating the optimum service rate at a specified quality of service for the transmission of data of different characteristics through a switch having a defined size. The invention is directed towards doing this without the need for human intervention.
STATEMENTS OF INVENTION
[0028] According to the invention, there is provided a method of estimating the optimum service capacity at a specified quality of service (QoS) for the transmission of packets of data traffic of different characteristics, the traffic being described by a predetermined type of descriptor (D) to allow the calculation of the estimated bandwidth requirement (BWR) for that traffic, through a switch node comprising a buffer having a defined size (b), comprising at time intervals, carrying out the steps of:
(a) configuring the service-capacity; (b) sampling the traffic; (c) extracting the descriptor (D); (d) calculating from the descriptor (D) the BWR for the configured service capacity; (e) using the calculated BWR to configure a new service capacity; (f) iteratively carrying out steps (b) through (e) until the calculated BWR and the configured service capacity coincide to provide a final service capacity; and (g) defining this final service capacity as the optimum service capacity for that traffic at that buffer.
[0036] A considerable advantage of the present invention is that it operates successfully without a knowledge of the precise form of the bandwidth requirement (BWR) for various service rate at a buffer of a switch. Indeed, relatively little knowledge is known. All that is required is to configure a service capacity, calculate the BWR to configure a new service capacity and keep on repeating this until the calculated rate of BWR and configured service capacity coincide. It is relatively simple and easily carried out.
[0037] In one way of carrying out the invention, the initial service capacity specified in step (a) is the previous optimum service capacity. This will lead to a quicker calculation as generally, working off a new optimum service capacity is most likely to lead to a service capacity relatively close to the previous optimum service capacity.
[0038] Ideally, the traffic is continuously monitored so that if the nature of the traffic changes, a new optimum service capacity is calculated. Further, it is envisaged that when the required target QoS changes from the target QoS initially set, the target QoS is reset and a new optimum service capacity is calculated.
[0039] It is envisaged that some or all of the various steps (a) to (g), as listed above, can be carried out in various jurisdictions, other than the step of configuring the service capacity for the transmission. Further, it will be appreciated that the method further comprises using the optimum service capacity to control the transmission of the traffic through the switch node.
[0040] In another method according to the invention, it is possible that a sample of the traffic is received with step (a), as listed above, being carried outside the jurisdiction and in which at least steps (c) to (g) are carried out within the jurisdiction. Again, it will be appreciated that the switch node may be remotely located with respect to where the method is carried out, except for the downloading of data to and from the switch node.
[0041] Further, the invention provides a closed loop control system comprising a communications network in which are interconnected:
user end systems for the delivery and reception of data; a switch node incorporating at least one buffer; means to configure a service rate; and a programmable controller having means to carry out the method of any preceding claim.
[0046] With this latter closed loop control system, the controller may be directly connected to a specific end user output source for the transmission of data to the switch node.
[0047] Further, the invention provides a computer program comprising program instructions for causing a computer to perform the method as laid out above.
[0048] In a further embodiment, the computer program comprises program instructions for causing a computer to provide the means as laid out above. Such a computer program may be embodied on a record medium, a computer memory, a read only memory or carried on an electrical signal carrier.
DETAILED DESCRIPTION OF THE INVENTION
[0049] The invention will be more clearly understood by the following description of an embodiment thereof given by way of example only with reference to the accompanying drawings in which:
FIGS. 1 to 4 are various graphs illustrating bandwidth requirement as a function of service rate, FIG. 5 is a flowchart illustrating the iterative process to estimate the optimum service rate, and FIG. 6 is a hardware configuration of part of a communications system.
[0053] As stated above, for resource provisioning, it is important to know the minimum service-capacity that must be provided at a buffer in the router to ensure that a given Quality of Service (QoS) target is met. We shall denote this rate in bit/sec. by BWR and generally refer to it as the required service capacity. The BWR depends on three factors. The first factor is the quality of service (QoS) that you require which may for example in the transmission of elastic data be described as the number of packets dropped i.e. those that have to be resent. In other words they are not accepted at a particular buffer and must be resent by the source. Typically as explained above, 1 in 10 5 packets dropped or alternatively that 1 in 10 3 packets are not delayed by more than 30 milliseconds are often considered acceptable.
[0054] The second factor is the size of the buffer which is preconfigured.
[0055] The third factor that effects the BWR is effectively the nature of the actual data being transmitted. This as already explained, can be described statistically and there are various methods of providing such a descriptor which relate to certain statistical properties of the data being transmitted. Accordingly therefore one can describe the bandwidth requirement as a function:
BWR=f ( D, b , QoS)
where:
D—is the descriptor of the relevant statistical properties of the traffic flow. b—buffer size QoS—Quality of Service
[0059] For elastic traffic, the traffic descriptor is a function of the available service-capacity.
D=g ( S )
[0060] The invention describes how an estimator designed to determine BWR for inelastic traffic can be used to determine the minimum service required to ensure that a given QoS target is met for elastic traffic. For a given service-capacity S, the estimator yields a value B(S) given by
B ( S )= f ( g ( S ), b , QoS)
[0061] It is observed experimentally that:
(a) B(S) is an increasing function of S (b) For small values of S. B(S) is greater than S, indicating that the QoS target is not achieved when the service-capacity has the value S. (c) For large values of S, B(S) is less than S, indicating that S exceeds the value required to achieve the QoS target.
[0065] It follows that the BWR for elastic traffic is that value S′ of the service capacity for which
S*=B ( S *).
[0066] Referring now to FIG. 2 , we know that for elastic traffic, the graph of B(S) against the service capacity S will be qualitatively similar to the graph drawn. The precise form of the function B(S) is not known a priori. An essential feature of this invention is that it operates successfully without this knowledge. Another essential feature is the specific point S* In FIG. 2 , at which the B(S) is equal to the service capacity for that particular traffic.
[0067] It follows that, for an elastic source, the Optimum Service Rate is the unique value S* for which S=B(S). Hence any method of solving iteratively the equation S=B(S) yields a method for determining S*. In this specification, methods for solving the equation iteratively and hence determining S* are described. As mentioned above, these methods do not rely on first determining the function B(S).
[0068] It will be appreciated that to carry out the invention, it is necessary to choose a suitable type of descriptor or descriptor format for allowing the bandwidth requirement to be determined. As stated already, there are many such descriptors (D) and the more accurate and appropriate the descriptor (D) chosen or predetermined, the better will be the calculation of the BWR.
[0069] Assume the buffer size b to be known.
[0070] Fix the QoS target Q.
[0071] Configure the service rate at some initial value S 1
[0072] Estimate the traffic descriptor for the source and use it together with the values b and
[0073] Q to determine the BWR value B 1 :=B(S 1 ) see FIG. 3 .
[0074] Next configure the service rate to be S 2 given by S 2 =B 1 see FIG. 4 .
[0075] Re-estimating the traffic descriptor and repeating the procedure, we use the scheme:
[0076] For N=1, 2, . . .
[0077] Put S N+1 =B N
[0078] to get a sequence S 1 , S 2 . . .
[0079] As N increases, S N converges to S*, which is the unique value of the service capacity such that
S*=B ( S *).
[0080] It will be appreciated, by considering FIG. 2 , that if S 1 <B(S 1 ), the sequence increases to S*; if S 1 >B(S 1 ), the sequence decreases to S*.
[0081] In practice, the service rates S 1 , S 2 . . . may be reconfigured at suitable time intervals such as for example 5 minutes. It also has to be appreciated that in many instances It will be necessary to carry out the operation indefinitely. A reason for this would be for example where the software packages or operations being run are changed. In which case, the bandwidth requirement function changes to, for example, B′(S). Now the operation has to be repeated and the new optimum service rate has to be obtained, in the sense that one now has to solve the new equation which is:
S=B ′( S )
[0082] Referring now to the flow process of FIG. 5 which illustrates the iterative process of calculating the optimum service rate S*. In step 10, the quality of service Q is set and the size of the buffer b is determined. A service rate S 1 is arbitrarily selected. The traffic flowing through a buffer is measured by sampling the traffic. A traffic descriptor D is extracted from the sampled traffic which is representative of the statistical property flow of the traffic in step 11 . In step 12 , the BWR for that selected service rate, having a particular quality of service and a fixed buffer size, along with the traffic descriptor, provides an estimate of the required service capacity in real-time. In step 12 , a new service rate is calculated from the estimated bandwidth requirement. In step 13 , a check is made whether the new service rate coincides with the estimated bandwidth requirement. If they do not coincide, then steps 11 and 12 are repeated iteratively until the estimated bandwidth requirement coincides with the service rate which is the optimum service rate S*. It will be-appreciated that the extent to which the BWR is required to coincide with the service capacity is determined by the network operator. In other words, the service rate S and the BWR do not have to exactly coincide, but be within a range that will maintain quality of service for the traffic flow. This process can be carried out at preset time intervals or alternatively when a change in the statistical property of the traffic flow is detected.
[0083] It will be appreciated that the invention can be carried out in many jurisdictions and that therefore it would not be unreasonable to find that certain operations are carried out in one country and more carried out another.
[0084] It is envisaged that there are many ways that the invention may be carried out by computers and similar equipment suitably programmed. Further the information and data generally supplied will allow many and varied control operations to be carried out using the invention.
[0085] Essentially what the present invention does is provide packet level quality of service on a data network where the rate at which a source emits data packets adapts to utilise all the available bandwidth. The present invention determines accurately the minimum service rate which is obviously the optimum service rate required to achieve a target level of service. For example in the remote querying of a database, the application level response time increases with an increase in packet delay caused by the queuing of packets in the buffer at a network element As has been explained above, in order to achieve acceptable response times ways must be found to achieve a quality of service target expressed as delay constraints, Present systems do not allow this.
[0086] The present invention provides a way of directly controlling packet level quality of service. Essentially the present invention is “lightweight” and capable of being incorporated in closed loop control systems as described with reference to FIG. 4 will allow the automation of the operation and avoids manpower intensive operations now required in changing the provisioning in a system with changing traffic patterns.
[0087] As will be appreciated by any mathematician, there are many iterative schemes to calculate the optimum service rate. Most of these have a trade off between speed of conversion and computational overhead.
[0088] One of the great advantages of the present invention is that there is no need to know the actual function, but simply to carry out the calculations. Depending on the number of calculations that have to be carried out before convergence is reached, it will be appreciated that if the results were to be plotted, much more accurate knowledge would be known regarding B(S) than was known. However, this is not necessary and does not provide any -great advantage to those operating the communications system.
[0089] Referring now to FIG. 6 , there is illustrated part of a communications network and hardware configuration for carrying out the present invention, indicated generally by the reference numeral 30 . A typical router or switch 31 receives a number of links 32 for the delivery and reception of data. Each link is connected to at least one buffer 33 Incorporated in the switch 31 . Each buffer 33 has an associated scheduler which schedules the service rate S for each buffer. In other words, the scheduler decides for each buffer 33 the maximum rate, measured in bits per seconds, that packets of data can be forwarded or received by each buffer 33 . Each buffer 33 is connected to a port 34 which in turn is connected to a larger link 35 which can receive or deliver data, depending on the application. This configuration is well known to the person skilled in the area of communication switching systems. Each buffer is allocated a particular service rate by the scheduler. The service rate is controlled by providing a closed loop control system by having a programmable controller 36 connected to the router. The controller 36 sets the service rate for each buffer 33 incorporated in the switch 31 .
[0090] In operation, the closed loop control samples the data traffic flowing through the switch 31 at any particular time. The controller 36 comprises a database 37 and a computer 38 . It will be appreciated that the database 37 , for example a server, and computer 38 can remotely operate with each other. They do not have to be in the same jurisdiction as the switch or indeed each other. The controller 36 selects an arbitrary service rate. This can be done by a user inputting a particular service rate via the computer 38 or can be selected by the database 37 . The controller 36 extracts a traffic descriptor D which is a description of the statistical properties of the traffic flow flowing through the buffer 33 at the time of the sampled traffic. The controller 36 calculates the BWR from the traffic descriptor D, the buffer size b and the required Quality of Service (QoS) for the buffer 33 . The controller 36 estimates a new service rate from the calculated BWR. This is illustrated in FIG. 3 in which the calculated bandwidth requirement B, provides a new service rate S 2 . The controller 36 iteratively carries out the above steps until the estimated bandwidth requirement and the configured service rate coincide to provide a final service rate.
[0091] This final service rate is the optimum service rate at which the buffer 33 should be served. It will be appreciated that the computer and the database can be at separate locations or indeed in separate jurisdictions, or alternatively housed on the one server, depending on the application, as long as closed loop control is achieved.
[0092] It will be appreciated that various aspects of the invention may be embodied on a computer that is running a program or program segments originating from a computer readable or usable medium, such medium including but not limited to magnetic storage media (e.g. ROMs, floppy disks, hard disks, etc.), optically readable media (e.g. CDROMs, DVDs, etc.) and carrier waves (e.g., transmissions over the internet). A functional program, code and code segments, used to implement the present invention can be derived by a skilled computer programmer from the description of the invention contained herein.
[0093] It will be appreciated therefore that a computerised program may be provided providing program instructions which, when loading into a computer, will constitute the means for organising and rearranging the traffic flow in accordance with the invention and that this computer program may be embodied on a record medium, a computer memory, a read only memory or carried on an electrical carrier signal. In this specification the terms “comprise, comprises, comprised and comprising” and any variation thereof and the terms “include, includes, included and including” and any variation thereof are deemed to be totally interchangeable and should be afforded the widest interpretation possible.
[0094] This invention is in no way limited to the embodiment shown and may be varied in both construction and detail within the scope of the claims.
|
The present invention provides a method and system for estimating the optimum service rate or bandwidth requirement (BWR) for a switch or router in a communications network for a particular traffic flow which contains elastic traffic, i.e. traffic subject to a feedback mechanism. The invention provides an iterative technique to estimate the optimum service rate from calculated BWRs for the particular traffic flow without initially knowing the precise form of the BWR for various service rates at a buffer of a switch. This is done by initially configuring a service capacity, calculating the BWR to configure a new service capacity and repeating this until the calculated BWR and configured service capacity coincide.
| 7
|
TECHNICAL FIELD
The present invention relates to base stations and communication methods of base stations.
BACKGROUND ART
A standards body of mobile communication methods, 3GPP, has recently been deliberating about LTE (Long Term Evolution). In the LTE, a frequency band of a system is divided into a plurality of resource blocks (RB), each of which includes one or more (for example, 12) subcarriers. In the LTE, assignment of resource block to a mobile station is performed in every subframe of 1 ms.
As shown in FIG. 4 , a communication frame of LTE applicable to TDD consists of 10 subframes. The subframes are categorized into UL subframe available for uplink communication from the mobile station to the base station, DL subframe available for downlink communication from the base station to the mobile station, and special subframe having both a UL region (data reception region) available for the uplink communication and a DL region (data transmission region) available for the downlink communication. FIG. 5 is a diagram illustrating an exemplary symbol arrangement in the special subframe. As shown in FIG. 5 , the top 9 symbols in the special subframe are the DL region for the downlink communication and the last 2 symbols across 3 symbols of a guard time are the UL region for the uplink communication. Various configurations of the special subframe, not limited to the symbol arrangement of the FIG. 5 , are defined as shown in a table in FIG. 6 .
Communications between the base station and a mobile station are performed using the subframes of 3 types described above. For example, physical channels such as PDCCH (Physical Downlink Control Channel), PDSCH (Physical Downlink Shared Channel) and the like are mapped on the DL subframes for the downlink communication. Among them, the PDSCH is used for transmission of user data separately transmitted to each mobile station and control information such as paging information and SIB (System Information Block) transmitted simultaneously to nearby mobile stations. In contrast, the UL subframe for the uplink communication is used for transmission of user data from each mobile station to the base station and control information such as random access from the nearby mobile stations to the base station on the physical channels such as PRACH (Physical Random Access Channel) and the like (for example, see 3GPP TS 36.211 (V8.7.0), “Physical Channels and Modulation”, May 2009).
SUMMARY OF INVENTION
Technical Problem
The conventional LTE assigns resources without a distinction between communications related to the control information between the base station and nearby mobile stations and communications related to the user data between the base station and each of the mobile stations. That is, the conventional LTE appropriately assigns, for the control information of the downlink and that of the uplink, a DL subframe and a UL subframe arbitrarily selected.
Such a resource assignment by the LIE causes a problem in introduction of AAS (Adaptive Antenna System). The AAS performs adaptive control on weight of each of a plurality of antenna elements constituent of an array antenna in accordance with a propagation environment, in order to change the directivity of radio waves. An adaptive array base station corresponding to the AAS appropriately controls beam forming, null steering and the like to a desired mobile station, by using antenna weights calculated based on a reference signal transmitted from the mobile station, in downlink transmission.
It is preferred that the AAS sets a pair of UL subframe and DL subframe and uses the pair for communication between the base station and the mobile station. This is based on that, if receiving the reference signal transmitted in the UL subframe from the mobile station, the base station can calculate an optimum transmission weight from the reference signal and perform the downlink communication in the DL subframe more efficiently.
FIG. 7 is a diagram illustrating an exemplary resource assignment by the conventional LTE. As shown in FIG. 7 , a subframe 2 as the UL subframe and a subframe 4 as the DL subframe are paired with each other. Here, although resource blocks 1 - 3 in the subframe 4 are assigned to a mobile station A, only resource blocks 1 - 2 in the subframe 2 are assigned to the mobile station A. In this case, since nearby mobile stations perform random access to the base station in the resource block 3 of the subframe 2 , the base station cannot calculate an optimum transmission weight for the mobile station A in the resource block 3 of the subframe 4 . Therefore, a transmission efficiency of the AAS is deteriorated.
Similarly, FIG. 8 is a diagram illustrating an exemplary resource assignment by the conventional LTE. As shown in FIG. 8 , the subframe 2 as the UL subframe and the subframe 4 as the DL subframe are paired with each other. Here, although resource blocks 4 - 6 in the subframe 2 are assigned to a mobile station B, only resource blocks 4 - 5 in the subframe 4 are assigned to the mobile station B. In this case, since the base station transmits Paging and the SIB to the nearby mobile stations in the resource block 6 of the subframe 4 , a transmission weight based on the reference signal transmitted in the resource block 6 of the subframe 2 from the mobile station is not used. Therefore, the transmission efficiency of the AAS is deteriorated.
There is therefore a need in the art for a base station and a communication method of a base station capable of assigning resources without deteriorating the transmission efficiency of the AAS.
Solution to Problem
In order to solve the above problems, a base station according to a first aspect of the present invention is a base station communicating with a mobile station by assigning at least a part of a communication frame including a plurality of wireless communication channels in a frequency direction to the mobile station, the communication frame including at least one special subframe having a data transmission region available for transmission to the mobile station and a data reception region available for reception from the mobile station, separated from the data transmission region in a time direction, the base station includes:
an assignment unit for assigning, in the special subframe, the data transmission region for transmission of downlink control information to a nearby mobile station and assigning the data reception region for reception of uplink control information from the nearby mobile station; and
a transmission and reception unit for transmitting the downlink control information in the data transmission region and for receiving the uplink control information in the data reception region.
A second aspect of the present invention is the base station according to the first aspect, wherein,
if the communication frame includes a plurality of special subframes,
the assignment unit assigns each data transmission region of the plurality of special subframes for transmission of same downlink control information.
A third aspect of the present invention is the base station according to the first or second aspect, wherein
the communication frame further includes an uplink subframe available for uplink communication from the mobile station and a downlink subframe, paired with the uplink subframe, available for downlink communication to the mobile station,
the base station further includes a calculation unit for calculating a transmission weight for the downlink subframe based on a signal received in the uplink subframe,
the assignment unit assigns the uplink subframe and the downlink subframe for communication with each mobile station related to user data, and
the transmission and reception unit transmits the user data to the mobile station by adaptive array control based on the transmission weight.
Although apparatuses are used as solutions according to the present invention as described above, it is to be understood that the present invention can also be implemented as methods, programs, and storage media storing the programs and hence they are included within a scope of the present invention.
For example, as a method implementing the present invention, a communication method of a base station, according to a fourth aspect of the present invention, is a method for communicating with a mobile station by assigning at least a part of a communication frame including a plurality of wireless communication channels in a frequency direction to the mobile station, the communication frame including at least one special subframe having a data transmission region available for transmission to the mobile station and a data reception region available for reception from the mobile station, separated from the data transmission region in a time direction, and includes the steps of:
assigning, in the special subframe, the data transmission region for transmission of downlink control information to a nearby mobile station and assigning the data reception region for reception of uplink control information from the nearby mobile station; and
transmitting the downlink control information in the data transmission region and receiving the uplink control information in the data reception region.
A fifth aspect of the present invention is the communication method of the base station according to the fourth aspect, wherein,
if the communication frame includes a plurality of special subframes,
at the step of assigning, each data transmission region of the plurality of special subframes is assigned for transmission of the same downlink control information.
A sixth aspect of the present invention is the communication method of the base station according to the fourth or fifth aspect, wherein
the communication frame further includes an uplink subframe available for uplink communication from the mobile station and a downlink subframe, paired with the uplink subframe, available for downlink communication to the mobile station, and
the communication method further includes calculating a transmission weight for the downlink subframe based on a signal received in the uplink subframe, wherein
at the step of assigning, the uplink subframe and the downlink subframe are assigned for communication with each mobile station related to user data, and
at the step of transmitting, the user data is transmitted to the mobile station by adaptive array control based on the transmission weight.
According to the present invention, it is possible to assign resources without deteriorating a transmission efficiency of AAS by assigning a special subframe for communication related to the control information between a base station and nearby mobile stations.
BRIEF DESCRIPTION OF DRAWINGS
Preferred embodiments of the present invention will now be described with reference to the accompanying drawings in which:
FIG. 1 is a functional block diagram illustrating a base station according to one embodiment of the present invention;
FIG. 2 is a diagram illustrating an exemplary resource assignment according to the embodiment of the present invention;
FIG. 3 is a flowchart illustrating operation of the base station shown in FIG. 1 ;
FIG. 4 is a diagram illustrating an exemplary configuration of a communication frame of LTE;
FIG. 5 is a diagram illustrating an exemplary symbol arrangement of a special subframe;
FIG. 6 is a diagram illustrating an exemplary configuration of the special subframe;
FIG. 7 is a diagram illustrating an exemplary resource assignment of a conventional LTE; and
FIG. 8 is a diagram illustrating another exemplary resource assignment of the conventional LTE.
DESCRIPTION OF EMBODIMENTS
FIG. 1 is a diagram illustrating a schematic configuration of an adaptive array base station 1 according to one embodiment of the present invention. The adaptive array base station 1 includes an array antenna ANT, a wireless communication unit (transmission and reception unit) 10 , an AAS processing unit 20 including a weight calculation unit 21 and a weighting unit 22 , a baseband processing unit 30 , a scheduler 40 and a wireless resource assignment unit (assignment unit) 50 . The wireless communication unit 10 , the AAS processing unit 20 and the baseband processing unit 30 may use interface equipment/circuits suitable for LTE, whereas the scheduler 40 and the wireless resource assignment unit 50 may be implemented with suitable processors such as a CPU or the like. The following is a detailed description of each of the units.
The wireless communication unit 10 , in processing of a reception system, converts a wireless signal with a carrier frequency received by the array antenna ANT into a baseband signal, and outputs the baseband signal to the weight calculation unit 21 . In addition, the wireless communication unit 10 , in processing of a transmission system, converts a baseband signal from the weighting unit 22 into a signal with a carrier frequency and transmits it to a mobile station via the array antenna ANT by adaptive array control.
In the AAS processing unit 20 , the weight calculation unit 21 for the reception system performs adaptive signal processing on the signal input from the wireless communication unit 10 and outputs the processed signal to the baseband processing unit 30 . In the adaptive signal processing, in particular, the weight calculation unit 21 , by using a reference signal transmitted in a UL subframe from the mobile station and other known information, calculates a transmission weight (phase/amplitude weight of each antenna element) for a DL subframe paired with the UL subframe from phase information obtained for each antenna element of the array antenna ANT and the like, in order to obtain a high transmission gain to the mobile station. On the other hand, the weighting unit 22 for the transmission system weights the signal input from the baseband processing unit 30 with the transmission weight obtained by the weight calculation unit 21 , and outputs the weighted signal to the wireless communication unit 10 .
The baseband processing unit 30 , in processing of the reception system, demodulates the signal input from the weight calculation unit 21 and outputs results of demodulation to the scheduler 40 separately for each mobile station. In addition, the baseband processing unit 30 , in processing of the transmission system, outputs a symbol stream of data to be transmitted to a mobile station, which is input from the wireless resource assignment unit 50 , to the weighting unit 22 .
The scheduler 40 determine a mobile station to assign resource blocks, based on received data from each mobile station input from the baseband processing unit 30 . Specifically, the scheduler 40 determines the mobile station to assign the resource blocks, according to a received signal quality of each resource block informed from the mobile station, channel quality information (CQI) or an amount of data to be transmitted.
The wireless resource assignment unit 50 assigns wireless resources to the mobile station determined by the scheduler 40 . As stated above, the subframes of LTE applicable to TDD are categorized into UL subframe available for uplink communication from a mobile station to the base station, DL subframe available for downlink communication from the base station to the mobile station, and special subframe including both a UL region (data reception region) available for the uplink communication and a DL region (data transmission region) available for the downlink communication. Here, the wireless resource assignment unit 50 assigns the special subframe for the communication related to control information between the base station and nearby mobile stations, such as Paging/SIB of the downlink and PRACH of the uplink. In addition, the wireless resource assignment unit 50 assigns the UL subframe and the DL subframe, paired with each other, for the communication with an individual mobile station related to user data. When assigning a pair of the UL subframe and the DL subframe to a plurality of mobile stations, the wireless resource assignment unit 50 assigns resources such that communication with each mobile station is performed on the same frequency band (resource block) of the UL subframe and the DL subframe.
FIG. 2 is a diagram illustrating an exemplary resource block assignment by the wireless resource assignment unit 50 . As shown in FIG. 2 , the DL region of the subframe 1 , which is the special subframe, is allocated to the Paging/SIB, and a part of the UL region is allocated to PRACH. In addition, in the pair of the UL subframe (subframe 2 ) and the DL subframe (subframe 4 ), resource blocks 1 - 3 are assigned for the communication to the mobile station A, and the resource blocks 4 - 6 are assigned for the communication to the mobile station B. Thereby, upon reception of reference signals in the subframe 2 as the UL subframe transmitted from the mobile station A and the mobile station B, the base station can calculate an optimum transmission weight to the subframe 4 as the DL subframe from the reference signals. Additionally, since the communication related to the control information between the base station and nearby mobile stations can be performed in the special subframe, such communication does not deteriorate AAS communication efficiency.
The wireless resource assignment unit 50 performs symbol mapping (assignment of amplitude and phase) in accordance with a modulation scheme on the transmission data including the control information to the mobile station and the user data and outputs a generated symbol stream to the baseband processing unit 30 .
FIG. 3 is a flowchart illustrating operation of the base station 1 shown in FIG. 1 . Upon reception of wireless signals from a mobile station via the array antenna ANT, the wireless communication unit 10 converts received wireless signals with the carrier frequency into baseband signals, and outputs the baseband signals to the weight calculation unit 21 (step S 101 ). By using the reference signal transmitted from the mobile station and other known information, the weight calculation unit 21 calculates a transmission weight which enables to obtain a high transmission gain to the mobile station, from phase information of each antenna array of the array antenna ANT and the like (step S 102 ). Specifically, the weight calculation unit 21 , based on the reference signal and the like transmitted in the UL subframe from the mobile station, calculates the transmission weight to a DL subframe paired with the UL subframe such that the high transmission gain to the mobile station can be obtained. The baseband processing unit 30 demodulates the signals input from the weight calculation unit 21 and outputs demodulation results to the scheduler 40 separately for each mobile station (step S 103 ).
The scheduler 40 determines a mobile station to assign resource blocks based on received data from each mobile station input from the baseband processing unit 30 (step S 104 ). The wireless resource assignment unit 50 assigns the wireless resources to the mobile station determined by the scheduler 40 (step S 105 ). Here, the wireless resource assignment unit 50 assigns a special subframe for the communication related to the control information between the base station and the nearby mobile stations. In addition, the wireless resource assignment unit 50 assigns, for the communication with the individual mobile station related to the user data, the UL subframe and the DL subframe paired with each other.
The wireless resource assignment unit 50 performs symbol mapping, in accordance with the modulation scheme, on the transmission data including the control information to the mobile station and the user data and outputs the generated symbol stream to the baseband processing unit 30 (step S 106 ). The baseband processing unit 30 outputs the symbol stream of the transmission data to the mobile station input from the wireless resource assignment unit 50 to the weighting unit 22 (step S 107 ). The weighting unit 22 weights the signal input from the baseband processing unit 30 with the transmission weight obtained by the weight calculation unit 21 , and outputs the weighted signal to the wireless communication unit 10 (step S 108 ). The wireless communication unit 10 converts the baseband signal from the weighting unit 22 into a signal with a carrier frequency and transmits the signal to the mobile station via the antenna array ANT by the adaptive array control (step S 109 ).
According to the present embodiment, the wireless resource assignment unit 50 assigns the special subframe for the communication related to the control information between the base station and nearby mobile stations. Accordingly, it prevents the Paging/SIB of the downlink and the PRACH of the uplink from interfering with the user data to the individual mobile station, and thereby enables resource assignment without deteriorating AAS transmission efficiency. In addition, since the special frame is assigned for transmission and reception of the control information, the mobile station near the base station needs only to receive the special subframe at predetermined intervals in Paging, for example. Thereby, it is possible to reduce power consumption of the mobile station.
In addition, the wireless resource assignment unit 50 assigns a pair of the UL subframe and the DL subframe for the communication with the individual mobile station related to the user data. It thus enables communication with the individual mobile station using an optimum transmission weight, which enhances the AAS transmission efficiency. Moreover, when assigning a pair of the UL subframe and the DL subframe to a plurality of mobile stations, the wireless resource assignment unit 50 assigns the resources such that the communication with each mobile station is performed on the same frequency band (resource block) of the UL subframe and the DL subframe. Thereby, it is possible to enhance the AAS transmission efficiency to the plurality of mobile stations as well.
Although the present invention is described based on the figures and the embodiment, it is appreciated that those skilled in the art may easily vary or modify in a multiple manner based on disclosure of the present invention. Accordingly, such variation and modification are included in a scope of the present invention. For example, a function or the like of each component or each step can be rearranged avoiding a logical inconsistency, such that a plurality of components or steps are combined or divided.
For example, if there are a plurality of special subframes in one communication frame, the wireless resource assignment unit 50 may transmit the same downlink control information, such as the Paging/SIB, in each DL region of the plurality of special subframes. Thereby, the base station can transmit the control information to the nearby mobile stations more definitely.
|
Provided is a base station for communicating with a mobile station by assigning at least a part of a communication frame including a plurality of wireless communication channels in a frequency direction. The communication frame includes at least one special subframe having a data transmission region available for transmission to the mobile station and a data reception region available for reception from the mobile station, separated from the data transmission region in a time direction. The base station includes an assignment unit 50 for assigning, in the special subframe, the data transmission region for transmission of downlink control information to nearby mobile stations and the data reception region for reception of uplink control information from the nearby mobile stations, and a transmission and reception unit 10 for transmitting the downlink control information in the data transmission region and for receiving the uplink control information in the data reception region.
| 7
|
FIELD OF THE INVENTION
[0001] The present invention relates to novel 4β-amino podophyllotoxin congeners as antitumour antibiotics. More particularly, the present invention relates to novel β-amino podophyllotoxin congeners of general formula A
[0000]
[0002] The present invention also relates to a process for the preparation of 40-amino podophyllotoxin congeners.
BACKGROUND OF THE INVENTION
[0003] Etoposide and teniposide are semi-synthetic podophyllotoxin derivatives that are in clinical usage as an anticancer drugs FIG. 1 (Chen. Y. Z.; Wang. Y. G.; Tian, X.; Li, J. X. Curr. Sci 1990, 59, 517.; Wang, J. Z.; Tian, X.; Tsumura, H.; Shimura, K.; Ito, H. Anti - cancer Drug Design, 1993, 8, 193). It is believed that analogues of 4′-demethyl epipodophyllotoxin exert their antitumour activity through stabilization of a cleavable complex between DNA and type II DNA topoisomerase, this leads ultimately to inhibition of DNA catenation activity and produces single and double strand breaks (Satio, H.; Yoshikawa, H.; Nishimura, Y.; Kondo, S.; Takeuchi, T.; Umezawa, H. Chem. Pharm. Bull. 1986, 34, 3733.; Chen, Y. Z.; Wang, Y. G.; Li, J. X.; Tian, X.; Jia. Z. P.; Zhang, Z. Y. Life Sci. 1989, 45, 2569) A number of studies have been carried out on the structural modification of glycoside by amino substituents that has improved the inhibitory activity on human DNA topoisomerase II as well as stronger activity in causing cellular protein length DNA breakage (Lee, K. H.; Imakura, Y.; Haruna, M.; Beers, S. A.; Thurston, L. S.; Dai, H. J.; Chen, C. H.; Liu, S. Y.; Cheng, Y. C. J Nat. Prod. 1989, 52, 606.; Liu, S. Y.; Hawang, B. D.; Haruna, M.; Imakura, Y.; Lee, K. H.; Cheng, Y. C. Mol. Pharmcol. 1989; 36, 8.; Lee, K, H.; Beers, S. A.; Mori, M.; Wang, Z. Q.; Kuo, Y. H.; Li, L.; Liu, S. Y.; Cheng, Y. C.; J. Med. Chem. 1990, 33, 1364.; Kamal, A.; Gayatri, N. L.; Reddy, D. R; Reddy, P. S. M. M.; Arifuddin, M.; Dastidar, S. G.; Kondapi, M. A.; Rajkumar M. Bioorg. Med. Chem. 2005, 13, 6218; Kamal, A.; Kumar, B. A.; Arifuddin, M.; Dastidar, S. G. Bioorg. Med. Chem. 2003, 11, 5135). In this context a large number of 4β-amino derivatives of podophyllotoxin and 4′-O-demethyl epipodophyllotoxin based compounds have been synthesized and investigated for their antitumour activity.
OBJECTIVE OF THE INVENTION
[0004] The main object of the invention is to provide the novel 4β-amino podophyllotoxin congeners as useful antitumour antibiotics.
[0005] Another object of the present invention is to provide a process for the synthesis of these new 4β-amino derivatives of podophyllotoxin as useful anticancer or antitumour agents.
[0006] Another object of the present invention is to provide new and stereoselective compounds based on the podophyllotoxin and 4′-O-demethylepipodophyllotoxin in good yields.
SUMMARY OF THE INVENTION
[0007] Accordingly the present provides novel 4β-amino podophyllotoxin congeners of general formula A as antitumour antibiotics.
[0000]
[0008] In an embodiment of the present invention the novel 4β-amino podophyllotoxin congeners formula A is represented by the following compounds of formula 3a-f and 4a-f
[0000]
[0009] In yet another embodiment the novel 413-amino podophyllotoxin congeners is represented by the following compounds:
4β-(1″-Anthrylamino)-4-desoxypodophyllotoxin (3a); 4β-(1″-Fluorenylamino)-4-desoxypodophyllotoxin (3b); 4β-(1″-Pyrenylamino)-4-desoxypodophyllotoxin (3c); 4β-(6″-Chrycenylamino)-4-desoxypodophyllotoxin (3d); 4β-[4″-(4″-Fluorobenzoyl)anilino]-4-desoxypodophyllotoxin (3e); 4β-(4″-{4″-[Di(2″-chloroethyl)amino]benzoyl}anilino)-4-desoxypodophyllotoxin (3f); 4′-O-Demethyl-4β-(1″-anthrylamino)-4-desoxypodophyllotoxin (4a); 4′-O-Demethyl-4β-(1″-fluorenylamino)-4-desoxypodophyllotoxin (4b); 4′-O-Demethyl-4β-(1″-pyrenylamino)-4-desoxypodophyllotoxin (4c); 4′-O-Demethyl-4β-(1″-chrycenylamino)-4-desoxypodophyllotoxin (4d); 4′-O-Demethyl-4β-[4″-(4″-fluorobenzoyl)anilino]-4-desoxypodophyllotoxin (4e) and 4′-O-Demethyl-4β-(4″-{4-[di(2″-chloroethyl)amino]benzoyl}anilino)-4-desoxy podophyllotoxin (4f).
[0022] The present invention further provides a process for the preparation of 4(3-amino podophyllotoxin congeners of general formula A as antitumour antibiotics
[0000]
and the said process comprising the steps of:
a) reacting podophyllotoxin of formula 1 with sodium iodide in dry acetonitrile, under stirring, followed by adding drop wise BF 3 OEt 2 at a temperature of 0-1° C. and continuing the stirring for a period of 0.3-0.6 hrs, at a temperature of 20-30° C., followed by evaporation in vacuo to obtain the compound of formula 2a,
[0000]
OR
reacting podophyllotoxin of formula 1 with sodium iodide in dry dichloromethane, under stirring, followed, by adding drop wise BF 3 OEt 2 at a temperature of 0-1° C. and continuing the stirring for a period of 5-6 hrs, at a temperature of 20-30° C., followed by evaporation in vacuo to obtain the compound of formula 2b,
[0000]
b) reacting the above said compound of formula 2a or 2b with anhydrous barium carbonate and the reagent selected from the group consisting of 1-anthraceneamine, 1-fluorenylamine, 4β-(1″-pyrenylamino)-4-deoxypodophyllotoxin, 1-pyrenylamine, 6-chrycenylamine, 4-amino-4′-fluorobenzophenone and 4-amino-4′-[di(2-chloroethyl)amino]benzophenone in dry tetrahydrofuran (THF), under notrogenand stirring for a period of 7-9 hrs, at a temperature of 20-30° C., followed by filtration, washing with water and drying by known method to obtain the desired corresponding, compounds of formula 3a-f and 4a-f
[0000]
[0028] In still another embodiment the novel 4β-amino podophyllotoxin congeners obtained are useful as antitumour antibiotics.
DETAILED DESCRIPTION
[0029] The process for the synthesis of new podophyllotoxin analogues as anticancer agents produces the novel and stereo-selective derivatives of the podophyllotoxin in good yields, where in the key step for the synthesis of these analogues is by direct nucleophilic substitution of C-4β-iodo intermediates. The 4β-iodopodophyllotoxin, which has been reacted with substituted or unsubstituted polyarylamines in a stereo-selective manner to afford the 4β-polyarylamino derivatives of podophyllotoxin.
[0030] These 4-iodopodophyllotoxin intermediates have been prepared by the iodination of the related podophyllotoxin compounds as described in the literature (Kamal, A.; Kumar, B. A.; Arifuddin, M. Tetrahedron Lett. 2003, 44, 8457.).
[0031] In an embodiment of the present invention, the naturally occurring podophyllotoxin lignan was isolated from Podophyllunt peltatum linnaeus.
[0032] In another embodiment of the present invention the synthesis of 4β-intermediates have been carried out from iodination of podophyllotoxin.
[0033] In yet another embodiment of the present invention 1-2 eq. of different unsubstituted and substituted Polyarylamine compounds have been used.
[0034] In still another embodiment of the present invention a variety of solvents were used for the nucleophilic substitution step, such as dichloromethane, chloroform and tetrahydrofuran.
[0035] In still another embodiment of the present invention bases like K 2 CO 3 , Et 3 N were used.
[0036] In still another embodiment of the present invention the purification of these analogues was done by column chromatography employing ethylacetate/hexane as eluent.
[0037] Thus the present invention provides new class of podophyllotoxin analogues, which were synthesized in a stereoselective manner.
[0038] A program was initiated in the laboratory for the design and synthesis of new 4β-aryl amino substituted podophyllotoxin congeners with enhanced antitumour activity and/or activity against etoposide resistant tumor cell lines. In these efforts new 4β-polyarylamino derivatives of podophyllotoxin have been synthesized and evaluated for their cytotoxicity and anticancer potency compared to adiramycin. The synthesis of these compounds has been carried out as described in the Scheme 1 using podophyllotoxin obtained from the resin.
[0000]
[0039] Some of the compounds of the present invention are given below:
a) 4β-(1″-Anthrylamino)-4-desoxypodophyllotoxin b) 4′-O-Demethyl-4β-(1″-anthrylamino)-4-desoxypodophyllotoxin c) 413-(1″-Fluorenylamino)-4-desoxypodophyllotoxin d) 4′-O-Demethyl-4β-(1″-fluorenylamino)-4-desoxypodophyllotoxin e) 40(1″-Pyrenylamino)-1-desoxypodophyllotoxin f) 4′-O-Demethyl-4β-(1″-pyrenylamino)-4-desoxypodophyllotoxin g) 4β-(6″-Chrycenylamino)-4-desoxypodophyllotoxin h) 4′-O-Demethyl-4β-(1″-chrycenylamino)-4-desoxypodophyllotoxin i) 4β-[4-(4″-(4″-Fluorobenzoyl)anilino]-4-desoxypodophyllotoxin j) 4′-O-Demethyl-4β-[4″-(4″-fluorobenzoyl)anilino]-4-desoxypodophyllotoxin k) 4β-(4″-{4″-[Di(2″-chloroethyl)amino]benzoyl}anilino)-4-desoxypodophyllotoxin l) 4′-O-Demethyl-4β-(4″-{4″-[di(2″-chloroethyl)amino]benzoyl}anilino)-4-desoxy podophyllotoxin The following examples are given by the way of illustration and therefore should not be construed to limit the scope of the invention.
Example 1
4β-(1″-Anthrylamino)-4-desoxypodophyllotoxin (3a)
[0053] To a solution of podophyllotoxin (414 mg, 1 mmol) in dry acetonitrile (10 mL), sodium iodide (298 mg, 2 mmol) was added and stirred for 5 min to this stirred suspension BF 3 .Et 2 (0.13 mL, 2 mmol) was added dropwise with at 0° C. and the stirring was continued for another 0.5 h at room temperature. This solution was then evaporated in vacuo and used for the next reaction without further purification. To the crude product, anhydrous barium carbonate (395 mg, 2 mmol) and 1-anthraceneamine (231 mg, 1.2 mmol) in 10 mL of dry THF under nitrogen was added and stirred for 8 h at room temperature. The reaction mixture was filtered, diluted with ethyl acetate and washed with water, 10% aqueous sodium thiosulphate solution, dried and purified via column chromatography using ethyl acetate/hexane mixture as eluent to get pure product in 90% yield.
[0054] m.p: 195-200° C. [α] 25 D : −39.0 (c=1.0, CHCl 3 )
[0055] 1 H NMR (CDCl 3 ): δ 3.1 (m, 1H), 3.3 (dd, 1H, J=13.6, 4.53 Hz), 3.78 (s, 6H), 3.8 (s, 3H), 3.97 (t, 1H, J=9.06 Hz), 4.43 (t, 1H, J=8 Hz), 4.67 (d, 2H, J=4.53 Hz), 4.95 (br, 1H), 5.97 (d, 2H, J=3.02 Hz), 6.33 (s, 2H), 6.43 (d, 1H, J=7.55 Hz), 6.6 (s, 1H), 6.8 (s, 1H), 7.28 (m, 1H), 7.43 (m, 3H), 7.94 (m, 2H), 8.24 (s, 1H), 8.35 (s, 1H).
[0056] 13 C NMR (CDCl 3 ): δ 38.78, 42.33, 43.75, 52.54, 56.41, 60.71, 69.0, 101.53, 108.75, 109.3, 110, 118.43, 118.81, 122.97, 125.44, 125.56, 125.85, 126.93, 127.80, 128.24, 130.68, 131.09, 131.82, 132.28, 132.54, 135.22, 142.43, 147.79, 148.40, 152.73, 174.64.
[0057] IR(KBr)cm −1 : 3409, 2903, 2834, 1774, 1586, 1503, 1481.
[0058] MS (FAB): 589 [M + ].
Example 2
4′-O-Demethyl-4β-(1″-anthrylamino)-4-desoxypodophyllotoxin (4a)
[0059] To a solution of podophyllotoxin (10) (414 mg, 1 mmol) in dry CH 2 Cl 2 (10 mL), sodium iodide (298 mg, 2 mmol) was added and stirred for 5 min to this stirred suspension BF 3 .OEt 2 (0.13 mL, 2 mmol) was added dropwise with at 0° C. and the stirring was continued for another 5 h at room temperature. Nitrogen was bubbled through the solution to drive of the excess hydrogen iodide. This solution was then evaporated in vacuo and used for the next reaction without further purification. To the above crude product, anhydrous barium carbonate (395 mg, 2 mmol) and 1-anthraceneamine (231 mg, 1.2 mmol) in 10 mL of dry THF under nitrogen was added and stirred for 8 h at room temperature. The reaction mixture was filtered, diluted with ethyl acetate and washed with water, 10% aqueous sodium thiosulphate solution, dried and purified via column chromatography using ethyl acetate/hexane mixture as eluent to get pure product in 65% yield.
[0060] m.p: 180-182° C. [α] 25 D : −59.0 (c=1.0, CHCl 3 )
[0061] 1 H NMR (CDCl 3 ): δ 3.11 (m, 1H), 3.39 (dd, 1H, J=13.6, 4.53 Hz), 3.83 (s, 6H), 3.97 (t, 1H, J=9.1 Hz), 4.46 (t, 1H, J=8.31 Hz), 4.73 (m, 2H), 5.45 (br, 1H), 5.98 (d, 2H, J=1.51 Hz), 6.4 (s, 2H), 6.47 (d, 1H, J=7.55 Hz), 6.63 (s, 1H), 6.82 (s, 1H), 7.35 (m, 1H), 7.48°(m, 3H), 7.97 (m, 2H), 8.24 (s, 1H), 8.35 (s, 1H).
[0062] IR(KBr)cm −1 : 3416, 2924, 2852, 1773, 1576, 1481. MS (FAB): 575 [M + ].
Example 3
4β-(1″-Fluorenylamino)-4-desoxypodophyllotoxin (3b)
[0063] This compound was prepared according to the method described for 3a employing 1-fluorenylamine (220 mg, 1.2 mmol) and podophyllotoxin (414 mg, 1 mmol) to get pure product in 75% yield.
[0064] m.p: 209-212° C.; [α] 25 D : −129.0 (c=1.0, CHCl 3 )
[0065] 1 H NMR (CDCl 3 ): δ 3.07 (m, 1H), 3.2 (dd, J=13.6, 4.53 Hz), 3.77 (s, 6H), 3.82 (s, 3H), 3.84 (s, 2H), 3.92 (br, 1H), 4.07 (t, 1H, J=9.06 Hz), 4.44 (t, 1H, J=8.31 Hz), 4.63 (d, 1H, J=4.53 Hz), 4.76 (m, 1H), 5.98 (d, 2H, J=3.02 Hz), 6.34 (s, 2H), 6.55 (s, 1H), 6.58 (dd, 1H, J=8.31, 2.27 Hz), 6.75 (m, 1H), 6.81 (s, 1H), 7.1-7.7 (m, 5H).
[0066] R(KBr)cm −1 : 3364, 2906, 2834, 1774, 1615, 1585, 1503, 1457.
[0067] MS (FAB): 577 [M + ].
Example 4
4′-40-Demethyl-4β-(1″-fluorenylamino)-4-desoxypodophyllotoxin (4b)
[0068] This compound was prepared, according to the method described for 4a employing 1-fluorenylamine (220 mg, 12 mmol) and podophyllotoxin (414 mg, 1 mmol) to get pure product in 63% yield.
[0069] m.p: 250-252° C. [α] 25 D : −105.0 (c=1.0, CHCl 3 )
[0070] 1 H NMR (CDCl 3 ): δ 3.0-33 (m, 2H), 3.74 (s, 6H), 3.79 (s, 2H), 3.88 (m, 1H), 4.34 (t, 1H, J=7.81 Hz), 4.52 (d, 1H, J=5.21 Hz), 4.86 (m, 1H), 5.96 (s, 2H), 6.28 (s, 2H), 6.5 (s, 1H), 6.67 (m, 1H), 6.81 (s, 1H), 6.86 (m, 1H), 7.06-7.58 (m, 5H).
[0071] IR(KBr)cm −1 : 3349, 2925, 2854, 1758, 1610, 1515, 1458.
[0072] MS (FAB): 563 [M + ].
Example 5
4β-(1″-Pyrenylamino)-4-desoxypodophyllotoxin (3c)
[0073] This compound was prepared according to the method described for 3a employing 1-pyrenylamine (265 mg, 1.2 mmol) and podophyllotoxin (414 mg, 1 mmol) to get pure product in 67% yield.
[0074] m.p: 190-193° C.; [α] 25 D : −122.0 (c=1.0, CHCl 3 )
[0075] 1 H NMR (CDCl 3 ): δ 3.19 (m, 1H) ; 3.34 (dd, 1H, J=14.16, 5.39 Hz), 3.82 (s, 6H), 3.84 (s, 3H), 4.02 (t, 1H, J=10.11 Hz), 4.5 (t, 1H, J=8.09 Hz), 4.7 (d, 1H, J=4.72 Hz), 4.86 (m, 1H), 5.11 (m, 1H), 6.01 (s, 2H), 6.37 (s, 2H), 6.62 (s, 1H), 6.83 (s, 1H), 7.1-8.1 (m, 9H).
[0076] IR(KBr)cm −1 : 3394, 2924, 1770, 1615, 1505, 1483.
[0077] MS (FAB): 617 [M + ].
Example 6
4′-O-Demethyl-4β-(1″-pyrenylamino)-4-desoxypodophyllotoxin (4c)
[0078] This compound was prepared according to the method described for 4a employing 1-pyrenylamine (265 mg, 1.2 mmol) and podophyllotoxin (414 mg, 1 mmol) to get pure product in 55% yield.
[0079] m.p: 148-153° C. [α] 25 D : −76.0 (c=1.0, CHCl 3 )
[0080] 1 H NMR (CDCl 3 ): δ 3.13 (m, 1H), 3.29 (dd, 1H, J=13.6, 4.53 Hz), 3.83 (s, 6H), 3.98 (t, 1H, J=10.57 Hz), 4.44 (t, 1H, J=8.31 Hz), 4.55 (m, 1H), 4.66 (d, 1H, J=5.29 Hz), 5.07 (m, 1H), 5.34 (br, 1H), 5.97 (s, 2H), 6.35 (s, 2H), 6.59 (s, 1H), 6.8 (s, 1H), 7.18 (m., 1H), 7.9 (m, 8 Hz).
[0081] IR(KBr)cm −1 : 3381, 2920, 1775, 1603, 1510, 1483.
[0082] MS (FAB): 603 [M + ].
Example 7
4β-(6″-Chrycenylamino)-4-desoxypodophyllotoxin (3d)
[0083] This compound was prepared according to the method described for 3a employing 6-chrycenylamine (296 mg, 1.2 mmol) and podophyllotoxin (414 mg, 1 mmol) to get pure product in 71% yield.
[0084] m.p: 157-160° C. [α] 25 D : −48.0 (c=1.0, CHCl 3 )
[0085] 1 H NMR (CDCl 3 ): δ 3.3 (m, 2H), 3.82 (s, 6H), 3.83 (s, 3H), 4.07 (t, 1H.; J=9.51 Hz), 4.61 (t, 2H, J=7.13 Hz), 4.72 (m, 2H), 5.21 (m, 1H), 6.0 (d, 2H, J=2.38 Hz), 6.38 (s, 2H), 6.57 (s, 1H), 6.86 (s, 1H), 7.4-9.0 (m, 11H).
[0086] IR(KBr)cm −1 : 3409, 2906, 1774, 1598, 1503, 1483.
[0087] MS (FAB): 643 [M + ].
Example 8
4′-O-Demethyl-4β-(6″-chrycenylamino)-4-desoxypodophyllotoxin (4d)
[0088] This compound was prepared according to the method described for 4a employing 6-chrycenylamine (296 mg, 1.2 mmol) and podophyllotoxin (414 mg, 1 mmol) to get pure product in 52% yield.
[0089] m.p: 158-160° C. [α] 25 D : −39.0 (c=1.0, CHCl 3 )
[0090] 1 H NMR (CDCl 3 ): δ 3.34 (m, 2H), 3.84 (s, 6H), 4.08 (t, 1H, J=102 Hz), 4.59 (m, 1H), 4.74 (m, 2H), 5.21 (m, 1H), 5.98 (s, 2H,), 6.34 (s, 2H), 6.51 (s, 1H), 6.83 (s, 1H), 7.4-9.0 (m, 11H).
[0091] IR(KBr)cm −1 : 3394, 2923, 1768, 1615, 1503, 1482.
[0092] MS (FAB): 629 [M + ].
Example 9
4β-[4″-(4″-Fluorobenzoyl)anilino]-4-desoaypodophyllotoxin (3e)
[0093] This compound was prepared according to the method described for 3a employing 4-amino-4′-fluorobenzophenone (258 mg, 1.2 mmol) and podophyllotoxin (414 mg, 1 mmol) to get pure product in 75% yield.
[0094] m.p: 106-110° C. [α] 25 D : −106.0 (c=1.0, CHCl 3 )
[0095] 1 H NMR (CDCl 3 ): δ 3.02 (m, 2H), 3.75 (s, 6H), 3.78 (s, 3H), 4.4 (m, 2H), 4.58 (m, 1H), 4.8 (m, 1H), 5.95 and 5.98 (ABq, 2H, J=1.51 Hz), 6.25 (s, 2H), 6.55 (m, 3H), 6.78 (s, 1H), 7.12 (m, 2H), 7.72 (m, 4H).
[0096] IR(KBr)cm −1 : 3348, 2923, 1772, 1641, 1596, 1504, 1481.
[0097] MS (FAB): 611 [M + ].
Example 10
4′-O-Demethyl-4β-[4″-(4″-fluorobenzoyl)anilino]-4-desoxypodophyllotoxin (4e)
[0098] This compound was prepared according to the method described for 4a employing 4-amino-4′-fluorobenzophenone (258 mg, 1.2 mmol) and podophyllotoxin (414 mg, 1 mmol) to get pure product in 65% yield.
[0099] m.p: 162-165° C. [α] 25 D : −129.0 (c=1.0, CHCl 3 )
[0100] 1 H NMR (CDCl 3 ): δ 3.02 (m, 2H), 3.79 (s, 6H), 4.36 (m, 1H), 4.52 (m, 2H), 4.79 (m, 1H), 5.35 (br, 1H), 5.95 and 5.98 (ABq, 2H, J=1.51 Hz), 6.28 (s, 2H), 6.51 (s, 1H), 6.57 (d, 2H, J=8.69 Hz), 6.76 (s, 1H), 7.13 (m, 2H), 7.68-7.79 (m, 4H).
[0101] IR(KBr)cm −1 : 3402, 2924, 1775, 1610, 1503, 1481.
[0102] MS (FAB): 597 [M + ].
Example 11
4β-(4″-{4″-[Di(2″-chloroethyl)amino]benzoyl}anilino)-4-desoxypodophyllotoxin (3f)
[0103] This compound was prepared according to the method described for 3a employing 4-amino-4′-[di(2-chloroethyl)amino]benzophenone (404 mg, 1.2 mmol) and podophyllotoxin (414 mg, 1 mmol) to get pure product in 65% yield.
[0104] m.p: 186-190° C. [α] 25 D : −110.0 (c=1.0, CHCl 3 )
[0105] 1 H NMR (CDCl 3 ): δ 3.13 (m, 2H), 3.64-3.91 (m, 17H), 3.99 (m, 1H), 4.26-4.48 (m, 2H), 4.63 (m, 1H), 4.81 (m, 1H), 5.99 (d, 2H, J=6.8 Hz), 6.33 (s, 2H), 6.55 (s, 1H), 6.57-6.74 (m, 4H), 6.8 (s, 1H), 7.66-7.8 (m, 4H).
[0106] IR(KBr)cm −1 : 3380, 2924, 2854, 1773, 1727, 1596, 1507, 1480.
[0107] MS (FAB): 733 [M + ].
Example 12
4′-O-Demethyl-4β-(4″-{4″-[di(2″-chloroethyl)amino]benzoyl}anilino)-4-desoxy podophyllotoxin (4f)
[0108] This compound was prepared according to the method described for 4a employing 4-amino-4′-[di(2-chloroethyl)amino]benzophenone (404 mg, 1.2 mmol) and podophyllotoxin (414 mg, 1 mmol) to get pure product in 51% yield.
[0109] m.p: 173-175° C. [α] 25 D : −124:0 (c=1.0, CHCl 3 )
[0110] 1 H NMR (CDCl 3 ): δ 3.12 (m, 2H), 3.65-3.88 (m, 14H), 3.99 (t, 1H, J=10.57 Hz), 4.48 (m, 2H), 4.62 (d, 1H, J=4.53 Hz), 4.82 (m, 1H), 5.34 (br, 1H), 5.98 (d, 2H, J=6.8 Hz), 6.33 (s, 2H), 6.55 (s, 1H), 6.57-6.74 (m, 4H), 6.8 (s, 1H), 7.66-7.8 (m, 4H).
[0111] IR(KBr)cm −1 : 3395, 2920, 1772, 1598, 1507, 1481.
[0112] MS (FAB): 719 [M + ].
Biological Activity:
In Vitro Evaluation of Cytotoxic Activity
[0113] Compounds 3a-f and 4a-f have been evaluated for their in vitro cytotoxicity in selected human cancer cell lines i.e., Liver (HEP-2), Neuroblastoma (IMR-32), Breast (MCF-7), CNS (SK-N-SH) and Colon (Colo-205, SW-620) origin by employing the sulforhodamine B (SRB) assay method (Skehn, P.; Storeng, R.; Scudiero, A.; Monks, J.; McMohan, D.; Vistica, D.; Jonathan, T. W.; Bokesch, H.; Kenney, S.; Boyd M. R. J. Natl. Cancer Inst. 1990, 82, 1107). The results (μM/ml) are summarized with standard drug Adriamycin in Table-1. All the new compounds were significantly cytotoxic towards the liver, CNS and colan cancer cell lines compared, to the standard drug tested, with the fixed concentration of the drug (10 μM).
[0000]
TABLE 1
In Vitrocytotoxicity data of compounds 3a-f and 4a-f
Growth Inhibition(%)
Con-
Neurobl-
CNS
Colon
Com-
centration
Liver
astma
Breast
SK-
Colo-
SW-
pound
(μM/mL)
HEP-2
IMR-32
MCF-7
N-SH
205
620
3a
1 × 10 −5
46
16
5
65
55
25
4a
1 × 10 −5
58
0
0
38
39
22
3b
1 × 10 −5
77
0
4
44
49
11
4b
1 × 10 −5
0
0
39
50
55
15
3c
1 × 10 −5
66
0
0
59
64
29
4c
1 × 10 −5
39
0
0
40
40
7
3d
1 × 10 −5
66
1
0
73
51
14
4d
1 × 10 −5
76
0
0
58
58
17
3e
1 × 10 −5
0
0
30
34
68
10
4e
1 × 10 −5
51
11
39
91
77
42
3f
1 × 10 −5
45
0
40
83
74
15
ADR
1 × 10 −6
23
0
23
36
18
21
ADR = Adriamycin is the control drug
[0114] Apart from this, some of these analogues were evaluated for Topoisomerase-I relaxation, Topoisomerase-II inhibition, DNA laddering assay and DNA cell cycle analysis. Compounds 3c, 4c, 3d and 4d were analyzed for topoisomerase-I assay at 100 μM ( FIG. 2 ) only compound 3d was found active and rest were not active. Compounds 3d, 4d and 4c were analyzed for topoisomerase inhibition assay. None of the compounds are active, however compound 3d shows better activity than others ( FIG. 3 ).
[0115] Compound 3d evaluated for DNA laddering assay. This compound at 0.5, 1, 5, and 10 μM concentration induced DNA fragmentation in leukemia (MOLT-4) cells after 24 hr incubation ( FIG. 4 ). Further this compound (3d) evaluated for DNA cell cycle analysis at 0.5, 1, 5, and 10 μM concentrations by treated with Lukemia (HL-60) cells indicated that it blocks the G1 Phase of cell cycle and there was increase in sub G1 cell population indicates apoptosis ( FIG. 5 ).
Procedure of the SRB-Assay
[0116] Single cell suspension of the tumor cells grown in tissue culture were made, cells counted and cell count adjusted to 1×10 5 to 5×10 5 Ninetysix (96) well plates were seeded with this cell suspension, each well receiving 100 μl of it. The plate was then be incubated at 37° C. temperature in CO 2 incubator for 24 hours. Drugs were added at appropriate concentrations after 24-hour, incubation followed by further incubation for 48 hours. Experiment was terminated by gently layering the cells in the wells with 30% TCA and plates were kept in refrigerator for 1 hour following which they were washed thoroughly with tap water, dried attained with 0.4% SRB in 1% acetic aid and finally, the bound SRB eluted with 10 mM tris. Absorbance was read at 540 nm, in the microtitre-plate reader. Optical density of drug-treated cells was compared with that of control cells and cell inhibition was calculated as percent values. Each compound was tested at 10, 20, 40 and 80 μg/ml in triplicate on human malignant cell lines.
Topoisomerase-I Relaxation Assay
[0117] Reaction was assembled in micro centrifuge tube that contains super coiled DNA 250 ng/μl & Topoisomerase-I (4 units) in assay buffer (10 mM Tris-HCl, pH 7.9, 0.15 M NaCl, 0.1% BSA, and 5.0 mM (beta)-mercaptoethanol). In each reaction 2 μl sample was added then volume was made up to 20 μl with water and then incubated at 37° C. Reaction was terminated by addition of 2 μl of 10% SDS. Each sample tube was treated with proteinase K and extracted once with chloroform: isoamyl alcohol. Products were resolved by 0.8% agarose gel electrophoresis in TAE buffer (40 mM tris-acetate, pH 8.0, and 1 mM EDTA) and stained with 0.5 μg/ml ethedium bromide (EtBr). Results are shown in FIG. 2 .
DNA Topoisomerase-II Inhibition Assay
[0118] Reaction was assembled in micro centrifuge tube that contains super coiled DNA 250 ng/μl & Topoisomerase-I (4 units) in assay buffer (A 0.1 volume and B 1 volume)). In each reaction 2 μl sample was added then volume was made up to 20 μl with water and then incubated at 37° C. Reaction was terminated by addition of 2 μl of 10% SDS. Each sample tube was treated with proteinase K and extracted once with chloroform: isoamyl alcohol. Products were resolved by 0.8% agarose gel electrophoresis in TAE buffer (40 mM tris-acetate, pH 8.0, and 1 mM. EDTA) and stained with 0.5 μg/ml, ethedium bromide (EtBr). Results are shown in FIG. 3 .
DNA Gel Electophoresis
[0119] DNA fragmentation was determined by electrophoresis of extracted genomic DNA form leukemia cell (MOLT4). Briefly, exponentially growing cells (2×10 6 cells/mL) in 6 well plate were treated with compound 3d in 0.5, 1, 5 and 10 μM concentrations for 24 hrs. Cells were harvested, washed with PBS, pellets were dissolved in lyris buffer (10 mM EDTA, 50 mM Tris pH 8.0, 0.5% w/v SDS and proteinase K (0.5 mg/mL) and incubated at 50° C. for 1 hr. Finally the DNA obtained was heated rapidly to 70° C., supplemented with loading dye and immediately resolved on to 1.5% agarose gel at 50 V for 2-3 hrs ( FIG. 4 ).
Flow-Cytometric Analysis of Phase Distribution of Nuclear DNA
[0120] Effect of compound 3d on DNA content by cell cycle phase distribution was assessed using HL-60 cells by incubating the HL-60 cells (1×10 6 ) 1 ml phosphate buffer saline were treated with 3d (0.5, 1, 5, 10 μM) for 24 hr. The cells were then washed twice with ice-cold PBS, harvested, fixed with ice cold PBS in 70% ethanol, and stored at −20° C. for 30 minutes. After Fixation, these cells were incubated with RNase A (0.1 mg/ml) at 37° C. for 30 min, stained with propidium iodide (50 μg/ml) for 30 min on ice in dark, and then measured for DNA content using BD-LSR flow cytometer (Becton Dickinson, USA) equipped with electronic doublet discrimination capability using blue (488 nm) excitation from orgon laser. Data were collected in list mode on 10,000 events for FL2-A vs. FL2-W ( FIG. 5 ).
[0121] In conclusion, the main advantages of the present inventions are that these new 4β-polyarylamine analogues of podophyllotoxin have exhibited promising in vitro cytotoxic activity. Further, these compounds have been prepared from podophyllotoxin upon reaction with BF 3 .OEt 2 /NaI followed by the addition of corresponding polyaryl amines in the presence of BaCO 3 at room temperature to provide the 4β-polyarylamino podophyllotoxin analogues in very good yields and in almost stereoselective manner.
|
The present invention provides novel β-amino podophyllotoxin congeners of general formula (A); R═CH 3 , or H; R 1 =(a) or (b) or (c) or (d) or (e) or (f). The present invention also provides a process for the preparation of 4β-amino podophyllotoxin congeners useful as antitumour agents.
| 2
|
FIELD OF THE INVENTION
[0001] The present invention relates to medical devices in general, and in particular to systems for performing myocardial revascularization.
BACKGROUND OF THE INVENTION
[0002] Myocardial revascularization is a surgical technique whereby small holes or craters are created in the myocardium to allow oxygenated blood within the ventricle to contact the myocardium. One technique, called transmyocardial revascularization (TMR), involves routing an energy delivery catheter through an opening in the chest wall to the exterior of the patient's heart muscle. Ablation energy is then delivered to the catheter to create a hole that extends from the epicardium, or exterior of the patient's heart, to the interior of the ventricle such that oxygenated blood flows into and out of the holes. These holes rapidly seal at the outside of the heart but remain open towards the interior of the ventricle. Another technique, called percutaneous myocardial revascularization (PMR), utilizes an energy delivery catheter that is routed through a patient's vasculature to the interior wall of the left ventricle. Ablation energy is then supplied to the ventricular wall to remove a portion of the endocardium and expose a portion of the myocardium to oxygenated blood flow.
[0003] Myocardial revascularization is most often used when an area of the myocardium is not receiving adequate blood flow because of clots or diseases that inhibit the ability of the vessels to supply blood to the heart. It is not known whether the procedure induces new blood vessels to form in the myocardium or simply deadens nerve endings in the myocardium to alleviate patient discomfort.
[0004] Not all cardiac tissue can be helped using myocardial revascularization. For example, if the myocardial tissue has been deprived of oxygenated blood for too long, it may be dead and no benefits to the tissue will be obtained if treated. Applying ablation energy to such myocardial tissue is not only a waste of time, but the tissue may be more susceptible to ventricular perforation. To increase the efficiency and efficacy of a myocardial revascularization procedure, there is a need for a system that can guide a physician to only perform a myocardial revascularization procedure in viable cardiac tissue.
SUMMARY OF THE INVENTION
[0005] The present invention is a method and apparatus for limiting the delivery of ablation energy to viable areas of the myocardium. An energy delivery catheter is routed to the patient's myocardium. A determination is made if the myocardium adjacent to the distal end of the catheter is viable and, if so, ablation energy is delivered through the catheter to the myocardial wall. If the tissue adjacent the distal end of the energy delivery catheter is not viable, then no ablation energy is delivered.
[0006] In one embodiment of the invention, tissue viability is determined by applying a test signal to the tissue and measuring the impedance of the tissue in response to the test signal applied. If the impedance is greater than a predefined amount, the tissue is deemed not to be viable. Therefore, no ablation energy will be delivered.
[0007] The energy delivery catheter may be routed through the patient's vasculature or through an opening in the patient's chest wall.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0009] [0009]FIG. 1 illustrates a system for performing myocardial revascularization according to the present invention;
[0010] [0010]FIG. 2 illustrates a pair of catheters that are used to position an energy delivery catheter at a desired location in the patient's heart;
[0011] [0011]FIG. 3 illustrates in further detail the energy delivery catheter used in one embodiment of the present invention to deliver the ablation energy; and
[0012] [0012]FIG. 4 is a flow chart of the steps performed by one embodiment of the present invention to limit the application of ablation energy to viable myocardial tissue.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] [0013]FIG. 1 illustrates the major components of the presently preferred system for performing PMR according to the present invention. A steerable catheter 10 is routed through a patient's vasculature and into the left ventricle of the heart 12 . In order to route the steerable catheter to the left ventricle, an incision is made into a patient's femoral artery and an introducer sheath approximately 12″ long (not shown) is introduced into the wound. Next, the steerable catheter 10 is advanced along the vasculature until it nears the patient's heart valve. A “pig tail” catheter (also not shown) is inserted into the steerable catheter 10 in order to push past a valve at the entrance of the left ventricle. The pig tail catheter is removed and an inner catheter (described below) including an energy delivery catheter 14 is advanced along the steerable catheter 10 into the left ventricle.
[0014] The energy delivery catheter 14 delivers ablation energy produced by an ablation energy source 16 . In the currently preferred embodiment, the ablation energy source 16 is a radio frequency (RF) voltage generator that is controlled to selectively supply RF electrical energy to the energy delivery catheter 14 . When the distal end of the energy delivery catheter 14 is adjacent to, or in contact with, an ischemic region 18 of the left ventricle, a physician triggers the RF voltage generator to supply a 400 millisecond radio frequency pulse to the energy delivery catheter 14 . The ablation energy is delivered to the interior of the heart muscle to ablate or remove a portion of the endocardial, or inner lining of the heart, thereby creating regions or craters 20 where the myocardium is exposed. The exposed myocardium is then in contact with the oxygenated blood that is flowing within the left ventricle. The delivery of the RF pulses can take place independently of the cardiac cycle.
[0015] In the presently preferred embodiment PMR device, the energy delivery catheter 14 is a unipolar device including a single electrode. A return electrode 21 is positioned on the exterior of the patient to provide a current path back to the RF voltage generator.
[0016] [0016]FIG. 2 illustrates the presently preferred steerable catheter 10 that routes the energy delivery catheter 14 into the patient's heart muscle. The steerable catheter 10 comprises an outer catheter 30 and inner catheter 32 that are relatively flexible at their distal ends. The outer catheter 30 has a predefined “J-shaped” bend 34 at its distal end, and the inner catheter 32 has a predefined “J-shaped” bend 36 at its distal end. The radius of the bend 36 is smaller than that of the bend 34 . Each of the catheters 30 , 32 has a connector at its proximal end with a pair of opposed “wings” or tabs on it. The diameter of the inner catheter 32 is selected such that it can be threaded into a lumen that extends along the length of the outer catheter 30 . When the inner catheter 32 is inserted into the outer catheter 30 , the tabs on the proximal ends of the catheters allow the inner catheter 32 to be rotated with respect to the outer catheter 30 . The predefined bends 34 and 36 cooperate to vary the orientation of a distal tip 38 of the inner catheter 32 . The bends 34 and 36 may be aligned so they both bend in the same direction, in opposite directions, or at any position in between.
[0017] As illustrated in FIG. 3 above, the energy delivery catheter 14 houses a flexible electrode 35 . The electrode 35 is threaded through two holes of a ceramic cap 37 at the distal end of the catheter 14 . Specifically, the electrode 35 exits a first hole 37 a in the distal direction and then is routed proximally through a second hole 37 b in the ceramic cap 37 such that a portion of the electrode 35 is exposed at the distal end of the catheter. The distal end of the electrode 35 does not extend all the way back along the length of the catheter 14 but terminates at a point generally near the distal end of the energy delivery catheter 14 . The ceramic cap 37 may include a pair of additional holes 37 c and 37 d, that allow fluids such as dyes or drugs to be supplied through a lumen in the energy delivery catheter 14 and delivered to the ablation site. Finally, the energy delivery catheter 14 may include a radiopaque marker band 39 that surrounds the ceramic cap 37 in order to enhance the visibility of the energy delivery catheter 14 under fluoroscopy or other imaging techniques, as the PMR procedure is being performed.
[0018] As indicated above, to prohibit the application of ablation energy to myocardial tissue that would not benefit from the procedure, the present invention determines the viability of such tissue prior to the delivery of ablation energy. FIG. 4 illustrates a series of steps performed by the present invention to ensure that ablation energy is not applied to non-viable cardiac tissue. Beginning with a step 50 , a physician positions the energy delivery catheter at the desired location on or inside the heart. As indicated above, the catheter may be placed either against the endocardial or epicardial layer of the heart muscle. At a step 52 , a test signal is delivered to the heart muscle and the heart's response to the test signal is measured at a step 54 .
[0019] From the results of the test signal, a decision is made at step 56 to determine whether the myocardium in the area adjacent the energy delivery catheter is viable. If the tissue is viable, the ablation energy is delivered at a step 58 . If the tissue is not viable, the physician is prevented from delivering ablation energy to that spot on the ventricle. The physician then moves the probe and processing returns to step 50 as described above.
[0020] In the presently preferred embodiment of the invention, the test signal delivered at step 52 is a low energy, high frequency RF energy pulse. Preferably, the signal has a frequency greater than 50 kHz in order to avoid fibrillating the heart. The impedance of the heart muscle in response to the test signal delivered is the presently preferred criteria by which viability of the heart is determined at step 54 .
[0021] If the impedance is greater than a predefined level, such as 1700 ohms, it is assumed that the heart muscle is dead or would otherwise not respond to the myocardial revascularization treatment, and no ablation energy is delivered at that point. In order to measure impedance, the ablation energy source 16 shown in FIG. 1 includes a circuit that determines the magnitude of the current received in response to the low power, RF test signal applied. Based on the magnitude of the current sensed, a switch or other control within the ablation energy source is inhibited from delivering an RF pulse to the cardiac tissue at that position. In the presently preferred embodiment of the invention, the test signal is delivered when the physician activates a foot pedal or other control to initiate the delivery of ablation energy. The test signal is delivered first and if the impedance indicates the tissue is viable, the ablation energy pulse follows immediately or very shortly thereafter.
[0022] Although the present invention uses a low energy, high frequency test signal in order to measure the impedance of the cardiac tissue, it will be appreciated that other criteria could be used to determine tissue viability. For example, the catheter may include an electrode or other sensor to determine if the cardiac tissue in the area of the electrode is responding to the heart's own pacing signals. If no tissue response is observed, no ablation energy will be applied to that portion of the heart muscle.
[0023] While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the scope of the invention. It is therefore intended that the scope of the invention be determined from the following claims and equivalents thereto.
|
A method and apparatus for limiting the application of ablation energy to viable myocardial tissue. An ablation energy generator produces a test signal that is applied to the heart muscle. The response of the heart muscle to the test signal is determined and used to analyze the viability of the heart tissue. If the heart muscle is viable, a higher powered ablation pulse may be delivered. If the tissue is not viable, no ablation energy is delivered. In one embodiment of the invention, the test signal is a low voltage, high frequency signal and the impedance of the tissue in response to the test signal is detected to determine tissue viability.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is related to the following co-pending U.S. patent applications all having the same inventive entity and being assigned to the same assignee:
U.S. patent application Ser. No. 564,134, titled, "A Remote Data Link Controller;"
U.S. patent application Ser. No. 564,138, titled, "A Remote Data Link Controller Having Multiple Data Link Handling Capabilities;"
U.S. patent application Ser. No. 564,135, "A Remote Data Link Receive Data Reformatter;"
U.S. patent application Ser. No. 564,133, "A Remote Data Link Transmit Data Formatter;"
U.S. patent application Ser. No. 564,136, "A Remote Data Link Address Sequencer and a Memory Arrangement for Accessing and Storing Digital Data."
BACKGROUND OF THE INVENTION
The present invention relates generally to data transmission between the switching systems of a telecommunication switching network and more particularly to a digital data format arrangement for the exchange of control messages between the peripheral processors of each switching system.
In modern digital telecommunication switching systems a concept of network modularity has been designed allowing the interconnection of small switching systems remote to a larger host system. These remote switching systems have capacities to handle between a few hundred and a few thousand telephone subscribers. The remote switching systems are normally used in areas where the installation of a large switching system would be uneconomical.
A high speed digital data link typically interfaces the host switching system to the remote system through which large amounts of voice and control data are exchanged. The voice data normally comprises subscriber calls switched through either the host or the remote system. The control data may be status exchanges between the host and the remote, i.e. centralized administration, billing and maintenance, or the direct control of the operation of the remote by the host.
The control data exchanges are originated in the sending system peripheral processor transmitted over the high speed digital data link to the receiving system peripheral processor where the data is interpreted. In order to relieve each peripheral processor from the burden of controlling the data link a remote data link controller is implemented in each system which performs all tasks involved in the formatting, transmission and reception of the control data.
The remote data link controllers are connected to each other via digital spans. These digital spans may be T1, T2 or T1C, T3 carriers using DS1, DS2 or DS1C, DS3 data formats, respectively. These digital spans transmit data at high speeds serially at a rate of approximately 1.5-45 megabits per second.
Each data link, in the absence of transmission errors, has the capability of handling upwards of 400 messages per second in each direction. Consequently, the data exchanged should have a format providing excellent error immunity, throughput and enhanced processing performance.
Accordingly, it is the object of the present invention to provide an efficient digital data format arrangement for the exchange of control messages between the peripheral processors of a telecommunications switching network.
SUMMARY OF THE INVENTION
In accomplishing the object of the present invention a data message format for conveying control information from a peripheral processor of one telecommunications switching system to a peripheral processor of at least one other telecommunications switching system is provided. Each telecommunications switching system is connected to the other by a digital data link and each includes a digital link controller connected between the peripheral processor and the digital data link.
The data message format of the present invention is comprised of at least one control word including a plurality of control bits, a data bit and a control word parity bit. The data message further includes a plurality of data words, each data word comprising a plurality of data bits and a data word parity bit for each data word.
Finally, a parity word is included having a plurality of parity bits with each parity bit providing parity for an associated plurality of bits of the preceding plurality of data and control words. The parity word also includes a parity bit for the parity word.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a telecommunications switching system including a remote data link controller.
FIG. 2 is a block diagram showing the interconnection of the two telecommunications switching systems via a T1 span.
FIG. 3 is a bit map of a channel, and a frame of a T1 digital span.
FIG. 4 is a bit map representation of the data format of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a time-space-time digital switching system along with the corresponding common control is shown. Telephone subscribers, such as subscribers 1 and 2, are shown connected to analog line unit 13. Analog line unit 13 is connected to both copies of the analog control unit 14 and 14'. Originating time switches 20 and 20' are connected to a duplex pair of space switch units 30 and 30' which are in turn connected to a duplex pair of terminating time switches 21 and 21'. Terminating time switches 21 and 21' are connected to analog control units 14 and 14' and ultimately to the telephone subscribers 1 and 2 via analog line circuit 13. Digital control units 15, 15' and 16, 16' connect the digital spans to the switching system. Digital span equipment may be implemented using a model 9004 T1 digital span, manufactured by GTE Lenkurt, Inc. Similarly, analog trunk unit 18 connects trunk circuits to the digital switching system via analog control units 17 and 17'.
A peripheral processor CPU 70 controls the digital switching system and digital and analog control units. Analog line unit 13 and a duplex pair of analog control units 14 and 14' interface to telephone subscribers directly. A duplicate pair of digital control units 15, 15' and 16, 16' control the incoming PCM data from the digital spans. Similarly, the analog trunk unit 16 and a duplex pair of analog control units 17 and 17' interface to trunk circuits. The analog and digital control units are each duplicated for reliability purposes.
The network of FIG. 1 also includes a duplicated REMOTE DATA LINK CONTROLLER (RDLC) 100, 100' which provides formatting and control of data transmitted and received between the peripheral processors of two or more switching systems. The RDLC can provide up to 16, 64 kilobits per second data links arranged for full duplex operation and is configured so that it can provide one full duplex data link for each of the 16 T1 spans. RDLC 100 can operate together with one or two digital control units (DCU), with each DCU capable of providing up to eight T1 carrier facilities.
Turning now to FIG. 2, two distantly located switching systems each including an RDLC is shown. A first system includes a duplicated peripheral processor (PP) 70, 70' connected to a duplicated PP I/O buffer 60 and 60'. Each PP I/O buffer 60 and 60' is in turn connected to a duplicated data link processor and control unit 80 and 80' and each data link processor and control unit 80 and 80', to an associated digital control unit (DCU) 15 and 15'.
DCU 150 and 150' of the second switching system is connected to DCU 15 and 15' via a T1 span signal pair. DCU 150 and 150' is connected to an associated data link processor and control 180 and 180' and via PP I/O buffer 160 and 160' to PP 170 and 170'.
For ease of explanation PP 70 will be the transmitting processor and PP 170 the receiving processor. It should be understood that either RDLC 100 or 101 is capable of transmitting as well as receiving.
Prior to examining the detailed operation of the RDLC, it is helpful to understand the format and protocol of the messages which are transmitted and received by the RDLC. Each message consists of eight, 8-bit bytes of data for a total of 64 bits. The peripheral processor I/O buffer provides four transmit message buffers and four receive message buffers for each of the 16 possible data links.
Normally, peripheral processor 70, 70' software, writes a message into a transmit message buffer of PP I/O buffer 60 and 60' associated with a particular data link and then issues a transmit command to data link processor and control 80 and 80'. The data link processor and control 80 and 80' responds by taking the message out of the transmit message buffer and formatting the data so that it can be transmitted over a T1 carrier. The data link processor and control 80, 80' then transmits the message to the distant end of the data link through DCU 15, 15' and the T1 span.
The message is received at the receiving DCU 150, 150' and is transferred to the data link processor and control 180 and 180' where it is reformatted. The received data message is then placed into an appropriate receive message buffer in the PP I/O buffer 160 and 160'. Data link processor and control 180 and 180' then causes an interrupt, alerting PP 170 and 170' to the fact that a message has been received. It should be noted that under normal conditions the RDLC functions in a duplicated configuration, that is, it matches all outgoing signals performed in the DCUs. With this arrangement there is one RDLC circuit for each of the two copies of the DCUs.
The nature of a T1 data and its format is shown in FIG. 3. Normally, each T1 span transmits and receives voice samples organized together into a frame. Each frame includes 24 voice samples with each voice sample associated with one channel of voice (or data). The channels are numbered 0-23. Normally, the RDLC will insert its data bytes in channel 0. The S bit carries a periodic pattern which, when detected, is used to identify the beginning of each frame of data.
Turning now to FIG. 3, a bit map representing the complete data format for one message is shown. The data format is byte oriented with one 8-bit byte being transmitted during each T1 data frame for each data link.
When the link is idle and not transmitting the transmitter sends idle patterns consisting of all ones. The beginning of a message is indicated by sending a control byte containing one or more zeros which may contain information conveying the sequence number of messages transmitted or received and/or acknowledgements between the RDLCs.
As can be seen in FIG. 3 only six control bits are used (XC, XB, XA, RC, RB, RA) in the control byte. The control bits have the following significance:
XC bit (bit 7) this bit is reset to indicate an acknowledgment message. If both the XC and RC bits are reset, the message is interpreted as a reset message.
XA, XB bits (bits 5 and 6) contain the sequence number associated with the transmitted message, i.e. which of the eight bytes is being transmitted. If the XC bit is reset, the sequence number has no significance and is ignored by the receiver.
RC bit (bit 4) when set, this bit indicates that bits RA and RB contain the sequence number of a message that is being acknowledged by this message. It should be noted that a single message may both contain data and an acknowledgment of a previous message.
RA, RB bits (bits 2 and 3) these bits may contain a sequence number (if RE is set) or if both XC and RC are reset, these bits indicate which of the associated PP copies should be forced into an active state. In this case the RA and RB bits indicate the function to be performed as follows:
______________________________________RA RB______________________________________0 0 Remove previous PP force0 1 Force Copy 1 PP1 0 Force Copy 0 PP1 1 Reset and restore previous PP force______________________________________
The first data bit to be transmitted is inserted in the bit 1 position of the control byte. The control byte further includes an odd parity bit in bit position 0.
The next nine bytes contain the remaining 63 bits of data, each byte containing seven bits of data plus an odd parity bit. The final message byte contains seven vertical parity bits plus an odd parity bit for the vertical parity byte. Each vertical parity bit provides even parity for ten of the preceding bits, i.e. P1 for bit 1 in each of the preceding ten bytes, P2 for bit 2, P3 for bit 3, etc. The next byte will contain idle pattern.
It should be noted that the idle pattern is unique in that it has even parity. This makes it easy for the receiver to synchronize with the incoming data stream and greatly reduces the chance that a receiver would accept an incorrect message because of improper synchronization.
Although the preferred embodiment of the invention has been illustrated, and that form described in detail, it will be readily apparent to those skilled in the art that various modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims.
|
A formatted data message for conveying control information from the peripheral processor of one telecommunications switching system to the peripheral processor of at least one other telecommunications switching system is provided. The data message format comprises a first control work including a plurality of control bits, a data bit and a parity bit for the first control word and a plurality of data words, each data word including a parity bit. The data words contain control information to be conveyed to the receiving peripheral processor. A parity word is included which provides parity for an associated plurality of the preceding data and control words.
| 7
|
OBJECT OF THE INVENTION
The present invention relates to a method for obtaining keratinocytes from mammals' embryonic stem cells.
A possible therapeutic application of such a method is the regeneration of tissues derived from keratinocytes, more particularly, the production of artificial skin.
STATE OF THE ART
The name “extracellular matrix” or “ECM” is the name generally given to the complex network of extracellular macromolecules which is in contact with most of the cells of pluricellular organisms.
The composition of the extracellular matrix and the form thereof vary depending on the tissue, so that it is more commonly referred to as extracellular matrices than as the extracellular matrix. However, extracellular matrices share in common their being made up of macromolecules which are essentially locally secreted proteins and polysaccharides being organized so as to form a three-dimensional network at the intercellular spaces level of most tissues.
Such macromolecules may include for example proteoglycans, fibrous proteins with an essentially structural function such as elastin and collagen, and fibrous proteins with an essentially adhesion function such as fibronectin and laminins.
The extracellular matrix is not only a biological “glue”, but it also forms highly dedicated structures such as cartilage, tendons, lamina basement membrane, skeleton and teeth.
Additionally, it has been found that extracellular matrices play a critical part in regulating the behaviour of cells they are in contact with. They are thus involved in as different phenomena as cellular development, proliferation, metabolism, shape and polarity of the cells. Another phenomenon where extracellular matrices are involved is the cell differentiation.
Embryonic stem cells are derived from embryonic totipotent cells. These are pluripotent cells capable to differentiate in vivo into any cellular type (Bradley et al., Nature 309, 255–256 (1984); Nagy et al., Development 110, 815–821 (1990)) and in vitro into a more limited number of cellular types (Doetschman et al., J. Embryol. Exp. Morph. 87, 27–45 (1985); Wobus et al., Biomed. Biochim. Acta 47, 965–973 (1988); Robbins et al., J. Biol. Chem. 265, 11905–11909 (1990); Schmitt et al., Genes and Development 5, 728–740 (1991)).
However, the embryonic stem cells are difficult to culture in a laboratory and their culture requires the addition in the culture medium of a differentiation inhibiting factor, commonly referred to as “LIF” (Leukemia Inhibiting Factor), so as to avoid any spontaneous differentiation phenomenon (Williams et al., Nature 336, 684–687 (1988); Smith et al., Nature 336, 688–690 (1988); Gearing et al., Biotechnology 7, 1157–1161 (1989)).
The LIF is a secretion protein able to be provided by maintaining embryonic stem cells on a nutrient layer of cells producing such a LIF (E. J. Robertson, Teratocarcinomas and Embryonic stem cells: a practical approach, Washington D.C., IRL Press (1987)) or, in the absence of a nutrient layer, by adding purified LIF to the culture medium (Pease et al., Exp. Cell. Res. 190, 209–211 (1990)).
It has been demonstrated that the spontaneous differentiation of embryonic stem cells occurs as soon as the LIF is removed from the culture medium where the cells are present, and that it could also be induced through manipulation under certain conditions (Gutierrez-Ramos et al., Proc. Nat. Acad. Sci. 89, 9111–9175 (1992)).
Such a differentiation occurs under the effect of the embryonic stem cells aggregation, causing embryoid bodies (three-dimensional structures) to be formed, from which cells differentiate from each other into various cellular types.
Rudnicki et al. disclosed a general method for inducing a differentiation of embryonic stem cells, the so-called “hanging drop method” (Rudnicki et al., <<Cell culture methods and induction of differentiation of embryonal carcinoma cell lines>>, in Teratocarcinomas and embryonic stem cells: a practical approach , (E. J. Robertson, op. cit.), 19–49 (1987), IRL Press, Oxford). In such a method, so that the embryonic stem cells differentiate from each other, it is required to form three-dimensional structures referred to as “embryoid bodies” such as hereinabove mentioned.
The absence of LIF in such a method is required for allowing the embryonic stem cells to be differentiated from each other. After 3 days, the formed embryoid bodies are transferred onto bacteriological Petri dishes and are kept suspended for 2 days, so as to avoid their adhesion and to enhance their growth. The embryoid bodies are then allowed to adhere on cellular culture dishes. As early as the second day after adhesion, various cellular types are to be observed within those bodies, amongst others, beating cells (cardiomyocytes). Depending on the culture conditions being used, skeletal and smooth muscle cells, nerve cells, glial cells and hematopoietic system derivatives are identified (Rathjen et al., <<Properties and uses of embryonic stem cells: prospects for application to human biology and gene therapy>>, Reprod. Fertil. Dev. 10(1), 31–47 (1998), Review).
Recently, culture conditions allowing to induce in a predominant and reproducible way the differentiation of embryonic stem cells towards a particular lineage have been developed (Rathjen et al., op. cit.).
It is from now on clearly observed that the LIF holds the pluripotent embryonic stem cells under a undifferentiated form, and that the removal thereof from the cellular medium allows such cells to initiate, under the form of embryoid bodies, a differentiation programme.
The document by Bagutti et al. (Bagutti et al., Developmental Biology 179, 184–196 (1996)) more particularly discloses the spontaneous differentiation of mouse embryonic stem cells into keratinocytes using the hanging drop method, the keratinocytes appearing as from the 21 st day.
However, there is currently not yet a method for inducing the differentiation of the embryonic stem cells into keratinocytes which would be a true alternative, in terms of speed and yield, to the hanging drop method.
AIMS OF THE INVENTION
The aim of the present invention is to provide a method and means for inducing the differentiation of embryonic stem cells into keratinocytes, allowing to more quickly obtain more differentiated keratinocytes, compared to the state of the art methods.
Another aim of this invention is also to provide a method and means for inducing the differentiation of mammal's embryonic stem cells into keratinocytes which would be reproducible and reliable.
SUMMARY OF THE INVENTION
The present invention relates to obtaining keratinocytes from mammals' embryonic stem cells, in particular to a method for inducing the differentiation of mammals' embryonic stem cells into keratinocytes, comprising the following steps of:
isolating an extracellular matrix secreted by at least one mammals' cell type,
cultivating mammals' embryonic stem cells in parallel in an undifferentiated condition in an appropriate culture medium,
seeding then said embryonic stem cells as a monolayer on said extracellular matrix or on one or more fractions thereof comprising particular components, including laminin-5, type IV collagen, type I collagen or fibronectins,
cultivating then said thus seeded embryonic stem cells in the absence of the above-mentioned LIF for a period of time sufficient for obtaining a differentiation into keratinocytes, and
collecting the thus obtained keratinocytes, isolating and amplifying them using known cloning techniques (dispase, trypsin, cell sorting).
Advantageously, the embryonic stem cells are previously held in an undifferentiated condition in the presence of the LIF, preferably at a concentration in the order of 10 3 units/ml of culture.
According to the invention, inducing the differentiation of embryonic stem cells on an extracellular matrix is initiated as early as the 8 th day and is widely progressing after 15 days. This time factor is in no way limiting and could be accelerated using various methods able to be adjusted by the man of the art.
Additionally, it is also possible to treat the embryonic strains before differentiation into keratinocytes through various genetic modifications, in particular, through genetic modifications on genes of the major histocompatibility complex (MHC), so as to create universal immunotolerant pluripotent lineages.
Most advantageously, the embryonic stem cells being seeded on the extracellular matrix are cultivated in the presence of BMP-4 and ascorbic acid.
Another aspect of the present invention relates to the production of artificial skin, more particularly, an epidermis tissue comprising said thus obtained keratinocytes, as well as their use for treating patients suffering from thermal wounds (more particularly, severely burnt people), vascular wounds (such as ulcers), or patients suffering from pathologies associated to healing deficiencies.
The present invention will be further detailed using the description of a preferred embodiment of the invention presented by way of non-limiting illustration of the object of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The hereunder presented examples illustrate the method according to this invention. In those examples, a CGR8 murine embryonic stem cell lineage (Mountford et al., Proc. Natl. Acad. Sci. USA 91, 4303–4307 (1994)), at the blastocyste stage, has been cultivated in an undifferentiated condition in the presence of LIF (Leukemia Inhibiting Factor) (10 3 units/ml) on previously gelatinized culture dishes (0.1% in PBS) under humid atmosphere at 37° C. and under 5% CO 2 in an incubator.
The culture medium consists in GMEM/BHK21 (Glasgow's Modified Eagles's Medium—GIBCO BRL) supplemented with 10% foetal calf serum (FCS; Hyclone), 0.23% sodium bicarbonate, 1% non essential amino acids, 2 mM glutamine, 1 mM sodium pyruvate and 0.1 mM β-mercaptoethanol.
These embryonic stem cells in an undifferentiated condition are then seeded, in the absence of LIF, either on an amorphous substrate (glass or plastic material, negative control), or on gelatine, either on coated laminas of extracellular matrix from various cell types (see hereunder). Cells from epithelial origin have thereby been tested (804G lineage; Rac-11P lineage; SCC25 lineage; MCF-10 A lineage; KHSV lineage; NBT II lineage; HaCaT lineage) as well as fibroblastic cells (J2 lineage; NIH-3T3 lineage); human dermis fibroblasts in a primary culture). The epithelial lineages produce, amongst others, high laminin-5 amounts, and form in vitro numerous anchorage structures of the hemidesmosome type (Langhofer M. et al., J. Cell Science 105, 753–764 (1993)).
The embryonic stem cells have also been seeded on coated laminas only with major components of the basal laminas (purified laminin-5; collagen of the purified type IV; collagen of the purified type I; purified fibronectins).
In order to collect their extracellular matrix, the above-mentioned lineages have been cultivated at confluence on the lamellas. Once confluence has been reached, those cells are removed using a solution consisting in PBS containing 20 mM ammonium hydroxide or a HBSS (Hanks balanced salt solution, GIBCO-BRL) solution containing 20 mM EDTA, 20 mM Hepes and 1 mM EGTA) so as to only keep the extracellular matrix intact on the lamellas. The thus “coated” lamellas have been stored at 4° C.
The presence of keratinocytes has been evaluated through immunofluorescent approach with mouse monoclonal antibodies raised against the 14 (K14; Sigma) and 5 (Dr. B. Lane, Dundee University, UK) cytokeratins. The 14 and 5 cytokeratins are part of intermediary filaments specific to the basal keratinocytes. The embryonic stem cells were cultivated on sterile glass lamellas with or without extracellular matrix being deposited. After being washed with PBS, the cells were fixed using cold methanol for 10 minutes at −20° C. The cells were then washed with PBS before being incubated for one hour with the anti-K14 primary antibody (1/100 th diluted in a PBS buffer containing 3 mg/ml BSA, in a humid chamber) or with the anti-K5 primary antibody (1/5 th diluted in the same buffer, in a humid chamber). After being again washed with PBS for 5 minutes, the lamellas were incubated for one hour in the dark with a relevant secondary antibody coupled to a marker. After a final rinsing operation, the lamellas were incubated with a nuclear marker (Hoechst or propidium iodide), 1/1000 th diluted for 10 minutes away from light, and then mounted on laminas after being washed with distilled water. All operations were performed at room temperature. The laminas were observed under a “Zeiss Axiophot” microscope.
The obtained results showed that, on an amorphous support, despite a spontaneous and anarchic differentiation, the cells did not differentiate into keratinocytes, even after a 15 day culture without LIF. The results on gelatine showed that only a tiny portion of CGR8 embryonic stem cells were differentiated into keratinocytes: a keratinocyte sporadic presence could be observed after 8 days of culture and such a proportion is increased at the 15 th day, the observed keratinocytes staying predominantly isolated, without forming clusters.
The results obtained on coated laminas with a total or partial fraction of the extracellular matrix of the cellular types were found to be drastically different from the results obtained on an amorphous support.
Results Obtained on the Extracellular Matrix Originating from the Various Cellular Types being Used
A keratinocyte differentiation has been obtained on the various extracellular matrices being investigated. However, the induction efficiency variations between those various matrices require to distribute them into two distinct categories: (A) matrices with a high induction capacity; (B) matrices with an average induction capacity (also see table I).
(A) Matrices with a High Induction Capacity of the Keratinocyte Differentiation
a) Extracellular matrix produced by NHF cells: the NHF (normal human fibroblasts) were obtained from prepuce biopsies and maintained in DMEM (Dulbecco's Modified Eagles's Medium—GIBCO BRL) supplemented with 10% SVF (Hyclone). The cells were maintained in a humid atmosphere at 37° C. and under 5% CO 2 in an incubator. At confluence, the NHF cells were removed and the CGR8 embryonic stem cells were seeded on the extracellular matrix deposited by the NHF cells.
On the 8th day of culture of the CGR8 embryonic stem cells on the matrix produced by the NHFs, numerous isolated keratinocytes could be identified through immunofluorescence. On the fifteenth day, more numerous keratinocytes could be observed in big clusters (“patches”) forming some kind of an epidermal small sheet. Numerous isolated keratinocytes can also be detected.
Thus, the presence of a matrix secreted by the NHF cells causes a significant effect on the differentiation of the embryonic stem cells into keratinocytes. Indeed, whereas no differentiation could be observed in a direct culture on an amorphous substrate even after a 15-day culture, a large amount of keratinocytes is obtained in a direct culture on the extracellular matrix produced by the NHF cells. Moreover, such a differentiation is earlier than that obtained via the embryoid bodies since as early as the 8 th day of culture in a monolayer without LIF, a high proportion of keratinocytes is to be observed.
b) Extracellular matrix produced by the NIH-3T3, Rac-11P, KHSV and NBT II cellular lineages:
the above-mentioned experiment (NHF cells) was reproduced on the matrix produced by the following cellular lineages:
i) NIH-3T3: ATCC, CRL 1658. Such cells were maintained in DMEM (Dulbecco's Modified Eagles's Medium—GIBCO BRL) supplemented with 10% SVF (Hyclone). The cells were maintained in a humid atmosphere at 37° C. and under 5% CO 2 in an incubator.
ii) Rac-11P: Sonnenberg A. et al. (1996) J. Cell Science 106:1083. Such cells were maintained in DMEM (Dulbecco's Modified Eagles's Medium—GIBCO BRL) supplemented with 10% SVF (Hyclone). The cells were maintained in a humid atmosphere at 37° C. and under 5% CO 2 in an incubator.
iii) KHSV: Miquel C. et al. (1996). Exp. Cell Res. 224:279–290. Such cells were maintained in DMEM (Dulbecco's Modified Eagles's Medium—GIBCO BRL) containing 50% Ham F12 medium (GIBCO BRL) and supplemented with 10% SVF (Hyclone), 0.4 μg/ml hydrocortisone, 0.1 ng/ml cholera toxin and 10 ng/ml Epidermal Growth factor. The cells were maintained in a humid atmosphere at 37° C. and under 5% CO 2 in an incubator.
iiii) NBT II : ATCC, CRL 1655. Such cells were maintained in DMEM (Dulbecco's Modified Eagles's Medium—GIBCO BRL) supplemented with 10% SVF (Hyclone). The cells were maintained in a humid atmosphere at 37° C. and under 5% CO 2 in an incubator.
In these four other examples, similar results are obtained to those obtained with the NHF cell matrix. Indeed, the deposit of the embryonic stem cells on the coated laminas with the extracellular matrix produced by such cellular lineages leads to the appearance of K14-positive keratinocytes as early as the 8 th day of culture in a monolayer. The qualitative and quantitative differences are shown in table 1.
(B) Matrices with an Average Induction Capacity of the Keratinocyte Differentiation
a) Extracellular matrix produced by the 804G lineage: the 804G lineage, derived from epithelial cells of rat's bladder (Riddelle K S et al., J. (1991) J. Cell Biol. 112, 159–168), has been previously cultivated in DMEM (Dulbecco's Modified Eagles's Medium—GIBCO BRL) supplemented with 10% SVF (Hyclone). The cells were maintained in a humid atmosphere at 37° C. and under 5% CO 2 in an incubator. At confluence, the 804G cells were removed and the CGR8 embryonic stem cells were seeded on the extracellular matrix deposited by the 804G cells.
On the 8th day of culture of the CGR8 embryonic stem cells on the matrix produced by the 804Gs, isolated keratinocytes could be identified through immunofluorescence. On the fifteenth day, more keratinocytes could also be detected.
Thus, the presence of a matrix secreted by the 804G cells causes a significant effect on the differentiation of the embryonic stem cells into keratinocytes. Indeed, whereas no differentiation could be observed in a direct culture on an amorphous substrate even after a 15-day culture, a large amount of keratinocytes is obtained in a direct culture on the extracellular matrix produced by the 804G cells. Moreover, such a differentiation is earlier than that obtained via the embryoid bodies since as early as the 8 th day of culture in a monolayer without LIF, a high proportion of keratinocytes is to be observed. The qualitative and quantitative differences are shown in table 1.
b) Extracellular matrix produced by the SCC25, MCF-10A and HaCaT cellular lineages:
the above-mentioned experiment (804G cells) was reproduced on the matrix produced by the following cellular lineages:
i) SCC25: ATCC CRL 1628. Such cells were maintained in DMEM (Dulbecco's Modified Eagles's Medium—GIBCO BRL) containing 50% Ham F12 medium (GIBCO BRL) and supplemented with 10% SVF (Hyclone) and 0.4 μg/ml hydrocortisone. The cells were maintained in a humid atmosphere at 37° C. and under 5% CO 2 in an incubator.
ii) MCF-10A: ATCC CRL 10317. Such cells were maintained in DMEM (Dulbecco's Modified Eagles's Medium—GIBCO BRL) containing 25% Ham F12 medium (GIBCO BRL) and supplemented with 10% SVF (Hyclone), 1.5 ng/ml triiodo-L-thyronin, 5 μg/ml insulin, 0.5 μg/ml hydrocortisone, 20 μg/ml adenine, 5 μg/ml apotransferrin and 2 ng/ml Epidermal Growth Factor. The cells were maintained in a humid atmosphere at 37° C. and under 5% CO 2 in an incubator.
iii) HaCaT: Boukamp P. et al. (1988). J. Cell Biol. 106:761–771. Such cells were maintained in DMEM (Dulbecco's Modified Eagles's Medium—GIBCO BRL) containing 50% Ham F12 medium (GIBCO BRL) supplemented with 10% SVF (Hyclone) and 1% of a non essential amino acid solution. The cells were maintained in a humid atmosphere at 37° C. and under 5% CO 2 in an incubator.
In these three other examples, similar results are obtained to those obtained with the 804G cell matrix. Indeed, the deposit of the embryonic stem cells on the coated laminas with the extracellular matrix produced by such cellular lineages leads to the appearance of K14-positive keratinocytes as early as the 8 th day of culture in a monolayer. The qualitative and quantitative differences are shown in table 1.
Results Obtained with the D3 Embryonic Stem Cell Lineage on the Extracellular Matrix Produced by the Above-Mentioned Lineages
The D3 lineage (Doetschman et al., J. Embryol. Exp. Morphol. 87, 27–45 (1985)) was previously cultivated on a nutrient layer of murine embryonic fibroblasts.
Results similar to those obtained with the lineage of CGR8 embryonic stem cells have been obtained.
Results similar to those obtained with the matrices were observed using the conditioned medium of the same cellular lineages.
The method according to the present invention has therefore the advantage, compared to the hanging drop method as applied by Bagutti et al. (op. cit.) for inducing the differentiation of mouse embryonic stem cells into keratinocytes, of allowing keratinocytes to be more efficiently and more quickly obtained.
This is particularly important in cases where it is required to mass produce such keratinocytes, as for example in the case of producing artificial skin. The skin is indeed an organ consisting in three tissues from different embryological origins: the ectoderm for the epidermis, the mesoderm for the dermis and the hypodermis. The keratinocytes account for 95% of the epidermal population and they permanently renew from a basal germinal layer following a differentiation programme ending to the formation of a stratum corneum consisting of corneocytes.
The production of artificial skin is a technology aiming at treating patients suffering from thermal wounds, more particularly severely burnt people, vascular wounds such as ulcers, as well as patients suffering from pathologies associated to healing deficiencies.
Three main pattern types for regenerating human skin in laboratory are currently available and implementable: the equivalent dermis (Procacci et al., J. Inv. Dermatol. 115, 518 (2000); Bell et al., Proc. Natl. Acad. Sci. USA 76, 1274–1278 (1979); Bell et al., J. Invest. Dermatol. 81, 2s–10s (1983)), the allogenic dermo-epidermal composite skin (Burke et al., Am. Surg. 194, 413–428 (1981)) and the allogenic culture epidermis (Hansbrough et al., J. Am. Med. Ass. 262, 2125–2140). Such different patterns are prepared from primary cultures of keratinocytes and/or fibroblasts.
Whereas such patterns are well suited for pharmaceutical studies, their use for therapeutic purposes is however considered unsatisfactory for a number of surgical teams over the world, more particularly as it is associated with graft rejection (Compron et al., Lab. Invest. 60, 600–612 (1989)).
The autograft of regenerated epidermis from a cutaneous biopsy on the patient, followed by a culture of the keratinocytes for about three weeks would be the best solution as it would prevent any immunological rejection risk. However, such a solution has the disadvantage of being long to implement.
Currently, for the surgeon, the expanded allograft of corpse skin remains the best cutaneous substitute. However, this solution is not feasible in the long term because, in addition to the problem of the lack of donors, such a solution exposes the patient to a potential viral contamination.
That is why attempts have been made for providing an alternative to such methods.
Since the culture of human embryonic stem cells is from now on possible in a laboratory, the represented methods allow for the unlimited achievement of graftable regenerated epidermis without rejection risk, the embryonic stem cells having the double advantage of being “immortal” without being immortalized and of being easy to handle through transfection and homologous recombination. In order that such keratinocytes remain in the recipient patient, modifications of some loci, such as that of the genes of the major histocompatibility complex playing a part in the recognition of foreign cells by the immune system, allow to create universal immunotolerant totipotent lineages.
Effect of various matrices on the keratinocyte differentiation Matrices D8 D15 Glass − − Gelatine −/+ + NHF +++ ++++ 3T3 +++ ++++ 804G ++ ++ Racll P ++ ++++ SCC25 ++ + MCF10 +++ + KHSV +++ +++ NBTII + +++ HaCaT + +
The ES cells were deposited on matrices secreted by cells from various origins. The presence of newly formed keratinocytes was detected on 8 (D8) and 15 days (D15) through anti-keratin 14 immunomarking.
The presence of K14-positive cells is quantitatively represented by:
(−) an absence of keratinocytes; (+) a low amount of keratinocytes;
average (++), high (+++) and very high (++++) amounts of keratinocytes.
Such a quantification represents the results of various independent experiments performed in triplicate.
Effect on the Differentiation of Additives in the Culture Medium
It has been experimentally observed that the embryonic stem cells (ES cells) could be induced to differentiate from one another in keratinocytes through the addition of BMP-4 in the culture medium, whatever the substrate on which the cells are cultivated.
BMP-4 is a morphogenic protein belonging to the TGF-β superfamily. It is known that the neuroectodermal cells, during the early embryonic development, become either epidermal or neuronal, depending on the BMP-4 local concentration, the high concentration of BMP-4 enhancing the formation of the epidermis (Wilson P. et al. (1997) Development 124, 3177–3184; Chang C. et al. (1997) Development 124, 827–837).
According to the method of the invention, as soon as the LIF factor has been removed, a 0,5 nM BMP-4 solution diluted in 0,1% PBS-BSA was added to the culture medium with which the embryonic stem cells are cultivated in a monolayer, and this treatment was repeated every 2 days. It was possible to observe, through immunomarking with a anti-cytokeratin-14 antibody, the appearance of an important proportion of keratinocytes on the 15 th day of treatment.
It was also observed that if, instead of adding to the culture medium a BMP-4 solution, a solution was added in the same conditions containing 50 μg/ml ascorbic acid, an important proportion of keratinocytes on the 15 th day of treatment appeared.
In addition, the deposition in the absence of LIF of undifferentiated stem cells, cultivated on an equivalent or de-epidermized dermis, allows for the formation of a double layer of keratinocyte differentiated cells as early as the 8 th day of immersion culture. Through immunofluorescence, all the cells adhering to the dermal substrate indeed proved to be positive for the cytokeratin-14. At the end of fourteen additional days of cell culture at the air-liquid interface according to the method disclosed by Basset-Seguin N. et al. (Basset-Seguin N. et al. (1990) Differentiation 44, 232–238), it is possible to obtain a stratified epidermis having all the markers specific for the various murine epidermis cell layers, as well as the deposit by the laminin-5 basal layer at the level of the basal lamina.
Comparatively, adding BMP-4 in the culture medium of embryonic stem cells, already upon the deposit on the equivalent dermis, allows to obtain a double layer of keratinocyte differentiated cells as early as the 4 th day of immersion culture.
|
The present invention relates to a method for inducing the differentiation of mammals' embryonic stem cells into keratinocytes, comprising the following steps of:
isolating an extracellular matrix secreted by at least one mammals' cell type, cultivating mammals' embryonic stem cells in parallel in an undifferentiated condition in an appropriate culture medium in the presence of LIF, seeding the embryonic stem cells as a monolayer on said extracellular matrix, cultivating the thus seeded embryonic stem cells in the absence of LIF for a period of time sufficient for their differentiation into keratinocytes, and collecting the thus obtained keratinocytes.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an auxiliary wheel attachments for bicycles, and particularly to a frame for attaching the auxiliary wheels to the bicycle, and wherein the frame is rigid enough to be used by adults.
2. Description of the Related Art
Auxiliary or training wheels are well known for preventing the tipping of a bicycle while a novice rider, who has not yet learned to balance on the bicycle's two wheels, practices riding the bicycle. While most of these devices have been intended for children who are learning to ride a bicycle for the first time, there have been few auxiliary wheel arrangements that were designed with adults in mind. Adults who might need and use auxiliary wheels also include the elderly and the handicapped.
Most training wheel devices are light in construction, with wheel diameters that are small to be in proportion to a child's bicycle. These devices are unsuitable for an adult because of the adult's larger size and weight, and thus larger size of bicycle. Furthermore, a lack of rigidity in construction is often a problem because of the lightweight construction of the frame holding the auxiliary wheels.
U.S. Pat. No. 6,523,848, issued Feb. 23, 2003 to Liu, describes a bicycle supportive wheel mounting structure having a wheel holder frame for removably attaching the supporting wheel to the rear wheel assembly. In addition to the numerous assembly pieces employed for securing the supporting wheel, a threaded U-shaped shackle piece is used for securing a flat mounting base to a seat stay (see column 2, lines 5–25). U.S. Pat. No. 6,113,122, issued Sep. 5, 2000 to Plana, shows a stabilizer training wheel assembly for a bicycle having two side wheels connected to the rear wheel axle by a set of single structural rods. One end of each rod is attached to a training wheel. Along its length, it forms a helical torsion spring and terminates in a U-shaped attachment member. A section of the U-shaped member engages the axle of the rear wheel and is secured in place by bolts. U.S. Pat. No. 5,492,354, issued Feb. 20, 1996 to Rainey, describes an apparatus for mounting an auxiliary wheel to a bicycle. As in the patent to Plana, a single rod, which is configured into a helical spring, is formed along its length, and is used for attaching the training wheels to the rear of the bicycle. A portion of the rod forms a straight shank, which engages the wheel axle.
German Patent document 3,728,017, published Aug. 22, 1987 to Trzaska, discloses the conversion of a bicycle into a vehicle for a disabled person with the use of auxiliary wheels. Two U-shaped brackets are used to secure the device to the rear wheel axle and the bicycle frame. The device further includes stabilizing props to provide the required rigidity to the frame. U.S. Pat. No. 3,437,352, issued Apr. 8, 1967, shows a bicycle safety wheel attachment comprised of a U-bolt attached training wheel assembly. The device attaches to the rear of the bicycle frame and has stabilizing rods and uses spacers at the wheel attachment portion to ensure that the training wheels rotate freely on the device. U.S. Pat. No. 2,723,133, issued Nov. 8, 1955 to Pawsat, describes a bicycle stabilizer and a one-piece frame-axle member therefor. The device is attached to the bicycle frame near the rear wheel using U-bolts. The device includes stabilizers to give the device added rigidity and support.
Other patent documents showing training wheel devices include U.S. Published Patent Application 2002/0135146, published Sep. 26, 2002 to Hsing (inclination prevention device for preventing tipping while turning); U.S. Pat. No. 2,723,133, issued Nov. 8, 1955 to Pawsat (training wheels that attach to the bicycle frame with U-bolts); U.S. Pat. No. 2,793,877, issued May 28, 1957 to Meier et al. (training wheels with leaf springs for restoring the bicycle to vertical); U.S. Pat. No. 2,817,540, issued Dec. 24, 1957 to Pawsat (training wheel frame that provides a foot rest for a passenger); U.S. Pat. No. 4,012,054, issued Mar. 15, 1977 to Moore, (bicycle safety devices for preventing the bicycle from tipping over backwards when the front wheel is raised off the ground); U.S. Pat. No. 4,810,000, issued Mar. 7, 1989 to Saunders (training wheels which raise up and down in response to turning and leaning of the bicycle); U.S. Pat. No. 5,064,213, issued Nov. 12, 1991 to Storch (training wheels with springs that tend to keep the bicycle vertical); U.S. Pat. No. 5,338,204, issued Aug. 16, 1994 to Herndon (training wheels with a handle for raising and lowering the wheels); U.S. Pat. No. 6,318,745, issued Nov. 20, 2001 to Sharp, III (training wheels with springs that tend to keep the bicycle vertical); U.S. Pat. No. 6,398,248, issued Jun. 4, 2002 to Dodson (conventional training wheels in combination with a training handle attached to the bicycle frame); U.S. Pat. No. 6,419,256, issued Jul. 16, 2002 to Clark (turning wheels that make a noise when in contact with the ground and rotating); U.S. Pat. No. 6,488,302, issued Dec. 3, 2002 to Coates (training handle that attaches to the bicycle frame); U.S. Pat. No. 6,588,788, issued Jul. 8, 2003 to Clark (turning wheels that make a noise when in contact with the ground and rotating); United Kingdom Patent Application No. 2,104,464, published Mar. 9, 1993 to Sullivan (outrigger for two-wheeled vehicles); United Kingdom Patent Application No. 2,117,336, published Oct. 12, 1983 to Wright (training wheels with springs that tend to keep the bicycle vertical); and German Patent Document 3,302,581, published Jul. 26, 1984 to Kinkel (device for converting a conventional bicycle to a bicycle for the disabled).
None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed. Thus, an auxiliary wheel attachment solving the aforementioned problems are desired.
SUMMARY OF THE INVENTION
The auxiliary wheel attachment of the present invention includes a structurally rigid, yet lightweight frame assembly made of stock steel strip pieces that are bent into appropriate shapes and then bolted together. Using a stock steel strip, such as a strip 1½ inches wide by 3/16 inches thick, allows the frame assembly to be manufactured at a lower cost compared to custom configuration frame parts. Only simple and conventional bending and cutting techniques are necessary for fabrication of the components of the frame. Also, the wheels used for the auxiliary wheel attachment may be stock parts, for example, 8-inch diameter lawn mower wheels.
Accordingly, it is a principal object of the invention to provide a bicycle auxiliary wheel attachment that is lightweight, yet sturdy enough to support the weight of an adult.
It is another object of the invention to provide a bicycle auxiliary wheel attachment in which the height of the wheels is adjustable depending on the size of the bicycle.
It is a further object of the invention to provide a bicycle auxiliary wheel attachment wherein the components of the attachment are made from stock steel strip, and formed using conventional cutting and bending techniques.
Still another object of the invention is to provide a bicycle auxiliary wheel attachment that is simple and convenient to install on a bicycle.
It is an object of the invention to provide improved elements and arrangements thereof for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an environmental, perspective view of an auxiliary wheel attachment according to a first embodiment of the present invention.
FIG. 2 is a partially exploded view of the auxiliary wheel attachment of FIG. 1 showing how the various parts are related.
FIG. 3 is an elevational view of the auxiliary wheel attachment of FIG. 1 , with the bicycle omitted, for purposes of clarity of the figure.
FIG. 4 is an exploded perspective view of a second embodiment of the auxiliary wheel attachment.
FIG. 5 is an elevational view of the auxiliary wheel attachment of FIG. 4 , with the bicycle again omitted for purposes of clarity of the view.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the present invention is shown mounted on a bicycle in FIG. 1 . The auxiliary wheel attachment is shown in partially exploded view in FIG. 2 , and in front elevational view in FIG. 3 . Referring to FIG. 3 , a curved brace 70 comprises a generally serpentine member with three distinct straight sections integrally formed together with two curved sections. In particular, first long straight section 71 is integrally formed with a first curved section 72 . The first curved section 72 , in turn, is integrally formed with short straight section 73 . The member then leads into a reverse curved section 74 that goes into a second long straight section 75 . Each of the long straight sections 71 and 75 have two bolt holes for receiving connection bolts 78 . Holes 77 ( FIG. 2 ), at the bottom end of straight section 75 , receive axle 220 for auxiliary wheel 200 . As seen in FIG. 2 , a spacer 211 (only one is shown) may be inserted between each wheel 200 and section 75 , so that wheel 200 does not rub against its section 75 . Further, although each wheel is shown with a separate bearing 210 , it is most common in the trade to provide the wheel and bearing as an integral assembly.
Further referring to FIG. 3 , strut 80 comprises three distinct straight sections integrally formed together with two curved sections. In particular, a first short straight section 81 is integrally formed with a first curved section 82 , which is, in turn, integrally formed with long straight section 83 . Straight section 83 leads into a second curved section 84 and then into a second short straight section 85 . In each of the straight sections 81 and 85 are bolt holes for bolts 78 .
FIG. 2 shows first and second flat plates 90 and 100 . Plate 90 has two bolt holes, and plate 100 has three bolt holes 101 . Two of these bolt holes 101 are spaced apart the same distance as the distance between the legs of U-bolt 92 .
Again referring to FIG. 3 , a curved member 120 comprises three distinct straight sections and three distinct curved sections. In particular, a first short straight section 121 is integrally formed with a first large radius section 122 , which is, in turn, integrally formed with a long straight section 123 . Integrally formed at the other end of straight section 123 is a second large radius section 124 leading into a small radius section 125 . Integrally formed at the end of small radius section 125 is a second short straight section 126 . Alternatively (and preferably), the curved member can be formed with three distinct straight sections and only two distinct curved sections. The curved section 124 could be eliminated, with straight section 123 ending in the sharply bent section 125 .
FIG. 2 shows a third flat plate 160 of the invention. This plate 160 has a single bolt hole 161 in the center.
FIG. 2 also shows a U-shaped member of the invention. Two short legs 191 are integrally formed with long base 190 by radius sections 193 . In the center of base 190 is a single bolt hole, and in the center of each of the legs 191 is a bolt hole.
Referring to FIGS. 1 , 2 and 3 , the assembly of the auxiliary wheel assembly 1 will be described. The top straight sections 71 and 81 of one curved brace 70 and one strut 80 are juxtaposed with one leg 191 of U-shaped member 190 , and connected together with a bolt 78 and nut 79 through the appropriate bolt holes. The process is then repeated for the other side of the assembly. Since the second short straight section 85 of strut 80 is now juxtaposed with the appropriate bolt hole of curved brace 70 , these are connected with a bolt 78 and nut 79 on both sides of the assembly. The first straight section 121 of curved member 120 is then juxtaposed with the appropriate bolt hole of one curved brace 70 and one hole of flat plate 90 and connected together with a bolt 78 and nut 79 .
The process is repeated for the other side. Since the second short straight section 126 of curved member 120 is now aligned with the appropriate bolt hole, a bolt 78 and nut 79 are used to connect together curved brace 70 and curved member 120 , and the process is repeated for the other side. All of the nut and bolt connections are made finger tight so that there is some movement possible between the various components.
At this point the auxiliary wheel assembly is ready for attachment to the bicycle. Reference to FIGS. 1 and 2 will assist in appreciating the following discussion. The upper part of the bicycle fork 230 is sandwiched between the U-shaped member 190 and the flat plate 160 and secured with a bolt 78 and nut 79 . This connection is screwed down tightly with a wrench. One of the flat plates 100 is placed against one leg of the lower frame member 240 with the holes intended for the U-bolt 92 on either side of the leg. U-bolt 92 is then passed through the appropriate holes and secured tightly thereto with nuts 93 . This process is repeated for the other side.
It is at this point that all of the connections are tightened down with a wrench so that the auxiliary wheel assembly is made completely rigid. Finally, the wheels with bearings 210 are attached to the appropriate axle holes with axle bolts 220 , spacers 211 (if needed and used), and axle nuts 225 so that they hold the bicycle in an upright position.
A second embodiment of the invention is shown in FIG. 4 . Parts 70 , 80 , 90 , 100 , 160 and 190 are the same as described for the first embodiment above. The elements particular to the second embodiment are shown in FIGS. 4 and 5 .
FIGS. 4 and 5 show a first L-shaped member 130 . A first long straight section 131 is integrally formed substantially perpendicular to a second long straight section 133 through a small radius 132 . The second long straight section 133 is integrally formed at the other end substantially perpendicular to a short straight section 135 by a second small radius 134 . Bolt holes 136 are provided in first straight section 131 and axle hole 137 is provided in the short straight section 135 .
Further referring to FIGS. 4 and 5 , first straight brace 140 comprises a long straight section 143 integrally formed at both ends to first and second short straight sections 141 and 145 by first and second radius sections 142 and 144 .
Again referring to FIGS. 4 and 5 , a second straight brace 150 of the second embodiment of the invention is similar to the first straight brace 140 except for somewhat different proportions. A long straight section 153 is integrally formed at both ends to first and second short straight sections 151 and 155 by first and second radius sections 152 and 154 .
FIGS. 4 and 5 further show a second L-shaped member 180 . First long straight section 181 is integrally formed to first short straight section 183 by first radius section 182 . First short straight section 183 is integrally formed to second long straight section 185 by second radius section 184 . Second long straight section 185 is integrally formed substantially perpendicular to third long straight section 187 by third radius section 186 . Third long straight section 187 is integrally formed substantially perpendicular to second short straight section 189 by fourth radius section 188 . Bolt holes 196 are provided in first long straight section 181 and second long straight section 185 . Axle hole 197 is provided in second short straight section 189 .
Referring again to FIGS. 4 and 5 , assembly of the second embodiment of the invention will be described. The top straight sections 71 and 81 of one curved brace 70 and one strut 80 are juxtaposed with one leg 191 of U-shaped member 190 and connected together with a bolt 78 and nut 79 through the appropriate bolt holes. The process is then repeated for the other side of the assembly. Since the bolt hole in the second short straight section is now aligned with the appropriate bolt hole of curved brace 70 , a bolt 78 and nut 79 are used to connect them together on both sides of the assembly. Next, the plate 90 is juxtaposed with the upper bolt hole 136 of first L-shaped member 130 and the appropriate bolt hole of curved brace 70 , and bolt 78 and nut 79 used to fasten them together. Another plate 90 is then juxtaposed with the upper bolt hole 196 of second L-shaped member 180 and the appropriate bolt hole of curved brace 70 , and bolt 78 and nut 79 used to fasten them together. Second flat plates 100 are attached to first flat plates 90 with bolts 78 and nuts 79 in the holes 101 not intended for the U-bolt 92 . Then the two straight braces 140 and 150 are installed by lining up their bolt holes with the appropriate bolt holes in L-shaped members 140 and 150 and fastened with bolts 78 and nuts 79 . All connections are fastened finger tight to allow adjustment of the wheel assembly to the bicycle.
At this point, the auxiliary wheel assembly is ready to attach to the bicycle. Again, reference is made to FIG. 1 to see the bicycle parts referred to below. The wheel assembly is positioned so that the second L-shaped member 180 is adjacent the sprocket side of the bicycle wheel. The upper part of the bicycle fork 230 is sandwiched between the U-shaped member 190 and the flat plate 160 and secured with a bolt 78 and nut 79 . This connection is screwed down tightly with a wrench. The second flat plate 100 is placed against one leg of the lower frame member 240 with the holes intended for the U-bolt 92 on either side of the leg. U-bolt 92 is then passed through the appropriate holes and secured tightly thereto with nuts 93 . This process is repeated for the other side.
It is at this point that all of the connections are tightened down with a wrench so that the auxiliary wheel assembly is made completely rigid. Finally, the wheels are attached to the appropriate axle holes with axle bolts 220 , bearings 210 , and axle nuts 225 so that they hold the bicycle in an upright position. It should be noted that unless the axle bolts are disposed in the bottommost axle holes, additional bolts and nuts will be required in the bottommost holes to make the assembly completely rigid.
It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
|
The auxiliary wheel attachment for a bicycle comprises flat metal strip material forming a frame that is rigid and strong enough to support the weight of an adult rider. The use of flat strip material allows the auxiliary wheel attachment to be fabricated using conventional metal cutting and bending techniques.
| 1
|
BACKGROUND OF THE INVENTION
The invention relates to a repeating rifle having a bolt action, comprising a breech housing, a breech body which can be moved and can be rotated in this breech housing and has a movable plug and a firing pin which is loaded by a firing pin spring and has a cocking piece, in which case the breech body has in its interior a cocking guide which interacts with the cocking piece.
AT PS 759051/393 discloses, for example, such a repeating rifle in which the cocking guide is incorporated in the bolt, at the bottom. Although the bolt handle is connected by the force of the firing pin spring to the breech body without any play, no measures are taken, however, to fix it in any position. The plug, which is connected to the breech body, is designed as a bolt safety device there, and can be rotated with respect to the breech body only for this purpose. It is equipped with a trigger vane which points to the rear, for which reason it is also referred to as a vane safety device.
Despite the direct bolt safety device, this design cannot satisfy the requirements now placed on safety and operating convenience. The safety device is bulky, cumbersome and difficult to move, and, in particular, interferes with the fitting of a telescopic sight. In order to remove the breech body, the trigger must be moved forward or, alternatively, the breech body can be fitted and removed even with a weapon which has not been made safe, but both of these are dangerous. The bolt handle cannot be fixed in any position and thus also represents a safety risk since it can inadvertently be entirely or partially unlocked, for example by being placed down on a rucksack.
An externally located, separate retaining spring was admittedly used for fixing the breech body as early as 1903 in the Mannlicher-Schonauer hunting rifle. However, such a retaining spring which acts all the time is stressed even when the breech is not cocked and thus unnecessarily increases the cocking resistance on opening, which detracts from the operating convenience.
The object of the invention is thus to provide a repeating rifle of the type described above wherein maximum safety and maximum operating convenience are achieved with the minimum possible structural complexity.
SUMMARY OF THE INVENTION
The foregoing object is achieved according to the invention wherein a cocking cam bush is guided such that it can be moved in the longitudinal direction in the breech body as the cocking guide, on which cocking cam bush the firing pin spring is supported, and in that the plug has a guide sleeve which interacts with the cocking cam bush.
The interaction of the cocking bush, the firing pin spring and the guide sleeve, in which case the cocking bush is coupled in a rotationally fixed manner to the breech body which can rotate, and the guide sleeve is coupled in a rotationally fixed manner to the plug which cannot rotate, results in the bolt being fixed in various angular positions and a direct bolt safety device, without its own separate springs. In addition, the preconditions are created for a range of other operational simplifications and safety measures.
In accordance with a further feature of the invention, the cocking cam bush has a locking guide which interacts with a cam on the guide sleeve and is formed by a saddle having rising flanks adjacent thereto on both sides, in which case the cam rests in the saddle when the breech body is located in the firing position, and in which case, when the breech body rotates in either direction, the cam moves the cocking cam bush against the stress of the firing pin spring, by sliding on one rising flank, or the other.
Thanks to the locking guide, the additional bolt safety device can also be brought into effect by moving the breech body to a further angular position by movement of the bolt handle, in which case the cam is pressed against one flank of the locking guide. In this further angular position, the bolt handle is resting entirely against the weapon. The saddle in the locking guide, which is loaded by the firing pin spring, holds the breech body in the firing position in a particularly simple manner. If the breech body is rotated counterclockwise for unlocking, the cam presses against the other rising flank of the locking guide. This displaces the cocking cam bush against the force of the firing pin spring. At the same time, the cocking cam bush interacts, however, via its cocking guide with the cocking piece, as a result of which an ergonomic force profile during unlocking and cocking is achieved, even with a cocking guide form that is simple to manufacture.
In an advantageous embodiment, the cocking piece has a release plunger which points downward, and the breech body has a recess at its rear edge, in which case this recess comes to rest in front of the release plunger only when the breech body is in the firing position. The rotation between the breech body and the plug with the guide sleeve is thus additionally used for the direct bolt safety device, for which purpose only the recess need be incorporated.
There are other options for locking the breech body in the position with the bolt safety device. One particularly simple option is to arrange a latching tab in the circumferential direction on the breech body and to mount a longitudinally located slide rod, which is operated by a safety catch, on the breech housing such that it can move, in which case the latching tab is held by the slide rod when the breech body is in the transportation safety position and the safety catch is inserted. In consequence, the breech body jumps to the firing position when the safety catch is released, and the bolt safety device is removed.
In a preferred embodiment, the cocking guide and the locking guide are combined on one radius on the cocking cam bush. The cocking cam bush thus becomes a component which is particularly easy to manufacture, as well as occupying little physical space.
A further simplification and advantageous force relationships are achieved in that the combined cocking guide and locking guide extends over an angle of 180° and is present twice on the cocking cam bush, in which case the guide sleeve has two cams spaced apart by 180°, and the cocking piece has teeth which are each located between two cams In consequence, the requirement for physical space is also kept very low, and the machining process is simple.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described and explained in the following text with reference to figures, in which:
FIG. 1 shows a partial vertical longitudinal section through a repeating rifle according to the invention,
FIG. 2 shows the section along II—II in FIG. 1, reduced,
FIG. 3 shows a schematic illustration of various positions.
DETAILED DESCRIPTION
In FIG. 1, the breech housing is denoted by 1 . In its interior, this has a cylindrical guide surface 2 in which a cylindrical breech body 3 is guided such that it can be moved longitudinally and can rotate. A plug 4 is arranged behind it and can be moved with the breech body 3 in the longitudinal direction, but cannot be rotated with the latter. An end cap 5 is also fitted to the plug 4 . A firing pin 6 is guided in the interior of the breech body 3 such that it can be moved longitudinally, and a firing pin spring 7 acts on it in the firing direction, with a cocking piece 8 being attached to its rear part. A trigger housing 9 is screwed to the underneath of the breech housing 1 . Only part of this can be seen and its contents are not illustrated, in the same way as a safety catch which is likewise present and is located in the trigger housing—for example in the rear part. A breech holder 10 is guided in the trigger housing 9 such that it can be moved vertically, and is spring-loaded in the upward direction. This breech holder 10 engages in a guide groove 11 in the breech body 3 . This guide groove 11 first of all runs in the circumferential direction and then forward in the axial direction over the majority of the length of the breech body 3 . There, it forms a stop which prevents the breech body 3 from being pulled out completely when the breech holder 10 is in the position shown. Finally, 12 also denotes a catch which is mounted in the trigger housing 9 , holds the cocking piece 8 against the force of the firing pin spring 7 in the firing position, and is released to fire a shot.
For this purpose, the cocking piece 8 has a release plunger 30 underneath at its rear end. Two cocking teeth which are offset through 180° are provided at the front end of the cocking piece, an upper tooth 31 and a lower tooth 32 . When the firing spring 7 is being cocked, these teeth interact with a cocking guide 34 , which is formed on a cocking cam bush 33 . This cocking cam bush 33 can be moved longitudinally, but is guided in a rotationally fixed manner in the interior of the breech body 3 , with the firing pin spring 7 being used as an opposing bearing. At its front end, the plug 4 forms a guide sleeve 36 which can be rotated with respect to the breech body 3 , and thus with respect to the cocking cam bush 33 . However, it is connected via segments 37 in the axial direction, which are guided in an inner circumferential groove in the breech body 3 . The figure does not show interruptions in the groove, which allow disassembling in a specific angular position. A longitudinal slot 38 is provided on the underneath of the plug 4 , through which slot the release plunger 30 projects. The firing pin 6 is connected in a rotationally fixed manner through this slot 38 to the plug 4 . At its front end, the guide sleeve 36 has cams 40 (shown by dashed lines) which are offset through 180°, against which the firing pin spring 7 presses the cocking guide 34 . The interaction of the cocking cam bush 33 , cocking piece 8 and guide sleeve 36 will be returned to later. A recess 41 is provided on the rear edge of the breech body 3 and, in the firing position when the safety catch has been released, allows the release plunger 30 to move forward. In all the other safety states, the recess 41 is rotated with respect to the release plunger 30 —the firing pin cannot be actuated. This results in a safety device which acts directly on the firing pin, a so-called bolt safety device.
The cross section in FIG. 2 shows a bolt handle 45 which is integrally or permanently connected to the breech body 3 , illustrated in three different positions. In the position 45 a , the breech body 3 is unlocked and can be moved in the longitudinal direction; rotating it onward through a specific angle 44 in the clockwise direction, which angle corresponds to the construction of the interlock (which is not illustrated) of the breech body, a position 45 b is reached, which is the firing position; rotating it onward through a relatively small angle 43 , a safe-for-transportation position is reached, in which the bolt handle rests very closely against the stock, which is indicated by 50 .
The plug 4 and the breech body 3 are also located in this position 45 c . A first latching tab 46 running in the circumferential direction and a second latching tab 47 can be seen on this breech body 3 , successively in the clockwise direction. The latter latching tab is considerably broader in the longitudinal direction than the first latching tab 46 . Only part of a slide rod 24 is shown, the rest being guided on the trigger housing 9 , on which the safety catch is also located. In the position shown, the first latching tab 46 is pressed by the force of the firing pin spring—as is still to be explained—against the slide rod 24 . The breech body 3 is thus held firmly in the safe-for-transportation position. Moving the slide rod 24 by means of the safety catch, which is not illustrated, releases the first latching tab 46 , and the breech body 3 jumps to the firing position, corresponding to the bolt handle position 45 b . In this position, the second latching tab 47 rests against the slide rod 24 . A turned-out region 49 , which is wedge-shaped in the circumferential direction, is provided to create space for the two latching tabs 46 , 47 in the breech housing 1 .
FIG. 3 shows the cocking guide 34 , which is spread out in the plane, of the cocking cam bush 33 . In the chosen representation of the various positions, it is fixed, the illustration showing a cam 40 on the guide sleeve 36 as well as the upper cocking tooth 31 of the cocking piece 8 in the various positions. In this case, the directional arrow 61 corresponds to a movement of the bolt handle 45 counterclockwise. In the preferred embodiment shown, the locking guide 51 and the cocking guide 52 are arranged in a row and there are two of them on the entire circumference since, in fact, there are also two cams 40 and cocking teeth 31 , 32 , offset through 180° with respect to one another.
The locking guide 51 consists of a saddle 53 with, adjacent to it on both sides, a first flank 54 and a second flank 55 , and, finally, a rounded region 56 which is followed by a steep grade 57 to the base 58 of the cocking guide 52 .
The cocking guide 52 then has a cocking ramp 59 , whose highest point follows a latch 60 . The various positions are denoted by numbers from 1 to 4 , and the reference symbols of the cocking tooth 31 and cam 40 are followed by an oblique line.
In the position 1 , the rifle is ready to fire. The bolt handle 45 is in the position b in FIG. 2; the cocking tooth 31 / 1 is held by the catch 12 (FIG. 1 ); the cam 40 / 41 is located in the saddle 53 . The cocking tooth 31 / 1 is located above the base 58 of the cocking cam.
If a shot is fired, the cocking piece 8 jumps forward, and the cocking tooth moves to the second position 31 / 2 .
In order to cock the firing pin spring and at the same time to unlock the breech body 3 , the bolt handle is rotated counterclockwise (arrow 61 ), during which two things happen: the cocking tooth 31 is pushed back along the cocking ramp 59 , the firing pin spring 7 being cocked, beyond the highest point into the position 31 / 3 , in which there may be, but need not be, a catch 60 . At the start of this rotational movement, the cam 40 must also move out of the saddle 53 along the first flank 54 and then continue without any longitudinal movement, until it comes to rest behind the rounded region 56 in the position 40 / 3 . During the first phase of this movement, the cocking cam bush 33 is, however, in fact forced to the left, as a result of which the cocking ramp 59 also moves somewhat backward. In consequence, the ergonomically favorable action of a sinusoidal shape is achieved, despite the straight cocking ramp 59 . By suitable selection of the rounded region 56 and/or of the catch 60 , the relevant parts are held in the indicated position even during the displacement movement which now follows, for loading.
If the bolt handle is now rotated to the firing position again, then the cam 40 once again moves out of the position 40 / 3 back to the position 40 / 1 , the saddle 53 once again marking the firing position. At the same time, the cocking tooth 31 once again moves back from the position 31 / 3 to the position 31 / 1 . In the process, it not only moves through the distance 44 ′ which corresponds to the angle 44 in FIG. 2, but is also moved backward somewhat. The reason for this is the locking movement of the breech, during which the firing pin spring 7 is tensioned further after striking against the catch 12 (FIG. 1 ).
If the safe-for-transportation position is now intended to be assumed, then the bolt handle 45 is rotated in the clockwise direction again through 43 ′, corresponding to the angle 43 in FIG. 2 . In the process, the cam 40 moves from the position 40 / 1 to the position 40 / 4 , having to climb up the second flank 55 against the force of the firing pin spring 7 . This position is then held owing to the fact that the first tab 46 shown in FIG. 2 is held by the slide rod 24 when the latter is in the safe-for-transportation position. If it is moved from this position, then the cam 40 snaps back into the saddle 53 once again, owing to the force of the firing pin spring 7 .
|
A repeating rifle having a bolt action comprises a breech housing ( 1 ), a breech body ( 3 ) which can be moved and can be rotated in this breech housing ( 1 ) and has a movable plug ( 4 ) and a firing pin ( 6 ) which is loaded by a firing pin spring ( 7 ) and has a cocking piece ( 8 ), in which case the breech body ( 3 ) has in its interior a cocking guide which interacts with the cocking piece ( 8 ). In order to achieve maximum safety and maximum operating convenience with as little physical complexity as possible, a cocking cam bush ( 33 ) is guided such that it can be moved in the longitudinal direction in the breech body ( 3 ) as the cocking guide, on which cocking cam bush the firing pin spring ( 7 ) is supported, and the plug ( 4 ) has a guide sleeve ( 36 ) which interacts with the cocking cam bush ( 33 ).
| 5
|
TECHNICAL FIELD
[0001] The invention relates to a device for reducing noise and heat emissions, which can be used for various types of instruments, in particular for laboratory instruments of the kind employed in laboratories.
BRIEF DESCRIPTION OF RELATED ART
[0002] Laboratory instruments are used in many industrial and scientific processes, e.g., in analysis of the chemical and pharmaceutical industries. Such laboratory instruments are used for different purposes, e.g., for chromatography or spectroscopy, and comprise various types of instruments, such as chromatographs (gas chromatographs, liquid chromatographs, thin-film chromatographs, anion-exchange chromatographs, etc.), spectroscopes (prism spectrometers, grating spectrometers, infrared spectrometers, atomic absorption spectrometers, electron energy loss spectroscopes, time-of-flight spectrometers, mass spectrometers, optical emission spectrometers (OES), spectral analyzers, radiation detectors, semiconductor detectors, etc.) and particle accelerators (linear accelerators, Van de Graaff accelerators, tandem accelerators, dynamitrons, cyclotrons, betatrons, etc.).
[0003] So that they can be easily monitored, serviced and maintained, such laboratory instruments are set up usually in a laboratory, typically on a table, where people are simultaneously present for work purposes. Such laboratory instruments often generate noise and emit heat to the environment. This noise and emitted heat can disturb working people and negatively affect their work. In addition, several such laboratory instruments are frequently located in a single laboratory, so that noise and heat from several instruments act on people present in the laboratory at the same time.
[0004] The negative effects of noise and heat emissions on humans are sufficiently known, and have been investigated in various studies. For example, a sound that is perceived as an annoyance due to noise and persists over a prolonged period of time can reduce performance and well-being, and put stress on the body. This can end up leading to hypertonia (high blood pressure), cardiocirculatory diseases and myocardial infarction (heart attack), or reduce gastric secretion, giving rise to peptic ulcers. Other consequences of noise exposure include an elevated risk of accident resulting from a masking of warning signals.
[0005] Another problem that can be encountered in the mentioned laboratory instruments is that use is often made of auxiliary units that also cause significant noise and heat emissions. For example, numerous laboratory instruments, as for example particle accelerators, utilize vacuum pumps. As opposed to the laboratory instruments themselves, these auxiliary units usually require less monitoring, servicing and maintenance. For this reason, they are frequently positioned close to the accompanying laboratory instruments to enable easy connections with the laboratory instruments, but without satisfying any special requirements as to ready accessibility. For example, one common configuration involves positioning the laboratory instrument on a table, and placing the accompanying auxiliary unit or accompanying auxiliary units under the same table.
BRIEF DESCRIPTION OF THE INVENTION
[0006] According to the invention, a device is provided for reducing noise and heat emissions from a laboratory instrument in a laboratory as characterized by the features of the independent claim.
[0007] Advantageous embodiments of the device according to the invention are described in the features of the dependent claims.
[0008] In particular, the device comprises a casing with sound-absorbing walls, wherein the casing forms an interior space for accommodating the laboratory instrument. At least one of the sound-absorbing walls has an air inlet, and the device has a flue connected with one of the sound-absorbing walls, so that the interior space of the casing is ventable via the air inlet and the flue. During operation of the laboratory instrument located inside the interior space of the device, the sound it generates is absorbed by the walls, so that essentially no noise, or only significantly reduced levels of noise, of the laboratory instrument can escape the device. Depending on the type of used laboratory instrument, the device can also comprise buffers, on which the laboratory instrument can be placed to reduce vibrations and noise. To prevent noise of escaping from the connection between the walls out of the device as well, the walls are, to more or less an extent, soundproofly interconnected. The walls and their connections are additionally arranged in such a way that essentially no heat generated by the laboratory instrument can escape the device. By means of the air that flows into the interior space through the one air inlet, or preferably through several air inlets, and that is again evacuated through the flue, waste heat produced by the laboratory instrument can be removed from the device. Such a device makes it possible to operate a laboratory instrument in a laboratory without people located in the laboratory being significantly impaired by waste heat and/or noise from the laboratory instrument.
[0009] Thereby, the flue can be connected with a ventilation system, e.g., a building ventilation system, so that the waste heat produced by the laboratory instrument can be removed from the laboratory without warming up the laboratory itself. By connecting the flue with a building ventilation system, the waste heat can be simultaneously used to heat the air being delivered into the building. The flue preferably has a flue connection piece on one of the walls for connecting the flue and ventilation system in this way.
[0010] The flue preferably has a fan, wherein the flue can be arranged as a pipe that houses the fan. The fan can route air from the interior space through the flue to the outside thereby generating an underpressure in the interior space. As a result of this underpressure, new air from outside the device is conveyed through the air inlet into the interior space continuously ventilating the interior space. The pipe can be set up within the interior space in such a way that the air flows through the interior space optimized to cool the laboratory instrument.
[0011] The device preferably has an insulation shell that covers the air inlet from the interior space of the casing. On one hand, such an insulation shell can be used to divert the air streaming in through the air inlet in a preferred manner, so that the interior space can be ventilated, and hence cooled, as effectively as possible. On the other hand, such an insulation shell can be used to effectively dampen noise penetrating through the air inlet from the interior space. Thereby, the insulation shell can have a sound dampening layer arranged on a plate, e.g., a plate made out of metal.
[0012] Preferably the interior space is separated by an intermediate wall into a first interior space and a second interior space. Thereby, the intermediate wall has an air passage that connects the first interior space with the second interior space. Thereby, the insulation shell is arranged to divert air streaming through the air inlet into the interior space in such a way that the air is routable through the air passage, and both the first interior space and the second interior space are ventilatable via the air inlet and the flue. In such a configuration, another instrument can be arranged in the same device separately from the laboratory instrument, wherein the first interior space is preferably situated on top of the second interior space. In particular when using the laboratory instrument, e.g., a particle accelerator, and an auxiliary unit belonging thereto, e.g., a vacuum pump, the auxiliary unit can hence be placed in the lower second interior space, and the laboratory instrument in the upper first interior space. The higher location of the first interior space makes the laboratory instrument readily accessible to a person for monitoring, servicing and maintenance.
[0013] The air inlet is here advantageously situated in the area of the second interior space. Thereby, the air passage has at least one inlet passage to route air from the second interior space into the first interior space, and at least one outlet passage to route air from the first interior space into the second interior space. As a result, the air can be routed in a preferred manner through both the first interior space and the second interior space, thereby yielding a continuous circulation of air through the first interior space and the second interior space.
[0014] The insulation shell preferably comprises a first shell section, which covers the air inlet from the second interior space, and a second shell section, which covers the air passage, and in particular its at least one inlet passage, from the second interior space, wherein the first shell section is tightly connected with the second shell section. Such an insulation shell can be used to route the air through the air inlet into the second interior space, from there along the first shell section and second shell section through the air passage into the first interior space, and from there in turn out of the first interior space via the flue.
[0015] In an embodiment of the air passage with an inlet passage and outlet passage, another insulation shell can also cover the at least one outlet passage from the interior space, wherein it can also be connected with the flue. As a result, the exhaust air exiting the first interior space via the outlet passage can be directly removed form the device without having to pass through and perhaps heat the second interior space.
[0016] The casing advantageously has a frame and panels arranged therein, which are sealedly connected with the frame. Since laboratory instruments and their auxiliary units are typically relatively heavy, the device preferably has a stable design. Such a frame can be used to easily impart the corresponding structural stability to the device. The frame, e.g., one made out of steel, can also be partially hollowed out to keep the weight of the device down as much as possible.
[0017] The panels preferably have a wood core mounted in steel elements, in particular a wood core made out of compressed wood. Such panels, in particular ones sealed with steel plates, have preferred sound absorption properties and heat retention properties on one hand, and enable a stable configuration of the device on the other hand, making it suitable for relatively heavy laboratory instruments.
[0018] The flue preferably has a fan, which is controllable by means of a temperature sensor. Thereby, the temperature sensor is preferably situated in the interior space. A controller regulates the speed of rotation of the fan, so that more air is conveyed through the device when the temperature sensor detects a higher temperature, and less air is conveyed through the device when the temperature sensor detects a lower temperature.
[0019] One of the casing walls can be arranged as a door for opening the interior space, wherein preferably at least two of the walls are arranged as doors, so that both the first interior space and second interior space can be opened. Such doors, each being tightly sealed when closed, can be used to easily gain access to the first interior space or the second interior space, respectively. Since the doors can be relatively heavy, e.g., when made out of a wood core mounted in steel plates, the device preferably has gas springs for support in opening and closing the doors.
[0020] Rolls are advantageously arranged on the casing for moving the device. Since the device can be very heavy as described above, e.g., weighing roughly 500 kilograms, and additionally heavy laboratory instruments and auxiliary units can also be arranged in the device, such rolls allow a person to move the device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Additional advantageous embodiments of the invention can be gleaned from the following description of exemplary embodiments of the invention with the help of the schematic drawing, wherein
[0022] FIG. 1 shows a side view of a first exemplary embodiment of a device according to the invention for reducing noise and heat emissions from a laboratory instrument in a laboratory;
[0023] FIG. 2 shows a front view along line C-C of the device from FIG. 1 ;
[0024] FIG. 3 shows a rear view along line D-D of the device from FIG. 1 ;
[0025] FIG. 4 shows a sectional view along line A-A of the device from FIG. 1 ;
[0026] FIG. 5 shows a sectional view along line B-B of the device from FIG. 1 ;
[0027] FIG. 6 shows a sectional view along line E-E of the device from FIG. 4 ;
[0028] FIG. 7 shows a side view of a second exemplary embodiment of a device according to the invention for reducing noise and heat emissions from a laboratory instrument in a laboratory;
[0029] FIG. 8 shows a side view of the device according to FIG. 7 opposite the side view from FIG. 7 ;
[0030] FIG. 9 shows a sectional view along line A-A of the device from FIG. 7 and FIG. 8 ;
[0031] FIG. 10 shows a sectional view along line B-B of the device from FIG. 7 and FIG. 8 ;
[0032] FIG. 11 shows a front view along line C-C of the device from FIG. 7 and FIG. 8 ; and
[0033] FIG. 12 shows a rear view along line D-D of the device from FIG. 7 and FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
[0034] Certain terms are used in the following description for practical reasons, and must not be construed as limiting. The words “right”, “left”, “bottom” and “top” denote directions in the drawing to which reference is made. The terms “inward” and “outward” denote directions toward or away from the geometric midpoint of the device and specified parts thereof. The terminology comprises the words expressly mentioned above, derivations of the latter, as well as words similar in meaning.
[0035] FIG. 1 shows a side view of a first exemplary embodiment of a device 1 according to the invention having a casing 2 with a frame 23 and panels 24 arranged therein. The panels 24 are tightly connected with the frame 23 in such a way as to form an upper first interior space 21 and a lower second interior space 22 separated from it by an intermediate wall (not visible on FIG. 1 ). The panel 24 of the first interior space 21 shown in the side view on FIG. 1 is arranged as a swinging gate 241 , which can be swiveled up by means of two gas springs 5 , so that the first interior space 21 can be opened, making it accessible from the side. The panel 24 of the second interior space 22 shown in the side view on FIG. 1 accommodates an air inlet 3 , through which air can stream into the second interior space 22 . The device 1 has a flue connection piece 43 that projects over the casing 2 , as shown on the right side of the side view on FIG. 1 .
[0036] The following statement applies to the entire remaining description. If, for purposes of clarity in the drawing, a figure contains reference signs but these are not mentioned in the text of the description relating directly thereto, reference is made to their explanation in preceding figure description.
[0037] FIG. 2 shows a front view of the device 1 , wherein the side view of the device 1 shown in FIG. 1 with the air inlet 3 is on the right side. FIG. 2 also depicts specific elements located inside the device 1 with dashed lines. The first interior space 21 is sealed off to the front by two horizontally adjacent panels 24 , wherein the right panel 24 is designed as a door 242 secured to the frame 2 by two hinges 243 . All doors 242 and swinging gates 241 open in directions denoted by the curved arrows in the drawings. The mentioned door 242 of the first interior space 21 can be swiveled to the right, so that the first interior space 21 can be opened and also accessed from the front side. The second interior space 22 is also sealed to the front by two horizontally adjacent panels 24 , wherein both panels are designed as doors 242 each secured to the frame 2 by two hinges 243 . The two doors 242 of the second interior space 22 can be swiveled outwardly, so that the second interior space 22 can also be opened and accessed from the front. As denoted by the gas spring 5 and correspondingly curved arrow, the panel on the side of the first interior space 21 opposite the side shown on FIG. 1 is designed as a swinging gate 241 .
[0038] Between the first interior space 21 and the second interior space 22 an air passage 8 is arranged, which has edge passages 81 located toward the left or right end of the device 1 as inlet passages, and two central passages 82 arranged in the middle as outlet passages. A vertical first shell section 61 of an insulation shell 6 covers the air inlet 3 to the inside. The insulation shell 6 has a sheet to which an insulating material is applied. A horizontal second shell section 62 forms a tight upper seal with the first shell section 61 , and covers the central passages 82 . A horizontal third shell section 63 is situated below, spaced apart from the first shell section 61 .
[0039] The interior space 22 also incorporates a flue 4 , which comprises a pipe 41 that is connected airtight with the second shell section 62 at its one end, and empties in the flue connection piece 43 at its other end. To the pipe 41 a fan 42 is arranged, which is functionally connected with the pipe 41 in such a way that the fan 42 can convey air in the direction of the flue connection piece 43 through the pipe 41 . The floor of the second interior space 22 has a horizontally buffered receptacle 7 for carrying an instrument that can absorb vibrations and sound produced by a device.
[0040] FIG. 3 shows a rear view of the device 1 . The first interior space 21 and the second interior space 22 each are sealed to the back by respective two horizontally adjacent panels 24 . The right panel 24 of the first interior space 21 is a door 242 secured by two hinges 243 to the frame 2 , which can be swiveled to the left, so that the first interior space 21 can be opened and also accessed from the back. The flue connection piece 43 is situated on the right panel 24 of the second interior space 22 .
[0041] In FIG. 4 a top view into the second interior space 22 is shown. The two edge passages 81 and the two central passages 82 each exhibit a grid 811 and 821 .
[0042] FIG. 5 shows a view on the intermediate wall 9 , which is tightly connected with the frame 23 and separates the first interior space 21 from the second interior space 22 . The intermediate wall 9 exhibits perforated screens 812 and 822 that abut the grids 811 of the edge passages 81 and the grids 821 of the central passages 82 . The intermediate wall 9 also has cable passages 91 and line passages 92 , which can be used to arrange cables or lines so that the first interior space 21 tightly adjoins the second interior space 22 .
[0043] In FIG. 6 the design of the flue 4 is shown, wherein the pipe 41 is connected with the second shell section 62 in such a way as to let air through, and empties into the flue connection piece 43 .
[0044] During operation of the device 1 , a laboratory instrument, e.g., a particle accelerator, can be arranged in the first interior space 21 on the intermediate wall 9 , and an auxiliary unit, e.g., a vacuum pump, can be accommodated on the receptacle 7 in the second interior space 22 . The laboratory instrument can be tightly wired with the auxiliary unit via the cable passages 91 , which may be necessary for controlling the power of the auxiliary unit, for example. The auxiliary unit can be tightly connected with the laboratory instrument in terms of function via the line passages 92 . For example, a vacuum line can be routed from the vacuum pump to the particle accelerator, and used by the vacuum pump to generate a vacuum in the particle accelerator required for operating the particle accelerator. The described configuration of the casing 2 in the area of the first interior space 21 makes it possible to open the first interior space 21 of the device 1 from all sides. As a result, the laboratory instrument can also be accessed from all sides, which is important for the simple monitoring, servicing and maintenance of the laboratory instrument.
[0045] Since the laboratory instruments and their auxiliary units are typically relatively heavy, the device 1 is massive and stable in design. The frame 23 is made out of hollow steel carriers, while the panels 24 consist of laminated wood plates mounted in steel plates. In addition to the mentioned advantageous bearing characteristics of such panels, the latter also absorb a relatively high level of sound, and are relatively poor conductors of heat, so that essentially no waste heat and noise from the laboratory instrument and auxiliary unit can exit the device 1 through the sealed casing 2 . Because the air inlet 3 of the device 1 is covered by the insulation shell 6 , the noise escaping through the air inlet 3 and heat exiting the air inlet 3 can also be minimized.
[0046] In order to cool the first interior space 21 and the second interior space 22 , heated air is relayed through the central passages 82 , the pipe 41 and the flue connection piece 43 out of the first interior space 21 and out of the device 1 by the fan 42 . This produces an underpressure in the first interior space 21 , effecting that fresh air is conveyed through the air inlet 3 on one hand along the first shell section 61 and on the other hand through the second interior space 22 via the two edge passages 81 into the first interior space 21 . As a result, air can be continuously circulated in the device 1 , making it possible to cool the laboratory instrument and the auxiliary unit. The flue connection piece 43 is ideally connected directly with the building ventilator, so that no waste heat can get into the laboratory in which the device 1 is located.
[0047] FIG. 7 shows a side view of a second exemplary embodiment of a device 10 according to the invention having a casing 20 with a frame 230 and panels 240 located therein. The panels 240 are tightly connected with the frame 230 so as to form an upper first interior space 210 and a lower second interior space 220 separated from it by an intermediate wall (not visible on FIG. 7 ). The panel 240 of the interior space 210 shown in the side view on FIG. 7 is arranged as a door 2420 secured to the frame 230 by two hinges 2430 , which can be swiveled to the right as shown by the curved arrow, so that the first interior space 210 can be opened, and hence accessed from this side. The interior space accommodates a gas spring 50 , with which the swinging gate 2410 shown on FIG. 11 can be opened. An air inlet 30 is arranged on the panel 240 of the second interior space 220 shown in the side view on FIG. 7 , through which air can stream into the second interior space 220 . On the right of the side view on FIG. 7 , the device 10 has a flue connection piece 430 that projects over the casing 20 .
[0048] In FIG. 8 a side of the device 10 opposite the side view presented on FIG. 7 is shown, which is essentially similar to the side of the device 10 shown on FIG. 7 , except that two horizontally adjacent panels 240 seal the first interior space 21 . The right one of these two panels 240 is here arranged as a door 2420 secured to the frame 230 by two hinges 2430 , which can be swiveled to the right as shown by the curved arrow, so that the first interior space 210 can be opened, and hence also accessed from this side. The two doors 2420 each have cable passages 2440 .
[0049] FIG. 9 shows a top view of the second interior space 220 , in which two vertical first shell sections 610 are arranged that each cover one of the two air inlets 30 , and each are tightly connected with a horizontal outer second shell section 620 a . A central second shell section 620 b is arranged in the middle of the device 10 . A grid 8110 is situated above each of the two outer second shell sections 620 a . Two parallel grids 8210 are positioned above the central second shell section 620 b . Further, a flue 40 with a pipe 410 is located in the second interior space 220 . The pipe 410 is connected with the central second shell section 620 b and flue connection piece 430 in such a way as to let air through. At the pipe 410 a fan 420 is arranged, which can convey air through the pipe 410 from the central second shell section 620 b out of the flue connection piece 430 .
[0050] FIG. 10 shows a top view of an intermediate wall 90 that is tightly connected with the frame 230 , and separates the first interior space 210 from the second interior space 220 . The intermediate wall 90 exhibits perforated screens 8120 and 8220 that each abut the grids 8110 and 8210 .
[0051] FIG. 11 shows the front side of the device 10 , while FIG. 12 shows the rear side. Respective two horizontally adjacent panels 240 seal the first interior space 210 each two on the front side of the device 10 and on the rear side of the device 10 . The right panel 240 on the front side is here arranged as a swinging gate 2410 , while the left panel 240 on the front side and the right panel 240 on the rear side each are arranged as doors 2420 each secured to the frame 230 by two hinges 2430 . Respective two horizontally adjacent panels 240 also seal the second interior space 220 each two on the front side of the device and on the rear side of the device 10 . The right panel 240 on the front side and the two panels 240 on the rear side are here arranged as doors 2420 each secured to the frame 230 by two hinges 2430 .
[0052] The two air inlets 30 are each covered by one of the two first shell sections 610 of an insulation shell 60 . The lower end of the left of the two first shell sections 610 is tightly connected with a horizontal third shell section 630 , while the lower end of the right of the two first shell sections 610 is connected at a distance with another horizontal third shell section 630 . Situated between the first interior space 210 and the second interior space 220 an air inlet 80 is arranged, which exhibits two lateral edge passages 810 and two middle central passages 820 . The two outer second shell sections 620 a each cover one of the two edge passages 810 , and the central second shell section 620 b covers the two central passages 820 .
[0053] Corresponding to the first exemplary embodiment of the invention described above, during operation of the device 10 , a laboratory instrument, e.g., a particle accelerator, can be arranged in the first interior space 210 on the intermediate wall 90 , and an auxiliary unit, e.g., a vacuum pump, in the second interior space 220 . The described configuration of the casing 20 in the area of the first interior space 210 allows the first interior space 210 of the device 10 to be opened from all sides. As a result, the laboratory instrument can also be accessed from all sides, which in turn can be important for the simple monitoring, servicing and maintenance of the laboratory instrument. The massive, sound-absorbing and heat-impermeable construction of the frame 20 , panels 240 and insulation shell 60 is also corresponding to the first exemplary embodiment.
[0054] In order to cool the interior space 210 and second interior space 220 , heated air is relayed through the central passages 820 , the pipe 410 and the flue connection piece 430 out of the first interior space 210 and out of the device 10 by the fan 420 . This produces an underpressure in the first interior space 210 , effecting that fresh air is conveyed through the two air inlets 30 on one hand along the two first shell sections 610 and on the other hand through the second interior space 220 via the two edge passages 810 into the first interior space 210 . As a result, air can be continuously circulated in the device 10 , making it possible to cool the laboratory instrument and auxiliary unit. The flue connection piece 430 is ideally connected directly with the building ventilator, so that no waste heat can get into the laboratory in which the device 10 is located.
[0055] Additional structural variations of the devices according to the invention described above can be realized. Express mention is made of the following ones:
[0056] The device can also have just a single interior space, which can be advantageous in particular when using laboratory instruments that require no auxiliary units.
[0057] The doors and swinging gates of the device can be optimized to suit device application.
[0058] Other materials can be used for the panels and the frame, depending on the laboratory instrument used. For example, the materials can be optimized to the weight of the laboratory instrument and/or its noise and heat production.
|
A device ( 10 ) for reducing noise and heat emissions from a laboratory instrument in a laboratory, comprising a casing ( 20 ) with sound-absorbing walls ( 240 ), wherein the casing ( 20 ) forms an interior space ( 210, 220 ) for accommodating the laboratory instrument. At least one of the sound-absorbing walls ( 240 ) has an air inlet ( 30 ). The device ( 10 ) further has a flue ( 40 ) arranged on one of the sound-absorbing walls ( 240 ), so that the interior space ( 210, 220 ) of the casing ( 20 ) can be vented via the air inlet ( 30 ) and the flue ( 40 ). During operation of the laboratory instrument situated in the interior space ( 210, 220 ) of the device ( 10 ), the sound generated by the laboratory instrument is absorbed by the walls, so that essentially no noise, or only significantly reduced levels of noise, generated by the laboratory instrument can escape the device ( 10 ). The walls ( 240 ) and their connections are also designed in such a way that essentially no heat generated by the laboratory instrument can escape the device ( 10 ). The air that flows into the interior space through the one air inlet ( 30 ), or preferably through several air inlets ( 30 ), being again evacuated through the flue ( 40 ) makes it possible to remove waste heat produced by the laboratory instrument from the device. Such a device ( 10 ) makes it possible to operate a laboratory instrument in a laboratory without people located in the laboratory being significantly impaired by waste heat and/or noise from the laboratory instrument.
| 4
|
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to hip joints and freeing of attachment elements thereof, and more particularly concerns freeing of hip joint liners from sockets to which they have become attached, over time.
[0002] There is need for a safe, easily and quickly performed method of freeing a hip joint liner from a socket to which it has become attached. This is particularly needed where metallic surfaces of the liner and socket have become attached, as for example after extensive rubbing or frictional contact. There is particular need for the method and apparatus as defined herein.
SUMMARY OF THE INVENTION
[0003] It is a major object of the invention to provide improved method and apparatus meeting the above needs. Basically, the method of the invention for removing a hip socket liner from surface attachments to a socket, includes:
[0004] a) providing a carrier and multiple penetrators carried to be displaced relative to the carrier,
[0005] b) applying the carrier to the liner so that the penetrators project toward a liner cup-shaped inner surface,
[0006] c) effecting controlled and limited forceful displacement of the penetrators so that tips defined by the penetrators penetrate said liner cup-shaped surface,
[0007] d) and transmitting jarring force to one of the liner and carrier whereby the liner is suddenly freed from said attachment to the socket. The freed liner is then withdrawn relative to the socket.
[0008] The cup-shaped interior surface is metallic, and outer surface attachment is spaced from said cup-shaped surface. At least three tips are typically employed (to penetrate directionally substantially normal to the cup-shaped liner surface.
[0009] A further object is to provide means to pull the carrier away from the liner to drag the liner, via the tips, free of engagement with the socket.
[0010] A further object is to provide axial force, and/or prying force, and/or vibration to assist liner extraction.
[0011] These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which:
DRAWING DESCRIPTION
[0012] FIG. 1 is a section taken through a cup-shaped acetabulum having a liner to be detached from the cup socket, and a carrier for penetration, received in the cup;
[0013] FIG. 2 is a view like FIG. 1 , showing forcible displacement of the penetrators to push the tips into the liner inner surface;
[0014] FIG. 3 is a view like FIG. 2 , but showing axial forcible detachment of the liner by axial displacement of the carrier and tips, directionally away from the acetabulum socket; and
[0015] FIG. 4 is a section showing position of penetrator tip penetration into the liner.
[0016] FIG. 5 is a view like FIG. 3 , but showing provision and use of means to push the liner free of the socket;
[0017] FIG. 6 is a plan view of a bracket useful in such pushing;
[0018] FIG. 7 is a view taken on lines 7 - 7 of FIG. 6 ; and
[0019] FIG. 8 is an edge view of under-cut structure facilitating prying and pushing apart of the liner and socket.
DETAILED DESCRIPTION
[0020] In FIG. 1 , a generally hemispherical acetabulum 10 has an inner cup-shaped surface 10 a. A liner 11 fits in the acetabulum, and has an outer convex ball shaped surface 11 a that becomes attached, over time, to the surface 10 a. During hip replacement surgery, it becomes necessary to remove liner 11 , which is difficult and prevents many problems.
[0021] In accordance with the invention, a carrier 13 is provided and sized to be axially received or inserted closely within the space surrounded by the liner interior cup-shaped surface 11 b. The common axis shown at 14 . Multiple penetrators 15 (at least three, but up to six) are carried by 13 , within generally radial through openings 16 in the carrier. Those penetrators have shafts 15 a movable endwise in the openings 16 , and shaped tips 15 b which are sharp, and presented toward the liner interior surface 11 b, at spaced locations about axis 14 . Those locations are preferably equally spaced about axis 14 . At that time, the carrier may endwise engage the liner, as at axial location 17 .
[0022] Means is provided for effecting controlled limited forceful outward displacement of the penetrators, so that their sharp tips are displaced toward and into the material of the liner cup-shaped surface lib. The tips are typically metallic, and harder than the liner material, which may also be metallic, to enable limited tip penetration into the liner. This condition is show in FIG. 2 and also FIG. 4 . Such displacement is typically effected by penetrator shaft end engagement with the outer tapered surface 26 a of a cam 26 , that surface being threaded conical, as shown. The cam is carried by a trapped shaft 43 to be rotated as indicated by arrow 30 . The shaft threading 43 a may engage the bore threads at 31 of a carrier wall 32 . That wall may also engage the rim 33 of the acetabulum part, as shown at 32 a, to position the cam.
[0023] As the penetrators are forced outward, they penetrate the liner as at grip locations 34 , see in FIG. 4 , which are located at equal spacing 35 a about axis 14 . Typically penetration is between 1/64 and ⅛ inch.
[0024] Thereafter, the carrier is forcibly pulled or displaced to the left, as in FIG. 3 , which effects simultaneous leftward bodily displacement of the penetrators, their tapered tips, and the liner 11 gripped by the tips. Subsequently the shaft 43 is rotated in the opposite direction, to allow inward bodily displacement of the penetrators and tips, freeing the liner from the carrier. The acetabulum may be held in position, as by a holder 60 , during such extraction of the liner. The penetrator tips are tapered so as to release from the liner as the cam 26 is displaced by shaft 43 rotation, as referred to. If desired, the assembly can be vibrated, as by tuning fork high frequency vibrator means so to assist jarring loose of the liner.
[0025] FIG. 1 also shows a puller hook 70 attached to the shaft 43 , to be pulled to assist forcible extraction of the liner from the acetabulum. Alternatively, a prying tool or blade 71 may be inserted into a notch 72 between the acetabulum and carrier, and twisted, to assist liner extraction.
[0026] Referring to FIG. 5 , it shows provision of means for transmitting pushing force acting between the carrier 13 and the hip socket 10 whereby the liner 11 is suddenly and/or forcibly freed from attachment to the socket. As shown, a pusher 80 , when rotated pushes the carrier to the left, in the direction of arrow 81 , whereby the pusher has operative connection to the carrier. Such a connection is shown in the form of a threaded connection 82 , typically made up after the carrier has been connected to the liner by rotation of screw 43 to effect carrier displacement of the penetrators 15 into the liner, at the tips of the penetrators.
[0027] A nut 84 has external thread 85 that is made up into internal thread 86 on the carrier annular part 87 , to make up connector 82 . This causes the pusher nut to initially move to the right until it is stopped by engagement with the end 88 a of spacer 88 engaging the socket, as at 89 . Alternatively a bracket 90 may be assembled against the socket end 89 , in position to block rightward travel of the nut. Continued rotation of the nut then causes the internal thread 86 on the carrier, and the carrier itself, to move bodily leftwardly, pushing the liner free of the socket, or free of an insert liner 92 carried by the socket, as in the case of a metal-to-metal ball joint where the liners 92 and 11 are “frozen” together.
[0028] Note that the nut 84 may have an end opening at 84 a, providing access to the turning knob 70 a on the stem carrying the cam 26 .
[0029] It will therefore be seen that the invention provides means for readily removing a liner “frozen” in position in a socket, obviating need for the surgeon to repeatedly hammer a tool against the liner in an attempt to free it. Such hammer impacts can cause severe damage to the socket structure, and the present invention precludes risk of such potential damage.
[0030] FIG. 6 shows bracket 90 having turned ends or fittings 91 at opposite sides of axis 93 to fit against the socket ends, when the bracket interior annulus 90 is assembled over the carrier part 87 . The bracket then transmits pressure from nut wall 92 to the socket end 89 .
[0031] FIG. 8 shows provision of multiple (typically six) under cut openings 96 formed in the periphery of part 88 , or in the bracket loop 99 , adjacent end 89 , to enable insert of the tip 100 a of a pry tool or bar 100 . Pivoting of bar 100 then enables tip 100 a to pry or push the structure 88 , 80 and liner free of the socket. A vibrating tuning fork may be used in place of bar 100 .
[0032] Multiple under cuts enable selective and successive insertion of tip 100 a in two or more under cuts, and prying at such multiple locations, to ensure liner release.
|
The method of removing a hip socket liner from surface attachment to a socket, that includes providing a carrier and multiple penetrators carried to be displaced relative to the carrier, inserting the carrier in the liner so that the penetrators project toward a liner cup-shaped surface, effecting controlling limited forceful displacement of tips defined by the penetrators toward and into said liner cup-shaped surface, and transmitting pushing force acting between the carrier and hip socket whereby the liner is suddenly freed from attachment to the socket.
| 0
|
This application is a divisional application of application Ser. No. 10/251,461 filed on Sep. 20, 2002 now U.S. Pat. No. 6,951,586, which is a divisional application of application Ser. No. 09/732,608 filed on Dec. 8, 2000, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates generally to the ability to provide a uniform application of polymeric diphenylmethane diisocyanate (pMDI) onto cellulose gypsum panels, boards and other surfaces, to create a substrate with increased strength and water resistance.
Exterior wall cladding is used as a barrier to keep exterior air and moisture out of the wall cavity. If water and moisture penetrate the wall cladding surface damage will result to the cladding board itself. Prior art exterior wall cladding was made out of gypsum sheathing or water-resistant gypsum board. It was found that the application of pMDI to a cellulose/gypsum based board greatly increased the board's strength and water resistance. The disclosed invention applies the pMDI to the cellulose/gypsum based board with an apparatus that provides a uniform coating across the board which results in increased water resistance and flexural strength.
SUMMARY OF THE INVENTION
The disclosed invention consists of an improved cellulose/gypsum based board, and means for conveying a gypsum and cellulosic board or panel to a spray station where pMDI resin is delivered through a series of spray nozzles to the face and back of the gypsum board or panel. A resin distribution system is used to supply the spray nozzles with pMDI. Optionally, to assist in the spreading of the pMDI resin over the surface of the cellulose/gypsum board to achieve complete coverage of the cellulose/gypsum-based substrate, a second spray system can be included. The nozzles of the second spray system may be adjusted to cover areas of the face and back of the board that are not covered by the first spray system. The resulting panel exhibits dramatically improved water resistance and flexural strength. Atmospheric moisture is sufficient to cure the pMDI matrix.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing illustrating a production line for forming cellulose/gypsum board having a head box, dewatering vacuums, a dewatering primary press, a secondary press, a drying kiln and a resin distribution system all for processing a rehydratable gypsum fiber slurry upon a conveyor,
FIG. 2 is a front view of the resin distribution system including a resin drum, a metering pump and the spray system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is directed to an improved cellulose/gypsum based board and to a method for applying polymeric diphenylmethane diisocyanate (pMDI) to a cellulose/gypsum based board, and in particular, the use of one or more spray systems to provide a uniform application of pMDI onto the cellulose/gypsum based board. The forming system, generally designated with the numeral 10 and shown in FIG. 1 , includes a head box 12 , vacuum boxes 14 , a wet (primary) press 16 , a secondary press 18 , and a drying kiln 20 . The function of the primary press 16 is 1) to nip a gypsum/cellulose fiber filter cake mat to a desired thickness and 2) to remove 80-90% of remaining water. The function of the secondary press 18 is to compress the board during setting to a calibrated final thickness and to aid in achieving flexural strength in the final product. The secondary press 18 has a continuous belt 22 that also aids in achieving smoothness to the board surface as the rehydrating mat expands against the belt 22 . The head box 12 is used to uniformly disperse a calcined slurry having at least about 70% liquid by weight, across the width of the forming table 24 , where vacuum boxes 14 are used to dewater the slurry into a mat of generally 28-41% moisture content (wet basis) (40-70% moisture content on a dry basis). The forming table 24 includes side dams to contain the slurry pond and a conveyor or forming wire 26 to move the slurry away from the head box 12 and towards the primary press 16 . As the slurry moves along the forming table 24 , the vacuum boxes 14 dewater the slurry into a mat, creating a decreasing water content gradient in the slurry going from the head box 12 towards the primary press 16 . At some point along this gradient, there is a zone referred to as the wet line, where it is observable that the slurry is changing into the wet mat. Put another way, one can see that the slurry is no longer fluid as the water is removed.
In the preferred embodiment, the slurry pond is further dewatered and formed into a filter cake by the application of additional vacuum boxes 14 . With reference to FIG. 1 , the conveyor or forming wire 26 carries the filter cake to the primary press 16 which further dewaters the filter cake and nips the material to a desired thickness. During this time, the board begins setting and expands to fill the nip gap. The board exits the primary press 16 and is carried on the conveyor 26 to the secondary press 18 . The secondary press 18 shapes the board to a final calibrated thickness. The board expands against the smooth belt 22 of the secondary press 18 which further aids in rendering a smooth surface and increased flex strength.
After exiting the secondary press 18 , the board is dried in a kiln 20 . A non-aqueous pMDI resin is spray-applied to the face and backside of the cellulose/gypsum board by using a spray system 28 that sprays at a preferable rate from about 9 to about 25 pounds per 1000 square feet of cellulose/gypsum board. The pMDI penetrates efficiently into the board. As the pMDI migrates through the board, a reaction takes place between water that is in the ambient air, plus any remaining/evaporating water in the board, and the pMDI that permeates into the board. The interaction between the pMDI and the water transforms the pMDI into polyurethane, which forms urethane linkages with the cellulosic fibers at and slightly below the surface of the board to seal the faces of the board. The polyurethane does not increase the overall thickness of the board but rather seeps into the board. The resin applied to the board by the spray system 28 thus does not remain suspended to cure as a mere coating on the surface due to the polymeric resin, like pMDI, interacting with the cellulosic fibers. Water from the ambient surroundings is sufficient to start the curing of the pMDI, and, thus the resin is applied to a dried board, which may have a small percentage of evaporating remaining free water that has not yet evaporated. The non-aqueous resin soaks into the board and reacts with the cellulosic fibers in the board. A polyurethane/cellulose matrix is formed. By treating the entire cellulose/gypsum board with pMDI, a polyurethane/cellulose matrix is formed that completely seals the board.
The resultant cellulose/gypsum board treated with the pMDI has an increase in flexural strength of 20-35% over the non-treated board. The typical curing time to allow for complete transportation of the pMDI into the polyurethane cellulose matrix within the board is approximately three days, but may vary depending upon ambient conditions.
The polyurethane/cellulose matrix formed does not increase the overall thickness of the board. The matrix becomes a water resistant layer of the board that is approximately ⅛ inch thick. A cellulose/gypsum board treated with pMDI on one side, allowed to cure, and completely submersed in water resulted in the deterioration of the untreated portion of the board. The treated portion of the board remained intact and was about ⅛ inch thick.
A water absorption test was performed on the surface of both an untreated cellulose/gypsum board and a board treated with pMDI to determine the quantity of water absorbed by the board. During the test, 100 square centimeters of the surface of the board was subjected to 100 milliliters of 70° F. water for two hours. The untreated board absorbed 92-100 grams of water during the two hour test period. The board treated with pMDI absorbed 0.5 grams of water for the 2 hour test period which is well below the acceptable limit for exterior cladding. Boards treated with pMDI were more scuff resistant than untreated boards and were less dusty when handled. These desirable qualities are beneficial because they enhance the marketability of the resultant product.
The spray system 28 , as shown in FIG. 2 includes a horizontal spray bar 30 equipped with equally spaced spray nozzles 32 , a manifold 34 , feed tubes 36 , a filtering system 40 , a positive displacement pump 38 and a storage container 42 . The spray bar 30 is an elongated tube that spans the width of the board. Typical sheets of cellulose/gypsum board are 48 inches in width. In the preferred arrangement, the spray nozzles 32 are attached to the spray bar 30 in three inch intervals. It has been found that placing the spray nozzles 32 three inches apart provides for enough spray overlap to adequately wet the board with pMDI. The spray nozzles 32 spray in a fan pattern and are positioned 8-10 inches above the board. Placing the nozzles 32 close to the board reduces the amount of overspray that is typically associated with spray systems. The spray nozzles 32 are not air assisted since it is desirable to reduce atomization of the pMDI so overspray can be kept to a minimum. Overspray decreases the pMDI transfer rate onto the board, which increases the amount of pMDI required to coat the cellulose/gypsum board and the amount of overall product required. The spray bar 30 is connected to the manifold 34 that delivers pMDI to different locations on the spray bar 30 by use of feed tubes 36 . The feed tubes 36 are vertically oriented and connect the spray bar 30 to the manifold 34 . The manifold 36 is supplied with pMDI under pressure from a positive displacement pump 38 . The pump 38 is connected to the storage container 42 by use of a supply line 44 . The supply line 44 also connects the pump 38 to the filter system 40 and the filter system 40 to the manifold 34 . The storage container 42 is typically a storage drum that is positioned upon a drum cart 46 . The storage container 42 also includes a valve 48 and a breather 50 to allow for the removal of pMDI. The breather 50 is utilized to allow air to displace the pMDI removed from the storage container 42 . The pump 38 is adjusted to the desired flowrate and pumps the pMDI through the filter system 40 and to the manifold 34 . The filter system 40 includes two filters 41 connected in parallel to filter out any particles that may clog the nozzles 32 . The filter system 40 is equipped with valves 52 to allow the supply line 44 to be closed off to prevent the leakage during the replacement of the filters 41 . By utilizing two filters 41 that are large enough handle the flowrate of the pMDI from the pump 38 , one filter 41 can be taken off-line for a filter replacement while the other filter 41 remains in service.
The invention is also useful for paper coated gypsum board wherein the paper provides the cellulosic fibers for forming the urethane linkages with the curing pMDI.
Various features of the invention have been particularly shown and described in connection with the illustrated embodiments of the invention. However, it must be understood that these particular arrangements, and their method of manufacture, do not limit but merely illustrate, and that the invention is to be given its fullest interpretation within the terms of the appended claims.
|
The disclosed invention consists of an improved gypsum based, cellulosic containing board and method for applying a resin to an untreated board at a spray station where pMDI resin is sprayed onto the front and back side of the board. A resin distribution system is used to supply the spray nozzles with pMDI. Optionally, a second spray station is included, if desired, to add additional pMDI resin over the surface of the board to achieve complete coverage. The improvement is an increased water resistance and flexural strength.
| 1
|
FIELD OF THE INVENTION
The present invention basically relates to a method for preparation of inorganic fine particle-organic fine crystal hybrid fine particle comprising; pouring an organic material having π-conjugated bond which is dissolved in water soluble solvent into aqueous dispersion in which inorganic fine particles are dispersed as a solution state, and co-precipitating said inorganic fine particle which forms a core and said organic material which forms a shell in said dispersion, coating said inorganic fine particle with fine crystal shell of said organic material thinner than 50 nm by controlling the size of said inorganic fine particle and by controlling adding amount of said organic material.
BACK GROUND OF THE INVENTION
It is known that the fine crystal particles of metal or semi-conductor indicate an interesting optical characteristic, and that therefore many researches are carried out. For example, it is known that an inorganic fine crystal exhibits the enhancement of three-order non-linear optical characteristic. Further, the fine particles having size between single atom and/or molecule and these bulk particles are classified as the meso size, because of the meaning of intermediate size, and its specific characteristic based on the size was investigated, especially, from the view points of fundamental science and optical application, for example, from the view point of improvement of non-linear optical property caused by a quantum confinement effect are greatly investigated. [Reffer to T. Cassagneau, T. E. Mallouk and H. Fendler, J. Am. Chem. Soc. 120 (1998) 7848, H. Weller; Angew, Int. Ed. Engl. 35 (1996) 1079]
In the meanwhile, the inventors of the present invention have accomplished the re-precipitation method for the preparation of fine crystals of organic compound having π-conjugated bond and their paper was already reported. This method is very useful as the fine crystallization method for a thermally unstable organic compound, because the generation of fine crystals can be carried out under very mild condition. Further, according to this method, it is possible to adjust the size of the organic fine crystals in the range of crystal size from several ten nanometers to several hundred nanometers. [H. Katagi, H. Kasai, S. Okada, H. Oikawa, K. Komatsu, H. Matsuda, Z. Lui and H. Nakanishi: Jpn. J. Appl. Phys. 35 (1996)1364, H. Kasai, H. S. Nalwa, H. Oikawa, S. Okada, H. Matsuda, N. Minami, A. Kakuta, K. Ono, A. Mukoh and H. Nakanishi: Jpn. J.Appl. Phys. 32 (1992) 1132, K. Yase, T. Hanada, H. Kasai, T. Sato, S. Okada, H. Oikawa, H. Nakanishi: Mol. Cryst. & Liq. Cryst. 294 (1997) 71]. By this method, various kinds of fine crystals whose size are adjusted were prepared, and the relationship between crystal size and optical characteristic was studied. And from the results of the study, blue shift in optical absorption along with the reducing of the crystalline size was observed. [H. Kasai, H. Kamatani, S. Okada, H. Matsuda and H. Nakanishi, Jpn. J.Appl. Phys., 35. 1221 (1996)]. The interesting fact is that, in the range of one order bigger size than the size of fine crystal of metals and semi-conductors, the excitonic absorption peak position of organic fine crystal blue shifts with the reduction of the crystal size. This phenomenon can not be simply explained by the quantum size effect, and is speculated to be caused by a certain interaction between an exiton and a phonon in organic crystalline lattice which is thermally loosened. [J. Harada and K. Ohshima: Surf Sci.106 (1981) 51].
However, to the date, there was no paper reporting the study of organic-inorganic hybrid fine crystal. Only the improvement of characteristic of a non-linear optical material composed of organic material and metal fine particles (by surface plasmon) is theoretically predicted. [A. E. Neeves and M. H. Birnboin: J. Opt. Soc. Am. B6 (1989) 787, J. W. Haus, H. S. Zhau, S. Takami, M. Harasawa, I. Homma and H. Komiya: J.Appl. Phys. 73 (1993) 1043, JP2-8822A publication, JP8-95099A publication]. In connection with the above, although the spectrum of ground state was not made clear, the improvement of non-linear optical characteristic in an amorphous polydiacetylene (PDA) thin film in which gold fine particles were dispersed was reported. [A. W. Olsen and Z. H. Kafafi: J. Am. Chem. Soc. 113 (1991) 7758]. Even if in the case of polydiacetylene which is concerned as one of the most promising material to realize an ultra high speed optical switching device, the enhancement of non-linear optical characteristic by more than one order is required, therefore, the fabrication of the hybrid fine crystal which was predicted by the above mentioned theory is the most important subject from the view point of the application.
In connection with these backgrounds, the subject of the present invention is to provide a method for preparation of organic-inorganic hybrid fine crystal. Further the subject of the present invention is to obtain organic-inorganic hybrid fine crystals having various sizes and forms based on the method, to obtain the data which relate to these various characteristics e.g., optical characteristic, and to provide a basic information of a novel device based on these data. Since said hybrid material is prepared as a hybrid material hybridized with organic fine crystal, it is obvious that the above mentioned method for organic fine crystal under mild condition is effective. Therefore, the inventors of the present invention started to investigate a new method for preparation of a hybrid material with inorganic fine particles using the above mentioned method. In the above mentioned re-precipitation method of organic fine crystal, the inventors of the present invention have found that the hybrid fine crystal characterized having an inorganic particle as a core and a fine crystal shell of the organic material surrounding the surface of the core can be formed by following method and dissolved the subject of the present invention. That is, the dispersion in which inorganic fine particles are dispersed is used as the poor solvent by adding compatible solvent with said poor solvent e.g. water, for example, acetone in which the material to form the organic fine crystal is dissolved.
DISCLOSURE OF THE INVENTION
The present invention is a method for preparation of inorganic fine particle-organic crystal hybrid fine particle comprising; pouring an organic material having π-conjugated bond as a water soluble solution into aqueous dispersion in which inorganic fine particles of 50 nm or less selected from the compound group consisting of metal fine particles, semi-conductor fine particles, fine particles of inorganic fluorescent material and fine particles of inorganic luminescent material are dispersed, co-precipitating said inorganic fine particle which forms a core into said organic material which forms a shell in said dispersion and coating said inorganic fine particle with fine crystal shell of said organic material of thinner than 50 nm by controlling the size of said inorganic fine particle and by controlling the adding amount of said organic material. Desirably, the present invention is the method for preparation of said inorganic fine particle-organic crystal hybrid fine particle, wherein the dispersion of metal fine particle used for the preparation of inorganic fine particle-organic crystal hybrid fine particle by the co-precipitation method is the dispersion in which meso size metal fine particles of 50 nm or less which can be obtained by reducing metal salt solution, more desirably is the method for preparation of said inorganic fine particle-organic crystal hybrid fine particle, wherein the inorganic particle is gold or silver, further desirably is the method for preparation of said inorganic fine particle-organic crystal hybrid fine particle, wherein the organic material having π-conjugated bond which forms the shell of organic fine crystal is diacetylene. Furthermore desirably, the present invention is the method for preparation of hybrid fine particle having a shell of π-conjugated polymer organic fine crystal of the same form as the monomer on the surface of an inorganic fine particle comprising, transforming the shell of the organic fine crystal of said inorganic fine particle-organic fine crystal hybrid fine particle to π-conjugated polymer organic fine crystal having the same form as the monomer by solid-state polymerization.
BRIEF ILLUSTRATION OF THE DRAWINGS
FIG. 1 is the example showing the preparation process of the inorganic fine particle-organic crystal hybrid fine particle of the present invention. Silver fine particles Ag are dispersed, diacetylene DCHD is poured into the dispersion with constant stirring by a stirrer S to generate silver fine particle-diacetylene fine particles Ag-DCHD H.NP by co-precipitation C.R. By standing S.D, silver fine particle-diacetylene fine crystals Ag-DCHD H.NC are deposited. Silver fine particle-polydiacetylene hybrid fine crystal Ag-pDCHD H.NC, which is the aimed product, can be obtained by solid-state polymerization S.S.P of diacetylene by ultraviolet irradiation UV.R.
FIG. 2 is the scheme for the generation of the inorganic fine particle-organic crystal hybrid fine particle of the present invention. Process 1 shows the state that diacetylene monomer droplet DCHD indicated by a large round mark O is added in NP aqueous dispersion of silver fine particles Ag indicated by a small round mark O. And in process 2, during standing S.D for 20 minutes, the fine particle Ag-DCHD-H.NC characterizing diacetylene monomer fine particle is formed on the surface of Ag fine particle. In the process 3, when diacetylene is irradiated with UV light, solid-state polymerization S.S.P of the diacetylene monomer fine crystal occurs, and silver fine particle-polydiacetylene hybrid fine particle Ag-PDCHD-H.NC can be obtained.
FIG. 3 shows the relationship between irradiation time of the inorganic fine particle-organic crystal hybrid fine particle to ultraviolet light and changes of visible absorption spectra, and the change of optical characteristic at the above mentioned hybridization.
FIG. 4 shows the change of the absorption spectrum of silver fine particles Ag NP and silver fine particles-poly (DCHD) fine crystal hybrid fine particles.
FIG. 5 shows the correlation between poly (DCHD) fine crystal size and the peak position of exciton absorption spectrum.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will be illustrated more in detail by following description.
A. The important point of this invention is illustrated by referring to the figures.
FIG. 1 illustrates the outline of the preparation process of the inorganic fine particle-organic crystal hybrid fine particle of the present invention.
In this drawing, the process is illustrated by the example using aqueous dispersion of silver fine particles and adding diacetylene (DCHD) solution. However, other fine particles of metal, such as Au, Pt, Pd, Rh, Cu, Ni, Co or Al can be used instead of Ag fine particles, and CdS, CdSe, ZnS, ZnSe or InAs can be also used as the fine particles of semi conductor.
As diacetylene, for example, 1,6-di(N-carbasolyl)-2,4-hexadiin (DCHD), which is the compound of chemical formula 1 is used. As the other compounds to be used instead of DCHD, any compounds which can maintain the form of monomer and the optical characteristic after solid-state polymerization are available such as compounds of, for example, 5,7-dodecadiin -1,12-diilbis(N-(butoxycarbonyilmethyl)carbamate (4BCMU), 2,4-hexadiin-1,6-diildi(p-toluenesulfonate) (PTS).
In the method for preparation of the inorganic fine particle-organic crystal hybrid fine particle shown in FIG. 1 , the first process in the operation is to pour acetone solution of DCHD into aqueous dispersion of Ag fine particles which is stirred strongly. The second process is the operation to generate Ag-DCHD fine particles by co-precipitation. The third process is the operation to generate hybrid crystal particles of Ag-DCHD fine crystal, Ag-DCHD-H.NC. The fourth process is the operation to generate Ag-poly (DCHD) hybrid fine crystal, Ag-pDCHD-H.NC, by solid-state polymerization of DCHD caused by the irradiation of UV light to the hybrid particles of Ag-DCHD fine crystal generated in the previous process.
FIG. 2 is the schematic model of the process of FIG. 1 which shows the generation of the inorganic fine particle-organic crystal hybrid fine particle of the present invention. The process 1 shows the existing forms of Ag fine particles Ag NP and DCHD droplet which is poured in dispersion in the first and the second processes of FIG. 1 .
B. Fine particle of metal which is the fine particle forming a core of the hybrid fine particle, such as silver, is prepared by reducing silver nitrate using sodium borohydride.
Other metal fine particle can be obtained by reducing metal acid or the salt such as halogenated auric acid or halogenated rhodium. Further, dispersion of fine particles of semi conductor material can be obtained by carrying out the synthesis of the semi conductor compound in dispersion medium under the presence of a doping agent.
Among the inorganic fine particles, the homogeneous, spherical and almost mono-dispersed fine particle is suitable for the improvement of the function of hybrid fine particles.
As the organic material which forms an organic fine crystal layer by co-precipitation method, diacetylenes which has non linear optical characteristic can be mentioned as the typical example. And as the compound which forms polymer single crystal by solid-state polymerization, said compound or the compounds described in Japanese Patent Laid Open Publications 62-25547, 2000-95762 or 8-95099 (refer to pages 4 and 5) can be mentioned. As the other monomer, 5,7-dodecadiin-1, 12-diilbis(N-(butoxycarbonylmethyl)carbamate) (4BCMU), or 2,4-hexadiin-1,6-diildi(p-toluenesulfonate) (PTS) can be mentioned.
D. The required condition to realize the co-precipitation for the solvent of these monomers is to dissolve said monomers, to have compatibility with the solvent in which inorganic fine particles are dispersed and to have the characteristic to reduce the solubility of monomer so as to co-precipitate organic fine particles by making compatible said solvent with the dispersing solvent.
E. As the means for solid-state polymerization, UV light, gamma-ray and electron beam can be used.
EXAMPLES
The present invention will be illustrated specifically according to the following Examples, however, is intending to make clear the usefulness of the present invention and is not intending to limit the scope of the present invention.
Example 1
1. 3.5 mg of sodium borohydride NaBH 4 was dissolved into 60 mL of ultrapure water and this aqueous solution was cooled approximately up to 4° C. Then, 20 mL of AgNO 3 aqueous solution (2.2×10 −3 M) which was previously maintained at the temperature of 12° C. was dropped into said NaBH 4 solution and the dispersion of Ag fine particles was prepared. The wave length absorption peak of the obtained dispersion was 395 nm and the diameter of Ag fine particle was approximately 15 nm by the measurement using SEM.
2. 200 μL (7.5 mM) of diluted acetone solution of DCHD monomer was poured into the aqueous dispersion (10 mL) of Ag fine particles by stirring strongly.
3. After maintained for 20 minutes, UV light was irradiated to the dispersion for 20minutes, then DCHD monomer crystal domain was converted to poly (DCHD) fine crystal domain by solid-state polymerization process. As the UV light source, 20 W UV light source (EF-160C/J, SPECTOOLINE Co., λ=254 nm) was used. The size, form and morphology of poly (DCHD) fine crystal, Ag fine crystal and hybrid fine crystal were evaluated by dynamic light scattering (DLS: DLS-700, Otsuka Electronics Co.,), scanning electronic microscope (SEM: S-900, Hitachi Ltd.) and transmission electronic microscope (TEM: JEM-2010, JEOL Ltd.).
For the measurement of visible-UV spectrum of the dispersion of poly (DCHD) fine crystals, metal fine particles and hybrid fine particles, UV-VIS spectrum meter (V-570DS, JASCO Ltd.) was used. By the SEM observation of the obtained hybrid fine crystal, two different types of fine crystal whose size and form are different were observed. One was the larger size crystal of approximately 180 nm being a specific rectangular poly (DCHD) fine crystal in which spherical Ag fine particle was embedded. While, many hybrid fine crystal were spherical crystal whose size was approximately 25 nm and was similar to the Ag fine particle.
However, it became clear that the all particles whose size is approximately 25 nm were larger than the Ag fine particle. Accordingly, it is obvious that the Ag fine particle is covered with domain of poly (DCHD) fine crystal. In other word, the structure is characterized as the Ag fine particle is embedded in the domain of poly (DCHD) fine crystal.
For the purpose to make clear this form, the observation using a transmission electronic microscope TEM was carried out. Several tiny black points were observed, and these black points were confirmed to be Ag fine particle and poly (DCHD) fine crystal layer surrounding said Ag fine particle were observed.
The color of the hybrid dispersion consisting of DCHD fine crystals and Ag fine particles was yellow and this color was changed to bluish violet by UV light irradiation for 20 minutes.
FIG. 3 shows the relationship between irradiation time of ultraviolet light to the inorganic fine particle-organic crystal hybrid fine particle and change of visible absorption spectrum. The absorption peak at 655 nm is caused by absorption spectrum of the exciton absorption of π-conjugated main chain and the absorbance increases with the time of irradiation of UV light.
The electronic interaction in hybrid fine crystal appears in red shift of the exciton absorption peak of poly (DCHD). As previously reported, the exciton absorption peak position is dependent on crystal size, and blue shifts along with the reduction of size of the crystal.
Therefore, as shown in FIG. 4 and FIG. 5 , in the case of only poly (DCHD) fine crystal with 25 nanometer size, the absorption peak locates around at 637 nm. However, although the size of the hybrid fine crystal is the same as that of the poly (DCHD) fine crystal, the position of exciton absorption peak of the hybrid fine crystal is actually 655 nm.
Consequently, the red shift of exciton absorption is related closely with the disappearance of plasmon absorption of Ag fine particles. The inventors of the present invention succeeded the preparation of hybrid fine particles composed of poly (DCHD) fine crystal (shell layer) and Ag fine particles domain (core part) and can present clearly the possibility of the electronic interaction between said two domains.
The generation of this interaction can be speculated as follows from the phenomenological view point.
1. The energy level of plasmon is not so largely different from the energy level of exciton.
2. Surface contact of organic compound with metal is complete in the limited nano space.
3. The volume ratio between organic compound and metal is most suitable in the hybrid fine crystal.
Especially, items 2 and 3 are very important. Both or either of organic compound or metal in bulk state are meaningless, and it is necessary to be contacted each other in limited nano space.
INDUSTRIAL APPLICABILITY
As the mentioned above, the method for preparation of the inorganic fine particle-organic crystal hybrid fine particle of the present invention by controlling form or size can improve not only the characteristics of the conventional fine particle by said form and/or size but also excellent effect to provide the possibility of new functional materials.
|
A method for preparation of inorganic fine particle-organic crystal hybrid fine particle comprising; pouring an organic material having π-conjugated bond as a water soluble solution into aqueous dispersion in which inorganic fine particles of 50 nm or less selected from the compound group consisting of metal fine particles, semi-conductor fine particles, fine particles of inorganic fluorescent material and fine particle of inorganic luminescent material, are dispersed, co-precipitating said inorganic fine particle which forms a core into said organic material which forms a shell in said dispersion and forming shell of fine crystal of said organic material on the surface of the core of said inorganic fine particles of 50 nm or less by controlling the size of said inorganic fine particle and by controlling the adding amount of said organic material.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Nonprovisional Patent Application, which claims benefit to U.S. Provisional Application Ser. No. 61/365,894 entitled “Heavy Particle Oil Separator Splash Shield,” filed Jul. 20, 2010, the complete disclosure thereof being incorporated herein by reference.
TECHNICAL FIELD
This disclosure relates to reduction in exhaust particulate emissions from a locomotive diesel engine, and specifically to a heavy particle oil separator splash shield.
BACKGROUND OF THE DISCLOSURE
The present disclosure relates to reduction in exhaust particulate emissions from a locomotive diesel engine, and specifically to a heavy particle oil separator splash shield.
Oil separators are designed to trap and recover small oil droplets and particulate matter from vapors emitted from engines. Specifically, the crankcase ventilation oil separator is used to prevent the build-up of combustible gases in the crankcase, by collecting oil and particulate matter from vapors.
Cam shaft drive gears and counterweights are generally located in close proximity to the passage leading to the oil separator. The cam shaft drive gears are lubricated through a system of oil passages within the crankcase and manifolds which mount or connect to the mounting shafts for the gears. Oil passing through the gears is splashed around and on to the gears to create the necessary lubrication between the mating gear teeth. This splashing causes heavy particle liquid oil droplets to enter directly into the passage to the oil separator from the crankcase. The purpose of the oil separator is to collect oil and particulate matter from vapors that pass through its element. Therefore, additional oil splashed into the separator from the cam shaft drive gears decreases the efficiency of the element of the oil separator, thus allowing more particulate matter to be released into the atmosphere.
Thus, it is an object of the present disclosure to provide a shield between the moving parts of the engine (including the cam shaft drive gears) and the oil separator filter to prevent heavy particulate oil droplets from saturating the oil separator. Specifically, the present shield minimizes heavy particle oil droplets in close proximity to the oil separator from entering the filter, thus preventing saturation of the oil separator element and increasing the efficiency of the oil separator. As a result, environmental pollution is reduced.
The following description is presented to enable one of ordinary skill in the art to make and use the disclosure and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiment and the generic principles and features described herein will be readily apparent to those skilled in the art. For instance, although described in the context of a two-stroke diesel engine, the present device may be employed in any diesel engine. Thus, the present disclosure is not intended to be limited to the embodiments shown, but is to be accorded the broadest scope consistent with the principles and features described herein.
SUMMARY
The present disclosure generally relates to a locomotive diesel engine and, more particularly, to a heavy particle oil separator splash shield. Specifically, provided is a system and method for reducing exhaust particulate emissions. The present shield minimizes heavy particle oil droplets from the cam shaft drive gears from entering the oil separator. As a result, the present shield minimizes saturation of the oil separator, thereby increasing the efficiency of the oil separator and reducing environmental pollution.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a locomotive.
FIG. 2 is a system diagram of a locomotive diesel engine having a conventional air system.
FIG. 3 is a partial cross-sectional view of a locomotive diesel engine.
FIG. 4 is a cross-sectional view of a positive pressure zone of a diesel engine.
FIG. 5 is a cross-sectional view of a negative pressure zone of a diesel engine.
FIG. 6 is a partial perspective view of a locomotive diesel engine of FIG. 3 .
FIG. 7 is a perspective view of an oil separator assembly for a diesel engine.
FIG. 8 is another perspective view of an oil separator assembly for a diesel engine.
FIG. 9 is a perspective view of the opening defined in the mounting flange on turbocharger housing leading to the oil separator.
FIG. 10 is a perspective view of the mounting location of the present splash shield.
FIG. 11 a is a side perspective view of the mounting location of the present splash shield of FIG. 10 .
FIG. 11 b is a side view of the mounting location of the present splash shield of FIG. 10 .
FIG. 11 c is another side perspective view of the mounting location of the present splash shield of FIG. 10 .
FIG. 11 d is a detailed front side view of the mounting location of the present splash shield of FIG. 10 .
FIG. 12 is a front perspective view of an embodiment of the present splash shield.
FIG. 13 is a side perspective view of an embodiment of the present splash shield.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present disclosure relates to reduction in exhaust particulate emissions from a locomotive diesel engine, and specifically to a heavy particle oil separator splash shield. The oil splash shield reduces the amount of heavy particle oil splashed from a cam shaft drive gear into the oil separator, thereby reducing engine exhaust particulate matter emissions. Specifically, a splash shield is positioned between the moving parts of the engine (including a cam shaft drive gear) and the oil separator to prevent direct path flow of heavy droplets into the oil separator such that excess oil does not saturate the element of the oil separator.
FIGS. 1-3 illustrate the present locomotive diesel engine generally comprising a turbocharger 100 having a compressor 102 and a turbine 104 which provides compressed air to an engine 106 having an airbox 108 , power assembly 110 , an exhaust manifold 112 , and a crankcase 114 . In a typical locomotive diesel engine, the turbocharger 100 increases the power capability of the engine 106 by pressurizing and increasing the amount of air transferred to the engine 106 . More specifically, the turbocharger 100 draws air from the atmosphere 116 which is filtered using a conventional air filter 118 . The filtered air is pressurized by a compressor 102 . The compressor 102 is powered by a turbine 104 . A larger portion of the compressed air is transferred to an aftercooler 120 (or otherwise referred to as a heat exchanger, charge air cooler, or intercooler) where the compressed air is cooled to a select temperature. Another smaller portion of the compressed air is transferred to a crankcase ventilation oil separator 122 (or otherwise referred to as an oil separator or lube oil separator) which evacuates the crankcase 114 in the engine 106 , entrains crankcase gas and filters entrained crankcase oil before release into the atmosphere 116 .
The engine 106 is divided into two distinct pressure zones: positive pressure 151 (above atmospheric pressure) and negative pressure 153 (below atmospheric pressure). The positive pressure zone 151 of a diesel engine 106 is illustrated in FIG. 4 , whereas the negative pressure zone 153 of a diesel engine 106 is illustrated in FIG. 5 . The engine 106 may include an eductor system to keep the crankcase 114 at a negative pressure whenever the engine is running. The top deck area of the engine is common to the engine sump through oil drain tubes, and the entire assembly is kept at negative pressure. Blower-equipped engines draw the crankcase 114 vapors through an oil separator 122 into the blower inlet. Turbocharger-equipped engines use an eductor (venturi) tube in the exhaust stack to draw the vapors through the oil separator 122 and expel them into the atmosphere.
The oil separator 122 is generally configured to trap and recover small oil droplets and particulate matter carried out through vapors from the crankcase. Specifically, the crankcase ventilation oil separator 122 is used to prevent the build-up of combustible gases in the crankcase 114 , by collecting oil and particulate matter from the vapors that flow through it. As shown in FIGS. 6-8 , in one embodiment, the oil separator 122 includes an elbow-shaped cylindrical housing containing a wire mesh screen element (not shown). However, any type of oil separator may be used. The oil separator 122 is mounted on the turbocharger mounting flange 111 . The elbow assembly connects the oil separator 122 to the eductor tube assembly 126 in the exhaust stack 124 . The eductor tube 126 in the exhaust stack 124 creates a suction which draws up vapor from the crankcase 114 through the separator element. The oil and particulate matter collects on the element and drains back to the crankcase 114 . The remaining gaseous vapor, generally free of oil and particulate matter, is discharged into the exhaust and vented to the atmosphere.
As described above, and further illustrated in FIG. 9 , cam shaft drive gears 117 and counterweights are generally located in close proximity to the passageway 115 leading to the oil separator 122 . The cam shaft drive gears 117 are lubricated through a system of oil passages within the crankcase and manifolds which mount or connect to the mounting shafts for the gears. Oil passing through the gears 117 is splashed around and on to the gears 117 to create the necessary lubrication between the mating gear teeth. This splashing causes liquid oil droplets to enter directly into the connection joint or passageway 115 to the oil separator 122 , which contaminate and saturate the element of the oil separator 122 more quickly and more heavily. The purpose of the oil separator 122 is to collect oil and particulate matter from vapors that pass through its element. Therefore, additional oil splashed into the separator from the cam shaft drive gears decreases the efficiency of the element of the oil separator 122 , thus allowing more particulate matter to pass through with the vapors and into the atmosphere.
In the present system, an oil splash shield 101 is provided from minimizing transfer of heavy oil droplets from the cam shaft drive gears 117 to the oil separator 122 of the locomotive diesel engine (e.g., as shown in FIGS. 10-13 ). In this system, the engine 106 includes a passageway 115 for allowing vapor to flow from the crankcase 114 to the oil separator 122 for filtration. Specifically, vapor flows from the crankcase 114 to the passageway 115 , via an opening 113 defined in the turbocharger mounting flange 111 , and enters the oil separator 122 . The oil splash shield 101 is situated adjacent to the mounting flange 111 leading to the oil separator 122 , such that the shield deflects splashing heavy oil droplets from the cam shaft drive gears 117 away from the oil separator 122 and back onto the cam shaft gears 117 . More specifically, the present shield 101 is situated adjacent to the opening 113 of the mounting flange 111 and is affixed to the housing 135 of the crankcase 114 . This placement of the shield 101 generally prevents large oil droplets, splashed from the engine in close proximity to the oil separator 122 , from contaminating and saturating the oil separator 122 element.
In one embodiment, as shown in FIGS. 10-13 , the present shield 101 is comprised of a member 131 that is selectively sized and shaped such that it extends the near extends near a portion of the opening 113 (and preferably the entire area of the opening 113 ) of the mounting flange 111 , which leads to the oil separator 122 . Although shown in this embodiment to be a U-shaped plate with rounded edges, the member 131 may be any comparable shape. The present shield 101 further includes a mounting element 119 for affixing the shield 101 to the housing 135 of the crankcase. The mounting element 119 defines a plurality of apertures 127 . Each aperture 127 may receive a fastening mechanism, such as a bolt, for affixing the shield to the housing 135 of the crankcase. The mounting element 119 is generally L-shaped and situated in relation to the member 131 to provide adequate support for the member 131 . When the mounting element 119 is affixed to the housing 135 , the member 131 is mounted such that it extends away from the crankcase 114 and gears 117 , as illustrated in FIGS. 11 a - 11 d.
Moreover, the member 131 is situated in relation to the moving parts of the engine (e.g., the cam shaft drive gears 117 ) such that it prevents flow of heavy particle oil droplets into the oil separator. Specifically, the member 131 is situated in the passageway between the crankcase 114 and oil separator 122 such that the shield 101 deflects splashing heavy oil droplets from the cam shaft drive gears 117 away from the oil separator 122 . The member 131 is positioned such that it is set away from (that is, not flush with) the opening 113 of the mounting flange 111 leading to the oil separator 122 . As a result, there is a clearance defined between the opening 113 of the mounting flange 111 and the shield 101 . This clearance is sized and shaped such that vapor flow is maintained from the crankcase 114 to the oil separator 122 such that the efficiency of the oil separator 122 is not compromised by the presence of the shield 101 . Thus, the member 131 prevents heavy particle oil droplets from saturating the element, while the larger aperture allows vapor to enter the oil separator 122 . Because the oil separator 122 element is not oversaturated with extraneous heavy particle oil droplets from the cam shaft drive gear 117 , it is able to more efficiently separate oil from the passing vapor. As a result, particulate emissions are reduced.
Additionally, the shield 101 may further include a plurality of support members 123 for maintaining the rigidity of the shield 101 . In the embodiment shown in FIGS. 10-13 , the support members 123 are in the form of support triangles; however, they may be any comparable shape. Specifically, the support members 123 maintain the L-shape of the mounting element 119 and secure the positioning of the member 131 .
In applications that cause back pressure in the exhaust system, such as exhaust silencers or extended exhaust piping runs, an air ejector system is used to increase crankcase vacuum. In this system, pressurized air from the left bank aftercooler duct is piped to the ejector, where it blows through a venturi, adding to the suction created by the eductor tube. Different size ejector nozzles may be used to aid in maintaining proper crankcase suction levels. To increase crankcase suction, a large diameter nozzle is applied, after the engine is inspected for other causes of low vacuum. Oil droplets and particulate matter collect in the oil separator, and drain back to the crankcase, while the vapors discharge, generally free of oil and particulate matter, into the exhaust and are vented to the atmosphere.
The present disclosure has been described in accordance with the embodiments shown, and one of ordinary skill in the art will readily recognize that there could be variations to the embodiments, and any variations would be within the spirit and scope of the present disclosure. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims.
|
The present disclosure generally relates to a locomotive diesel engine and, more particularly, to a heavy particle oil separator splash shield. Specifically, provided is a system and method for reducing exhaust particulate emissions. The present shield prevents large oil droplets in close proximity to the oil separator from easily entering the element, thus preventing less saturation of the oil separator and increasing the efficiency of the oil separator. As a result, environmental pollution is reduced.
| 5
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to corner trim structure for roofing and siding.
2. Prior Art
Available corner trim for use with sheet siding or roofing for buildings is largely of one piece construction, typically with external fastening flanges, although two piece structures are shown in published art, such as U.S. Pat. Nos. 1,772,417; 1,800,609; 3,500,600; 3,667,177 and 3,875,713. Known cover trim is often recessed for sheet edge insertion, leaving gaps where valleys exist in the siding, or contour trimming is often required along an edge that abuts the siding to fit closely and follow the contour of the siding. Fasteners used with one piece constructions are exposed, and often in two-piece construction as well. See, e.g., U.S. Pat. No. 3,500,600. In snap together construction shown in published art, e.g., U.S. Pat. Nos. 1,772,417 and 3,875,713, the parts are separable after assembly. These and other shortcomings of known cover trim represent significant disadvantages that have been overcome with the present invention.
SUMMARY OF THE INVENTION
The improved corner trim structure of this invention is especially for use with formed metal sheet roofing and siding with ridges and valleys that extend parallel to the corner and that must be accommodated. The present structure overcomes shortcomings and disadvantages of known corner trim used for this purpose.
Corner trim embodying this invention is of two-piece construction that snaps together positively and permanently when assembled and installed. Both pieces are extruded of slightly flexible and resilient material, such as synthetic resin (plastic), e.g., so-called rigid vinyl. One piece serves as a support, which is fastened directly to frame structure or the like that forms a structural corner, e.g., a corner of a building. The other piece is a cover, resilient enough to snap over a retainer portion of the support. The cover conceals the support and fasteners that secure the support to the frame structure and also overlaps the edges of siding or roofing sheets at the corner of the frame structure. The preferred embodiment of the cover has two angularly-related sides of unequal width, each with an inturned edge flange so that ridges of the siding or roofing sheets that run parallel to the cover edges can be accommodated by a choice of the positioning of the cover. Resilience of the cover also allows accommodation for ridges and provides a gripping action on the support.
Gripping of the support by the cover is accomplished through retaining elements that straddle a portion of the support and space the cover outwardly from the valleys of the roofing or siding sheets, so cover surfaces extend generally parallel to the general extent of the siding, while overlying ridges of the siding. The retaining elements are constructed to cooperate with the support to permanently interconnect the cover and support and to stabilize the two in a stationary relationship. The interconnecting structure allows the cover to be snapped onto the support in a direction toward the corner apex of the building structure, along a line or plane that bisects the corner angle, so relative movement of the cover edge flanges across the siding or roofing surfaces, which movement might be obstructed by ridges of the siding or roofing, is minimized.
The edge flanges of the cover are advantageously shorter than the distance from the respective cover surface to the valleys of the roofing or siding sheets so that small ridges and lower sloped portions of higher ridges do not displace the cover surfaces from a substantially parallel relationship with the extent of the overlapped sheets.
These and other features and advantages of the invention will become more apparent from the detailed description that follows, when considered in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a partial perspective, unassembled, view of cover trim structure embodying the present invention; and
FIG. 2 is a cross sectional view of the corner trim structure shown in FIG. 1, assembled, and illustrating the manner in which it is supported on a building framework to cover the edges of formed metal sheet roofing or siding.
DETAILED DESCRIPTION
A preferred embodiment of corner trim structure for use with formed metal sheet roofing and siding, illustrative of the present invention, is shown in FIGS. 1 and 2 of the drawing and indicated generally by reference numeral 10. The trim structure 10 is comprised of a support 12 and a cover 14 that snap together in use. When installed as shown in FIG. 2, the cover 14 overlaps edges of metal sheets 16 used for siding, as shown, or roofing. Both the support 12 and the cover 14 are of one-piece construction, extruded, and advantageously of vinyl plastic.
The support 12 is comprised of an elongated angle portion 18 for mounting along a corner 20 of a building frame 21 (a vertical corner as shown), and a cover-retainer portion 24 to be gripped by the cover 14 for holding it to the support 12.
The angle portion 18 has a first planar part 26 and a second planar part 28 oriented at right angles to each other and meeting to form a first apex 30. When secured to the building frame 21, the angle 18 is held by fasteners, such as nails 31, driven through the planar parts 26, 28. The cover-retainer portion 24 has elongated parts 32, 34, which are generally planar and meet in a second apex 36 at the juncture of their external surfaces. In the preferred embodiment, the parts 32, 34, while generally planar, are curved slightly transversely, as shown, to better pilot snap-on portions of the cover 14 into interengaging relationship. Each part 32, 34 is supported by a longitudinal web portion 38, 39, respectively. The longitudinal web portions join the parts 32, 34 at a location approximately midway between the apex 36 and distal edges 41, 42, respectively, of the parts 32, 34. The webs 38, 39 space the cover-retainer portion (i.e., the parts 32, 34), from the angle portion 18 (i.e., from the first and second planar parts 26, 28), to allow gripping by the cover 14 beneath the cover-retainer portion. Advantageously, the webs locate the cover-retainer portion so the apex 36 and the apex 30 are in a common plane that bisects the angle between the planar parts 26, 28. To best facilitate assembly of the cover and retainer, the general convergence of the parts 32, 34 form an included angle of less than 90°, for example, 74° in the preferred embodiment.
The cover 14 is comprised of a first elongated side 46, a second elongated side 48, and an elongated curved portion 50 that integrally joins the two sides. The general extent of the sides 46, 48 forms an acute included angle A therebetween. In the preferred embodiment, the sides 46, 48 are planar. Each side 46, 48 terminates at its distal end in a flange 52, 54, respectively, that is turned inwardly of the included angle A. In a preferred embodiment, the width of the sides 46, 48, i.e., the distance from the curved portion 50 to the flanges 52, 54, is different for each side. This allows a choice of orientation of the cover 14 to best fit the contours of the siding or roofing sheets 16, which typically have ridges, such as ridges 16a-d in the embodiment shown. Depending upon the width of the building, different ridges may be adjacent the edge of the sheet underlying the corner trim structure. The alternative orientation of the cover 14 is shown in phantom in FIG. 2, showing that the alternative orientation in the embodiment shown is not as satisfactory with the particular siding structure and arrangement depicted.
Two retaining elements 56, 58 form a part of the cover 14. Each extends inwardly of the included angle A and along a different one of the sides 46, 48, adjacent the juncture of each side with the curved portion 50. The retaining elements 56, 58 extend in a direction perpendicularly to the respective sides 46, 48, and extend inwardly a distance from the sides greater than the width or inward extent of the flanges 52, 54. Each retaining element 56, 58 terminates at its unsupported end in an inturned flange 60, 62, respectively.
When the structure 10 is not assembled, the angle A between the sides 46, 48 is smaller than it is when the structure is assembled. By way of example, in a cover in which the angle A is intended to be 90° when the cover is assembled to the support 12, the angle A is approximately 84° prior to assembly, when the cover is in an undistorted or unstressed condition. Also, with the cover in unassembled condition, the flanges 60, 62 of the retaining elements are relatively close, closer than when the cover and retainer are assembled. In assembly, the retaining elements and sides are stressed apart, distorting the cover, with the resilience of the material tending to press the flanges of the retaining elements and the sides closer together.
The relationship of the cover 14 and retainer 12, when assembled, is shown in FIG. 2. The inturned flanges 60, 62 of the retaining elements fit between the generally planar parts 32, 34 of the cover-retainer portion and the first and second planar parts 26, 28 of the angle 18. The thickness of the inturned flanges 60, 62 is just slightly less than the distance between the angle 18 and the cover-retainer portion 24 so the flanges can be received with a clearance fit, and the width of the flanges 60, 62, is equal to the distance from the distal edges 41, 42 to the webs 38, 39. As a result of this construction, the retaining elements 56, 58 of the cover interengage with the support 12, and not only secure the cover, but also press sideways against the parts 32, 34 and webs 38, 39 to stabilize the relationship between the cover and support.
While the preferred material of the cover 14 is so-called rigid vinyl, it is inherently flexible enough and resilient enough so that the sides 46, 48 flex to the degree necessary along their length beyond the juncture with the retaining elements 56, 58 to accommodate low ridges of the siding sheets that might underlie the flanges 52, 54 without clearance even through the flanges are shorter than the retaining elements. The width of the retaining elements 56, 58 (i.e., the distance from the sides 46, 48 to the flanges 52, 54) is chosen to accommodate the highest ridge 16a beneath the sides 46, 48. In use, the cover is oriented to avoid interference between the side flanges 52, 54 and the highest ridges 16a.
The cover 14 is applied to the support 12 by forcing the flanges 60, 62 against the surfaces 32, 34 on each side of the apex 36. The resilience of the cover 14 allows the flanges 60, 62 to spread apart and slide along the surfaces 32, 34 and over the distal edges 41, 42. The flanges then snap into place between the angle 18 and the cover-retainer 24, holding the two parts permanently together in a stabilized relationship. Because each apex 30, 36 is in a common plane that bisects the angle between the planar parts 26, 28, the cover flanges 52, 54 approach the underlying siding 16 on each side of the corner with a minimum of movement in a direction along the surface of the siding. This minimizes the interference from ridges of the siding during assembly of the cover trim structure. That is, by the construction of the support 12 and cover 14, the cover is moved toward the corner in a direction that causes the flanges 52, 54 to approach the respective siding sheet at 45° angles, rather than, for example, one flange approaching at 90° and the other approaching parallel to the siding.
While a preferred embodiment of the invention has been described in detail, it will be appreciated that modifications or alterations may be made therein without departing from the spirit and scope of the invention set forth in the appended claims.
|
A corner trim structure for use with formed metal sheet roofing and siding, comrising a snap-together support and resilient cover, permanently and firmly interconnected once assembled, and constructed to accommodate the ridges of roofing and siding sheets without specific contouring.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 USC 119 from Japanese Patent Application No. 2003-432569, the disclosure of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an image forming device which records images on sheets of recording media (papers or the like of predetermined sizes), and to a sheet supplying device which conveys sheets one-by-one from a stack of sheets.
[0004] 2. Description of the Related Art
[0005] Generally, in an image forming device such as a copier or a printer or the like, images are formed on recording media sheets in an image forming section. These sheets are stacked in a sheet supplying device which is provided within the image forming device, and are successively supplied from the sheet supplying device to the image forming section.
[0006] As shown in FIG. 16 , a sheet supplying device 100 has a presser plate 102 on which sheets (recording media) are placed. The presser plate 102 is urged upward by a coil spring 104 . Above the presser plate 102 , a supporting shaft 106 is supported so as to rotate freely with respect to a main body frame 130 (not all of the main body frame 130 is illustrated). A feed roller 108 , which is half-moon-shaped and conveys the sheets, is fixed to the supporting shaft 106 . Core rollers 110 are attached to the both sides of the feed roller 108 . The core rollers 110 rotate in a state of contacting a separating pad 112 provided at the main body frame 130 .
[0007] Cams 114 are fixed to the both end portions of the supporting shaft 106 . The cams 114 abut rollers 124 provided at flanges 122 which project from the both side portions of the presser plate 102 .
[0008] A driven gear 116 is attached to one end portion of the supporting shaft 106 . A portion of the peripheral surface of the driven gear 116 is cut out. A driving gear 118 , which is driven to rotate by a motor (not illustrated), is meshably disposed at the lower side of the driven gear 116 . The driving gear 118 meshes with the driven gear 116 at a predetermined timing so as to transmit the driving force of the driving gear 118 to the driven gear 116 , such that the supporting shaft 106 can rotate one time.
[0009] As shown in FIG. 17A , at times other than when sheets are being fed, the portions of the cams 114 where the eccentric radii are large abut the rollers 124 of the presser plate 102 , and press the presser plate 102 downward in a direction resisting the urging force of the coil spring 104 . At this time, the sheets stacked on the presser plate 102 are set apart from the feed roller 108 .
[0010] As shown in FIG. 17B , when the cams 114 rotate in the direction of the arrow due to the rotation of the supporting shaft 106 , the rollers 124 rotate while abutting the cams 114 , and the presser plate 102 is pushed upward by the urging force of the coil spring 104 . The feed roller 108 and the core rollers 110 also rotate together with the rotation of the supporting shaft 106 .
[0011] As shown in FIG. 17C , when the cams 114 rotate further in the direction of the arrow, the rollers 124 move along the cams 114 , and the presser plate 102 is gradually pushed upward. As shown in FIG. 17D , the presser plate 102 rises to the position at which the rollers 124 abut bearing portions 114 a of the cams 114 . At this time, the topmost portion of the stack of sheets stacked on the presser plate 102 contacts the feed roller 108 , and the sheets are fed out as the feed roller 108 rotates. Conveying, in an overlapping manner, of the sheets which are fed out is prevented by the friction with the separating pad 112 .
[0012] When the cams 114 rotate further, the presser plate 102 is pushed downward in the direction of resisting the urging force of the coil spring 104 , and the cams 114 rotate one time. In this way, the presser plate 102 is lowered to the position shown in FIG. 17A . (See, for example, Japanese Patent No. 2619959.)
[0013] In the sheet supplying device 100 shown in FIG. 16 , the presser plate 102 is moved upward and downward by the rotation of the cams 114 provided at the supporting shaft 106 of the feed roller 108 , and feeding of the topmost sheet of the stack of sheets is carried out. However, when an attempt is made to increase the accommodating capacity (the feeding capacity) of the sheets stacked on the presser plate 102 , a problem arises in that the cams 114 inevitably become large.
[0014] Namely, in the feeding operations shown in FIGS. 17A through 17D , when the presser plate 102 is raised, the topmost portion of the stack of sheets is pressed by the feed roller 108 and feeding is carried out. When the presser plate 102 is lowered, the topmost portion of the stack of sheets is moved away to a position at which it does not contact the feed roller 108 . Accordingly, when an attempt is made to increase the sheet accommodating capacity, the stroke of the presser plate 102 must be made to be large, and the cams 114 become large. Namely, there is the relation that the size of the cams 114 which move the presser plate 102 upward and downward determine the sheet accommodating capacity. Accordingly, a way to satisfy the antithetical needs for an increase in the sheet accommodating capacity and a decrease in the overall size of the device is desired.
SUMMARY OF THE INVENTION
[0015] The present invention has been made in view of the above circumstances and provides a sheet supplying device and an image forming device which enable the device to be made compact overall and which enable an increase in the accommodating capacity of sheets (e.g., recording media).
[0016] In accordance with one aspect of the present invention, there is provided a sheet supplying device comprising: a base; a tray on which a stack of sheets can be placed, the tray being able to be raised and lowered with respect to the base; a feed roller provided rotatably at the base and positioned above the tray, and when the feed roller rotates while frictionally engaging with a topmost sheet of the stack of sheets, the feed roller can convey the sheet; a driving mechanism able to drive the feed roller to rotate; an urging member urging the tray toward the feed roller; a first eccentric cam rotatably provided at the base, and including a large-radius outer peripheral portion whose radius is large and a small-radius outer peripheral portion whose radius is small, the first eccentric cam rotating interlockingly with rotation of the feed roller; and a second eccentric cam rotatably provided at the tray, and including a large-radius outer peripheral portion whose radius is large and a small-radius outer peripheral portion whose radius is small, the second eccentric cam being able to engage with the first eccentric cam, wherein, when the respective small-radius outer peripheral portions of the first eccentric cam and the second eccentric cam substantially contact one another, the tray approaches the feed roller so as to be able to convey the sheet, and when the respective large-radius outer peripheral portions of the first eccentric cam and the second eccentric cam substantially contact one another, the tray moves away from the feed roller so as to be unable to convey the sheet.
[0017] In accordance with another aspect of the present invention, there is provided a sheet supplying device comprising: a base; a tray on which a stack of sheets can be placed, the tray being able to be raised and lowered with respect to the base; a feed roller provided rotatably at the base and positioned above the tray, and when the feed roller rotates while frictionally engaging with a topmost sheet of the stack of sheets, the feed roller can convey the sheet; a driving mechanism able to drive the feed roller to rotate; an urging member urging the tray toward the feed roller; a first eccentric cam provided rotatably at the base, and having a first rotating supporting shaft, and including a large-radius outer peripheral portion, whose radius is large, and a small-radius outer peripheral portion, whose radius is small, such that the first rotating supporting shaft is disposed between the large-radius outer peripheral portion and the small-radius outer peripheral portion, the first eccentric cam rotating interlockingly with rotation of the feed roller; a second eccentric cam provided rotatably at the tray, and having a second rotating supporting shaft, and including a large-radius outer peripheral portion, whose radius is large, and a small-radius outer peripheral portion, whose radius is small, such that the second rotating supporting shaft is disposed between the large-radius outer peripheral portion and the small-radius outer peripheral portion; and a third eccentric cam having a third rotating supporting shaft, and including a large-radius outer peripheral portion, whose radius is large, and a small-radius outer peripheral portion, whose radius is small, such that the third rotating supporting shaft is disposed between the large-radius outer peripheral portion and the small-radius outer peripheral portion, wherein the first rotating supporting shaft, the third rotating supporting shaft, and the second rotating supporting shaft are lined up in that order in a vertical direction and are separated from one another and parallel to one another, the third rotating supporting shaft can move translationally in the vertical direction, and in a first case in which the large-radius outer peripheral portion of the first eccentric cam substantially contacts one of the large-radius outer peripheral portion and the small-radius outer peripheral portion of the third eccentric cam, and the large-radius outer peripheral portion of the second eccentric cam substantially contacts another of the large-radius outer peripheral portion and the small-radius outer peripheral portion of the third eccentric cam, the tray moves away from the feed roller so as to be unable to convey the sheet, and in a second case in which the small-radius outer peripheral portion of the first eccentric cam substantially contacts the small-radius outer peripheral portion of the third eccentric cam, and the small-radius outer peripheral portion of the third eccentric cam substantially contacts the small-radius outer peripheral portion of the second eccentric cam, the tray approaches the feed roller so as to be able to convey the sheet.
[0018] In accordance with yet another aspect of the present invention, there is provided a sheet supplying device comprising: a base; a tray on which a stack of sheets can be placed, the tray being able to be raised and lowered with respect to the base; a feed roller provided rotatably at the base and positioned above the tray, and when the feed roller rotates while frictionally engaging with a topmost sheet of the stack of sheets, the feed roller can convey the sheet; a driving mechanism able to drive the feed roller to rotate; an urging member urging the tray toward the feed roller; a first eccentric cam provided rotatably at the base, and having a first rotating supporting shaft, and including a large-radius outer peripheral portion, whose radius is large, and a small-radius outer peripheral portion, whose radius is small, such that the first rotating supporting shaft is disposed between the large-radius outer peripheral portion and the small-radius outer peripheral portion, the first eccentric cam being able to rotate independently of rotation of the feed roller; a second eccentric cam provided rotatably at the tray, and having a second rotating supporting shaft, and including a large-radius outer peripheral portion, whose radius is large, and a small-radius outer peripheral portion, whose radius is small, such that the second rotating supporting shaft is disposed between the large-radius outer peripheral portion and the small-radius outer peripheral portion; and a third eccentric cam having a third rotating supporting shaft, and including a large-radius outer peripheral portion, whose radius is large, and a small-radius outer peripheral portion, whose radius is small, such that the third rotating supporting shaft is disposed between the large-radius outer peripheral portion and the small-radius outer peripheral portion, wherein the first rotating supporting shaft, the third rotating supporting shaft, and the second rotating supporting shaft are lined up in that order in a vertical direction and are separated from one another and parallel to one another, the third rotating supporting shaft can move translationally in the vertical direction, and in a first case in which the large-radius outer peripheral portion of the first eccentric cam substantially contacts one of the large-radius outer peripheral portion and the small-radius outer peripheral portion of the third eccentric cam, and the large-radius outer peripheral portion of the second eccentric cam substantially contacts another of the large-radius outer peripheral portion and the small-radius outer peripheral portion of the third eccentric cam, the tray moves away from the feed roller so as to be unable to convey the sheet, and in a second case in which the small-radius outer peripheral portion of the first eccentric cam substantially contacts the small-radius outer peripheral portion of the third eccentric cam, and the small-radius outer peripheral portion of the third eccentric cam substantially contacts the small-radius outer peripheral portion of the second eccentric cam, the tray approaches the feed roller so as to be able to convey the sheet.
[0019] In accordance with still yet another aspect of the present invention, there is provided an image forming device having a sheet supplying device, the sheet supplying device comprising: a base; a tray on which a stack of sheet-shaped recording media can be placed, the tray being able to be raised and lowered with respect to the base; a feed roller provided rotatably at the base and positioned above the tray, and when the feed roller rotates while frictionally engaging with a topmost recording medium of the stack of recording media, the feed roller can convey the recording medium; a driving mechanism able to drive the feed roller to rotate; an urging member urging the tray toward the feed roller; a first eccentric cam provided rotatably at the base, and including a large-radius outer peripheral portion whose radius is large and a small-radius outer peripheral portion whose radius is small, the first eccentric cam rotating interlockingly with rotation of the feed roller; and a second eccentric cam provided rotatably at the tray, and including a large-radius outer peripheral portion whose radius is large and a small-radius outer peripheral portion whose radius is small, the second eccentric cam able to engage with the first eccentric cam, wherein, when the respective small-radius outer peripheral portions of the first eccentric cam and the second eccentric cam substantially contact one another, the tray approaches the feed roller so as to be able to convey the recording medium, and when the respective large-radius outer peripheral portions of the first eccentric cam and the second eccentric cam substantially contact one another, the tray moves away from the feed roller so as to be unable to convey the recording medium.
[0020] Other objects, features and advantages of the present invention will be apparent to those skilled in the art from the explanation of the preferred embodiments of the present invention illustrated in the appended drawings, and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Preferred embodiments of the present invention will be described in detail based on the following figures, wherein:
[0022] FIG. 1 is a perspective view showing a sheet supplying device relating to a first embodiment of the present invention;
[0023] FIG. 2 is a perspective view showing a receiving portion and a pin which restrict rotation of a second cam of the sheet supplying device of the first embodiment;
[0024] FIGS. 3A through 3D are side views showing workings of the sheet supplying device of the first embodiment;
[0025] FIGS. 4A through 4D are side views showing other workings of the sheet supplying device of the first embodiment;
[0026] FIGS. 5A through 5D are side views showing yet other workings of the sheet supplying device of the first embodiment;
[0027] FIGS. 6A through 6C are side views showing still yet other workings of the sheet supplying device of the first embodiment;
[0028] FIG. 7 is a schematic structural diagram showing an example of an image forming device into which the sheet supplying device of the first embodiment is incorporated;
[0029] FIGS. 8A and 8B are respectively a side view and a perspective view of a sheet supplying device relating to a second embodiment of the present invention;
[0030] FIGS. 9A and 9B are side views showing workings of a sheet supplying device relating to a third embodiment of the present invention;
[0031] FIGS. 10A and 10B are side views showing workings of the sheet supplying device of the third embodiment;
[0032] FIG. 11 is a plan view showing a sheet supplying device relating to a fourth embodiment of the present invention;
[0033] FIGS. 12A through 12C are side views showing workings of the sheet supplying device of the fourth embodiment;
[0034] FIGS. 13A through 13C are side views showing other workings of the sheet supplying device of the fourth embodiment;
[0035] FIGS. 14A and 14B are side views showing workings of a sheet supplying device relating to a fifth embodiment of the present invention;
[0036] FIGS. 15A and 15B are side views showing other workings of the sheet supplying device of the fifth embodiment;
[0037] FIG. 16 is a perspective view showing a conventional sheet supplying device; and
[0038] FIGS. 17A through 17D are side views showing workings of the conventional sheet supplying device.
DETAILED DESCRIPTION OF THE INVENTION
FIRST EMBODIMENT
[0039] Hereinafter, a sheet supplying device of a first embodiment of the present invention will be described in detail with reference to FIGS. 1 through 7 .
[0040] As shown in FIG. 7 , a sheet supplying device 10 is provided at the lower portion of an image forming device 200 , and successively feeds, one-by-one, recording media (sheets) P to a process cartridge 204 structuring an image forming section.
[0041] As shown in FIGS. 1 and 7 , presser plates 14 , on which the sheets P are stacked, are provided in the sheet supplying device 10 . Insertion holes 58 , through which pass poles 56 which stand upright at a base 18 , are formed at both end portions of the presser plate 14 in a direction orthogonal to the sheet feeding direction. The presser plate 14 can move upward and downward while being guided by the poles 56 . The presser plate 14 is urged upward by coil springs 20 provided at the base 18 .
[0042] A supporting shaft 22 is disposed above the presser plate 14 . The supporting shaft 22 is supported so as to be freely rotatable with respect to a main body frame of the image forming device 200 . A half-moon-shaped feed roller 24 , which feeds the sheets P (not shown in FIG. 1 ) which are stacked on the presser plate 14 , is fixed to the supporting shaft 22 . Core rollers 26 , whose radii are somewhat smaller than the radius of the half-moon-shaped feed roller 24 , are fixed to the both sides of the feed roller 24 .
[0043] As shown in FIG. 1 , a separating roller 28 is rotatably supported at the portion of a main body frame 300 opposing the feed roller 24 and the core rollers 26 . The separating roller 28 is formed as a member whose surface has great frictional force. Due to the rotation of the supporting shaft 22 , the core rollers 26 rotate in a state of abutting the separating roller 28 . Further, the peripheral surface of the feed roller 24 can feed the topmost sheet P out by rotating while abutting the stack of sheets P stacked on the presser plate 14 .
[0044] First cams 30 are fixed to both end portions of the supporting shaft 22 . The first cams 30 have arc-shaped portions 30 a which are fan-shaped and whose eccentric radii are larger than the radius of the feed roller 24 .
[0045] A driven gear 32 is mounted to one end portion of the supporting shaft 22 . A portion of the outer periphery of the driven gear 32 is toothless. A driving gear 34 , which is driven to rotate by an unillustrated motor, can mesh with the driven gear 32 . When the sheets P are to be fed, the driving force of the driving gear 34 is transmitted to the driven gear 32 at a predetermined timing by an unillustrated control device, such that the supporting shaft 22 , the feed roller 24 , the core rollers 26 and the first cams 30 rotate one time in the direction of arrow A (see FIGS. 3A through 3D ).
[0046] As shown in FIG. 1 , flanges 36 which project upward are formed at positions of the both sides of the presser plate 14 which positions oppose the first cams 30 . Second cams 38 are rotatably supported by rotating shafts 39 at the flanges 36 . First cam followers 40 , which can abut the first cams 30 , are provided so as to project out at end sides of the flanges 36 , at the sides of the second cams 38 which sides are opposite the sides in the feeding direction. Concave portions 42 are formed beneath the first cam followers 40 . The second cams 38 can enter into the concave portions 42 when the second cams 38 are rotating.
[0047] Second cam followers 44 are mounted to the base 18 beneath the concave portions 42 of the first cam followers 40 . As shown in FIG. 3A , due to the second cams 38 abutting the second cam followers 44 , the second cams 38 are held in a state (posture) in the direction of abutting the first cams 30 . Rollers 46 are provided at the regions of the second cams 38 which regions abut the first cams 30 . Convex and concave portions may be formed in the peripheral surfaces of the rollers 46 in order to prevent slippage between the rollers 46 and the first cams 30 . As shown in FIG. 3A , when the arc-shaped portions 30 a of the first cams 30 , whose eccentric radii are large, abut the portions of the second cams 38 where the eccentric radii are large, the presser plate 14 is pushed downward to its lowermost position.
[0048] Because the coil springs 20 push the presser plate 14 upward, the second cams 38 abut the second cam followers 44 in addition to abutting the first cams 30 .
[0049] When the first cams 30 rotate in the direction of arrow A, components of force which rotate the second cams 38 in the opposite direction so as to counteract this, are applied to the second cams 38 so that the second cams 38 rotate in the direction of arrow B (see FIG. 3C ).
[0050] As shown in FIG. 2 , pins 48 project at the inner sides (the feed roller 24 sides) of the second cams 38 . L-shaped receiving portions 50 , which are structured by the flanges 36 and the first cam followers 40 , are provided at the presser plate 14 . When the second cams 38 rotate in the direction of arrow B, the pins 48 are received in the receiving portions 50 , and rotation of the second cams 38 is restricted due to the self-weights thereof.
[0051] In this sheet supplying device 10 , the number of sheets P which can be stacked on the presser plate 14 (the number of sheets which can be accommodated) is about 250 sheets for regular paper, and about 200 sheets for thick paper.
[0052] Hereinafter, operation of the sheet supplying device 10 will be described with reference to FIGS. 3A through 6C .
[0053] As shown in FIG. 3A , when the sheets P are not being fed, the arc-shaped portions 30 a of the first cams 30 abut the portions of the second cams 38 where the eccentric radii are large, so as to push the presser plate 14 downward in the direction of resisting the urging forces of the coil springs 20 . Pressing forces F in the direction of the arrow and due to the urging forces of the coil springs 20 are applied to the first cams 30 . At this time, the presser plate 14 is positioned at its lowermost position, and the sheets P (not illustrated) stacked on the presser plate 14 are set apart from the feed roller 24 .
[0054] As shown in FIG. 3B , when the first cams 30 rotate in the direction of arrow A due to the rotation of the supporting shaft 22 , components of force in the direction opposite the rotating direction are applied to the second cams 38 which are abutting the first cams 30 , and the second cams 38 rotate in the direction of arrow B while abutting the second cam followers 44 . The rollers 46 of the second cams 38 are abutting the first cams 30 , and the first cams 30 rotate smoothly due to the rollers 46 .
[0055] As the second cams 38 rotate, the eccentric radii of the abutting regions thereof become shorter, and the presser plate 14 is pushed upward by the urging forces of the coil springs 20 . Due to the rotation of the supporting shaft 22 , the feed roller 24 and the core rollers 26 as well rotate in the direction of arrow A.
[0056] As shown in FIG. 3C , when the first cams 30 rotate 40° in the direction of arrow A, the second cams 38 rotate in the direction of arrow B while abutting the second cam followers 44 , and the presser plate 14 rises up smoothly. At this time, the second cams 38 enter into the concave portions 42 of the first cam followers 40 while rotating.
[0057] As shown in FIG. 3D , when the first cams 30 rotate 42.5° in the direction of arrow A, the second cams 38 rotate further in the direction of arrow B while abutting the top portions of the second cam followers 44 , and the presser plate 14 is raised upward by the urging forces of the coil springs 20 . When the second cams 38 rotate further in the direction of arrow B and the pins 48 of the second cams 38 engage with the receiving portions 50 , further rotation of the second cams 38 is impeded.
[0058] As shown in FIG. 4A , when the first cams 30 rotate 50° in the direction of arrow A, the angular positions of the second cams 38 do not change because the pins 48 are engaged with the receiving portions 50 . Accordingly, the second cams 38 come away from the second cam followers 44 . The presser plate 14 rises further due to the abutment of the first cams 30 and the second cams 38 . Then, due to the rotation of the supporting shaft 22 , the feed roller 24 and the core rollers 26 also rotate further in the direction of arrow A.
[0059] The presser plate 14 rises until the topmost portion of the stack of sheets P stacked on the presser plate 14 abuts the feed roller 24 . Then, the stack of sheets P abuts/engages with the feed roller 24 , and due to the feed roller 24 rotating while abutting the topmost sheet P, the sheet P is fed out. At the conveying direction downstream side of the sheet P, the reverse surface side of the sheet P contacts the separating roller 28 at a predetermined pressure. Due to the friction between the sheet P and the separating roller 28 , feeding of the sheets P in an overlapping manner is prevented, and a single sheet P is conveyed.
[0060] When a small number of the stacked sheets is conveyed, as shown in FIG. 4B , when the first cams 30 rotate in the direction of arrow A by 64.43°, the second cams 38 abut bearing portions 30 b of the first cams 30 , and the presser plate 14 reaches it uppermost position.
[0061] When the presser plate 14 is at its uppermost position, the first cam followers 40 provided at the presser plate 14 are positioned rearward of the supporting shaft 22 (i.e., at the side opposite the feeding direction side of the supporting shaft 22 ), such that the first cam followers 40 are prevented from interfering with the supporting shaft 22 . Thereafter, as shown in FIGS. 4C and 4D , when the first cams 30 rotate in the direction of arrow A, the second cams 38 slidingly contact the bearing portions 30 b of the first cams 30 , and the presser plate 14 is held at its uppermost position.
[0062] As shown in FIG. 5A , when the first cams 30 rotate 250.79° in the direction of arrow A, due to the distal ends of the arc-shaped portions 30 a abutting and pressing the first cam followers 40 , the presser plate 14 is pushed in the direction against the urging forces of the coil springs 20 (i.e., is pushed downward).
[0063] As shown in FIG. 5B , when the first cams 30 rotate 270° in the direction of arrow A, the second cams 38 abut the second cam followers 44 due to the lowering of the presser plate 14 . Then, the pins 48 of the second cams 38 separate from the receiving portions 50 , and the second cams 38 rotate in the direction of arrow C while abutting the second cam followers 44 .
[0064] As shown in FIG. 5C , when the first cams 30 rotate 290° in the direction of arrow A, due to the arc-shaped portions 30 a pushing the first cam followers 40 , the presser plate 14 is lowered, and the second cams 38 rotate in the direction of arrow C by abutting the second cam followers 44 .
[0065] As shown in FIGS. 5D and 6A , when the first cams 30 rotate further, the arc-shaped portions 30 a press the presser plate 14 downward while the arc-shaped portions 30 a slide along the first cam followers 40 , and the second cams 38 rotate further in the direction of arrow C by abutting the second cam followers 44 .
[0066] As shown in FIG. 6B , when the first cams 30 rotate 340° in the direction of arrow A, the arc-shaped portions 30 a move away from the first cam followers 40 and abut the second cams 38 .
[0067] As shown in FIG. 6C , due to the first cams 30 rotating 360° in the direction of arrow A (i.e., due to the first cams 30 rotating one time), while the first cams 30 and the rollers 46 abut one another, the second cams 38 are rotated to their initial positions, and the presser plate 14 is pushed downward to its lowermost position.
[0068] In the present sheet supplying device 10 , by rotating the first cams 30 and the second cams 38 respectively, the presser plate 14 is raised and lowered. Therefore, the stroke of the presser plate 14 can be made to be large, and the first cam followers 40 and the supporting shaft 22 do not interfere with one another when the presser plate 14 is at its uppermost position. Therefore, even if the first cams 30 are made to be small, the sheet P accommodating capacity can be increased, and the sheet supplying device 10 can be made to be compact.
SECOND EMBODIMENT
[0069] Hereinafter, a second embodiment of a sheet supplying device relating to the present invention will be briefly described with reference to FIGS. 8A and 8B .
[0070] Note that the same reference numerals are applied to members and portions which were described in the first embodiment, and repeat description will be appropriately omitted.
[0071] In a sheet supplying device 70 shown in FIGS. 8A and 8B , springs 74 , which urge the second cams 38 in the direction of arrow B, are wound around rotating shafts 72 of the second cams 38 . Ones of ends of the springs 74 are attached to the second cams 38 , whereas the other ends are attached to the flanges 36 .
[0072] In this way, as the presser plate 14 rises, the second cams 38 rotate in the direction of arrow B in a state of abutting the second cam followers 44 . On the other hand, when the presser plate 14 falls, the second cams 38 rotate in the direction resisting the urging forces of the springs 74 (i.e., in the direction of arrow C) due to the second cams 38 abutting the second cam followers 44 .
[0073] In this way, by the simple structure of providing the springs 74 which urge the second cams 38 , the behavior of the second cams 38 at times when the presser plate 14 is moving upward and downward can be stabilized.
THIRD EMBODIMENT
[0074] Hereinafter, a third embodiment of a sheet supplying device relating to the present invention will be described briefly with reference to FIGS. 9A, 9B , 10 A, and 10 B.
[0075] Note that the same reference numerals are applied to members and portions which were described in the first and second embodiments, and repeat description will be appropriately omitted.
[0076] In a sheet supplying device 80 shown in FIG. 9B , second cams 82 are rotatably supported at the presser plate 14 via the rotating shafts 39 . Springs such as in the second embodiment are not provided at the second cams 82 .
[0077] Second cam followers 84 , which abut the second cams 82 and rotate the second cams 82 in a given direction, are provided beneath the concave portions 42 of the first cam followers 40 .
[0078] Third cam followers 86 are provided at positions which oppose the second cam followers 84 , with the second cams 82 therebetween. The third cam followers 86 restrict rotation of the second cams 82 in the direction of moving away from the second cam followers 84 .
[0079] The surfaces of the third cam followers 86 which surfaces abut the second cams 82 have configurations which curve along the loci of rotation of the second cams 82 . The third cam followers 86 can make the second cams 82 rotate continuously in the given direction.
[0080] The second cam follower 84 and the third cam follower 86 are formed as an integral part and mounted to the base (see FIG. 1 ).
[0081] Next, operation of the present sheet supplying device 80 will be described.
[0082] As shown in FIG. 9A , the second cams 82 abut the second cam followers 84 and the third cam followers 86 at the both sides. The portions of the second cams 82 where the eccentric radii are large abut the portions of the first cams 30 where the eccentric radii are large. At this time, the presser plate 14 is positioned at its lowermost position against the urging forces of the springs 20 .
[0083] When the first cams 30 rotate in the direction of arrow A due to the rotation of the supporting shaft 22 , components of force in the direction opposite to the direction of rotation of the first cams are applied to the second cams 82 . The second cams 82 rotate in the direction of arrow B while abutting the second cam followers 84 . At this time, because the abutment surfaces of the third cam followers 86 are formed in configurations which curve along the loci of rotation of the second cams 82 , the second cams 82 rotate continuously without joggling. As the second cams 82 rotate, the presser plate 14 rises smoothly.
[0084] As shown in FIG. 9B , due to the rising of the presser plate 14 , the second cams 82 separate from the second cam followers 84 . At this time, the rotation of the second cams 82 is restricted by the pins and the receiving portions (which are not illustrated) (see FIG. 2 ). Then, due to the rotation of the first cams 30 , the presser plate 14 rises up to its uppermost position.
[0085] As shown in FIG. 10A , when the first cams 30 rotate further in the direction of arrow A, the first cams 30 abut the first cam followers 40 and push the presser plate 14 downward. Due to the lowering of the presser plate 14 , the second cams 82 abut the second cam followers 84 , and the second cams 82 rotate in the direction of arrow C (see FIG. 10B ).
[0086] As shown in FIG. 10B , as the presser plate 14 is lowered, the second cams 82 abut the third cam followers 86 , and rotation of the second cams 82 in the direction of arrow C is restricted. Due to the first cams 30 separating from the first cam followers 40 and abutting the second cams 82 , the presser plate 14 is lowered to its lowermost position.
[0087] In this sheet supplying device 80 , the third cam followers 86 are disposed at positions opposing the second cam followers 84 with the second cams 82 therebetween. Therefore, rotation of the second cams 82 in the direction of moving away from the second cam followers 84 can be restricted. As a result, the second cams 82 rotate so as to smoothly follow the second cam followers 84 . Due to such a structure, even if the springs 74 (see FIGS. 8A, 8B ) of the second embodiment are not provided, similar effects can be achieved.
[0088] Note that, instead of mounting the second cam follower 84 and the third cam follower 86 as an integral part to the base (see FIG. 1 ), the second cam follower and the third cam follower may be structured as separate parts, and the third cam follower may be mounted to the presser plate 14 .
FOURTH EMBODIMENT
[0089] Hereinafter, a fourth embodiment of a sheet supplying device relating to the present invention will be described in detail with reference to FIGS. 11 through 13 C.
[0090] Note that the same reference numerals are applied to members and portions which were described in the first embodiment, and repeat description will be appropriately omitted.
[0091] As shown in FIGS. 11 and 12 A, in a sheet supplying device 160 , a supporting shaft 166 is rotatably provided at a main body frame 301 . Oval first cams 150 and rod-shaped members 156 , which are longer than the portions of the first cams 150 where the eccentric radii are large, are fixed to the supporting shaft 166 . As shown in FIG. 11 , the free end of the rod-shaped member 156 is bent inwardly and forms an abutment portion 156 a which abuts the first cam follower 40 of the presser plate 14 .
[0092] Oval second cams 154 are rotatably supported at the presser plate 14 by the rotating shafts 39 . The second cams 154 abut second cam followers 164 which are mounted to the main body frame 301 (not shown in FIGS. 12A through 12C ), and are urged in the direction of arrow B by unillustrated springs.
[0093] As shown in FIG. 11 , long holes 159 , 161 which extend in the vertical direction are formed in the first cam follower 40 and the main body frame 301 . A rotating shaft 158 of an oval third cam 152 is slidable in the vertical direction along the long holes 159 , 161 . The third cams 152 can abut second cam followers 162 which are mounted to the main body frame 301 (not shown in FIGS. 12A through 12C ). The third cams 152 are urged in the direction of arrow C by springs which are not shown.
[0094] The first cams 150 are driven to rotate in the direction of arrow A due to the rotation of the supporting shaft 166 . The third cams 152 and the second cams 154 are driven cams which rotate following the rotation of the first cams 150 .
[0095] As shown in FIG. 12A , the supporting shaft 166 of the first cams 150 and the rod-shaped members 156 is a different shaft than the supporting shaft 22 of the feed roller 24 , and can be driven to rotate separately from the feed roller 24 .
[0096] Next, operation of the present sheet feeding device 160 will be described with reference to FIGS. 12A through 12C and FIGS. 13A through 13C .
[0097] As shown in FIG. 12A , the presser plate 14 is pushed downward to its lowermost position due to respective portions of the first cams 150 , the third cams 152 , and the second cams 154 , at which portions the eccentric radii are large, abutting one another and the abutment portions 156 a of the rod-shaped members 156 abutting the first cam followers 40 .
[0098] As shown in FIG. 12B , when the first cams 150 rotate in the direction of arrow A, accompanying this rotation, the rod-shaped members 156 also rotate, and the abutment portions 156 a separate from the first cam followers 40 . As the first cams 150 rotate, the third cams 152 rotate followingly in the direction of arrow C (which is the urging direction of the unillustrated springs) while abutting the second cam followers 162 . As the third cams 152 rotate, the rotating shafts 158 begin to slide along the long holes 159 .
[0099] As the third cams 152 rotate, the second cams 154 rotate in the urging direction of the unillustrated springs (the direction of arrow B) while abutting the second cam followers 164 . Due to such rotation of the first cams 150 and the third cams 152 and the second cams 154 , the presser plate 14 rises upward due to the urging forces of the springs 20 .
[0100] As shown in FIG. 12C , when the first cams 150 rotate further in the direction of arrow A, the third cams 152 rotate further in the direction of arrow C, and the rotating shafts 158 slide in the long holes 159 . Accompanying this, the second cams 154 also rotate in the direction of arrow B. When the third cams 152 and the second cams 154 have respectively rotated 90°, rotation thereof is restricted due to the unillustrated pins and receiving portions.
[0101] Due to the portions of the first cams 150 , the third cams 152 , and the second cams 154 , at which portions the eccentric radii are small, abutting one another, the presser plate 14 rises to its topmost position. At this time, the first cam followers 40 do not interfere with the abutment portions 156 a of the rod-shaped members 156 and the supporting shaft 166 of the first cams 150 . When the presser plate 14 is raised, the sheets P are supplied by the feed roller 24 (see FIG. 1 ).
[0102] Thereafter, as shown in FIG. 13A , when the first cams 150 rotate in the direction of arrow A, the abutment portions 156 a of the rod-shaped members 156 abut the first cam followers 40 , and push the presser plate 14 downward against the urging forces of the springs 20 .
[0103] As shown in FIG. 13B , when the first cams 150 rotate further in the direction of arrow A, the first cams 150 abut the third cams 152 , and the third cams 152 abut the second cam followers 162 , and the third cams 152 rotate in the direction of arrow E which is opposite to the urging forces of the springs (not shown). Together therewith, the rotating shafts 158 of the third cams 152 are slid along the long holes 159 . The second cams 154 , which are abutting the third cams 152 , abut the second cam followers 164 and rotate in the direction of arrow D which is opposite to the urging forces of the springs (not shown).
[0104] As shown in FIG. 13C , when the first cams 150 have rotated one time in the direction of arrow A, the rotating shafts 158 of the third cams 152 slide along the long holes 159 , and the portions of the first cams 150 , the third cams 152 , and the second cams 154 , at which portions the eccentric radii are large, abut one another. In this way, the presser plate 14 falls to its lowermost position.
[0105] In the present sheet supplying device 160 , the presser plate 14 is raised and lowered by the combination of the three cams. Therefore, even if the eccentric radii of the respective cams 150 , 152 , 154 are not made to be large, the stroke of the presser plate 14 can be made to be large. Therefore, the sheet P accommodating capacity can be increased, and the device can be made compact overall.
FIFTH EMBODIMENT
[0106] Hereinafter, a fifth embodiment of a sheet supplying device relating to the present invention will be described in detail with reference to FIGS. 14A, 14B and FIGS. 15A, 15B .
[0107] Note that the same reference numerals are applied to members and portions which were described in the first and fourth embodiments, and repeat description will be appropriately omitted.
[0108] As shown in FIG. 14A , first cams 170 are provided so as to be rotatable by a supporting shaft 176 at the main body frame (not illustrated) of a sheet supplying device 180 . The supporting shaft 176 is driven to rotate separately from the supporting shaft 22 of the feed roller 24 . Second cams 174 are rotatably supported by rotating shafts 182 at the presser plate 14 . The second cams 174 can abut the second cam followers 164 . Springs for urging in a given direction are not provided at the second cams 174 .
[0109] Third cams 172 are rotatably supported by rotating shafts 178 between the first cams 170 and the second cams 174 , so as to abut the first cams 170 and the second cams 174 . The rotating shafts 178 can slide vertically along long holes (not illustrated) provided in the main body frame. The third cams 172 can abut the second cam followers 162 . Springs for urging in a given direction are not provided at the third cams 172 .
[0110] The first cams 170 are driven to rotate 900 in opposite directions (the direction of arrow A and the direction of arrow D), due to the rotation of the supporting shaft 176 . The third cams 172 and the second cams 174 are driven cams which rotate followingly accompanying the rotation of the first cams 170 .
[0111] Next, operation of the present sheet supplying device 180 will be described.
[0112] The presser plate 14 is pushed downward to its lowermost position due to the respective portions of the first cams 170 , the third cams 172 , and the second cams 174 , at which portions the eccentric radii are large, abutting one another.
[0113] As shown in FIG. 14A , when the first cams 170 rotate in the direction of arrow A, the third cams 172 rotate followingly in the direction of arrow C while abutting the second cam followers 162 . Together therewith, the rotating shafts 178 start to slide. Due to the rotation of the third cams 172 , the second cams 174 rotate followingly in the direction of arrow B while abutting the second cam followers 164 . Due to the rotation of the first cams 170 and the third cams 172 and the second cams 174 , the presser plate 14 rises upward due to the urging forces of the springs 20 .
[0114] As shown in FIG. 14B , at the time when the first cams 170 rotate 90 ° in the direction of arrow A due to the rotation of the supporting shaft 176 , when the third cams 172 followingly rotate 90 ° in the direction of arrow C, the rotation of the third cams 172 is restricted due to the pins and the receiving portions which are not shown. Accompanying the rotation of the third cams 172 , the second cams 174 also followingly rotate 90 ° in the direction of arrow B, and the rotation of the second cams 174 is restricted due to the pins and the receiving portions which are not shown.
[0115] Due to respective portions of the first cams 170 , the third cams 172 , and the second cams 174 , at which portions the eccentric radii are small, abutting one another, the presser plate 14 rises to its topmost position. When the presser plate 14 is raised, the sheets P are supplied by the feed roller 24 (see FIG. 1 ).
[0116] Thereafter, as shown in FIG. 15A , when the first cams 170 are driven to rotate in the direction of arrow D (the direction opposite to the direction of arrow A) by the supporting shaft 176 , the lowering of the presser plate 14 due to the rotation of the first cams 170 begins. At this time, the third cams 172 and the second cams 174 remain stopped because their rotation is restricted.
[0117] As shown in FIG. 15B , when the first cams 170 rotate further in the direction of arrow D, the third cams 172 abut the second cam followers 162 , and thereby rotate followingly in the direction of arrow E.
[0118] Moreover, due to the second cams 174 abutting the second cam followers 164 , the second cams 174 rotate followingly in the direction of arrow F, and push the presser plate 14 downward.
[0119] The presser plate 14 moves downward to its lowermost position due to the first cams 170 rotating further in the direction of arrow D, and the portions of the first cams 170 , the third cams 172 , and the second cams 174 , at which portions the eccentric radii are large, abutting one another.
[0120] In the present sheet supplying device 180 , the presser plate 14 can be moved upward and downward by the combination of the three cams. Therefore, even if the eccentric radii of the respective cams 170 , 172 , 174 are not made to be large, the stroke of the presser plate 14 can be made to be large. Therefore, the sheet P accommodating capacity can be increased, and the device can be made compact overall.
EMBODIMENT OF THE IMAGE FORMING DEVICE
[0121] Lastly, an embodiment of an image forming device, to which the sheet supplying device 10 of the first embodiment is applied, will be described in detail with reference to FIG. 7 .
[0122] The process cartridge 204 , in which an image forming section has been integrally formed into a unit, is provided in the present image forming device 200 . A photosensitive body drum 216 , which rotates in a given direction, is provided at the interior of the process cartridge 204 . A charging roller 218 , which charges the photosensitive drum, a developing roller 220 , which develops an electrostatic latent image formed on the photosensitive body drum, and a transfer roller 222 , which transfers the developed toner image on the photosensitive body drum onto the sheet P, are disposed at the periphery of the photosensitive body drum 216 from the rotating direction upstream side. A cleaning member 224 , which cleans the surface of the photosensitive body drum after transfer, is provided at the downstream side of the transfer roller 222 in the rotating direction of the photosensitive body drum 216 . An exposure device 214 , which illuminates image light onto the photosensitive body drum 216 , is provided in the image forming device 200 between the charging roller 218 and the developing roller 220 .
[0123] The sheet supplying devices 10 of the present invention, in which the sheet-shaped sheets P are stacked, are provided in two levels, one above the other, at the lower portion of the image forming device 200 . Feeding cassettes 206 , 208 , in which the sheets P of respectively different sizes can be accommodated, are disposed at the sheet feeding devices 10 so as to be able to be pulled out to the exterior thereof. The feed rollers 24 , which remove and convey the sheets P one-by-one as described above, are provided at the sheet P removing positions of the feeding cassettes 206 , 208 .
[0124] Two sets of conveying rollers 210 , 211 and conveying rollers 212 , 213 are provided which convey the sheets P, which have been supplied from the feed rollers 24 , to a position opposing the photosensitive body drum 216 and the transfer roller 222 . A fixing unit 250 , which is provided with a heat roller 252 and a pressure roller 254 , is installed at the downstream side of the transfer roller 22 in the conveying direction of the sheets P. A discharged sheet tray 230 , to which the sheets P are discharged after fixing, is provided at the downstream side of the fixing unit 250 .
[0125] An opening/closing cover 232 is provided at the image forming device 200 . By opening the opening/closing cover 232 , the fixing unit 250 can be installed in the image forming device 200 . When the fixing unit 250 is installed in the image forming device 200 , simultaneously therewith, a connector of the fixing unit 250 and a connector of the image forming device 200 are joined together. By closing the opening/closing cover 232 , the image forming device 200 is set in a state in which operation is possible.
[0126] In this image forming device, an electrostatic latent image is formed on the surface of the photosensitive body drum 216 due to the photosensitive body drum 216 being charged by the charging roller 218 and image light being illuminated thereon from the exposure device 214 . The electrostatic latent image is developed by the developing roller 220 , such that a toner image is formed on the photosensitive body drum 216 .
[0127] The sheet P is supplied from the feeding cassette 206 of the sheet supplying device 10 due to the rotation of the feed roller 24 , and the sheet P is conveyed by the conveying rollers 210 , 211 and the conveying rollers 212 , 213 to the position opposing the photosensitive body drum 216 and the transfer roller 222 . Then, the toner image on the photosensitive body drum 216 is transferred onto the sheet P by the transfer roller 222 . Due to the application of heat and pressure between the heat roller 252 and the pressure roller 254 of the fixing unit 250 , the toner image on the sheet P is fused such that the image is fixed on the sheet P. Thereafter, the sheet P on which the image has been formed is discharged out to the discharged sheet tray 230 .
[0128] In the image forming device 200 in which the sheet supplying device 10 of the first embodiment is incorporated, when the presser plate 14 is raised up and the sheet P is supplied by the rotation of the feed roller 24 , the presser plate 14 and the supporting shaft 22 of the feed roller 24 do not interfere with one another, and the accommodating capacity of the sheets P can be increased even if the first cams 30 are not made to be large. Namely, the sheet supplying device 10 , and accordingly, the image forming device 200 , can be made to be compact.
[0129] Note that, instead of the sheet supplying device 10 of the first embodiment, any of the sheet supplying devices of the second through fifth embodiments can be incorporated into the image forming device. In this way, the sheet P accommodating capacity can similarly be increased, and the image forming device can be made to be compact.
|
A sheet supplying device has: a base; a tray; a feed roller provided rotatably at the base and positioned above the tray. When the feed roller rotates while frictionally engaging with a topmost sheet of the stack of sheets, the feed roller can convey the sheet. The sheet supplying device further includes a driving mechanism able to drive the feed roller to rotate; an urging member urging the tray toward the feed roller; a first eccentric cam rotatably provided at the base, and including a large-radius outer peripheral portion and a small-radius outer peripheral portion, the first eccentric cam rotating interlockingly with rotation of the feed roller; and a second eccentric cam rotatably provided at the tray, and including a large-radius outer peripheral portion and a small-radius outer peripheral portion, the second eccentric cam being able to engage with the first eccentric cam.
| 1
|
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the priority of German Patent Application, Serial No. 10 2012 015 644.8, filed Aug. 7, 2012, pursuant to 35 U.S.C. 119(a)-(d), the content of which is incorporated herein by reference in its entirety as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a spring, and more particularly to a load-bearing spring for a motor vehicle.
[0003] The following discussion of related art is provided to assist the reader in understanding the advantages of the invention, and is not to be construed as an admission that this related art is prior art to this invention.
[0004] Springs find application in many fields, e.g. as load-bearing spring used for a motor vehicle and associated to a shock absorber or forming part thereof. With such a shock absorber with load-bearing spring, individual wheels of the vehicle are supported by the vehicle body. For this use, the spring is normally implemented as helical spring with cylindrical base configuration. In addition, springs have been known of different geometric configuration, e.g. spiral springs, leaf spring, disk springs etc. Such springs also find wide application. The task of such springs is to absorb and to reduce or store forces. When exposed to a force, the spring deforms and undergoes a change in geometry.
[0005] Springs permit a relative movement between two dynamically coupled components and provide an energy store. Some applications, for example in a motor vehicle, involve a control of driver assist or regulating systems which impact the operation of the motor vehicle and may involve an electronic stability program (ESP), anti-lock braking system (ABS), automatic damping system etc. For such applications, it would be useful to have information about actual force conditions in the area of the spring for example or also about other areas of interest.
[0006] It would therefore be desirable and advantageous to provide an improved spring to obviate prior art shortcomings and to enable determination of information especially about actual force conditions in the area of the spring.
SUMMARY OF THE INVENTION
[0007] According to one aspect of the present invention, a spring made of a fiber composite includes a metal thread connected to the spring and having an electrical resistance which changes in dependence on a deformation of the spring.
[0008] The present invention resolves prior art problems by providing a spring of fiber composite with at least one metal thread which is firmly connected to the spring and configured to follow any deformation of the spring as a result of a change in geometry caused by forces exerted on the spring. As the metal thread tracks the change in geometry of the spring, the electric resistance of the metal thread changes. This electric resistance can now be easily detected using a suitable control device that is operably connected to the metal thread. The measured actual resistance correlates with a respective deformation of the spring which in turn correlates necessarily with defined force conditions. By integrating the spring according to the invention in the form of four load-bearing springs in a motor vehicle, a defined initial state can be established, when the vehicle is in idle state and not subject to a load. This idle state can be used for example as reference state. Any stress on the vehicle, e.g. by weight or load change during operation, causes a respective change in geometry of the metal threads, thereby causing defined changes in resistance. By determining the respective resistance, a precise correlation can be established in relation to the introduced force, i.e. the spring force or wheel contact force can be directly ascertained.
[0009] Depending on the application of the spring according to the invention in the motor vehicle, this information can now be used to control respective driver assist or regulating systems such as electronic stability program, anti-lock braking system or damping control for influencing the chassis. In addition, determination of the wheel contact force may also be used to utilize maximum adhesion potential of the tires on the road surface.
[0010] As metal thread, any type of thread may be used which has a defined, advantageously linear resistance profile in dependence on a deformation of the spring. Presence of a linear resistance profile is preferred, although not required of course. It is sufficient, when basically a defined correlation between resistance and thread geometry is known and can be stored in the control device.
[0011] For applications in motor vehicles, there is basically the possibility to store resistance-force characteristic diagrams with respect to different temperatures, for example staggered in intervals. The electric resistance is a function of the temperature. In order to be able to still correctly determine the respective force condition also under extreme situations of great temperature fluctuations, as encountered during operation of a motor vehicle between temperatures of up to −40° and temperatures of up to +40°, the provision of a temperature-staggered presence of characteristic diagrams is useful. The given temperature can easily be ascertained by equipping the motor vehicle with a temperature sensor which measures the outside temperature so that the control device can then select the respective, temperature-related characteristic diagram and determine the respective forces in combination with the resistance measurement.
[0012] Although it is generally sufficient to provide the spring with only a single metal thread, it may be appropriate in some instances to provide several metal threads whose change in resistance can be determined separately. As a result, there is the possibility to obtain redundant resistance values so as to ensure the measurement of at least one resistance value when, for whatever reasons, a metal thread fails. Moreover, determination of several resistance values allows a check of plausibility of a leading resistance value through comparison with the other resistance values and when affirming the plausibility to use the leading resistance value as basis for the further control/regulation.
[0013] The metal thread may be arranged in various geometric ways. For example, the metal thread can be integrated inside the spring. It is also conceivable to arrange the metal thread on an outer side of the spring, optionally underneath a respective protective paint or the like. A metal thread may, for example, extend longitudinally along the spring, i.e. in parallel relationship to the inner core and embedded in the fiber composite, e.g. a resin-fiber-matrix. This is possible, when the matrix forms the desired shape by winding resin-impregnated fiber fabric or the like about the core which is elongated in initial state, and subsequent compression molding. As an alternative, it is also conceivable to wind the metal thread(s) helically about the inner core.
[0014] According to another advantageous feature of the present invention, the metal thread has ends which can be guided outwards from the fiber composite (resin-fiber-matrix) for allowing contacting. Advantageously, the ends of the metal thread can be guided outwards from ends of the spring to realize a greatest possible length of the integrated metal thread. The thread ends may have appropriate terminals for contact and connection to the control device.
[0015] According to another advantageous feature of the present invention, the fiber composite can be made of GFRP (glass fiber reinforced plastic) or CFRP (carbon fiber reinforced plastic). The fiber composite may, of course, also be made of any other suitable material.
[0016] The spring may be configured in any suitable shape or form. For example, the spring may be constructed in the form of a helical spring, spiral spring, leaf spring, disk spring, or torsion bar spring. Of course, other spring types are conceivable as well.
[0017] According to another aspect of the present invention, a motor vehicle includes a vehicle wheel, and a damping device having a spring made of a fiber composite and including a metal thread which is connected to the spring and has an electrical resistance which changes in dependence on a deformation of the spring.
[0018] According to another advantageous feature of the present invention, a control device can be provided and configured to determine a force value, commensurate with a spring force or a wheel contact force, in response to an ascertained resistance value, and to control at least one operating system of the motor vehicle as a function of the determined force value. As described above, any type of driver assist or regulating system of the vehicle may be involved hereby.
[0019] According to another advantageous feature of the present invention, the control device can be configured to determine a plausibility of the ascertained resistance value as a function of further resistance values, as ascertained on a spring. This assumes that each individual spring has at least two metal threads which deliver separate geometry-dependent resistance values.
[0020] According to another advantageous feature of the present invention, the control device can be configured to separately ascertain resistance values of a plurality of metal threads of the spring, and to determine an averaged or weighted force value as a function of all ascertained resistance values.
[0021] According to another advantageous feature of the present invention, the control device can be configured to store plural characteristic diagrams associated to defined temperatures or temperature intervals and relating to a geometry-dependent resistance profile of the metal thread, and to select a temperature-associated one of the characteristic diagrams in dependence on an ascertained room temperature. The thus-selected characteristic diagram can subsequently be used as basis for the force value determination. The temperature dependence of the resistance profile, although preferably slight, can also be taken into account for the force value determination.
BRIEF DESCRIPTION OF THE DRAWING
[0022] Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
[0023] FIG. 1 is a basic illustration of a spring according to the present invention in the form of a helical spring useful as load-bearing spring for a motor vehicle;
[0024] FIG. 2 is a sectional view of one embodiment of a spring with metal thread;
[0025] FIG. 3 is a sectional view of another embodiment of a spring with metal thread; and
[0026] FIG. 4 is a simplified, schematic illustration of a motor vehicle according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0027] Throughout all the figures, same or corresponding elements may generally be indicated by same reference numerals. These depicted embodiments are to be understood as illustrative of the invention and not as limiting in any way. It should also be understood that the figures are not necessarily to scale and that the embodiments are sometimes illustrated by graphic symbols, phantom lines, diagrammatic representations and fragmentary views. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted.
[0028] Turning now to the drawing, and in particular to FIG. 1 , there is shown a basic illustration of a spring according to the present invention, generally designated by reference numeral 1 and configured in the form of a helical spring useful as load-bearing spring for a motor vehicle. The spring 1 is made of fiber composite. By way of example, FIGS. 2 and 3 show two embodiments of the spring 1 of fiber composite, comprised of a cured matrix 2 which is made of resin or the like, in which a plurality of individual threads 3 , for example glass fibers or carbon fibers, are dispersed. Even though FIGS. 2 and 3 show a random arrangement of the fibers 3 , it is, of course, also conceivable, to integrate the fibers in the form of a woven or non-woven fabric, i.e. with aligned fibers. FIGS. 2 and 3 thus show merely basic illustrations by way of example.
[0029] As shown in FIGS. 2 and 3 , the spring 1 has an inner core 4 which is made, for example, of elastic material. The provision of such a core 4 is, however, not necessarily required. Arranged about the core 4 is the resin matrix 2 and the fibers 3 to stiffen the entire spring 1 and to predominantly define the spring characteristics.
[0030] As shown in FIGS. 1-3 , a metal thread 5 is integrated in the spring 1 and, as shown in FIG. 1 , is guided outwards at the ends of the spring 1 and connected at respective contact points to a control device 10 via a line connection. The metal thread 5 is made of a material which has a greatest possible change in resistance in response to a change in geometry of the metal thread 5 , caused by a change in geometry of the spring 1 . The metal thread 5 is embedded firmly and immobile in the resin matrix 2 so as to precisely track even a slightest spring movement or change in geometry of the spring 1 . As a result, the metal thread 5 is also caused to undergo a geometric change. This, in turn, results in a change of the electric resistance of the metal thread 5 . The change of the electric resistance may hereby be slight. The control device 10 measures the electric resistance by applying a small measuring current so that the measured resistance value can be used to determine the momentary force which correlates to the change in geometry of the spring and thus to the change in resistance. Knowledge of this force value can then be used for control or regulation of subsystems, as will be described with reference to FIG. 4 .
[0031] As shown in FIG. 2 , the metal thread 5 is integrated in the spring 1 to run virtually longitudinally along and in parallel relation to the inner core 4 . The metal thread 5 thus extends along the length of the spring 1 , i.e. the length of the metal thread 5 roughly corresponds to the length of the spring 1 . Such a course of the metal thread 5 can, for example, be building up the matrix 2 and the fibers 3 for example via resin-impregnated fiber fabrics and winding thereof about the core 4 . The metal thread 5 can be placed between two such layers. Subsequently, the longitudinal winding is transformed into the desired spring shape and the matrix 2 is cured.
[0032] FIG. 3 shows an example in which the metal thread 5 is wound helically about the inner core 4 , i.e. the metal thread 5 winds like a double helix about the core 4 but also about the central spring axis according to the helical shape of the spring 1 . The dotted line indicates a winding of the metal thread 5 about the core 4 . Such a guidance of the metal thread 5 becomes possible for example by winding the matrix 2 including the fibers 3 about the inner core 4 via rotating fiber drums from which the fibers are payed out. The metal thread 5 can be fed via such a drum so as to incorporate a multilayered wound fiber structure.
[0033] Any curable matrix may be used as matrix 2 , advantageously on polymer basis such as, for example, epoxy resin or the like. Any metal thread that changes its resistance geometry-dependent in a defined manner may be used as metal thread 5 .
[0034] Referring now to FIG. 4 , there is shown a simplified, schematic illustration of a motor vehicle according to the present invention, generally designated by reference numeral 6 . The motor vehicle 6 has four wheels 7 of which only two are shown in FIG. 4 . Each wheel 7 is operably connected to a damping device 8 which includes a shock absorber 9 and a spring 1 according to the present invention. Each spring 1 has at least one metal thread 5 . Each metal thread 5 is connected via respective lines with the control device 10 which is capable to ascertain the electric resistance of each individual metal thread 5 . As shown by the basic illustration of FIG. 4 , the control device 10 stores one or more characteristic curves 11 which indicate the resistance profile and the associated force applied on the respective spring 1 . The respective characteristic curve forms the basis from which the actual force values such as spring force or wheel contact force can be computed, as will be described hereinafter. These force values can be fed to the control or regulation of further associated driver assist systems 12 (e.g. ESP system), 13 (e.g. ABS system), or 14 (e.g. automatic damping control).
[0035] As further shown in FIG. 4 , the motor vehicle 6 is equipped with a temperature sensor 15 which provides information about the ambient or room temperature in the area of the springs 1 , i.e. measures ultimately the outside temperature. Several temperature-specific characteristic diagrams can be stored in the control device 10 and are associated to defined temperatures or defined temperature intervals. On the basis of determined actual ambient temperature, the control device 10 selects the associated characteristic curve which then forms the basis for the subsequent control.
[0036] Even though FIGS. 1-3 show springs having a single metal thread 5 , it is, of course, conceivable to provide the spring 1 with two or more separate metal threads 5 . Each individual metal thread 5 thus changes its resistance as the spring undergoes a change in geometry. The control device 10 is able to determine the change in resistance of each of the metal threads 5 . The individual resistance values may be analyzed for plausibility purposes or may be averaged.
[0037] As described above with reference to the exemplary embodiment of FIG. 4 , the respective force values are determined on the basis of characteristic curves. This represents only one option. It is also conceivable to determine the force values through computation according to the following relationship:
[0000]
R
=
ρ
1
A
=
ρ
4
·
1
D
2
·
π
[0000] wherein:
ρ: specific resistance l: is wire length A: cross sectional area D: diameter of wire
[0042] The change in resistance at stress is generally:
[0000]
Δ
R
=
δ
R
δρ
·
Δρ
+
δ
R
δ
1
·
Δ
1
+
δ
R
δ
d
·
Δ
d
[0043] Through differentiation and transformation, the relative change in resistance can be computed by the following relationship:
[0000]
Δ
R
R
=
Δρ
ρ
+
Δ
1
1
-
2
·
Δ
d
d
[0044] The relative change in resistance is dependent on the length and transverse elongation:
[0000]
ɛ
=
Δ
1
1
and
ɛ
ρ
=
Δ
d
d
=
-
μ
·
ɛ
.
[0045] As a result, it follows:
[0000]
Δ
R
R
=
k
·
Δ1
1
=
k
·
ɛ
[0000] wherein κ represents the so-called k-factor:
[0000]
k
=
Δρ
ρ
·
ɛ
+
1
+
2
·
μ
[0000] wherein:
ε: relative change in length ε ρ : relative change in cross section μ: transverse strain k: k factor.
[0050] The spring force is determined for a helical spring with metal thread 5 in the outermost layer according to the relationship:
[0000]
F
=
π
d
3
·
ɛ
·
G
8
Dm
[0000] wherein:
F: force D: diameter of the thread ε: elongation G: shear modulus D m : mean diameter of the helical spring cylinder.
[0056] While the invention has been illustrated and described in connection with currently preferred embodiments shown and described in detail, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit and scope of the present invention. The embodiments were chosen and described in order to explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
[0057] What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims and includes equivalents of the elements recited therein:
|
A spring made of a fiber composite includes a metal thread which is connected to the spring and has an electrical resistance which changes in dependence on a deformation of the spring. The metal thread can be integrated inside the spring or may also be arranged on an outer side of the spring.
| 5
|
TECHNICAL FIELD
This invention relates generally to interconnected lock assemblies used to secure doors. More particularly, the present invention relates to an interconnected lock assembly which provides a feature to remotely lock the interconnected lock assembly. This application claims the benefit of U.S. Provisional Application No. 60/176,996 filed Jan. 19, 2000, herein incorporated by reference.
BACKGROUND OF THE INVENTION
An interconnected lock assembly is characterized by an inside handle, either knob or lever, which simultaneously retracts both a deadlatch and a deadbolt. Such a lock assembly is commonly found in public accommodations such as hotels and motels in which, for security purposes, the occupant wishes to set both a deadlatch and a deadbolt. The same type of lock assembly may also be found in a residential or other environments. It is particularly important that both locks be retracted by the turning of a single inside operating member as it has been found that in the event of a fire or other panic situation it is desirable that the occupant only need turn a single knob or lever to operate all of the lock mechanisms in a particular door.
Such interconnected lock assemblies have been on the market for a number of years. Some interconnected lock assemblies are adjustable to compensate for varying distances between the latch assemblies. The adjustable feature is particularly helpful if there is a slight misalignment of the latch assembly bores, or when retrofitting an existing door if the distance between bore centerlines is not the same as the distance between the latch assemblies of the interconnected lock. U.S. Pat. No. 6,128,933 discloses an adjustable interconnected lock which enables interconnection of an exterior assembly that has an adjustable spacing between the exterior dead bolt assembly and a lower lock assembly.
One problem with interconnected lock assemblies is that when leaving, the user can open the door by using just the interior handle, even if the door is locked, but must use a key to lock the door behind them. This can provide an inconvenience especially when the keys are not readily available, the user is carrying objects, the user does not have a key, or the user is in a hurry. Thus the convenience and ease of operation provided by the interconnect lock is lost.
The foregoing illustrates limitations known to exist in present interconnected lock assembly designs. Thus, it is apparent that it would be advantageous to provide an alternative directed to overcoming one or more of the limitations set forth above. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an interconnected lock assembly with a locking mechanism which can throw the deadbolt and lock the door in response to a remote control signal. This and other objects of the present invention are provided by an interconnected lock assembly for mounting in a door. The interconnected lock comprising a first lock assembly including an inside handle and an outside handle, and a second lock assembly interconnected to said first lock assembly. The second lock assembly comprises a deadbolt assembly operably connected to a deadbolt latch. The deadbolt latch comprises a deadbolt movable between an extended position and a retracted position. The interconnected lock further comprises a locking mechanism selectively engageable by a remote control signal to move the deadbolt to an extended position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of the interconnected lock assembly with remote locking of the present invention;
FIG. 2 is a perspective view of the assembled interconnected lock assembly with remote locking in accordance with the present invention of FIG. 1;
FIG. 3 is a side elevational view of the assembled interconnected lock assembly with remote locking, shown without the escutcheon assembly, in accordance with the present invention of FIG. 1;
FIG. 4A is an rearward perspective view of the escutcheon assembly, in accordance with the present invention of FIG. 1;
FIG. 4B is an frontal perspective view of the escutcheon assembly, in accordance with the present invention of FIG. 1;
FIG. 5 is an exploded perspective view of the backplate assembly in accordance with the present invention of FIG. 1;
FIG. 6A is a partial side elevational view of the backplate assembly with the carrier component removed and the remote locking solenoid removed, showing the catch mechanism components;
FIG. 6B is a partial side elevational view of the backplate assembly with the carrier component removed and the remote locking solenoid removed, revealing the catch mechanism in a disengaged catch position;
FIG. 7A is an partially exploded perspective view of the deadbolt latch assembly and strike plate showing the deadbolt in an extended position;
FIG. 7B is an partially exploded perspective view of the deadbolt latch assembly and strike plate showing the deadbolt in a partially extended position;
FIG. 7C is an partially exploded perspective view of the deadbolt latch assembly and strike plate showing the deadbolt in a retracted position;
FIG. 8A is a partial side elevational view of the backplate assembly with the carrier component removed, revealing the remote locking mechanism components;
FIG. 8B is a partial side elevational view of the backplate assembly with the carrier component removed, revealing the remote locking mechanism in a disengaged catch position; and
FIG. 9 is a top plan view of the remote locking transmitter used with the remote locking feature of the present invention.
DETAILED DESCRIPTION
Referring now to the drawings, wherein similar reference characters designate corresponding parts throughout the several views, there is generally indicated at 10 an adjustable interconnected lock assembly with a remote locking feature of the present invention. Referring specifically to FIGS. 1 and 2, lock assembly 10 comprises a first or lower interconnected lock assembly 18 comprising outside housing assembly 12 , rose 14 , and outside knob/lever 16 , attached from the outside of a door (not shown) through a first or lower bore in the door, and through a back plate assembly 20 positioned on the inside of the door, to inside housing assembly 22 . Interconnect cam 24 , escutcheon assembly 28 , and inside knob/lever 26 are attached to inside housing assembly 22 on the inside of the door. Although not shown, a latch assembly could be operably connected between outside housing assembly 12 and inside housing assembly 22 . Interconnected lock assembly 10 also comprises a second or upper interconnected lock assembly 40 comprising a deadbolt housing assembly 42 and a deadbolt latch assembly 44 . Deadbolt housing assembly 42 is attached from the outside of the door through a second or upper bore and operably connected to deadbolt latch assembly 44 , and through back plate assembly 20 and secured thereto by deadbolt plate 46 and mounting screws 48 . Deadbolt housing assembly 42 is operably connected to a deadbolt pinion 50 which engages a deadbolt rack 52 connected to back plate assembly 20 as discussed in detail below. The lower interconnected lock 18 and upper interconnected lock 40 are standard configurations that are well-known in the art, and as such, the workings of these locks will not be described in detail, except as they relate to the present invention.
Referring now to FIG. 3, interconnected lock 10 shown with escutcheon assembly 28 removed. Back plate assembly 20 comprises a carrier component 54 vertically movable on, and slidably attached to a back plate 56 by a plurality of tangs 58 . Deadbolt rack 52 is oriented vertically and fixedly attached to carrier component 54 such that it engages pinion 50 . Interconnected lock 10 is adjustable in that upper lock assembly 40 can move up or down to properly fit the upper bore of the door. Deadbolt plate 46 is movable within a slot 62 in back plate 56 to allow the proper positioning of upper lock assembly 40 . Upper lock assembly 40 is then secured to deadbolt plate 46 by mounting screws 48 which secure upper lock assembly 40 in a fixed position. Deadbolt assembly 42 is operably connected to deadbolt pinion 50 by a driver bar 60 which is co-rotatingly attached to deadbolt pinion 50 . Carrier component 54 is shown in a 15 raised, or unlock position. When carrier component 54 is in a lowered, or locked position, a mating cam surface 64 of carrier component 54 engages cam 24 . Cam 24 is attached to knob/lever 26 in a co-rotating manner such that rotation of knob/lever 26 rotates cam 24 which engages mating cam surface 64 , causing carrier component 54 to move vertically, upwardly to a raised, or unlock position. 20 The rack 52 attached to carrier component 54 causes deadbolt pinion 50 to rotate as carrier component 54 moves either upward or downward. Driver bar 60 co-rotates with deadbolt pinion 50 . Rotation of driver bar 60 causes retraction and extension of deadbolt 90 of deadbolt latch assembly 44 in a standard fashion. Accordingly, as carrier component 54 moves upward, deadbolt 90 of deadbolt latch assembly 44 is retracted, allowing the door to be opened. Deadbolt 90 is shown in an extended position and a retracted position in FIGS. 7A and 7C, respectively. Deadbolt 90 is distinguished from standard deadbolts in that deadbolt 90 includes a cam surface 96 at a distal end. While cam surface 96 is similar to cam surfaces used in standard spring latch assemblies, cam surface 96 only partially extends along the extended deadbolt 90 as best shown in FIG. 7 C. Accordingly, the door cannot be closed when the deadbolt 90 is in an extended position. However, when the deadbolt 90 is partially extended in a manner that cam surface 96 is configured as shown in FIG. 7B, the door can be closed as cam surface 96 will engage strike plate 94 , forcing deadbolt 90 to retract. It should be noted that depression of deadbolt 90 results in deadbolt latch assembly 44 rotating deadbolt pinion 50 in a standard manner, moving carrier component 54 to a raised position.
Referring now to FIGS. 4A and 4B, escutcheon assembly 28 comprises escutcheon 30 , thumbturn 32 , and thumbturn link component 34 . Thumbturn 32 is coupled to thumbturn link component 34 in a co-rotating manner through an aperture in escutcheon 30 . Thumbturn link component 34 comprises at least one pin 36 which engages an aperture 38 in rack 52 , linking thumbturn 32 to carrier component 54 . It is noted that rack 52 can be positioned on either side of carrier component 54 such that a pin 36 will engage an aperture 38 in rack 52 , allowing thumbturn 32 to be appropriately attached for right and left-hand opening doors. Movement of the carrier component 54 results in rotation of thumbturn 32 , and conversely, rotation of thumbturn 32 causes movement of carrier component 54 and extension and retraction of said deadbolt 90 .
Referring now to FIG. 5, the back plate assembly 20 is shown in greater detail. To enable the remote locking function of the present invention, interconnected lock 10 utilizes carrier component 54 which is biased in a downward, or locked position. Accordingly, a spring carriage 72 is attached to carrier component 54 . Spring carriage 72 houses a spring 74 such that one end of spring 74 is attached to the assembled spring carriage 72 /carrier component 54 and the other end of spring 74 is fixedly attached to back plate 56 . Spring 74 is of sufficient strength to cause carrier component 54 to move downward to locked position and cause extension of deadbolt 90 of deadbolt latch assembly 44 . Backplate assembly 20 further comprises an electronic module 66 housing a power component 68 shown as a plurality of batteries to operate an automatic locking solenoid 70 and a signal receiver 75 . Electronic module 66 may also be used to power a speaker 78 or status lights 91 .
In order to prevent spring 74 from returning carrier component 54 to a locked position, back plate assembly includes a catch mechanism 80 comprising a catch component 82 , a catch release 84 , and a spring trigger rod 86 as shown in FIGS. 6A and 6B. Catch component 82 and catch release 84 are each pivotally attached to back plate 56 by a pin 88 . Catch release 84 is biased toward catch component 82 by catch release spring 83 . Spring trigger rod 86 is affixed to carrier component 54 and moves along a guide portion 92 in catch component 82 . Spring trigger rod 86 is also biased toward spring 74 .
The operation of interconnected lock 10 is best described in a dynamic manner starting with carrier component 54 positioned in a lowered, or locked position. Interconnected lock 10 includes a keyless exit feature which enables automatic locking actuation. Movement of carrier component 54 from a locked position to an unlocked position can be accomplished by either rotating inside knob/lever 26 , rotating thumbtum 32 , or by turning a key to rotate the rotating driver bar 60 of deadbolt assembly 42 , typically with a key. As carrier component 54 moves upward, spring trigger rod 86 moves upward along guide portion 92 of catch component 82 from its initial position A, shown in FIG. 6 A. Movement of carrier component 54 and attached rack 52 causes rotation of pinion 50 and driver bar 60 , retracting deadbolt 90 of deadbolt latch assembly 44 . At the end of the carrier component 54 travel, the deadbolt 90 of deadbolt latch assembly 44 is fully retracted. Spring trigger rod 86 , now at position C, and catch release 84 , biased by catch release spring 83 , force a tab feature 93 of catch 82 to move underneath spring carriage 72 in a manner locking carrier component 54 in an unlocked position. Spring 74 is now in an extended position, storing energy needed to extend the deadbolt 90 . At this point, further opening and closing of the door will not affect catch mechanism 80 as the guide path of the spring trigger rod 86 does not release the spring carriage 72 . Spring trigger rod 86 will move upward from position A to position C along guide path 92 of catch component 82 . When carrier component 54 moves downward, trigger spring rod 86 will move downward from position C, through position B, back to position A. Spring trigger rod 86 deviates from guide path 92 in the downward direction. Guide path 92 of catch component 82 is configured with a ramp portion between lowered portions generally corresponding to positions A and C. Between positions A and C, trigger spring rod 86 moves up a ramp portion to a drop-off 76 shown generally adjacent to position B. In the downward direction, spring trigger rod 86 is forced by the wall of drop-off 76 to move off of catch component 82 to a position below a portion of catch release 84 . In normal operation of the lock 10 , spring trigger rod 86 will continue downward from position B and return to position A. Accordingly, standard operation of the lock does not affect the catch mechanism.
In order to actuate the keyless exit feature, when deadbolt 90 of deadbolt latch assembly 44 is retracted, thumbturn 32 is rotated to an intermediate position. Rotation of thumbturn 32 causes thumbturn link component 34 to rotate. At least one pin 36 of thumbturn link component 34 engages rack 52 , such that rotation of thumbturn 32 causes carrier component 54 to move partially downward, partially extending deadbolt 90 of deadbolt latch assembly 44 . In addition, spring trigger rod 86 moves from position C to a position adjacent catch release 84 , shown as position B.
Referring now to FIG. 6B, operation of the keyless exit feature is shown. The deadbolt 90 is in a partially extended position such as that shown in FIG. 7 B. When cam surface 96 of deadbolt 90 is driven back by a strike plate 94 of the door jamb (not shown) such as when the door is closed, linear movement of deadbolt 90 within deadbolt latch assembly 44 is converted to rotation of deadbolt pinion 50 in a standard manner. Rotation of deadbolt pinion 50 causes carrier component 54 to move upward, moving spring trigger rod 86 to position D, forcing catch release 84 to rotate and free catch 82 . This action allows spring carriage 74 /carrier component 54 to move downward under the force of spring 72 . As carrier component 54 moves downward, the deadbolt 90 of deadbolt latch assembly 44 is fully extended via the interaction of the deadbolt pinion 50 and rack 52 .
When the keyless exit function is not in use, interconnected lock 10 will operate as a normal, or standard, interconnected lock.
The remote locking feature of the present invention utilizes solenoid 70 operably connected to catch release 84 as shown in FIG. 8A. A remote signal device 98 is utilized with the remote locking mechanism, shown in FIG. 9 as a standard keychain transmitter of the type used to unlock cars, garages, etc., When the remote locking signal is received by signal receiver 75 , solenoid 70 retracts catch release 84 , allowing catch component 82 to rotate away from spring carriage component 72 , as shown in FIG. 8 B. Carrier component 54 is then permitted to move downward under the biasing force of spring 74 . As previously described, downward movement of carrier component 54 causes extension of deadbolt 90 of deadbolt latch assembly 44 , thus locking the door.
Although the present invention has been described above in detail, the same is by way of illustration and example only and is not to be taken as a limitation on the present invention. Accordingly, the scope and content of the present invention are to be defined only by the terms of the appended claims.
|
An interconnected lock assembly with a locking mechanism which can throw the deadbolt and lock the door in response to a remote control signal. The interconnected lock comprising a first lock assembly including an inside handle and an outside handle, and a second lock assembly interconnected to said first lock assembly. The second lock assembly comprises a deadbolt assembly operably connected to a deadbolt latch. The deadbolt latch comprises a deadbolt movable between an extended position and a retracted position. The interconnected lock further comprises a locking mechanism selectively engageable by a remote control signal to move the deadbolt to an extended position.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for controlling the rotation of a reel of filamentary material.
2. Description of the Prior Art
In the processing of wire, or other filamentary material, the wire supply usually is coiled on a reel which is mounted on a wire feeding apparatus, such as a turntable that can rotate to allow the wire to be delivered to the wire processing machine.
Free-running turntables have been used as rotatable mounts for the reels. However, free-running turntables have limitations and disadvantages which have been magnified by a trend to multi-reel processing machines and larger weight coils for increased productivity.
At start-up when a free-running turntable is employed, a sufficient pull must be applied on the wire to be uncoiled in order to overcome the starting torque of the turntable and to establish a constant momentum of the reel. An intolerable load may be imposed on the processing devices, causing damage to equipment and/or loss of material and production time.
Tangling may also be encountered at start-up, especially when heavy coils are employed. A tangle may occur in the reel as the first few outgoing laps of wire are drawn tightly within the coil. The result of the tangle may be malfunction or damage to the processing equipment, or alternatively, the coil may be pulled off the turntable.
Further problems may be encountered during the shut-down of the system when the turntable continues to rotate freely, thus causing the outer laps of wire to loosen and drop about the base of the turntable. Some of the laps of wire must then be gathered and rewound, and the turntable must be prepared for a restart.
In view of the above difficulties associated with free-running turntables, it has been recognized that there is a need for a mechanism whereby the rotation of a reel can be controlled to adjust the tension of the out-going material. Numerous devices have been developed in an attempt to improve the free-running turntable.
For example, U.S. Pat. No. 2,923,493, issued Feb. 2, 1960 to Fitzgerald et al, discloses a device wherein the rotation of the reel is normally free-turning, but the tension in the out-going material can be controlled by the application of a manually adjustable braking mechanism which is forcibly applied by means of pressurized air. The device has an auxiliary feature comprising an air cylinder having a vertically reciprocatable piston rod to engage and disengage the device from the reel.
U.S. Pat. No. 3,081,957, issued Mar. 19, 1963 to Van de Bilt, describes a wire-feeding apparatus wherein a reel having a horizontally mounted axis of rotation can be driven by a pneumatic cylinder which engages the reel via a free-wheel transmission, and a spring-forced brake can be released by a second pneumatic cylinder, both cylinders being actuated by a valve or slide which is adjusted by a device responding to the pull exerted on the outgoing wire. Here the driving and braking forces are applied by two distinctly different and independently operated mechanisms.
U.S. Pat. No. 3,137,452, issued June 16, 1964 to Winders, discloses a mechanism whereby the rotation of a reel is powered by an electric motor operating at constant speed and engaged through a chain, belt or cable to a variable speed pulley connected on a drive shaft in the unit. Braking is achieved through a mechanism, separate from the drive unit as in the Van de Bilt apparatus, incorporating a shoe and drum arrangement actuated by means of a pressurized fluid cylinder.
It is an object of the present invention to provide an improved apparatus for the feeding of filamentary material, for example wire, from a reel wherein the rotation of the reel may be controlled throughout start-up, production and shut-down.
SUMMARY OF THE INVENTION
In accordance with the present invention, a device for controlling the rotation of a reel of filamentary material comprises rotatable reel support means, means for sensing tension of the filamentary material, a reciprocatable element controlled by the tension sensing means to move to a first position in response to low tension and to reciprocate in response to a higher tension, and a clutch operable by the reciprocatable element to brake the reel support means when the reciprocatable element is in the first position, and to accelerate the reel support means when the reciprocatable element is responding to said higher tension. The reciprocatable element may also be movable to another position to allow the reel support means to rotate freely in response to an intermediate tension. Further features of the invention will appear from the claims and from the following description of a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a perspective view of a preferred embodiment of the invention showing the general arrangement;
FIG. 2 is a schematic diagram of the pneumatic valve system, the valves being positioned for free wheeling of the reel;
FIG. 3 is a perspective view of components of the device, but viewed from the left hand side of FIG. 1, on a larger scale, with the reel lid and parts of the walls of the frame removed;
FIG. 4 is a further enlarged top view of parts of the device as they would be seen by a person standing to the north-east of FIG. 3, with the reel braked and at rest;
FIG. 5 is a top view similar to FIG. 4, with the reel free wheeling (as for FIG. 2); and
FIGS. 6 to 9 are schematic and broken away side views, also as they would be seen by a person standing to the north-east of FIG. 3, illustrating various operative conditions as the control arm at the right is rotated counterclockwise.
For clarity of illustration, the relative proportions of some of the parts are not consistent in all the views of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the invention, as shown in the drawings, is a pneumatically driven device which automatically controls the rotation of a reel of wire in response to the tension of the wire being unwound.
FIG. 1 illustrates the general arrangement of the preferred embodiment with a reel 1 of coiled wire positioned for operation on the device. The reel 1, having its rotational axis vertical, rests on a platter 2 which in turn rests on enlarged portion 3 (FIG. 3) of a vertical reel supporting shaft 4. The platter is centered on the shaft 4 by a cylindrical sleeve 5 fixed to the platter and keyed to the shaft, and the platter carries radial flange members 6 which register with the inner core 8 of the reel. Wire 9 leading from the reel 1 to a processing unit (not shown) is threaded over a pulley 10 and is retained by a keeper 11 adjustably mounted, as at 11a, at the upper end of an upwardly extending arm 12 which, as will be described, serves as means for sensing the tension in the wire 9. The major portion of the device is housed within a frame 13. The enlarged portion 3 of the shaft is suitably journalled in the frame 13.
FIG. 3 illustrates the arrangement of the major components of the device within the frame 13. The device is powered to brake or accelerate the rotation of the reel 1 by operation of an air cylinder 20 fixed to the base 14 of the frame 13 by means of brackets 21 and pedestals 22. The cylinder 20 has a piston 20a (FIG. 2) the movement of which is controlled by a poppet-exhaust-operated four way valve 23 of conventional construction. By means of a valve system described in detail later, air supplied to the cylinder from line 23a through valve 23 can cause the reciprocatable piston rod 24 to extend fully, to retract fully, or to reciprocate between two intermediate points. The speed of the piston strokes is controllable by a conventional throttle control 23b (FIG. 3) by which the exhaust of air from valve 23 can be throttled. The piston rod has at its end a clevis 25 and the clevis has, midway along its length, a rigid transverse pin and roller 26 which interacts with the slotted end 27 of the camming lever 28 of a friction clutch mechanism generally designated as 30. At the free end of the clevis is a rigid transverse pin 31 about which a pressure lever 32 is pivotably mounted. A spring 33, extending between the lever 32 and a pin 34 on the clevis, urges an end 32a of lever 32 to pivot in a direction towards a pin 40 of the clutch mechanism 30.
The clutch 30 includes top and bottom plates 41, 42 which are rigidly connected together by bolts 40, 43, 44, 45, 46. The plates are located above and below a drum portion 47 of the shaft 4 and have sufficient clearance around the shaft portion 3 to permit some lateral shifting of the plates relative to the shaft as clutch shoes 51, 52 engage and disengage the drum 47, as described below. When the shoes 51, 52 are not gripping the drum 47, the plates and shoes are free to swing about the axis of the shaft, the lower end of the shaft 4 being supported by a thrust bearing (not shown). The shoe 52 is fixed to the clutch plates by the bolts 44, 45, 46, and the opposite shoe 51 can be pressed inwardly against the drum 47 by rotation of camming lever 28 in a counterclockwise sense, as viewed in FIG. 4. The lever 28 is pivotable about pin 43, and such counterclockwise rotation of the lever to press the shoe 51 against the drum 47 also draws the shoe 52 into engagement with the drum because of pressure exerted by the lever 28 on pin 43.
Thus braking action is achieved when the piston rod 24 is moved to the braking position of FIG. 4. The end 32b of pressure lever 32 comes into engagement with the end of a brake adjustment rod 55. This forces the opposite end 32a of the lever against the pin 40, and an arm 27a of camming lever 28 is pressed against roller 26 causing the camming lever 28 to rotate counterclockwise about pin 43 and force the brake shoes 51, 52 against the drum 47.
The brake is released when the rod 24 is extended to the free wheeling position of FIG. 5. Here the pressure lever 32 is out of contact with the brake adjustment rod 55, but the piston rod 24 has fixed to it a bracket 56 which, at its end 56a adjacent the clutch 30, carries a longitudinally slidable pressure pin 57 that is urged in the direction of the camming lever 28 by a spring 58. This yieldably urged pin 57 presses the camming lever 28 against the clutch pin 40, out of engagement with the brake shoe 51 so that the shaft 4 can rotate freely. The bracket 56 has at its opposite end a lug 56b which opens pilot valves A and B at opposite ends of the piston stroke, the valves A and B (as well as a valve E) being mounted on a side wall 59 of the frame 13. This lugged end of bracket 56 is forked (FIG. 3) at 56c to embrace loosely the longitudinal brake adjustment rod 55.
The brake adjustment rod 55 is longitudinally slidable in bearings (not shown) mounted on the side wall 59 of the frame. As best seen in FIG. 6, the rod 55 has, at its end remote from the pressure lever 32, a bolt extension 55a. Bolt 55a passes slidably through a sleeve 60 that is threaded into the end wall 61 of the frame 13, the bolt 55a being headed at 55b outside the frame. A spring 62, in compression between the sleeve 60 and the rod 55, urges the rod in the direction of the pressure lever 32. The compression in the spring 62 can be adjusted by screwing the bolt 55a further into or out of the rod, thereby providing a simple means of adjusting the braking force that is applied to the pressure lever 32 when it engages the adjustment rod 55. The longitudinal position of the rod 55, relative to the end 32b of the lever, can be adjusted by screwing the sleeve 60 relative to the end wall 61.
The sensing arm 12 is pivotally mounted at 65 on the side wall 59 of the frame 13. Above the pivot point 65 the arm has a transverse post 66 (FIG. 6) mounted in line with the end of a longitudinal cam shaft 70. The cam shaft passes through the end wall 61 and is longitudinally slidable in bearings such as 71 (FIG. 3) mounted on the side wall 59. At its opposite end the shaft 70 is spring pressed by a spring 72 which bears against end wall 73 of the frame, so that an abutment 74 on the shaft is normally held against the frame end wall 61. Counterclockwise rotation of the arm 12, as shown in FIGS. 6-9 causes post 66 to move the cam shaft 70 to the left. Linear motion of the cam shaft to the left causes the faces of cams on shaft 70 to interact with rollers to open valves C, D, E, mounted on the side wall 59, in the sequence shown in FIGS. 6-9.
Below its pivot point 65 the sensing arm 12 carries a striker plate 76 having an abutment 76a in line with the end 55b of the brake adjustment rod. With the sensing arm resting in its furthest clockwise position (that shown in FIG. 6), i.e., with no tension in the wire 9, the weight of arm 12 is applied via the abutment 76a to the end of brake adjustment rod 55, thereby applying additional braking force to pressure lever 32.
The exhaust valves A, B and the control valves C, D form a valve system which establishes the operating mode of the cylinder 20 (i.e., retraction, extension or reciprocation of piston rod 24) by control of air flow to and from the poppet valve 23. Valve 23 is a conventional two position valve which directs the air to one end of the cylinder or the other depending on whether the valve's outlet line 81 or its other outlet line 82 is connected to exhaust.
The air lines interconnecting the valves are schematically illustrated in FIG. 2. Both ends of control valve 23 are supplied with compressed air from line 23a through bleeder lines 23b, 23c. Valve C is connected into the outlet line 81 and permits exhaust of air from the left hand end of valve 23 when valves C and A are open. Valve D is connected into the other outlet line 82 and permits exhaust of air from the right hand end of valve 23 when valves D and B are open. When both valves A and C are open and one of the valves B and D is closed, the control valve 23 directs compressed air from line 23a into the blind (right) end of the cylinder 20 while the opposite end of the cylinder 20 is allowed to exhaust back through the poppet valve to exhaust port 23d. Thus, the piston rod 24 extends to the left. When both valves B and D are open and one of valves A and C is closed, the air flow in the cylinder is reversed and the piston rod 24 retracts, air from the right hand end of cylinder 20 exhausting through port 23e.
FIGS. 6 to 9 show different valve conditions that are determined by different positions of the sensing arm 12. At start-up, with little or no tension in the wire 9, the arm 12 is in the position of FIG. 6. With the condition of FIG. 6, valve C is closed. Therefore air cannot exhaust through A, and the piston rod remains retracted as in FIG. 4 with full braking applied to the reel.
As tension of the wire 9 increases the sensing arm 12 pivots counterclockwise, pushing the cam shaft 70 to the left. This causes valve D to close and valve C to open. Exhaust can occur through valves A and C causing the piston rod 24 to extend and thus to move lug 56b out of engagement with valve A (closing it) and into engagement with valve B (opening it) so that the free wheeling condition of FIGS. 7, 5 and 2 is achieved.
If wire tension increases, the reel needs to be given forward impetus to relieve the tension. The further wire tension pulls arm 12 further counterclockwise, moving the cam shaft 70 further to the left so that both valves C and D are open, exhaust through B and D can occur, and the piston rod retracts, closing B and opening A, whereby the piston rod extends again, and whereby there is continued reciprocation of the piston rod 24 while the increased tension condition of FIG. 8 prevails. On each retraction stroke the end 32a of lever 32 contacts the pin 40, closing the clutch 30 under light pressure from spring 33, but the force is insufficient to create any braking effect on the drum 47, the force merely being sufficient to preset the clutch for the next extension stroke of the piston. On each extension stroke, with the clutch so preset, the clutch 30 grips drum 37 without delay or bounce, the lever 28 being rotated clockwise around pivot 43 to move the clutch mechanism to the closed condition of FIG. 4, so that during the initial portion of the extension stroke, with the shoes 51, 52 gripping the shaft drum 47, the shaft is given a forward impulse, to relieve the tension on the wire. If the tension is relieved, the device reverts to the free wheeling condition of FIGS. 5 and 7. If, however, the wire tension continues to increase, the arm 12 is pulled to the extreme counterclockwise position of FIG. 9. Valve D closes, so that piston rod reciprocation ends with the rod 24 in the extended (free wheeling) position. Valve E opens, thereby opening an air line 83 (FIG. 2) to a shut-off or warning device (not shown) to signal that an excessive wire tension has been reached.
It is therefore seen that the device automatically applies a braking force to the shaft 4 when wire tension is small, applies acceleration forces to the shaft when tension is higher, and allows free rotation of the shaft at intermediate tensions. The drive mode, with acceleration forces given to the shaft, may be maintained with the arm 12 anywhere from about, for example, 10° to 15° from the vertical so that wire tension is maintained within a range corresponding to this range of control arm inclinations. During the drive mode, the piston rod reciprocates between positions short of its fully extended and fully retracted positions, the lengths of the reciprocatory strokes being determined by the positions of the valve stems of valves A and B.
During shut-down the reel 1 must be allowed to slow to a stop without undue loss of tension of the wire 9. As tension in the wire diminishes the arm 12 swings clockwise, thus restoring the conditions which cause the piston rod to retract and to apply braking force.
While the invention has been described with particular reference to the preferred embodiment illustrated, other embodiments within the scope of the following claims will occur to those skilled in the art.
|
To control the rotation of wire being fed from a reel, the tension of the wire is sensed by a pivotable arm which, through a valve system, controls operation of a pneumatic cylinder having a reciprocatable piston rod which coacts with a friction clutch. The rod in one position causes the clutch to brake the reel, in response to low tension, and in another position allows the reel to rotate freely, in response to a higher tension, and the rod is reciprocatable to impart accelerating pulses to the reel through the clutch in response to a still higher tension.
| 1
|
BACKGROUND OF THE INVENTION
This invention relates generally to tunneling machines, and more particularly to tunneling machines having a rotary boring or cutting head for boring passages through soft rock, hard rock and minerals.
The digging of a tunnel through soft material, such as clay and soft rock, or only partially consolidated materials, has long been done by machines having a rotary cutting head having cutters which scrape and dig away at the material, which is then collected and removed rearwardly from the tunnel. However, when such machines are used against harder materials, and particularly very hard igneous and metamorphic rocks, such scraping-type cutters cannot be used, and it is necessary to employ rotary, percussive-type tools which chip away small fragments from the mass of rock by impact. The use of such cutters has long been known for drilling wells and other relatively small diameter holes, but efforts to adapt such cutters to larger machines for use in drilling tunnels have met with considerable difficulty because of the necessary forces involved and the shock loads encountered.
A reliable and proven machine has been developed for cutting hard rock at a fast enough cutting rate to make it competitive with prior drilling methods. That machine is set forth in U.S. Pat. No. 3,383,138. According to that patent, a fixed supporting frame is anchored in the tunnel by two axially spaced sets of projecting arms, each set of which has four arms equidistantly spaced and actuated by hydraulic cylinders to position the frame without regard to the weight of the machine. A movable frame is carried centrally within the supporting frame by sets of torque arms at each end, which both support the moving frame and transmit the reaction torque from the moving frame to the supporting frame. A cutter head is mounted in bearings at the front end of the moving frame and carries a cutter plate having a number of roller cutters mounted thereon. A drive shaft extends the length of the moving frame to project beyond the rear of the supporting frame where the shaft is driven by a plurality of motors which drive an encircling ring gear. Hydraulic cylinders acting between the supporting frame and the cutter head apply the force directly to the bearing supporting the cutter head to cause the moving frame to move relative to the supporting frame. After the moving frame is moved through its full range of movement, a jack is lowered at the rear end to support the moving frame by the jack and the cutter head to allow the supporting frame to have the arms retracted and moved forward to the next position, where the supporting frame is again anchored to allow the cutting movement to continue.
While such a tunneling machine can cut hard rock at a fast enough cutting rate to make it competitive with prior tunneling machines, contractors have demanded even faster cutting rates to minimize on-the-job dwell time and to meet contractual bidding demands. According to prior art practices, and as has been indicated above, a substantial portion of the available drilling time is expended in moving the gripping legs to an advanced position while the cutting head is idle at the tunnel face.
SUMMARY OF THE INVENTION
This invention provides a tunneling machine which is adapted to cut tunnels on a continuous basis and which is adapted to apply continuous pressure on the tunnel face even during repositioning of the gripping legs.
The tunneling machine according to this invention includes at least two supporting frames each having a plurality of extendible feet which are adapted to grip the tunnel wall. The support frames are provided with axial bores therethrough and a hollow piston extends through all of the bores for longitudinal movement along the axis of the tunnel. The piston is provided with piston heads for each of the hollow pistons which are slidable along the bores so that fluid pressure may be employed to advance the hollow piston. A drive shaft is rotatably mounted in the hollow piston and is fixed against longitudinal movement with respect to the piston. One end of the drive shaft carries a rotatable cutter head thereon, and the other end of the shaft is driven by a plurality of motors through a ring gear.
A tunneling operation is carried out by extending at least one pair of extendible feet against the walls of the tunnel to securely hold at least one of the support frames relative to the tunnel wall. The piston chamber of each support frame which is clamped to the wall is pressurized to push the cutter head against the face of the tunnel. While the cutter head is being advanced in this manner, the unclamped support feet are moved forward to a clamping position. As soon as the first-mentioned hollow piston nears the end of its stroke, the second-mentioned support frame is clamped in position to continue to push the cutter head, and the first-mentioned extendible feet are released so that its support frame may be repositioned for subsequent pushing action. Thus, the tunneling operation is continuous and there is no need to pause for the repositioning of support feet. To aid in supporting and steering the machine during the drilling operation, front and rear support feet are provided which are merely dragged along as the tunneling operation progresses.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the tunneling machine;
FIGS. 2A, 2B, 2C, and 2D are sequential schematic views showing the progression of the machine and the relative positions of its parts as a tunnel is dug;
FIG. 3 is a cross sectional view, the plane of the section being indicated by the line 3--3 in FIG. 1; and
FIG. 4 is a cross sectional view, the plane of the section being indicated by the line 4--4 in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, there is illustrated a tunnel boring machine 10 having supporting frame members 11 and 12. Each support frame 11 and 12 is braced against the tunnel walls to position the machine in proper alignment and to absorb the torque and thrust forces produced by the cutting action. Each support frame 11 and 12 carries a pair of horizontal, radially extending clamp legs 13, 14, 15, and 16. Each leg 13-16 includes a saddle 17 having a piston bore 18 in which is mounted a piston 19, which may be pressurized by a suitable hydraulic source to drive the piston inwardly or outwardly. Each piston has a pressure pad 20 attached thereto by a ball 25 which is received in a spherical socket 26. The ball and socket connection between the pad 20 and its piston 19 permits movement of the pad relative to the piston to compensate for uneven tunnel wall portions. The foregoing arrangement provides a compact foot and provides an arrangement wherein fluid pressure is applied to a greater area of the pressure pad, as compared to prior art arrangements wherein pressure is applied to the pad by conventional piston and cylinder arrangements. The longitudinal axis of the support frames 11 and 12 may be guided and aligned for steering purposes by adjusting the relative radial extension of the pads by the pistons 19.
Within bores 27 and 28 of the support frames 11 and 12, there is provided an elongated, hollow tube 29 which extends beyond the front and rear portions of the support frames 11 and 12. The hollow, elongated tube 29 has an annular piston head 30 adjacent its forward end which divides a space between the bore 27 and the elongated tube 29 into forward and rearward compression chambers 21 and 22, respectively. Those chambers are sealed at their outer ends by front and rear ring seals 31 and 32, respectively. The hollow tube 29 further includes a ring 33 which constitutes an annular piston head which divides a space between the bore 28 and the hollow tube 29 into forward and rearward pressure chambers 23 and 24, respectively. Those chambers are sealed at their outer ends by front and rear ring seals 34 and 35, respectively. As is illustrated in FIG. 3, the support frames 11 and 12 are both in a forward position with respect to the hollow tube.
The forward end of the hollow tube 29 carries an enlarged bell-shaped housing 36 which supports the outer race of a bearing 37. The bearing 37 is preferably of the high capacity, double-row, tapered roller-type adapted to absorb both radial loads and thrust loads in either direction. The split inner race of the bearing 37 is secured to the outer surface of a cutter head hub portion 38 of a drive shaft 39, which extends through the hollow tube 29 to journal the drive shaft for rotation with respect to the hollow piston.
A rotatable cutter head 40 is fixed to the forward end of the drive shaft 39 by a noncircular fit between the forward end of the drive shaft and the hub portion 38. As may be appreciated, keys may be used as an alternative. A plurality of inside saddles 41 are located in predetermined positions on the forward end face of the cutter head 40 by locating dowel pins (not shown) and are welded to the cutter head 40. Each inside saddle 41 carries an inside roller cutter 42. In a similar manner, a number of gauge saddles 43 are located in predetermined positions on the front face of the cutter head 40 by locating dowel pins (not shown) and suitably welded to the cutter head. A gauge roller cutter 44 is rotatably journaled in a suitable manner to each of the gauge saddles 43. The gauge saddles 43 support the gauge cutters 44 in such a manner that the axis of rotation of the gauge cutters 44 is at an angle to the axis of the rotation of the inside cutters 42, so that the tunnel end face is provided with a slightly relieved portion adjacent the cylindrical tunnel wall. A center cutter (not shown) is also provided. The details of the arrangement of the cutter head are conventional and are disclosed in more detail in U.S. Pat. No. 3,383,138, the disclosure of which is herein incorporated by reference.
The drive shaft 39 is rotated by electric drive motors 45 and 46 through gear reduction transmissions 47 and 48. The transmissions 47 and 48 are mounted on a housing 52 carried on the rear end of tube 29 and are provided with pinion gears 49 and 50 which mesh with and drive a ring gear 51 fixed to the rear end of drive shaft 39. It will be understood that this arrangement can use any number of drive motors, and these drive motors can be single or multiple-speed units if it is desired to vary the rotating speed of the cutting head. Likewise, the amount of reduction provided by the gear reduction transmissions is also selected to give the proper speed for the cutter head.
Since, as will be described in greater detail hereinafter, the machine is supported during the cutting action at only one of the support frames 11 and 12, it is free to rotate about a transverse axis defined by the clamp legs on the particular support frame which is gripping the tunnel walls. For this reason, it is necessary to provide vertical support for the tunnel boring machine both in front of and behind the support frames 11 and 12. Accordingly, at the rear end of the machine beneath the rear housing 52 is mounted a vertically extending hydraulic cylinder 57 and a rear support foot 56 adapted to engage the bottom surface of the tunnel. At the front end of the machine, at the bearing housing 36, are mounted a pair of front cylinders 58 and 59, and their support feet 60 and 61, respectively. These front cylinders extend outwardly and downwardly at an angle (see FIG. 4), and can be used in unison to raise and lower the cutter head 40 and, by their selective alternative use, can be used to provide a certain amount of lateral tilting or shifting of the cutter head. In any case, it will be understood that all three of the support feet 56, 60, and 61 are extended against the tunnel wall surface and slide along it while the machine is progressing forwardly during cutting, and each of these feet will supply sufficient upward force for the machine to keep it in proper alignment in the tunnel.
The cyclic operation of the machine, which allows it to maintain a continuous forward cutting action, is best shown in connection with the schematic views of FIG. 2. As shown at FIG. 2A, the rear support frame 12 has its clamp legs 15 and 16 retracted, and is at a rearward position on the hollow tube 29 and is therefore inactive. The front support frame 11 has its clamp legs 13 and 14 extended into gripping contact with the tunnel walls, and its rearward chamber 22 is therefore pressurized while its forward chamber 21 is allowed to drain to reservoir. The pressure within the rearward chamber 22 causes a forward thrust to push the cutter head 40, which is being continually rotated by the drive motors 45, forwardly against the end face of the tunnel so that the rock can be broken away in the well known manner.
While the machine is moving forward and as tube 29 slides forwardly with respect to the front support frame 11, the position of the rear support frame 12 is advanced along forwardly with respect to the hollow tube 29 by pressurizing the forward chamber 23 of rear support frame 12 until that frame moves to the position shown in FIG. 2B, which also shows the hollow tube 29 at the forward position with respect to the front support frame 11. Just before the hollow tube 29 reaches the end of its forward stroke with respect to the front support frame 11, the clamp legs 15 and 16 of the rear support frame, now in the position shown in FIG. 2B, are extended so that for a short period of time all four of the clamp legs 13-16 are in gripping contact with the sidewalls of the tunnel. At this time, both of the rearward chambers 22 and 24 will be pressurized simultaneously for a short period of time, and since this doubles the effective area, constant forward cutting force is maintained by reducing the pressure in both of these chambers to half the level that is used when only a single chamber is used to provide the forward thrust.
After this brief period of time, when both legs are clamped, the front clamp legs 13 and 14 are withdrawn when the hollow tube 29 has reached the forward end of its stroke with respect to the front support frame 11. However, the cutting continues without hesitation because of the pressurization of the rearward chamber 24 and the clamping at the rear support frame 12 now provides the forward thrust. After the front clamp legs 13 and 14 are retracted, the forward chamber 21 on front support frame 11 is then pressurized to cause the front support frame 11 to move forwardly along tube 29 until it reaches the front position as shown in FIG. 2C. Again, at a point of time when the hollow tube 29 has reached the forward end of its stroke with respect to the rear support frame 12, the front clamp legs 13 and 14 are extended so that for a short period of time all four clamp legs are again engaging the sidewalls of the tunnel, and during this time the thrust pressure is again reduced in half to maintain the same total forward thrust. Thus at this point, while the front clamp legs 13 and 14 maintain their gripping force, the rearward clamp legs 15 and 16 are withdrawn, as shown in FIG. 2D, which completes the cutting cycle.
With this arrangement, the forward movement of the cutter head 40 is truly continuous and without hesitation, even during the transfer of the gripping from the one support frame to the other, because of the short period of overlap in which both support frames are in gripping contact with the tunnel and provide a forward thrust. While the machine is operating with only a single support frame in gripping contact with the tunnel, the other support frame is advanced forward along the hollow tube 29 to be in a more forward position to again take over the gripping of the tunnel walls and provide a forward thrust when the other support frame nears the end of its stroke.
It will be understood that otherwise the operation of the machine is conventional and the cutter head is provided with all the usual accessories, such as scrapers and mud buckets for removing the debris and transferring them to a conveyor shown at 63, passing rearwardly over the top of the machine to the auxiliary equipment behind the tunneling machine. Likewise, it is possible to provide the usual ventilation line 62 for bringing in fresh air to the front of the machine, and the necessary operator's console (not shown) can be provided adjacent the rear housing 52 out of the way of the two moving support frames 11 and 12.
While the machine has been shown as a hard rock boring machine, it is recognized that it may also be outfitted with a shield surrounding the machine rearwardly of the cutter head 40, with suitable openings for the front support feet 60 and 61, as well as the pressure pads 20 on the clamp legs 13-16. Such a shield may be advanced by suitable means, such as hydraulic cylinders, to follow along behind the cutter head 40, but it is recognized that under those circumstances it may be necessary to temporarily stop the forward motion of the cutter head 40 to allow the thrust cylinders for the shield to be repositioned to continue their forward movement. However, such pauses or hesitations would be much shorter than otherwise, since it is only necessary to reposition the shield advancing mechanism and not the clamping legs themselves, and such pauses for repositioning the shield drive mechanism can be done at any point during the cutting cycle as set forth hereinabove.
While the preferred embodiment uses internal annular hydraulic pressure chambers on the hollow tube 29 and front and rear support frames 11 and 12, this arrangement is best suited for machines for boring relatively small diameter tunnels. When the invention is applied to larger machines, it is recognized that external thrust cylinders may be employed with suitable mounting arrangements to act between each of the support frames and the frame carrying the rotating cutting head. Furthermore, each of the support frames may use more than two clamp legs located at peripherally spaced positions or axially spaced positions with respect to each of the support frames.
While a preferred embodiment of this invention has been shown and described, it should be understood that various modifications and rearrangements of the parts may be resorted to without departing from the scope of the invention as disclosed and claimed herein.
|
A tunneling machine adapted to cut tunnels on a continuous basis and to apply continuous pressure on the tunnel face even during repositioning of the gripping legs is disclosed. The machine includes at least two supporting frames having a plurality of extendible feet which are adapted to grip the tunnel wall. The support frames are provided with axial bores therethrough, and a hollow piston extends through all of the bores for longitudinal movement along the axis of the tunnel. In accordance with the method, a tunneling operation is carried out by extending at least one pair of extendible feet against the walls of the tunnel to securely hold at least one of the support frames relative to the tunnel wall. The piston chamber of each support frame which is clamped to the wall is pressurized to drive the cutter head against the face of the tunnel. While the cutter head is being advanced in this manner, unclamped support feet are moved forward to a clamping position to take over when the first-mentioned support feet reach the end of their effective stroke. This operation is repeated to apply continuous thrust pressure to the cutting head.
| 4
|
This invention relates to improved photodiodes. More particularly, this invention relates to a photodiode having reduced reflectivity and enhanced long wavelength response.
BACKGROUND OF THE INVENTION
Avalanche and p-i-n photodiodes detect light by absorption of incident light and the detection of the free electrical charge generated in the absorption process. The optical reflectivity of the light entry surface is typically high, thus reducing the fraction of the incident light which actually enters the device and is absorbed. The most common approach to reduce that reflectivity has been to add an anti-reflection coating to the light entry surface.
In a number of materials, silicon in particular, the absorption length for a range of wavelengths is small. Thus, a significant fraction of the light in this wavelength range will not be absorbed before passing through the device. A partial solution to this problem has been to place a reflector on the surface opposed to the entry surface thus reflecting the light back through the sensitive region and doubling the path length for light absorption.
An alternative approach to reduce the incident surface reflectivity and to increase the light path length in the device has been to contour either the entry or back surface or both surfaces of the device. Haynos et al, Proceedings of the International Conference on Photovoltaic Power Generation, Hamburg, Germany, pp. 487-500, September, 1974, have disclosed a silicon photovoltaic solar cell in which a high density of tetrahedra with dimensions of about 2 microns in height and 2 microns at their base have been formed on the entry surface of the cell by chemically etching the surface using an anisotropic etchant. Light incident on this tetrahedrally shaped surface is partially transmitted and partially reflected. The portion reflected is then incident on a neighboring tetrahedron and is again partially transmitted and partially reflected. Thus, the incident light undergoes at least two interactions with the entry surface before leaving the device, thus reducing the device reflectivity.
Muller, Technical Digest of the International Devices Meeting, Washington, D.C., December, 1976, pp. 420-423, has disclosed a p-i-n photodiode having a sphere segment grating on the photodiode surface opposed to the light entry surface so that some of the light reflected from the back surface will be scattered at angles greater than the critical angle for total internal reflection and be trapped within the crystal. The sphere segments are pits about 3 microns in diameter and less than 1 micron deep resulting from etching though pinholes statistically distributed in a photoresist layer on the surface. Muller found that a considerable portion of light incident on such a grating is reflected at such an angle that it leaves the photodiode after only one reflection and thus did not provide significant improvement. Muller also disclosed an optimum grating, an asymmetrically grooved surface which is obtained by anisotropic etching of a surface oriented about 10° off of a (111) plane.
These structures provide enhancement of the spectral response. However, in photoconducting devices where an external electrical field is applied, the surface contouring, particularly for the grooves and pyramids, can result in local regions of high electrical field which lead to nonuniformities in the spectral response of the device and to electrical breakdown and noise. Irregularities and nonuniformities in the surface contour will also lead to a nonuniform response across the surface of the device. It would be desirable to provide a photodiode having contoured surfaces without the presence of the nonuniformities and local regions of high electrical field present in the prior art devices.
SUMMARY OF THE INVENTION
A photodiode is comprised of a semiconductor body having two opposed surfaces; regions of first and second conductivity types extending a distance into said first and second opposed surfaces such that said regions of first and second conductivity type do not overlap; and first and second electrically conducting layers overlying portions of said regions of first and second conductivity type to provide electrical contact to said regions. The invention is an improved photodiode wherein a portion of a surface, either the light entry surface or the opposed surface of the photodiode, is contoured in the form of a regular array of indentations extending a distance into the photodiode thereby reducing the reflectivity of the entry surface or increasing the light absorption length in the photodiode.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a cross-sectional view of the p-i-n photodiode of the invention.
FIG. 2 is a schematic illustration of a top view of the p-i-n photodiode of the invention.
FIG. 3 is a schematic illustration of a cross-sectional view of the avalanche photodiode of the invention.
FIG. 4 is a schematic illustration of a cross-sectional view of a semiconductor body during the contouring process.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 show schematic illustrations of a cross-sectional view and a top view, respectively, of a p-i-n photodiode of the invention. The p-i-n photodiode is comprised of a semiconductor body 12 having opposed surfaces14 and 16. A portion of the first surface 14 is contoured in a regular array of indentations 18 extending into the semiconductor body 12 from thefirst surface 14. The semiconductor body 12 is divided into three regions; a low conductivity region 20, a region 22 which is of a first conductivitytype and which extends a distance into the semiconductor body 12 from the contoured first surface 14, and a region 24 which is of a second conductivity type opposite to that of region 22 and which extends a distance into the semiconductor body 12 from the second surface 16. Depending upon the conductivity type of the low conductivity region 20, the region 22 of the first conductivity type and the region 24 of the second conductivity type, a p-n junction is formed either at the interface23 between the region 22 of the first conductivity type and the low conductivity region 20 or at the interface 25 between the region 24 of thesecond conductivity type and the low conductivity region 20. A passivating layer 26 may overlie a portion of the second surface 16. An electrically conducting layer 28 overlies a portion of the second surface 16 and provides electrical contact to the region 24 of the second conductivity type and may also serve as a light reflector. An electrically conducting layer 30 overlies a portion of the first surface 14 and provides an electrical contact to the region 22 of the first conductivity type. An anti-reflection coating 32 may overlie a portion of the first surface 14 through which light enters the photodiode.
In FIG. 2 the lands 21 between the regular array of indentations 18 are regions where the first major surface 14 has not been perturbed.
FIG. 3 is a schematic illustration of a side view of an avalanche photodiode 50. In FIG. 3, parts that are similar to the p-i-n photodiode 10 are labeled similarly. The avalanche photodiode 50 is distinguished from the p-i-n photodiode 10 of FIG. 1 in that (a) a region 52 of a third conductivity type which is opposite to that of the region 24 of a second conductivity type extends into the low conductivity region 20 a distance beyond the region 24 of the second conductivity type and (b) in that the low conductivity region 20, the region 22 of a first conductivity type, and the region 52 of a third conductivity type are all of the same conductivity type. The p-n junction then occurs at the interface 54 between the region 24 of a second conductivity type and the region 52 of athird conductivity type.
A channel stop ring 58 extends a distance into the low conductivity region 20 from the second major surface 16 and extends about the perimeter of, but does not contact, the region 24 of a second conductivity type. The channel stop ring 58 has the same conductivity type as the low conductivity region 20. This stop ring is not required but is typically used to reduce surface leakage currents.
FIG. 4 shows a schematic illustration of a semiconductor body 12 during theprocess of formation of the indentations 18 on a major surface 14. A masking layer 94 overlies the surface 14 of the semiconductor body 12. Openings 96 are formed in the masking layer 94. Indentations 18 are etchedthrough these openings into the depth of the semiconductor body and laterally, thus undercutting the masking layer 94.
The low conductivity region 20 may be electrically insulating or slightly conducting. Preferably it is of p-type conductivity silicon having a resistivity of about 3000 ohm-cm.
A regular array of indentations 18 covering a portion or all of the surface14 of the semiconductor body 12 are formed using etching techniques described below. The indentations 18 typically extend over a portion of the major surface contiguous with the region 22 of the first conductivity type. The center-to-center spacing of the indentations 18 is determined bythe mask used to define the openings in the masking layer 94 shown in FIG. 4 and can vary from about 3 microns to about 100 microns but preferably isabout 25 microns to 75 microns. The indentations may have a diameter on thefirst surface 14 less than, equal to, or greater than the center-to-center spacing. Preferably the diameter is greater than the center-to-center spacing; that is, the indentations overlap, producing what is in effect a square pattern with slightly rounded corners and with about ten percent ofthe original surface area in the lands 21 between the indentations 18.
The indentations 18 are typically hemispherically or almost hemisphericallyshaped with a depth about equal to the radius of the indentation at the major surface 14. Typical depths range from about 2 to 50 microns and preferably about 12 to about 35 microns. Hemispherically shaped indentations are preferred but not required. Indentations which are not hemispherical, for example about 50 microns in diameter and about 12 to 15microns in depth, have given satisfactory results.
The region 22 of the first conductivity type may be either n- or p- type having a sheet resistivity of about 5 to 200 ohms per square and is preferably a heavily p-type conducting region having a sheet resistivity of about 20 ohms per square. This region is typically formed using diffusion techniques after the indentations are formed.
The region 24 of a second conductivity type has a conductivity opposite to that of the region 22 of the first conductivity type and is preferably n-type conducting, having a sheet resistivity of about 5-200 ohms per square and typically about 20 ohms per square.
The p-n junction occurs either at the interface 23 between the region 22 ofthe first conductivity type and the low conductivity region 20 or at the interface 25 between the region 24 of the second conductivity type and thelow conductivity region 20, depending upon the conductivity types of the different regions. Typically, the low conductivity region 20 is lightly p-type conducting, the region 22 of the first conductivity type is p-type conducting, and the region 24 of the second conductivity type is n-type conducting. The p-n junction then occurs at the interface 25 between the region 24 of the second conductivity type and the low conductivity region 20.
The passivating layer 26, which overlies a portion of a second major surface 16 is an electrically insulating material, typically silicon dioxide about 0.5 micron thick which may be formed by standard thermal oxidation techniques. This layer may overlie a portion of the surface contiguous with the region 24 of the second conductivity type and is designed to reduce surface current leakage.
The electrically conducting layer 28 which overlies a portion of the secondmajor surface 16, contiguous with the region 24 of the second conductivity type, serves as the electrical contact to this region and may also serve as a reflector of light transmitted through the diode to this interface. Typically the layer is a metal, or a sequence of metal layers, which will reflect the incident light.
The electrically conducting layer 30 forms the electrical contact to the first surface 14. This layer may be a transparent coating which may cover the entire surface including the portion through which light enters the photodiode or it may be a metal which covers a portion of the surface and extends around that portion of the surface through which light enters the device. The thickness and constituents of this layer are immaterial so long as the layer is electrically continuous and good electrical contact is made to the region 22 of the first conductivity type.
The anti-reflection coating 32 may overlie that portion of the first surface 14 through which light enters the device. The wavelength of the incident light and the optical index of refraction of the constituent materials of this layer will determine its thickness. A layer of silicon monoxide about 1350 Angstroms thick is suitable for an anti-reflection coating in the wavelength range of 1060 nanometers.
In the avalanche photodiode shown in FIG. 3, the region 22 of a first conductivity type, the low conductivity region 20 and the region 52 of a third conductivity type are all of the same conductivity type although having varying magnitudes of their conductivity. Typically, these regions are of a p-type conductivity with the region 22 of the first conductivity type heavily p-type conducting, the low conductivity region 20 lightly p-type conducting, and the region 52 of a third conductivity type having p-type conductivity. The p-n junction in this case is at the interface 54 between the region 24 of the second conductivity type and the region 52 ofa third conductivity type.
The alternative arrangement to this where the n- and p-type conductivities are interchanged may be desirable in some materials such as III-V compounds. However, in silicon a carrier generated in the low conductivityregion 20 which would be swept towards the p-n junction and detected would in this case be the hole. Since the ionization coefficient for holes in silicon is very low, the avalanche gain would also be very low thus makingthe arrangement less desirable, though feasible.
In FIG. 3 the contoured surface is opposed to the surface contiguous to thep-n junction. Alternatively, the surface contiguous to the p-n junction maybe contoured although this is not the optimal configuration because of the high electric fields near the junction region. It is not necessary, however, that the light entry surface be contoured. Alternatively, light may enter the photodiode through the surface contiguous with the p-n junction and pass through the photodiode before striking the contoured surface.
A channel stop ring 58 having a conductivity of the same type as the low conductivity region 20 may be used to reduce surface leakage currents. Thestop ring 58, which is typically formed by diffusion techniques, extends into the main body about 20 microns.
The indentations 18 are formed by etching through openings 96 in a barrier layer 94, as shown in FIG. 4, which overlies the first surface 14 of the semiconductor body 12. The barrier layer 94 is typically silicon dioxide having a thickness of about 0.8 micron, sufficient to mask the surface against the etchant used. The openings 96 in the barrier layer 94 may be formed by standard photolithographic techniques and etching the barrier layer 94. I have found that openings having dimensions which are small compared to the spacings between openings in the barrier layer 94 will produce, with etching, indentations which are close to hemispherically shaped. If, however, the openings in the barrier layer 94 become too small, then the etching action may not be uniform. The openings, which maybe either circular or square, are typically about 12 microns in diameter and spaced about 50 microns apart in a regular array.
The exposed semiconductor body is then etched with an isotropic etchant which removes material both below the openings in the barrier layer 94 andlaterally under the barrier layer 94, thus undercutting this layer as shownin FIG. 4. The etching process is stopped when the barrier layer is almost completely undercut at which point the indentations are almost touching one another in the direction of closest spacing of the openings. The barrier layer 94 is then removed and the etching process continued preferably until the indentations overlap along the direction of closest spacing. This overetching produces what is in effect an almost square pattern with rounded corners. I have found that continuing the etching process until the indentations are square does not produce as high a device quantum efficiency as compared to stopping the etch before the pattern has become square. The sharp edges that remain in the corners point away from the sensitive interior of the device and will thus not produce regions of high electric field.
A suitable isotropic etchant for use with the silicon semiconductor body isa solution of 70% by weight aqueous nitric acid, 48% by weight aqueous hydrofluoric acid, 100% by weight acetic acid, and deionized water in the ratio 18:2:1:1 by volume. Other etchants which will etch silicon isotropically may also be suitable for this use.
A measure of the performance of a photodiode is the quantum efficiency which is the ratio of the number of electron-hole pairs generated by absorption of the incident light beam and detected to the number of incident light quanta. A decrease in surface reflectivity will increase the number of light quanta which enter the photodiode and thus increase the quantum efficiency. An increase in the path length for optical absorption in the photodiode increases the number of electron-hole pairs generated and thus increases the quantum efficiency and the spectral response.
EXAMPLE 1
A p-i-n photodiode having a surface contoured in a regular array of indentations was fabricated and tested as follows.
A p-type silicon wafer having a resistivity about 3000 ohm-cm was used. A p-n junction was formed by diffusing an n-type dopant, here phosphorus, about 10 microns into a surface of the wafer.
A silicon dioxide barrier layer was then formed on the opposed surface using standard techniques. Square openings, 12 microns on a side and spaced about 50 microns apart, were formed in the silicon dioxide layer using standard photolithographic techniques. The silicon surface beneath the barrier layer was then etched for about four minutes using the isotropic nitric acid, hydrofluoric acid and acetic acid etchant describedabove, at which point the silicon dioxide layer was almost completely undercut. The etching was stopped, the silicon dioxide layer was removed, using an etchant specific to this layer and the silicon surface was etchedagain in the isotropic etchant for about 30 to about 45 seconds. The indentations formed, which overlapped one another in the direction of closest spacing of the openings in the silicon dioxide layer, had a depth of about 25 microns and a center to center spacing of about 50 microns.
The contoured surface was then diffused with boron to form a p+ region contiguous with this surface. A metallic layer was then evaporated onto a portion of this surface to make electrical contact to the p+ region. A silicon monoxide anti-reflection coating about 132.5 nanometers thick was applied to the contoured surface using standard evaporation techniques. A light reflective and electrically conducting layer was then formed on the surface opposed to the contoured surface by sequentially evaporating about1000 Angstroms of aluminum, about 500 Angstroms of chromium and about 2500 Angstroms of gold.
The p-i-n photodiode thus fabricated was tested by exposure to a beam of 1060 nanometer radiation. The quantum efficiency of the device, having a sensitive thickness of about 150 microns, was measured to be about 47% as compared to 24% for a device with the same effective thickness which was fabricated using the same processes but absent the contoured surface.
EXAMPLE 2
An avalanche photodiode having a surface contoured in a regular array of indentations was fabricated and tested as follows.
A p-type silicon wafer having a resistivity of about 3000 ohm-cm. was used.A p-type conducting layer was formed in one major surface of the wafer by ion implantation and drive-in diffusion. An n-type conducting layer was then formed in a region contiguous to this surface by standard diffusion techniques forming a p-n junction between these two layers.
The opposed surface was then contoured and doped and the electrical contacts, and reflecting and anti-reflecting layers formed as in Example 1.
An avalanche photodiode fabricated by this method and having a sensitive thickness of about 110 microns was then exposed to a beam of 1060 nanometer radiation. At a reverse bias of 30 volts, less than the avalanche threshold, the avalanche photodiode had a quantum efficiency of about 41% as compared to a quantum efficiency of 20% for an avalanche photodiode with the same effective thickness which was fabricated in the same manner except for the absence of the contoured surface.
The avalanche photodiode fabricated with a contoured surface and fabricatedby the process described above was found to have significantly improved gain uniformity for 1060 nanometer radiation across the surface of an individual device by illuminating only a portion of the sensitive area andan improved yield in devices from a wafer.
|
The light entry surface or back surface of an avalanche or p-i-n photodiode is contoured in a regular array of indentations which are hemispherical or almost hemispherical in shape. Light incident on the photodiode undergoes multiple interactions with the contoured surface, thus reducing the entry surface reflectivity and increasing the optical path length in the photodiode, and thereby enhancing its long wavelength response.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Chilean Patent Application No. CL 1464-2014, filed 4 Jun. 2014, which is hereby incorporated herein as though fully set forth.
FIELD OF THE INVENTION
[0002] The present invention is related to a product based in seaweeds, that is useful to be applied in all types of crops. More specifically, it refers to a biostimulant from seaweeds, that is useful to be applied in all type of vegetal crops, either agricultural or forest, with the purpose to avoid chemical fertilizers that are polluting or harmful to human health and to the environment.
BACKGROUND
[0003] Currently there is a wide range of methodologies to obtain seaweed-based fertilizers.
[0004] The pending patent request WO2013/108188 describes a method to obtain fertilizers. The method the application of high pressures to seaweeds to release its intracellular content. This extract is complemented with zeolite and meat and bone meal (MBM). The application does not claim the product in its current commercial form, i.e. pellet or grind down. This document is part of the state of the art.
[0005] Patent EP1534757 claims a process to obtain a fertilizer and phycocolloids in parallel. The extraction of the fertilizer includes washing the seaweeds; blend the seaweed through milling; filtering and recovery of the liquid phase; addition of a certain preservative; concentration through evaporation or by the use of membranes. The method does not mention acid and/or base treatment, and for that reason the incorporation of a preservative is probably required. This patent is part of the state of the art.
[0006] Patent CL 47236 from the Universidad de los Lagos claims a method that includes the use of HCl as the acidifying agent and K 2 CO 3 as the alkalizing agent for the treatment of the seaweeds Macrocystis pyrifera and Ulva rigida , obtaining a liquid final product (Makromix).
[0007] Comparatively, the product of the present invention is superior to other products obtained by comparable procedures, because of the particularity of the process and the raw material used, allow to achieve a higher bioavailability of the nutrients contained in the seaweeds and this is traduced in better yields, both in the modalities of foliar (soil) application as in the phase of seed germination.
[0008] In the quest of better field results, the present invention differs in key aspects from the process that delivers a superior product, like the use of a different pool of seaweeds, the use of acetic acid and KOH, that finally result in higher process yield and quality of the final product.
DESCRIPTION OF THE INVENTION
[0009] Because of the growing demand on products that are organic, environmentally friendly and harmless to human health, the need for natural biostimulants has been raised, that are similar or more effective that the traditional stimulants used. The present invention discloses a biostimulant that is capable to increase the growth rates and yields of a wide range of crops.
[0010] In order to efficiently obtain the product, with a better performance to that described in the state of the art, the present invention claims a method for the preparation of a natural vegetal biostimulant, that includes the treatments of seaweeds with acetic acid as acidifying agent, and KOH as alkalizing agent. The present invention also includes the use of american leonardite, to finally obtain a dry product, that is easy to use, transport and store.
[0011] The present invention claims a method that takes advantage in the availability of seaweeds of low commercial price as raw material to produce a biostimulant, that is useful to be applied on seeds, aerial parts of the plants or soil. To accomplish this, red and brown algae from the Macrocystis and Gracilaria genera have been selected, like, for example, M. pyrifera and G. chilensys , respectively.
[0012] Red and brown algae contain high concentrations of vegetal hormones or phytohormones, free amino acids and oligosaccharides. The composition claimed, due to the utilization of these seaweeds and the innovative method of elaboration, extracts and preserves, and in consequence provides to the vegetal or seed treated high concentrations of three phytohormones: auxins, cytokinins and gibberellins, that are required for the optimal development of plants.
[0013] Furthermore, 17 amino acids present in seaweeds that are necessary for protein synthesis (alanine, arginine, aspartic acid, cysteine, glycine, glutamic acid, histidine, isoleucine, leucine, lysine, methionine, phenylalanine, proline, serine, threonine, tyrosine and valine) ensure a better development of the plants. In normal conditions plants produce their own amino acids, but in stress conditions photosynthesis is reduced and in consequence its metabolism is slowed down. The product from this patent, delivers exogenously these amino acids and reduces the stress in plants, increasing the absorption of nutrients and improving its translocation and the permeability of the cell membranes.
[0014] In addition, oligosaccharides (laminaran, manitol) activate the function of phytoalexins in cultivated plants, resulting in a higher vigor and resistance of the plant to diseases and plagues, optimizing the technical use of them.
[0015] In sum, the method claimed allows the extraction of nutrients contained in seaweeds foliage, without degradation nor requiring the reincorporation of those nutrients from external sources.
[0016] Finally, the present invention provides a great amount of organic matter, that is beneficial to improve the soil treated, by means of humic and fulvic acids incorporation that come from leonardite, that is a fossil mineral that is found together with lignite and that is the main source of these acids. This solid, concentrated and humidified organic matter, contain humic substances, that help to improve the soils both in a physical-chemical and biological manner. It can be applied together with solid and liquid fertilizers to obtain a better performance. Is an intermediate material, between turf and lignite, and is derived from the transformations (diagenesis) of vegetal remains, buried at approximately 10 meters, when together with water percolation from rain and the presence of atmospheric oxygen, led to a progressive enrichment of the humic substances.
[0017] It is possible that brown lignite may be confused with leonardite, even that they have clear differences: lignite suffers a carbonization process, whereas leonardite does not, and at the same time, leonardite has a high oxygen content and lignite loses almost all of it, and finally, leonardite has an open structure, and lignite comprises, because of the pressure suffered during its burial.
Main Functions of Leonardite:
[0018] Acts as a soil corrective, achieving the rehabilitation of soils by providing them a fluffy structure, reducing compression and favoring ventilation and porosity of soil; it helps to water retention; it favors root growth; it reduces the need of mineral fertilizers; it improves the quality and size of crops; it accelerates the plant's vegetative cycle; it improves the soil physical-chemical properties; it improves the soil salinity; it has a high power to chelate cations.
FIGURE DESCRIPTION
[0019] FIG. 1 : Flowchart that exemplifies the complete process for biostimulant extraction.
DETAILED DESCRIPTION OF THE INVENTION
[0020] In the following pages the physical-chemical fundaments are described for each of the steps of the process and the evidence that show the optimal results as well as the detailed procedure to reproduce those results with the available resources.
Seaweed Milling
[0021] Seaweed milling has as primary aim to facilitate the use of them during storage, salt removal or washout and the acid treatment. Another benefit derived from milling is to reach a particle size that allows to reagents uniformly penetrate to the seaweed, resulting in more homogenous reactions and so it gives better monitoring of chemical treatments. The use of this maneuver will result in obtaining fragments, that make possible to perform in a satisfactory way the subsequent treatments. This is done using a grinder. With this mechanism a more uniform particle size is obtained resulting in more mass fluidity during seaweed's chemical treatments. The preferred particle size ranges between 5 and 10 mm.
[0022] For processing in the factory, 1000 kg of fresh seaweed are used, they are deposited in a 5000 L capacity vat (tank). If seaweeds will not be immediately processed, they can be stored for 24 hours without freshwater.
[0023] Seaweeds are employed in a ratio of Macrocystis:Gracilaria from between 70:30 to 95:5 respectively.
Salt Removal or Washout
[0024] This step consists in washing the seaweeds with water, in order to eliminate and remove mineral salts, seawater excess, sand, small mollusks, etc. The process is carried out with water at room temperature for until 60 min.
Acid Treatment of Seaweeds
[0025] The acid treatment step has two basic functions. First it is done to remove the soluble mineral salts and organic matter in excess, that was not removed by the previous wash, as well as the sediments and organisms associated to seaweeds. Second, is to perform an ion-exchange chemical reaction mainly between calcium ions and other divalent cations, like magnesium and strontium, that are contained in seaweeds as divalent metal alginates, and originating alginic acid (HAlg).
[0026] Although there is currently in the state of the art a process that employs HCl, we have discovered that the use acetic acid results in superior acid treatment. Both HCl and acetic acid run in a similar way in the chelate fixation that is required in the acid process. However, acetic acid is accepted in the organic process without HCl limitations, such as its low boiling point, that implies a higher acid loose at the temperature in which the acid treatment is done, with respect to acetic acid. Additionally, HCl treatment only tolerates a 1.5% of the acid, an amount that is not enough for an efficient chelate fixation in a short time of reaction.
1. The Reaction Carried Out is the Following:
[0027] Ca(Alg) 2 +2CH 3 COOH----->2HAlg+Ca(CH 3 COO) 2
[0028] Physically, this is a heterogeneous reaction between solid seaweed particles and the acid solution.
2. Liquid/Solid (US) Relation.
[0029] The ratio of water respect to the volume of processed seaweeds has two purposes; first, is to provide fluidity to the mass in order to obtain an homogeneous reaction, second is to remove the mineral salts and solids associated to seaweed particles.
a) Factors Implied in Mass Fluidity.
[0030] Mass fluidity depends not only in the liquid amount but also in the particle size. The smaller the size of the particle the lesser the amount of water required. However, the minimal size of the particle is limited by two important factors:
Viscous nature of seaweeds: Naturally, fresh seaweed have a viscous texture, which is incremented after fractioning by the release of fucoidins in the cutting edges. Separation of liquid:solid phases: Very small particles are not convenient because of the complications in the mechanisms to separate solids and because of the increased loss of small particles
[0033] In conclusion, a particle size between 5 to 10 mm present an homogeneous fluidity with a minimal liquid solid relationship of 2:1.
b) Removal of Mineral Salts and Soluble Organic Matter.
[0034] Humid seaweeds contain an 8-10% of mineral salts and soluble material. These impurities often causes interferences in some of the steps of the process of preparation of the biostimulant, so it is necessary to reduce them at the beginning of the process. A 1.5-3.0% reduction avoid significant interferences in subsequent reactions. In previous experiences, the process for salt removal was standardized to 1.0-3.0% levels, applied a 30 minutes wash in a liquid:solid relation of 2:1. With this washing system the water consumption is optimized and an efficient reduction in salt content is achieved.
3. Acid Consumption.
[0035] During the acid wash of seaweeds a ion-exchange reactions occurs between de divalent metal salts from alginic acid that is contained in seaweeds (Ca 2+ , Mg 2+ , Sr 2+ ) and proton H + . This treatment is done in order to transform all the alginate salts contained in the seaweed to its generic form of alginic acid.
[0036] Depending on the alginate content in the seaweed, this reaction consumes an amount of acid close to the stoichiometric relationship.
[0037] In practice, the total expense of acid, including the lost in residues should be the closest to said relationship. This will be depend on the efficiency of the wash mechanism.
[0038] The washing system suggested for salt removal was used to optimize acid consumption.
[0039] The average expense recorded is between 55 and 65 L of acetic acid, more preferentially between 58 and 62 L of acetic acid for 1,000 kg of fresh seaweed.
4. Time and Temperature of Reaction.
[0040] Time and temperature notably influence a reaction's kinetics. These parameters determine the viscosity of the final product due to the susceptibility of alginic acid to break down at high temperatures or prolonged exposures to acid.
[0041] The reaction time is from 90 to 120 minutes at a temperature of 45-65° C., time that is satisfactory to complete the reaction y there is no alginate degradation, protecting the compounds from seaweeds, and obtaining a chelated base.
[0042] The parameters previously mentioned are resumed in Table 1:
[0000]
liquid/solid relationship
2:1
Amount of acetic acid
55 to 65 L
Total time of residency
90-120 min
Temperature of reaction
45-65° C.
Wash
30 min
Batch Size
1,000 kg of fresh seaweeds
[0043] Once the acid treatment is finished, the mixture is filtered with sieve, recovering the solid particulate, that will be subject to digestion or alkaline treatment.
Digestion and Extraction (Alkaline Treatment)
[0044] During digestion and extraction a neutralization reaction occurs between alginic acid contained in algae particles and a potassium alkali, producing in this case a potassium alginate en aqueous solution. The reaction carried out is the following:
[0000] HAIg+KOH------------>KAlg+H 2 O
[0045] This reaction is one of the most delicate of the process, because a big proportion of the performance and the quality of the final product depends on the adequate control of the physical-chemical parameters that affects it.
[0046] Physically, this is a heterogeneous reaction between the solid particles from the acid pretreated seaweed and the alkaline solution. The alkali penetrates in the algae particle, converting the insoluble alginic acid in soluble sodium or potassium alginate in aqueous media, finally resulting in a very viscous solution with millimetric insoluble cellulose filaments. The total dissolution of the particles determine the maximal yield of the raw material.
[0047] Basically the reaction is completed at a pH higher than 7, preferentially 8.5 to 14, in a reaction time that can range from 120 to 150 min depending on the following factors:
[0048] a) Temperature. The temperature is one of the most important factors in the reaction due to its control in the reaction's kinetics and the viscosity of the final product. The range in which the viscosity can be controlled varies from 70 to 82° C.
[0049] b) Particle size: A particle's size <10 mm gives very good results with the appropriate combination of the other parameters.
[0050] c) liquid:solid relationship and stir. During digestion is recommended to have a fluidity that allows to homogeneously stir the suspension using minimal water.
[0000] A 2:1 liquid:solid relationship respect to fresh seaweeds results in a viscosity that allows a homogenous stir of the suspension and gives enough aqueous media to dilute the extract.
[0051] d) pH. In the process described optimal results were obtained using a pH range between 8.5 and 14 (given by the use of potassium hydroxide). Under these conditions maximal yields between 3.5 and 3.8% of potassium alginate were obtained, that are the base of the alkaline extract used as biostimulant from fresh seaweeds. The alkali consumption is between 45 and 50 kg of potassium hydroxide per initial ton of fresh seaweed.
[0052] The parameters previously mentioned are resumed in Table 2:
[0000] Temperature 70-82° C. pH 8.5-14 Time 120-150 min liquid/solid relationship 2:1 % of KOH respect to fresh seaweeds 3 to 6%
The digestion is carried out as follows:
[0053] Potassium hydroxide is dissolved in water at 60-65° C. and milled seaweeds or the solid particulate recovered from the acid treatment are added, then the mixture is stirred for 120 to 150 min at 70-82° C. pH is adjusted with potassium hydroxide. The final product of this reaction is a viscous solution (400-600 Cps) of potassium alginate with millimetric cellulose residues.
[0054] The end of the hydrolysis step is initiated lowering the temperature of the mixture, followed by the filtration of the alkaline extract.
5. Filtration
[0055] The aim of filtration is to clarify the solution of the alkaline extract, removing the cellulose insoluble particles that remains from digestion step. The monitored parameters in this stage are the filtrate purity and filtrate velocity, which depends on the filtration media used. Preferentially the filtration of the solution is carried out with a primary and a secondary filter with a final net size of 50, without excluding another compatible methods.
6. Leonardite Processing
[0056] Leonardite is subjected to an activation process through chemical hydrolysis to separate it in humic and fulvic acids (active components) and other non hydrolysable components (clays and humines). This helps to extract all the nutrient capacity of leonardite in short time, process that in a natural manner will take several years.
[0057] Digestion is done in aqueous media, with KOH and controlled temperature. For each 100 kg of leonardite 500 L of water at 40-45° C. are used, and between 47 and 53 kg, more preferentially between 50 and 51 kg of KOH. The mixture is stirred at 45-50° C. for 30 to 40 min.
[0058] Once the digestion of leonardite is finished, it is mixed with the alkaline extract from seaweed, recovered from the alkaline treatment, in a concentration that ranges from 5 to 20% v/v.
7. Drying
[0059] The process consists in pulverize the fluid inside a chamber subjected to a controlled stream of hot air. This fluid is atomized in millions of individual microdrops by a rotating disc or a spray nozzle. By this process the area of contact of the pulverized product is enormously augmented and inside the chamber the hot air stream induces the rapid vaporization of water in the center of each microdrop were the solid is located, resulting in a smooth dry without a big thermal shock, transforming the product in powder and finishing the process with the collection of this powder.
[0060] The final product is a fine powder, resulting from the drying of the mixture from the extract from processed seaweeds and the solubilized american leonardite. This presentation facilitates transportation, storage and preservation, keeping the biological properties of the product.
[0061] For application on ground, the product is simply dissolved in water, reconstituting the extract (28 gr×L) depending on the requirements, being able to be applied by irrigation or spray.
[0062] The product has been stored under these conditions for periods longer than 3 years, keeping the biostimulant properties of the product, a feature that is favored for its powder presentation format and its low hygroscopy.
EXAMPLES
Monitoring of a Consignment in the Factory
[0063] The following is a description of a typical operational process in the factory including the monitoring that is performed in every step of the process starting with a base of a 1,000 kg consignment of fresh seaweeds.
Preparation of a Consignment
[0064] Seaweeds must be fresh. At the beginning of the process the following preparations must be done:
[0065] 2,000 L of water with 61 L of acetic acid are prepared in the acid wash tank.
[0066] 2,000 L of water are stored in the digestion tank.
[0067] Reagents are heated to a temperature close to 45-50° C. and the acid wash can now begin.
Procedure of the Operation
[0068] 1. Collect 900 kg of Macrocystis pyrifera and 100 kg of Gracilaria chilensis.
2. Fraction them to a size between 5 to 10 mm in the milling machine, wash and weight 1,000 kg;
3. Incorporate 2,000 L of water and 61 L of acetic acid at 45-65° C. with constant stirring for 100 min. Once finished, the liquid phase is eliminated and it is washed with water.
4. 2,000 L of water are added, and the temperature is set to 60° C.; 48 kg of potassium hydroxide are dissolved and milled seaweeds are added. Temperature is raised to 79° C. under constant stirring for 2 hours. pH is adjusted at 8.65 and the mixture is cooled down.
5. Filtration. Once the residual particles have sedimented, a filtration takes place, eliminating the particulate; american leonardite is incorporated, hydrolized at 10% v/v.
6. Adjust pH to 7, if required, with phosphoric acid, acetic acid or other suitable acids.
7. Dry until obtain the powder.
6. Leonardite Processing
[0069] For obtaining humic and fulvic acids.
500 L of water at 45° C. are employed. The mixture is stirred until the end of the process. 50 kg of KOH and 100 kg of american leonardite are added. Temperature is hold at 45° C. for 30 to 35 minutes, until the initial product is completely dissolved.
Example 1
Comparative Assay in Wheat
[0070]
[0000]
Variety
Pandora INIA
Seed dose
220 kg × Ha
Total area
18 ha
Bioestimulant application area
1 ha
Makromix application area
1 ha
Control area
16 ha
[0071] Treatment was applied to seeds pre-sowing and then to the plant in the end of culm state.
[0000]
SCHEDULE OF APPLICATIONS
Date/period
Product
Dose
Watering
Area
15-Jul/Pre-
Biostimulant
0.5 L × 100
1 L × 100 kg
1 ha
sowing
kg of seed
15-Jul/Pre-
Makromix
0.5 L × 100
1 L × 100 kg
1 ha
sowing
kg of seed
25-Oct/End
Biostimulant
3 L × ha
66 L × ha
16 ha
of culm
25-Oct/End
Makromix
3 L × ha
66 L × ha
16 ha
of culm
[0072] Both treatments showed differences respect to control, in the measures of root growth, vegetative development and plat height, evidencing notorious differences in harvest yield and the milling quality.
[0000]
MEASUREMENTS
05-Nov
Biostimulant
Makromix
Control
Root growth
15
14.5
14
Roots lenght m/m
40
38
38
Plant weight Grs.
91
78
68
HARVEST
15-Feb
Biostimulant
Makromix
Control
qq × ha.
71.3
66.23
60.46
CALIDAD MOLINERA
20-Feb
Biostimulant
Makromix
Control
Hectoliter weight kg/HL
85.3
85.3
84.6
Dry gluten kg/HL
11.93
10.4
9.9
Example 2
Comparative Assay in Raspberry
[0073] In raspberry crop, Meeker variety, the following assay was performed in a total area of 1.98 ha:
[0000]
Bioestimulant application area
0.92 ha
Makromix application area
0.94 ha
Control area
0.12 ha
[0074] Four applications of each fertilizer were done, at a rate of 6.5 L per ha, in a period of 80 days. In both applications a higher development of buds and shoots as well as an apparent increase in vigor, additionally a higher need of fertilization is observed, mostly nitrogen after each application, a fact that is probably explained by the increase in the plant's rate of biomass development.
[0075] The yield in kg of pulp per hectare was evaluated. Yield of each treatment according to quality and expressed in kg/ha.
[0000]
Classification
According quality
Biostimulant
Makromix
Control
IQF > 18
2,777.75
2,509.66
2,430.48
IQF < 18
1,860.38
1,869.00
1,789.37
Pulp
486.875
438.347
463.1487
Total yield
5,125
4,817
4,683
Example 3
Comparative Assay in Eucalyptus
[0076] A seed from Puacho 3 (Anchile) was employed, subjected to 3 days of soaking in water and 30 seconds of soaking in Sodium hypochlorite, 21 days of cold and 3 days in chamber. Pine bark from Madexpo and 3 kg of NPK (3-33-3) was used as substrate.
[0077] 30 seed trays with 96 cavities each were used. A solution of 1% of Biostimulant and Makromix was applied. A second application was performed at a concentration of 0.5%.
Procedure:
[0078] Two treatments plus the control (Ultrasol) were done, each one with 5 replicas. Sowing was carried out using an automatic sow seed machine. After that a solution with 1% fertilizer was applied with a watering can. Then, trays were taken to the germination chamber at a fixed temperature of 27° C. for 3 days.
[0079] Once initiated germination, trays were taken to a farm building with temperatures ranging between 20 and 30° C. during day and 4 and 15° C. during night. Watering, depending on weather conditions, was done twice a day.
[0080] The controlled variables controlled were the germination percentage, root collar diameter (RCD) and average height after 10 days of sow.
[0081] Second application was done with 0.5% dilution in 1,500 cc of water. After 36 days of sow, a second control of germination was done.
[0082] Results were the following:
[0000]
% Germination
Average height
Fertilizer
1st measurement
2nd measurement
1st measurement
2nd measurement
Biostimulant
77.5
77.08
1.08
2.74
Makromix
59.79
58.54
1.02
2.12
Ultrasol
76.88
75.83
1.04
2.70
Example 4
Comparative Assay in Grape
[0083]
[0000] Variety Red Globe Location Copiapó-Chile Cultivated field 8 years Total area 5 ha Biostimulant applied area 2 ha Makromix applied area 2 ha Control area 1 ha
The following application protocol was employed for both products:
[0000] Application period Dose Watering 40 cm bud 3 L × ha 1.6 L × ha Curdle 3 L × ha 1.6 L × ha Bunch closure 3 L × ha 1.6 L × ha Veraison 3 L × ha 1.6 L × ha
Parameters were measured 15 days pre-harvest and during harvest.
[0000]
measurement 15 days pre-harvest
Biostimulant
Makromix
Control
Bunch weight
506
490
456
Equatorial diameter
19.5
19.2
19
Brix degrees
18.6
18.4
18.3
Harvest
Bunch weight
694
642
636
Equatorial diameter
23.8
22.1
21.96
Polar diameter
2.8
2.7
2.7
Brix degrees
19.35
19.1
19
[0084] It is evident the differences between treatments and control, in all the parameters measured, being the treatment with Biostimulant notoriously superior with respect to Makromix and Control.
Example 5
Comparative Assay in Tomato
[0085]
[0000]
Variety
Titan
Total Area
0.6 ha
Biostimulant Area
0.3 ha
Makromix Area
0.3 ha
Layout of plantation
1.2 m between row y 0.2 over row
Watering
Drip irrigation with tape. 4 L × m linear
Applications
8 foliar applications with 400 L × ha
Dose
2 L × ha in C7
[0086] Eight applications of each treatment were done, every 20 days. In the 2 first applications no differences were observed in plant development, however, starting the third application the vigor of the Biostimulant-treated seedlings was increased, resulting in a notorious increase in total yield and in a better fruit quality at harvest.
[0000]
HARVEST Kg × ha
Quality
Bioestimulant
Makromix
Tomato 1 st
175,109
117,600
Tomato 2 nd
50,031
39,210
Tomato 3 rd
25,015
39,190
Total
250,155
196,000
|
Process to elaborate a biostimulant based on seaweeds, comprising acid and alkaline treatment of the algae. The process comprises incorporating American Leonardite and subsequent spraying of product. The invention comprises the composition obtained and its use as germination promoter, root stimulator, among others.
| 0
|
BACKGROUND OF THE INVENTION
[0001] The present invention relates to mobile shredders for shredding documents and other materials at customer sites.
[0002] With the increasing incidence of identity theft and other misuse of private or proprietary information, the desirability and necessity of protecting such information is becoming increasingly important. In recent years, laws have been passed in various jurisdictions regulating the use and protection by businesses, health care providers, and other entities, of sensitive or private information on customers, patients, and the like. At the federal level in the United States, the HIPAA and Gramm-Leach-Bliley laws require specific measures, such as document shredding, in order to comply with the laws' provisions for protecting certain designated types of information.
[0003] Discarding of sensitive documents in an unshredded state is risky because identity thieves, investigative journalists, and other unscrupulous individuals often engage in “dumpster diving” to retrieve documents from trash dumpsters or garbage cans. Accordingly, the demand for document shredding has surged. For entities having a small amount of documents requiring shredding, personal-sized shredders that are purchased or leased may be adequate. However, for many businesses and other organizations, the large volume of documents and other materials to be shredded makes such an approach impractical. Accordingly, document-shredding service providers have arisen to meet the increasing demand for large-volume shredding.
[0004] In the early history of document-shredding services, typically the documents to be shredded were picked up by the service provider and transported to a central facility for shredding. This form of shredding service still represents the prevalent one today. Central document shredding certainly can accomplish its intended purpose, if carried out properly. The drawbacks to central shredding include the necessity of strictly safeguarding the documents against theft or unauthorized access throughout the entire chain of custody from the time the documents are picked up from the customer to the time they are shredded, the necessity of properly documenting the chain of custody and the measures taken to safeguard the documents, and the fact that the users cannot independently verify that the documents were in fact shredded. This latter factor can give rise to a general sense of unease among some users of central shredding services.
[0005] Consequently, there is now a trend toward on-site document shredding using mobile shredders. A mobile shredder generally consists of a truck having a shredder mounted therein, and a storage volume for storing the shredded material. Typically, the users place the materials to be shredded in bins or “toters” that usually have wheels for rolling the bins to a location for pickup, such as a curbside location on a street. Mobile shredders typically have some type of bin lift and dump mechanism, such as those commonly employed on garbage collection trucks, for lifting the bins and emptying them into the shredder.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention is aimed at improving upon various aspects of mobile shredders. In accordance with one embodiment of the invention, a mobile shredder for shredding documents and other materials comprises a truck having a truck body defining an enclosure and including a partition in the enclosure that divides a storage volume from the remainder of the enclosure for storage of shredded material in the storage volume, a single-shaft rotary shredder mounted in the enclosure outside the storage volume, the rotary shredder comprising a rotor having cutters rigidly mounted thereon, a bin lift and dump mechanism operable to transport material to be shredded from outside to inside the enclosure so as to deliver material to the rotary shredder, and a discharge conveyor operable to transport shredded material from the rotary shredder through the partition to the storage volume. In a preferred embodiment, the floor of the storage volume comprises a walking floor, and the enclosure has rear doors that are openable to allow shredded material to be discharged from the storage volume through the open rear doors when the walking floor is operated.
[0007] In another preferred embodiment, a controller is operatively coupled to the walking floor and to the discharge conveyor, and is operable to control compaction of the shredded material in the storage volume by alternately operating in a first mode wherein the discharge conveyor is operated and the walking floor is stationary, and a second mode wherein the discharge conveyor is operated and the walking floor is operated to carry shredded material away from the discharge conveyor.
[0008] The bin lift and dump mechanism in one embodiment of the invention includes a bin-engaging member structured and arranged to grasp a bin that contains material to be shredded, and a powered lift device coupled with the bin-engaging member and operable to lift the bin-engaging member from a first position generally vertically upward to a second position that places the bin in a generally upright orientation adjacent the rotary shredder, and operable then to move the bin-engaging member to a third position that tips the bin so as to dump the material to be shredded from the bin into the rotary shredder. Advantageously, the mobile shredder includes a load sensor associated with the rotary shredder and operable to provide a signal indicative of a load level of the shredder, and the bin lift and dump mechanism further comprises a controller operatively coupled with the load sensor and with the lift device of the lift and dump mechanism. The controller is operable to automatically operate the lift device through a cycle from the second position to the third position and then back to the second position, and is further operable to suspend the cycle to prevent the bin from being emptied into the rotary shredder when the load level indicated by the load sensor exceeds a predetermined limit and to resume the cycle to empty the bin into the rotary shredder when the load level falls below the limit.
[0009] In one preferred embodiment, the rotary shredder has a single rotor having an outer surface formed generally as a surface of revolution about an axis, the shredder further including a counter knife arranged in opposition to the outer surface of the rotor, a space being defined between the counter knife and the outer surface of the rotor for passage of material being shredded, and a plurality of cutters rigidly affixed to the outer surface of the rotor, the cutters and counter knife cooperating to shred material. The rotary shredder also advantageously includes an infeed hopper disposed for receiving material to be shredded, and a hydraulic ram positioned beneath the hopper and operable to advance material to be shredded into the space between the rotor and counter knife.
[0010] The rotary shredder can be driven in various ways. In one embodiment, a hydraulic drive is coupled to the rotor of the shredder and is operable to receive pressurized hydraulic fluid and drive the rotor, and the mobile shredder includes a hydraulic pump that supplies pressurized hydraulic fluid to the hydraulic ram and to the hydraulic drive of the shredder. The truck comprises an engine including a drive train, and a power takeoff unit is coupled between the drive train and the hydraulic pump for driving the hydraulic pump. The mobile shredder includes a programmed controller operable to control operation of the hydraulic pump and associated valves, and a sensor system in communication with the controller and operable to monitor a plurality of operating parameters of the rotary shredder and truck, the controller being programmed to provide an alarm indication when one or more of the operating parameters is outside a predetermined normal range. Preferably, the controller is operable to provide a relatively low level of alarm when the sensor system indicates an abnormal condition of the rotary shredder or associated components, and to provide a relatively higher level of alarm when the sensor system indicates an abnormal condition of the truck.
[0011] The sensor system can monitor a level of fuel remaining in a fuel tank for the engine, and the controller can provide a first type of alarm indication when the level of fuel falls below a predetermined first value (e.g., one-eighth of a tank). For example, the first type of alarm indication can be effected by causing the vehicle horn to sound intermittently with a relatively low frequency (e.g., the horn can sound for half a second, once every five seconds). The controller can provide a second type of alarm indication (e.g., the horn can sound for half a second, once every second) when the level of fuel falls below a predetermined second value (e.g., one-sixteenth of a tank). Alternatively or additionally, the controller can be operable to shut down the engine when the level of fuel falls below a predetermined level so as to avoid running out of fuel; this is particularly advantageous for diesel trucks wherein running out of fuel is a major event.
[0012] The power takeoff unit preferably is selectively engageable with and disengageable from the drive train, and the mobile shredder preferably includes a programmed controller operable to control operation of the hydraulic pump and to control engagement and disengagement of the power takeoff unit with the drive train. The mobile shredder can include various sensors for monitoring conditions and detecting when it is safe or unsafe to engage or disengage the power takeoff unit or to shut down the hydraulic pump. For example, in one embodiment, an engine RPM sensor can measure engine RPMs, and the controller can prevent the power takeoff unit from being engaged with or disengaged from the drive train when the engine RPMs are above a predetermined limit. It is also possible to employ a transmission sensor to detect whether or not a transmission of the drive train is in a neutral gear, and the controller can prevent the power takeoff unit from being engaged with the drive train unless the transmission is in a neutral gear.
[0013] In another embodiment, the mobile shredder includes a pump sensor operable to measure a load level of the hydraulic pump, and the controller is operable to prevent the hydraulic pump from being shut down when the load level measured by the pump sensor is above a predetermined limit.
[0014] In accordance with a further aspect of the invention, a mobile shredder includes a bin lift and dump mechanism operable to lift a bin that contains material to be shredded and to tip the bin to dump the material into the rotary shredder, the bin lift and dump mechanism comprising a lift device traversable upwardly and downwardly within a channel defined in one side of the truck body, the channel being open along an outer surface of the one side of the truck body. A movable door is connected to the truck body and is movable between a closed position closing the channel and an open position permitting access to the channel so that a bin can be lifted by the bin lift and dump mechanism. The mobile shredder includes an actuator coupled with the door for opening and closing the door.
[0015] Preferably, a door sensor system is operable to detect whether the door is in the open position or in the closed position, and a programmed controller in communication with the door sensor system is operable to control operation of the rotary shredder and to control operation of the actuator for the door.
[0016] In another embodiment, a programmed controller is operable to control operation of the rotary shredder, and an operator control panel is coupled with the controller and includes a plurality of operator controls manipulable by an operator, the operator controls including at least a start control for initiating operation of the bin lift and dump mechanism. Preferably, the controller is operable to operate the bin lift and dump mechanism in either an automatic mode wherein the bin lift and dump mechanism goes through a complete cycle of lifting a bin, dumping the material from the bin into the rotary shredder, and lowering the bin back down without continuous operator intervention, or a manual mode allowing an operator to control operation of the bin lift and dump mechanism. The controller preferably is programmed to operate in the automatic mode upon an operator continuously depressing the start control for at least a predetermined minimum amount of time.
[0017] In yet another aspect of the invention, a mobile shredder includes a sensor system comprising sensors for measuring a plurality of operating parameters associated with the mobile shredder, a programmed controller coupled with the sensor system and operable to control operation of the rotary shredder and the bin lift and dump mechanism, an operator interface coupled with the controller and including operator controls manipulable by an operator to cause the controller to execute routines programmed in the controller, and a visual display for displaying information for an operator. The controller includes a memory storing an event history file and is operable to record significant events in the history of operation of the mobile shredder in the event history file, and the operator interface is operable to display the event history file on the visual display.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0018] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0019] FIG. 1 is a top elevation of a mobile shredder in accordance with one embodiment of the invention, partially broken away to show internal features of the mobile shredder;
[0020] FIG. 2 is a road-side elevation of the mobile shredder, along line 2 - 2 in FIG. 1 ;
[0021] FIG. 3 is a curb-side elevation of the mobile shredder, along line 3 - 3 in FIG. 1 ;
[0022] FIG. 4 is a perspective view of the mobile shredder, generally from curb-side;
[0023] FIG. 5 is a view along line 5 - 5 in FIG. 3 , showing the bin lift and dump mechanism being operated through a lift and dump cycle;
[0024] FIG. 6 is a detailed perspective view of the bin-engaging part of the bin lift and dump mechanism;
[0025] FIG. 7A is a perspective view of the bin lift and dump mechanism, showing a bin being lifted from ground level to a raised level;
[0026] FIG. 7B is a perspective view showing the bin being tipped to dump its contents into the shredder;
[0027] FIG. 8 is a cross-sectional view along line 8 - 8 in FIG. 5 , showing the infeed hopper, ram, shredder, and discharge auger in accordance with one embodiment of the invention;
[0028] FIG. 9 is a perspective view showing details of the movable door for closing the channel of the bin lift and dump mechanism;
[0029] FIG. 10 is a rear perspective view of the mobile shredder, showing the rear doors open in preparation for discharging shredded material from the storage volume;
[0030] FIG. 11 is a top elevation of the walking floor, with the slats partially broken away to show the hydraulic drive arrangement;
[0031] FIG. 12 is a cross-sectional view along line 12 - 12 in FIG. 11 ;
[0032] FIG. 13 is a perspective view of a clamp member for one group of slats of the walking floor;
[0033] FIG. 14 is a schematic diagram of the hydraulic system of the mobile shredder;
[0034] FIG. 15A depicts the controls panel for the mobile shredder;
[0035] FIG. 15B shows a portion of a touch screen of the controls panel;
[0036] FIG. 16 depicts a main maintenance manual menu displayed on the touch screen;
[0037] FIG. 17 depicts a main troubleshooting menu displayed on the touch screen when selected from the main menu of FIG. 15A /B;
[0038] FIG. 18 depicts a mobile shredder inputs and outputs page displayed on the touch screen when selected from the main troubleshooting menu of FIG. 17 ;
[0039] FIG. 19 shows a job setup page displayed on the touch screen when selected from the main menu of FIG. 15A /B;
[0040] FIG. 20 depicts an event history page displayed on the touch screen when selected from the main troubleshooting menu of FIG. 17 ; and
[0041] FIG. 21 shows a machine operation page displayed on the touch screen when selected from the main menu of FIG. 15A /B.
DETAILED DESCRIPTION OF THE INVENTION
[0042] The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
[0000] Overall System Description
[0043] A mobile shredder 100 in accordance with one embodiment of the invention is depicted in FIGS. 1-4 . The mobile shredder 100 comprises a truck having a cab 102 for accommodating a driver and passenger, and a truck body 104 of generally box-shaped construction. The truck body has a floor 106 , a road-side wall 108 , a curb-side wall 110 , a ceiling 112 , a front wall 114 , and a pair of rear doors 116 . The walls 108 , 110 , 114 and ceiling 112 and rear doors 116 can comprise various materials, but advantageously comprise a fiber-reinforced polymer (FRP) material such as fiber glass or the like, for high strength-to-weight ratio.
[0044] The truck body defines an interior space that is subdivided into two portions by a partition 118 that extends between the two side walls 108 , 110 at a location axially spaced behind the front wall 114 . As further described below, the space between the partition 118 and the rear doors 116 defines a storage volume 120 for storage of shredded material. The space forward of the partition defines a location for the primary working components of the mobile shredder.
[0045] Thus, in the forward space of the truck body, a single-shaft rotary shredder 130 is mounted on the floor 106 . The structure and operation of the rotary shredder 130 are described in detail below in connection with FIG. 8 , but for present purposes it is sufficient to note that the rotary shredder receives material to be shredded, shreds the material into small flake-like pieces, and passes the shredded material to a discharge conveyor 140 , which advantageously can comprise an auger as shown. The discharge conveyor is located forward of the partition 118 and is arranged to convey the shredded material through an opening in the partition into the storage volume 120 as shown in FIG. 2 .
[0046] Also located forward of the partition 118 is a bin lift and dump mechanism 150 operable to lift a bin B containing material to be shredded and to tip the bin to dump the contents of the bin into the rotary shredder 130 . The structure and operation of the bin lift and dump mechanism 150 are described below in connection with FIGS. 5, 6 , 7 A, and 7 B.
[0047] The floor of the storage volume 120 , in one embodiment of the invention, comprises a “live” or “walking” floor 180 as further described below in connection with FIGS. 11 through 13 . The walking floor 180 is operable to discharge the shredded material out the rear end of the storage volume 120 when the rear doors 116 are opened.
[0000] Single-Shaft Rotary Shredder
[0048] The single-shaft rotary shredder 130 is generally of the type described in U.S. Patent Application Publication No. US 2004/0118958A1 and in European Patent EP 419 919 B1, the entire disclosures of which are incorporated herein by reference. With primary reference to FIGS. 1 and 8 , the single-shaft shredder comprises a rotor 131 that carries cutters as further described below, and a counter knife 132 that works in conjunction with the rotor to grind up or shred material fed into the space where the rotor and counter knife converge. The counter knife is generally stationary, although it can be flexibly supported so that it can “give” to some extent when a very hard object (e.g., a piece of metal or a rock) is inadvertently fed into the space between the rotor and counter knife, the flexibility thereby tending to prevent damage to the machine. The ground up or shredded material exits through a screen 133 having apertures suitably sized to regulate the size of the pieces of shredded material. The shredder 130 also includes a hopper 134 for receiving material to be shredded, and a hydraulic ram 135 or the like for feeding the material into the space between the rotor and counter knife.
[0049] The rotor 131 is generally cylindrical in form, but the outer surface of the rotor defines a series of circumferential ridges or ribs (not shown) that project radially outwardly. Each rib can have opposite side faces that are conical and oppositely inclined to the rotor axis, and a radially outermost surface that is parallel to the rotor axis. Thus, in the axial direction along the rotor, the outer surface defines a series of alternating peaks (where the ribs are) and valleys between the peaks. The counter knife 132 has a series of teeth (not shown) that are axially aligned with the valleys between the ribs of the rotor, there being one such tooth for every valley in the rotor surface. Correspondingly, there are V-shaped recesses between the teeth of the counter knife that are axially aligned with the ribs of the rotor; thus, the rotor surface and the counter knife are complementary in configuration.
[0050] Rigidly mounted to the outer surface of the rotor 131 are a plurality of cutters 136 that are axially aligned with the ribs and with the V-shaped recesses in the counter knife. Material that is fed into the space between the rotor 131 and counter knife 132 is cut by the cutters 136 as they mesh with the counter knife. Various configurations can be used for the rotor surface, the cutters, and the counter knife, depending on the nature of the materials to be shredded. Where plastic film may constitute some of the materials to be shredded, the shredder design described in the aforementioned U.S. Patent Application Publication No. 2004/0118958A1, having both V-shaped cutters and flat cutters, is particularly advantageous. Where the materials to be shredded constitute substantially entirely paper documents and the like, alternative designs such as that described in the aforementioned EP 419 919B1 can be used.
[0051] In operation, materials to be shredded are dumped into the infeed hopper 134 of the rotary shredder. The hydraulic ram 135 is operated to push the materials into the space between the rotor 131 and counter knife 132 . The materials are shredded and pass through the screen 133 into the discharge conveyor 140 .
[0052] The rotary shredder 130 is hydraulically driven. A hydraulic drive 137 receives pressurized hydraulic fluid from a hydraulic pump 190 ( FIG. 14 ) and drives the rotor 131 . The hydraulic ram 135 also is driven by pressurized hydraulic fluid from the pump 190 . The supply of hydraulic fluid to the hydraulic drive 137 and hydraulic ram 135 is controlled by suitable electrically controlled valves 202 ( FIG. 14 ) or the like, the operation of which is controlled by a computer controller as further described below.
[0000] Discharge Conveyor
[0053] The discharge conveyor 140 is best seen in FIG. 8 . It comprises an auger 142 having helical flights 144 mounted on a central shaft 146 . The auger 142 is disposed within a cylindrical casing 147 that defines an opening therein for receiving shredded material from the rotary shredder. The auger is driven by a hydraulic drive 148 that receives pressurized hydraulic fluid from the pump 190 ; suitable valves 202 ( FIG. 14 ) are employed for controlling the supply of hydraulic fluid to the drive 148 . The cylindrical casing 147 communicates with an opening through the partition 118 so that shredded material is fed by the auger 142 through the opening into the storage volume 120 of the truck.
[0000] Bin Lift and Dump Mechanism
[0054] The bin lift and dump mechanism 150 is now described with primary reference to FIGS. 5, 6 , 7 A, and 7 B. The bin lift and dump mechanism comprises a bin-engaging member 151 structured and arranged to grasp a bin B that contains material to be shredded, and a powered lift device coupled with the bin-engaging member 151 and operable to lift the bin-engaging member from a first position (e.g., ground level as shown in solid lines in FIGS. 5 and 7 A) generally vertically upward to a second position (the middle position shown in phantom lines in FIG. 5 ) that places the bin in a generally upright orientation adjacent the rotary shredder 130 , and operable then to move the bin-engaging member 151 to a third position (the top position in FIG. 5 ) that tips the bin so as to dump the material to be shredded from the bin into the rotary shredder.
[0055] As best seen in FIG. 6 , the powered lift device includes a pair of spaced chains 152 arranged in vertically extending loops about drive sprockets 153 and idler sprockets 154 ( FIG. 7A ). A drive shaft 155 connects the two drive sprockets 153 of the respective chains 152 , and the drive shaft is coupled to a hydraulic drive 156 that receives pressurized hydraulic fluid from the hydraulic pump 190 ( FIG. 14 ) for driving the shaft and hence the drive sprockets so that the chains rotate. A transverse rod 157 is attached at its opposite ends to the chains 152 . Adjacent each end of the rod 157 , the lower end of a link arm 158 is pivotally mounted to the rod; the upper end of each link arm 158 is pivotally connected to the lower end of a generally L-shaped link arm 159 . The upper ends of the L-shaped link arms 159 have rollers 160 mounted thereon, and the rollers are arranged to roll along respective vertical track members 161 each located adjacent one of the chains 152 . Rollers 160 are also affixed to the L-shaped link arms 159 at positions proximate the lower ends of the arms, for rolling along the track members 161 . The vertex of each L-shaped link arm 159 is non-pivotally attached to a respective end of a transversely extending mounting portion 162 of the bin-engaging member 151 at an upper end of the bin-engaging member.
[0056] The track members 161 define upper stops (not shown) that limit how far the upper rollers 160 of the L-shaped link arms can travel vertically upward. When the hydraulic drive 156 is operated to drive the chains 152 so as to lift the transverse rod 157 vertically upward, the link arms 158 push the L-shaped link arms 159 upward, and both pairs of rollers 160 roll along the track members until the upper pair of rollers are stopped from further upward travel by the stops. However, the transverse rod 157 can continue to travel upwardly; this further upward travel is accommodated by rotation of the L-shaped link arms 159 about the upper pair of rollers 160 , which causes the lower pair of rollers 160 to leave contact with the track members 161 . This rotation of the L-shaped link arms 159 about the upper rollers 160 causes the bin-engaging member 151 to be pivoted to tip the bin B and dump its contents into the rotary shredder as shown in the top position in FIG. 5 .
[0057] The lift and dump mechanism 150 is located in an opening or channel 163 in the curb-side wall 110 of the truck body. A movable door 164 is provided for covering the channel 163 when the lift and dump mechanism is not being used, such as when the mobile shredder is traveling on the road. The door 164 is shown in its closed position in solid lines in FIGS. 1, 3 , and 5 , and is shown in its open position in phantom lines in FIGS. 1, 3 , and 5 , and in solid lines in FIGS. 4, 7A , 7 B, and 9 . The door 164 is supported by arms 165 that are mounted on a rotatable vertical shaft 166 coupled to a rotary pneumatic actuator 167 ( FIG. 9 ) or the like. The shaft 166 and actuator 167 are mounted to the truck body, recessed within the channel 163 . Rotation of the actuator 167 in one direction opens the door 164 , and rotation in the other direction closes the door. Advantageously, a sensor associated with the actuator 167 detects when the door is open or closed, and the computer controller is operable to prevent operation of the rotary shredder unless the door is open.
[0058] The operation of the lift and dump mechanism 150 is also controlled by the computer controller, which regulates operation of the hydraulic drive 156 by controlling suitable electrically controlled valves 202 ( FIG. 14 ) so as to control the supply of hydraulic fluid to the drive. Advantageously, the controller is programmed to control the lift and dump mechanism in such a way as to avoid overloading the rotary shredder 130 . More particularly, the controller is programmed to prevent the lift and dump mechanism from tipping a bin to dump its contents into the rotary shredder whenever a load level of the shredder, as detected by a suitable sensor 138 ( FIG. 14 ), is above a predetermined limit.
[0059] In one embodiment, an operator control panel 170 ( FIG. 15A ) is coupled with the controller and includes a plurality of operator controls manipulable by an operator, the operator controls including a start button 171 a for initiating operation of the bin lift and dump mechanism. Preferably, the controller is operable to operate the bin lift and dump mechanism in either an automatic mode wherein the bin lift and dump mechanism goes through a complete cycle of lifting a bin, dumping the material from the bin into the rotary shredder, and lowering the bin back down without continuous operator intervention, or a manual mode allowing an operator to control operation of the bin lift and dump mechanism. The controller preferably is programmed to operate in the automatic mode upon an operator continuously depressing the start button 171 a for at least a predetermined minimum amount of time.
[0060] In an automatic mode cycle, once the start button 171 a has been depressed for at least the predetermined minimum amount of time, the controller takes over control of the lift and dump mechanism. With reference to FIG. 5 , the controller then operates the lift and dump mechanism to lift the bin B from ground level up to a raised holding level (middle position in FIG. 5 ). If the load level of the rotary shredder is above the predetermined limit, the bin is held at this holding level until the load level falls below the limit; the bin is then lifted farther up and tipped to dump its contents into the rotary shredder. The controller then turns the control of the lift and dump mechanism back over to the operator for manual control.
[0061] In the manual or operator-controlled mode of operation, with the bin at the holding level, the start button 171 a can be depressed to cause the bin to be tilted once again to empty the bin into the shredder. This can be necessary, for example, if some of the contents remain in the bin after the automatic dumping cycle. Alternatively, with the bin at the holding level, the operator can press the stop button 171 b to cause the bin to be lowered back to the ground.
[0062] The operator control panel 170 preferably is arranged behind a door 172 that can be closed to prevent access to the panel. The door 172 can comprise a flexible material that is foldable and slides in tracks 173 similar to an automobile sun roof. The door can be opened and closed by an electric motor (not shown). In one embodiment, the computer controller is operable to prevent operation of the rotary shredder when the controls door 172 is in the closed position.
[0000] Walking Floor
[0063] The walking floor 180 is now described with primary reference to FIGS. 11 through 13 . The walking floor comprises a plurality of axially extending, parallel slats arranged in three groups 182 a , 182 b , 182 c that alternate in “a, b, c, a, b, c . . . ” fashion.
[0064] The slats advantageously are generally I-shaped in cross-section, having depending dovetails 183 that are clamped in clamp members 184 a , 184 b , 184 c , respectively, for the three groups of slats. All of the first clamp members 184 a are affixed to a transversely extending support plate 185 a so they move together as a unit, and likewise the second group of clamp members 184 b are affixed to support plate 185 b , and the third group of clamp members 184 c are affixed to support plate 185 c . Thus, each group of slats is independently movable, as a unit. Each group of slats is driven by its own hydraulic cylinder 186 a , 186 b , 186 c , respectively, that form a drive unit 187 . Thus, the hydraulic cylinder 186 a is coupled with the support plate 185 a for the first group of slats 182 a , and likewise the other two hydraulic cylinders 186 b and 186 c are respectively coupled with the support plates 185 b and 185 c . The hydraulic cylinders are operated in unison so that all of the slats 182 a, b, c are advanced rearwardly at the same time so as to move the shredded material resting on the walking floor toward the rear of the truck. Then one hydraulic cylinder is operated at a time to slide each group of slats forward; thus, all of the first slats 182 a are slid forward as shown by the arrows in FIG. 11 , then all slats 182 b are slid forward, and finally all slats 182 c are slid forward. When one group at a time is moved, the pile of shredded material atop the walking floor tends to stay in place because of the friction between the material and the two stationary groups of slats. Thus, the material is “walked” rearwardly to gradually move the shredded material out the open rear doors 116 of the truck.
[0000] Power Takeoff and Hydraulics
[0065] FIG. 14 is a schematic diagram of the hydraulic system of the mobile shredder in accordance with one embodiment of the invention. As noted, a hydraulic pump 190 supplies pressurized hydraulic fluid to various hydraulically driven components of the mobile shredder. A pump sensor 191 monitors a load level of the pump; advantageously, the computer controller is programmed to prevent the pump from being shut down when the load is above a predetermined level. The hydraulic pump is driven by a power takeoff unit 192 that is selectively engageable and disengageable. The power takeoff unit's engagement with and disengagement from the transmission 194 is controlled by the mobile shredder's computer controller. A transmission sensor 195 can detect whether or not the transmission is in a neutral gear; advantageously, the controller is programmed to prevent engagement of the power takeoff unit with the transmission if the transmission is not in neutral.
[0066] Hydraulic fluid is contained in a reservoir 198 ; temperature of the hydraulic fluid in the reservoir is monitored by a temperature sensor 199 . The reservoir also includes a breather cap 200 and a fluid level sensor 201 . The hydraulic pump 190 supplies pressurized hydraulic fluid to the rotary shredder drive 137 , to the walking floor drive 187 , to the bin lift and dump drive 156 , to the hydraulic ram 135 , and to the discharge auger drive 148 . The pressurized hydraulic fluid is supplied to these components via a plurality of electrically controllable valves (e.g., spool valves controlled by solenoids or the like), collectively designated by reference number 202 . The valves 202 are coupled with the computer controller, which controls the valves to supply hydraulic fluid or discontinue supply of hydraulic fluid to each of the various components as needed. Hydraulic fluid is returned to the reservoir 198 via an oil filter 204 and a thermal transfer cooler 206 .
[0000] Operator Controls
[0067] The operator controls for the mobile shredder are now described with primary reference to FIGS. 15A, 15B , and 16 - 21 . As already noted, the mobile shredder includes a controls panel 170 , as depicted in FIGS. 15A and 15B . The controls panel includes control buttons for controlling the various components of the mobile shredder. The control buttons include: the previously described lift and dump start button 171 a , and a lift and dump stop button 171 b for interrupting operation of the lift and dump mechanism during an automatic cycle; a walking floor start button 174 a and a walking floor stop button 174 b ; a total system start button 175 a and a total system stop button 175 b ; a system reset button 176 a and an emergency stop button 176 b ; and a rotary shredder start button 177 a and a rotary shredder stop button 177 b . There are no separate start and stop controls for the discharge auger, as the auger starts and stops with the system, and thus is effectively controlled by the system start and stop buttons 175 a,b . The controls panel also includes a number of gauges for monitoring hydraulic pressure in the various hydraulically driven components, including: a lift and dump pressure gauge 171 c ; a walking floor pressure gauge 174 c ; a total system pressure gauge 175 c , which monitors the hydraulic pressure delivered by the hydraulic pump; a discharge auger pressure gauge 176 c ; a rotary shredder pressure gauge 177 c ; and a hydraulic ram pressure gauge 178 c.
[0068] The controls panel 170 also includes a touch screen 210 operable to display various types of information to an operator and further operable to allow the operator to interact with the computer controller in various ways. The touch screen includes a number of regions 212 , 214 , 216 , 218 that constitute interactive touch control buttons which, when touched, cause the computer controller to execute various tasks. The computer controller is programmed to display text and/or graphics in registration with one or more of the buttons to signify to the operator what operation will be carried out when each button is touched. For example, the touch screen can display a main menu ( FIG. 15B ) on which the button 212 displays the text “Maintenance Manual” (or alternatively displays a graphical icon); when the button 212 is touched on the main menu, the computer controller is caused to display on the touch screen a maintenance manual menu ( FIG. 16 ) allowing the operator to bring up any of various maintenance manuals for the various systems of the mobile shredder; the maintenance manual is stored in a memory device (e.g., a hard disk drive or the like) connected with the computer controller. The maintenance manuals can include digital video clips illustrating various maintenance procedures, in addition to text (in searchable or non-searchable form). The maintenance manual menu can include various buttons or icons for different mobile shredder systems manuals, such as a truck manual icon, a shredder manual icon, a truck body manual icon, and the like.
[0069] The main menu of the touch screen can also display the text “Troubleshooting” or the like in registration with the button 214 such that when the button 214 is touched, the computer controller causes the touch screen to display a troubleshooting menu ( FIG. 17 ) that draws on a knowledge base stored in the memory device connected to the controller so as to provide the operator with information to assist in determining possible causes for various malfunctions of the mobile shredder. The troubleshooting menu can include buttons or icons allowing the operator to display other pages such as an input/output (I/O) page ( FIG. 18 ), an event history page ( FIG. 20 ), a troubleshooting guide (not shown), and the like.
[0070] When the event history icon on the troubleshooting menu of FIG. 17 is selected, an event history page as shown in FIG. 20 is displayed on the touch screen 210 . The event history page displays a list of all significant events in the history of the operation of the mobile shredder, as detected by various sensors and as recorded in a memory device connected with the computer controller, along with the date and time of each event. If any alarm was triggered, it is also recorded in the event history file stored in the memory device.
[0071] The main menu can further display the text “Job Setup” or the like in registration with the button 216 such that when the button 216 is touched, the computer controller causes the touch screen to display a job setup menu ( FIG. 19 ) that allows the operator to select, add, delete, and edit various information regarding customers.
[0072] The main menu can also display the text “Machine Operation” or the like in registration with the button 218 so that when the button 218 is touched, the computer controller causes the touch screen to display a machine operation page ( FIG. 21 ) that allows the operator to selectively view text and/or graphics and/or digital video of various aspects of operating the mobile shredder. The machine operation page also displays certain key operating parameters such as hydraulic fluid temperature, system hydraulic fluid pressure, shredder hydraulic fluid pressure, auger hydraulic fluid pressure, machine run hours, shredder or cutter hours, and the like. The machine operation page also includes icons allowing the operator to perform certain operations such as manual ram reversal, manual shredder rotor reversal, reset the cutter hours (e.g., after an overhaul), and printing of a certificate for a customer indicating how much material was shredded, the date and time of shredding, and other information.
[0000] System Alarms
[0073] The computer controller advantageously is programmed to detect, via suitable sensors connected to the controller, various abnormal conditions of the mobile shredder and to initiate different levels of alarm depending on the abnormal condition that is detected. The alarm system advantageously includes relatively low-level alarms for certain conditions and higher-lever alarms for other more-serious conditions. For example, in one embodiment of the invention, the controller is operable to provide a relatively low level of alarm when the sensor system indicates an abnormal condition of the rotary shredder 130 or associated components (shredder drive 137 , hydraulic ram 135 ), and to provide a relatively higher level of alarm when the sensor system indicates an abnormal condition of the truck.
[0074] One type of abnormal truck condition that can generate an alarm is low fuel level. Thus, based on a fuel level sensor, the computer controller can cause a relatively low-level alarm to be given (e.g., by causing the truck's horn to sound intermittently at a relatively low frequency, such as once every 5 seconds) if the fuel level falls below a certain value (e.g., one-eighth of a tank). A higher level alarm (e.g., causing the horn to sound once every second) can be initiated if the fuel level falls to a dangerously low level (e.g., one-sixteenth of a tank). Alternatively or additionally, the controller can be operable to shut down the engine when the level of fuel falls below a predetermined level (e.g., one-sixteenth of a tank) so as to avoid running out of fuel; this is particularly advantageous for diesel engines wherein running out of fuel is a major event requiring re-priming of the engine to restart it. Other alarms can also be generated for other types of malfunctions, and any alarm states can be stored in the event history file, as previously noted, which can assist the operator or maintenance personnel in diagnosing and repairing the mobile shredder as needed.
[0075] Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
|
A mobile shredder comprises a truck having a truck body defining an enclosure and including a partition in the enclosure that divides a storage volume from the remainder of the enclosure for storage of shredded material in the storage volume, a single-shaft rotary shredder mounted in the enclosure outside the storage volume, the rotary shredder comprising a rotor having cutters rigidly mounted thereon, a bin lift and dump mechanism operable to transport material to be shredded from outside to inside the enclosure so as to deliver material to the rotary shredder, and a discharge conveyor operable to transport shredded material from the rotary shredder through the partition to the storage volume. The floor of the storage volume can comprise a walking floor, and the enclosure can have rear doors that are openable to allow shredded material to be discharged through the open rear doors when the walking floor is operated.
| 1
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Non-Provisional Application of U.S. Provisional Patent Application No. 60/927,348, entitled “WELDING CONTACT TIP WITH CONDUCTIVE MICROFIBER BRUSH”, filed May 3, 2007, which is herein incorporated by reference.
BACKGROUND
[0002] The present invention relates generally to contact tips for welding applications.
[0003] A range of welding applications and apparatus are known in the field, typically adapted for a particular type of welding operation. For example, in one operation commonly referred to as metal inert gas (MIG) welding, a wire is fed from a spool through a welding torch. An electrical charge is placed on the wire via the torch and, as the wire makes contact with a grounded workpiece, an arc is formed. The arc heats the workpiece as well as the wire, melting the weld location and adding the wire to the weldment. In many such applications, a shielding gas is applied via the torch that at least partially surrounds a progressive weld pool to aide in the formation of the weld and to protect the weld during solidification of the molten metal.
[0004] Various other arrangements and applications exist for wire feed welders. In general, these function similar to the MIG systems described above, but may include wires with a composite structure made of a sheath surrounding a filler material, often disposed in the sheath in a form of a metal powder. Such wires may also include flux cores with materials that protect the weld in lieu of a shielding gas.
[0005] In all of these wire feed welding techniques, a persistent problem exists in maintaining good electrical contact between the wire and the charged portions of the torch. That is, the torch typically includes a series of electrically coupled conductive elements that convey charge to the wire as it passes through the torch. One of these elements is a contact tip, the function of which is to transmit electrical current from the torch to the passing wire. However, because the wire must generally freely pass through the torch as it is driven by a motor and drive mechanism from a spool, less than optimal contact may be made at certain points in the operation. If contact is lost or even temporarily interrupted between the contact tip and the wire, a degraded weld may result, particularly from interrupted or sporadic arcs, re-arcing, less than optimal arcs, and so forth.
[0006] Various arrangements have been devised in attempts to maintain improved contact between elements of welding torches and welding wire. However, these have yet to provide highly reliable contact mechanisms in a range of conditions. Moreover, because certain components of the torch, such as the contact tip, may need to be changed from time to time as they wear or are degraded (such as by weld sputter), certain proposed mechanisms in the art that are not well-suited to the actual conditions present in welding applications or such easy change-out are simply not practical.
[0007] There is a need, therefore, for improved technique for maintaining good electrical contact between a charged welding torch or components of a welding torch and welding wire.
BRIEF DESCRIPTION
[0008] The present invention provides a novel approach to this problem designed to resolve certain of these drawbacks in the art. In particularly, the invention provides a contact tip that includes a conductive brush that transmits electrical charge to a welding wire fed through the contact tip. The brush may be inserted in a side aperture of the contact tip and may extend into a pathway traversed by the wire during operation. The brush may transmit electric current to the welding wire directly, but may also urge the welding wire toward a sidewall of the contact tip, insuring even greater electrical contact as the wire traverses the tip. In certain embodiments, more than one such brush may be employed, and these may extend into the passage of the welding wire from different positions around the contact tip. The contact tip may be adapted to conform to a conventional shape or form factor so that it may simply replace existing contact tips already in the field to improve existing welding systems by retrofit.
DRAWINGS
[0009] 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:
[0010] FIG. 1 is a diagrammatical overview of an exemplary wire welding system including a contact tip in accordance with aspects of the present invention;
[0011] FIG. 2 is a side elevation view of an exemplary welding torch including the inventive contact tip;
[0012] FIG. 3 is an exploded view of the end of the torch of FIG. 2 illustrating the contact tip in place between the torch neck assembly and the torch nozzle;
[0013] FIG. 4 is a partial sectional view through the contact tip, illustrating a conductive brush disposed in the contact tip for maintaining good contact with a welding wire;
[0014] FIG. 5 is a more detailed view of the brush of FIG. 4 in the contact tip, in contact with a welding wire traversing the contact tip during operation;
[0015] FIG. 6 is a partial sectional view of an alternative configuration for the contact tip including a plurality of conductive brushes;
[0016] FIG. 7 is an elevational view of a brush insert of the type that may be used in the contact tips illustrated in the previous figures;
[0017] FIG. 8 is top view of the brush insert of FIG. 7 ; and
[0018] FIG. 9 is a sectional view through the brush insert of FIG. 7 taken along line 9 - 9 .
DETAILED DESCRIPTION
[0019] FIG. 1 illustrates an exemplary wire-feed welding system 10 that incorporates a contact tip in accordance with aspects of the invention. The exemplary welding system 10 includes a welding torch 12 and one or more welding resources 14 that may be utilized to perform a welding operation on a workpiece 16 . Placement of the welding torch 12 at a location proximate to the workpiece 16 allows electrical current, which is provided by a power source 18 and routed to the welding torch 12 via a welding cable 20 , to arc from the welding torch 12 to the workpiece 16 . In summary, this arcing completes an electrical circuit that includes the power source 18 , the welding torch 12 , and the workpiece 16 . Particularly, inoperation, current passes from the power source 18 , to the welding torch 12 via the welding cable 20 , to a wire electrode (see, e.g., FIG. 5 ), to the workpiece 16 , which is typically grounded. This arcing generates a relatively large amount of heat that causes the workpiece 16 and/or filler metal of the welding wire to transition to a molten state, thereby forming the weld.
[0020] In addition to the power source 18 , the welding resources 14 may include a wire feeder 22 that provides a consumable wire electrode (such as wire 70 shown in FIG. 5 ), through the welding cable 20 to the welding torch 12 . A wide array of wire electrodes may be used in accordance with the present techniques, including traditional wire electrodes or gasless wire electrodes. As discussed further below, the welding torch 12 conducts electrical current to the wire electrode via a contact tip located in a neck assembly 24 and supported by a securing member or nozzle 26 to facilitate arcing between the egressing wire electrode and the workpiece 16 .
[0021] To shield the weld area from contaminants during welding, to enhance arc performance, and to improve the resulting weld, the exemplary system 10 includes a shielding material source 28 that feeds an inert shielding gas to the welding torch 12 via the welding cable 20 . It is worth noting, however, that a variety of shielding materials for protecting the weld location may be employed in addition to, or in place of, the inert shielding gas, including active gases, various fluids, and particulate solids. Further, other embodiments, such as those employing gasless wire electrodes, may not greatly benefit from a shielding material and, accordingly, may or may not include the shielding material source 28 .
[0022] Referring to an exemplary embodiment of the welding torch, illustrated in FIG. 2 , advancement of these welding resources (e.g., welding current, wire electrode, and shielding gas) is effectuated by actuation of a trigger 30 secured to a handle 32 of the welding torch 12 . By depressing the trigger 30 of the exemplary welding torch 12 , a switch (not shown) disposed within the trigger is closed, causing the transmission of an electrical signal that commands delivery of the welding resources into the welding cable 20 and to the neck assembly 24 .
[0023] Turning to FIG. 3 , an exemplary torch assembly is shown, including a contact tip along with other torch components. Notably, the assembly includes a diffuser 34 , a contact tip 36 , and the nozzle 26 . In the exemplary welding system, the diffuser 34 operates to receive the welding current, the wire electrode, and the shielding material. A generally conical seating location 38 of the diffuser 34 corresponds with a mating surface 40 of the contact tip 36 , thereby facilitating the centering and engagement of the contact tip 36 with the diffuser 34 . A shoulder 42 is also formed on the contact tip adjacent to the mating surface 40 for aide in centering the contact tip within the fuser 34 and the nozzle 26 . A wire path 44 extends through the contact tip and accommodates the welding wire as described in greater detail below. It also describes below, a conductive brush extends into this path 44 for aide in transmitting electrical current from the contact tip to the welding wire. A channel or bore 46 is formed in the nozzle 26 and at least partially surrounds the contact tip during operation. The channel and the surrounding nozzle help to guard the contact tip from weld splatter and damage during operation. On an opposite end of the nozzle, a seating surface 48 is formed for receiving the diffuser 34 which, in the illustrated embodiment, is threaded into the nozzle. The illustrated diffuser has a threaded portion 50 that is received in the nozzle for both attaching the nozzle to the diffuser and for capturing the contact tip therebetween. An internal shoulder 52 within the nozzle surrounds the shoulder 42 of the contact tip and further aides in the maintaining the contact tip in alignment and contact with both the diffuser and the nozzle. In operation, welding gas may be transmitted from the diffuser 34 through openings or channels 54 and around the contact tip, through the nozzle to shield welds made by advancing wire fed through the assembly.
[0024] FIG. 4 is a partial sectional view of the contact tip 36 with a conductive brush 56 installed in the contact tip body 58 . As noted above, the body may be contoured and formed to fit within and be retained by the other components of the torch. Any conventional or new shape of contact tip may be accommodated, and the body may be shaped to conform to existing designs, making the contact tip completely retrofitable for improving existing welding torches. Again, the body itself is made of a conductive material, such as copper. In the illustrated embodiment, a side aperture 60 is formed and the brush 56 is disposed in the side aperture. The aperture may be of any form, such as rectangular, oblong, circular, oval, and so forth. In general, the aperture will conform to the outer perimeter configuration of the brush.
[0025] The brush itself includes a holder 62 and a collection of fibers or microfibers 64 held by the holder and extending from the holder through the contact tip sidewall. In a presently contemplated embodiment, the holder may be made of a conductive material such as copper. The microfibers of the brush may be made of any suitable material, such as metal, high temperature plastic, carbon fiber, and so forth. In a presently contemplated embodiment, shoulders 66 are formed in the side aperture 60 and the holder 62 is press-fit into the side aperture until it reaches a final position adjacent to the shoulders. The shoulders keep the brush from protruding further into the aperture and appropriately locate the brush in the contact tip. The holder or the contact tip body, or both, may then be slightly deformed or staked to hold the brush in place. Alternatively, a liquid silver or high temperature solder or weld may be provided to maintain the brush in place in the contact tip. The microfibers themselves may be of any suitable dimensions, with presently contemplated microfibers being between 7 and 150 microns in diameter. Fibers with smaller diameters may provide enhanced performance, such as fibers below about 50 microns in diameter. The microfibers will extend into the passageway through the contact tip. In a presently contemplated embodiment, for example, the microfibers extend approximately to the center line 68 of the passageway through the contact tip, although different extensions may be envisaged.
[0026] FIG. 5 illustrates these structures in operation. In the illustration of FIG. 5 , a welding wire 70 is being advanced through the contact tip. The passageway through a contact tip is intentionally somewhat larger than the wire to allow the wire to advance relatively freely through the contact tip as it is fed by the wire-feed system. The fibers 64 of the brush 56 contact the wire 70 and pass current from the contact tip body to the wire. Moreover, in the illustrated embodiment, the fibers may exert a lateral force on the wire that drives the wire toward an opposite wall 72 of the contact tip. Both direct contact with the microfibers and enhanced contact with the sidewall of the contact tip improve the transmission of electrical current to the wire. However, it should be noted that sufficient electrical current may be transmitted to the wire by one or more brushes alone, although the additional transmission from the sidewall is contemplated in a present embodiment.
[0027] FIG. 6 illustrates an alternative configuration of the contact tip in which a plurality of brushes 74 are provided at different locations along the contact tip. As in the previous embodiment, the contact tip body has apertures 76 formed therein with shoulders that appropriately position the brushes. The brushes may again be press-fit, staked, or otherwise held in place in the contact tip. The fibers from each brush again extend into the passageway through which the welding wire passes during welding operations. Where multiple brushes are used, these may be placed in a line along the wall of the contact tip, in diametrically opposite locations (as shown in FIG. 6 ) or at different radial positions around the wire passageway.
[0028] FIGS. 7 , 8 and 9 illustrate a presently contemplated configuration for a brush insert 78 that can be used for the brushes described above. While the elongated configuration shown in these figures is presently contemplated, and generally conforms to the embodiment illustrated in FIG. 4 , other configurations, such as generally square, round, oval, elongated, and so forth may be envisaged. As illustrated in FIG. 7 , the holder 62 may be formed of a casing that is disposed around the fibers 64 . The holder casing may be made of a conductive material, such as copper. As best shown in top view of FIG. 8 , a central opening 80 is thus formed in the holder and the fibers 64 may be placed in this opening. The holder may then be compressed or crimped as illustrated by the arrows in FIG. 9 to capture the fibers between side and end panels of the holder. In a presently contemplated embodiment such crimping is sufficient to maintain the fibers in place and to maintain good electrical contact between the holder and the fibers. Alternatively, however, conductive boding materials, solders, and the like may be used either between the fibers or between the holder and the fibers, as well as on top of the fibers, where desired.
[0029] The arrangements described above have been found to provide extremely effective contact between the contact tip and welding wire. The arrangements exhibit negligible wear and operate for long periods, maintenance free. It is estimated that the contact tips described above may provide several times the life expectancy of conventional contact tips that they may replace. Moreover, the contact tips provide for much better electrical contact and, consequently, better weld quality. Moreover, where desired, the same contact tip may be used for multiple wire sizes owing to the extension of the fibers into the passageway of the contact tip. As will be appreciated by those skilled in the art, this might alleviates the need to change the contact tip when different wire sizes are employed as is the case with conventional contact tips.
[0030] While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
|
A contact tip is provided for wire welding applications. The contact tip includes one or more conductive brushes fitted to a conductive contact tip body. Fibers of the brush extend into a passageway traversed by welding wire in operation. Electrical current is transmitted to the brush assembly and through the brush fibers to the welding wire. The fibers may transmit the current directly and also may enhance contact of the welding wire with one or more walls of the contact tip. Improved electrical contact and weld quality are obtained.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a 371 U.S. National Stage Application of International Application No. PCT/JP2013/076930, filed on Oct. 3, 2013, and published in Japanese as WO 2014/054727 A1 on Apr. 10, 2014. This application claims priority to Japanese Application No. 2013-129369, filed on Jun. 20, 2013 and Japanese Application No. 2012-221811, filed on Oct. 4, 2012. The entire disclosures of the above applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a diaphragm damper.
Further, the present invention relates to a diaphragm damper which is used for reducing pulsation generated in a high-pressure pump used in an engine.
2. Description of the Conventional Art
There has been conventionally known a high-pressure pump which pressurizes fuel supplied from a fuel tank on the basis of a reciprocating movement of a plunger so as to pressure feed to an injector side.
In this kind of high-pressure pump, a fuel chamber is formed in a fuel inlet side, and the fuel is pressurized and discharged by repeating “suction stroke” which sucks the fuel from the fuel chamber to a pressurizing chamber when a plunger moves down, “metering stroke” which returns a part of the fuel in the pressurizing chamber to the fuel chamber when the plunger moves up, and “pressurizing stroke” which pressurizes the fuel when the plunger further moves up after a suction valve is closed.
The high-pressure pump mentioned above has a diaphragm damper for reducing the pulsation generated in the fuel chamber built-in.
Further, the high-pressure pump is variously designed to enhance an effect of reducing the pulsation in the diaphragm.
For example, Japanese Unexamined Patent Publication No. 2004-138071 discloses a device which employs an elastic member for a support member supporting a metal diaphragm constructing a diaphragm damper (Japanese Unexamined Patent Publication No. 2004-138071).
However, in the device described in Japanese Unexamined Patent Publication No. 2004-138071, since the elastic member pinches the metal diaphragm from both upper and lower side directions, a space occupied by the elastic member becomes large, thereby blocking a space in which the fuel flows within the fuel chamber.
Therefore, an amount of the fuel which can be sucked into the fuel chamber is reduced, and there is a risk that the effect of reducing the pulsation by the diaphragm can not be sufficiently obtained.
Further, parts of the high-pressure pump oscillate on the basis of an operation of a suction valve, a plunger and a discharge valve, at the driving time of the high-pressure pump.
The oscillation is transmitted to the fuel, and is transmitted as the pulsation to a piping which is connected to the high-pressure pump, and there is a problem that an abnormal noise is generated due to resonance of the oscillation.
Consequently, there has been proposed a diaphragm damper which is structured such as to support an outer peripheral portion of the metal diaphragm by a rubber-like elastic member and a wave washer (a pressing member) (Japanese Unexamined Patent Publication No. 2012-132400).
However, since the diaphragm damper is structured such as to elastically support the outer peripheral portion of the metal diaphragm by the rubber-like elastic member and the wave washer (the pressing member), a structure is complicated, and the rubber-like elastic member and the wave washer (the pressing member) has a reduced degree of freedom in shapes.
As a result, it has been hard to optionally set an amount of volume change caused by the resonance frequency and the pressure, and it has been hard to achieve optimization of a diaphragm damper performance.
SUMMARY OF THE INVENTION
Problem to be Solved by the Invention
The present invention is made by taking the problem mentioned above into consideration, and an object of the present invention is to provide a diaphragm damper which does not change the conventional metal diaphragm attaching structure, does not obstruct the space in which the fuel flows within the fuel chamber, can optionally set the amount of volume change on the basis of the resonance frequency and the pressure, and can achieve the optimization of the diaphragm damper performance.
Means for Solving the Problem
The diaphragm damper according to the present invention is a diaphragm damper structured such that a high-pressure gas is sealed in a high-pressure chamber formed by two discoid metal diaphragms which are bonded to each other in their outer peripheral portions, wherein a rubber-like elastic member is arranged within the high-pressure chamber.
Effects of the Invention
The present invention achieves the following effects.
According to the diaphragm damper of the invention described in a first aspect, the rubber-like elastic member is arranged within the high-pressure chamber. As a result, the conventional metal diaphragm attaching structure is not changed, the space in which the fuel flows within the fuel chamber is not obstructed, it is possible to optionally set the amount of volume change on the basis of the resonance frequency and the pressure, and it is possible to achieve the optimization of the diaphragm damper performance.
According to a diaphragm damper of the invention described in a second aspect, the rubber-like elastic member is constructed by a discoid sheet portion which is provided so as to come into contact with each of two discoid metal diaphragms, and a plurality of rubber projections which are arranged circumferentially between the sheet portions. As a result, it is possible to effectively damp the resonance of the metal diaphragms without obstructing deformation of the center portion in which the metal diaphragms are deformed most greatly.
According to a diaphragm damper of the invention described in a third aspect, the rubber projection is integrally formed with the sheet portion and is structured such as to alternately extend from the one sheet portion toward the surface of the other sheet portion. As a result, balance of the rubber-like elastic member is good, and it is possible to effectively damp the resonance of the metal diaphragms.
According to a diaphragm damper of the invention described in a fourth aspect, a leading end of the rubber projection is formed into a circular arc shape in its cross section. As a result, the following property is good in relation to the deformation of the metal diaphragms, and it is possible to effectively damp the resonance of the metal diaphragms.
According to a diaphragm damper of the invention described in a fifth aspect, the rubber-like elastic member is arranged in a center portion of the high-pressure chamber so as to be concentric with the metal diaphragms. As a result, the displacement caused by the pressure of the metal diaphragm does not become uneven. Therefore, it is possible to effectively damp the resonance of the metal diaphragms.
According to a diaphragm damper of the invention described in a sixth aspect, the rubber-like elastic member is in contact with both of two metal diaphragms. As a result, it is possible to more effectively damp the resonance of the metal diaphragms.
According to a diaphragm damper of the invention described in a seventh aspect, the rubber-like elastic member is provided with a plurality of positioning leg portions which come into contact with an outer peripheral portion of the metal diaphragms. As a result, since it is possible to inhibit the rubber-like elastic member from moving within the high-pressure chamber, it is possible to more stably damp the resonance of the metal diaphragms.
According to a diaphragm damper of the invention described in an eighth aspect, end portions of a plurality of positioning leg portions are integrally formed with a ring-shaped portion which comes into contact with an outer peripheral portion of the metal diaphragms. As a result, it is possible to more enhance the damping of the resonance in the metal diaphragms, and it is possible to more securely inhibit the rubber-like elastic member from moving within the high-pressure chamber. Therefore, it is possible to more stably damp the resonance of the metal diaphragms.
According to a diaphragm damper of the invention described in a ninth aspect, the rubber-like elastic member is constructed by two discoid portions which come into contact with each of two metal diaphragms in their whole surfaces, and a connection portion which connects the two discoid portions to each other in their center portions. As a result, since the rubber-like elastic member comes into contact with the metal diaphragm in a wider range, it is possible to more securely damp the resonance of the metal diaphragms.
According to a diaphragm damper of the invention described in a tenth aspect, the metal diaphragm is formed a repeated pattern of annular concave portions and annular convex portions which are formed into concentric circles. As a result, it is possible to more securely obtain a pulsation absorbing action of the diaphragm damper.
BRIEF EXPLANATION OF THE DRAWINGS
FIG. 1 is a plan view of a diaphragm damper according to the present invention;
FIG. 2 is a cross sectional view along a line B-B in FIG. 1 ;
FIG. 3 is a three-dimensional perspective view of a rubber-like elastic member which is used in FIG. 2 ;
FIG. 4 is a plan view of the other diaphragm damper according to the present invention;
FIG. 5 is a cross sectional view along a line A-A in FIG. 4 ;
FIG. 6 is a three-dimensional perspective view of a rubber-like elastic member which is used in FIG. 5 ;
FIG. 7 is a view showing a second aspect of the diaphragm damper according to the present invention in the same manner as FIG. 5 ;
FIG. 8 is a three-dimensional perspective view of a rubber-like elastic member which is used in FIG. 7 ;
FIG. 9 is a three-dimensional perspective view of a rubber-like elastic member according to a third aspect which is used in the diaphragm damper according to the present invention;
FIG. 10 is a three-dimensional perspective view of a rubber-like elastic member according to a fourth aspect which is used in the diaphragm damper according to the present invention;
FIG. 11 is a three-dimensional perspective view of a rubber-like elastic member according to a fifth aspect which is used in the diaphragm damper according to the present invention; and
FIG. 12 is a view showing a diaphragm damper according to the present invention which uses the rubber-like elastic member shown in FIG. 11 , in the same manner as FIG. 5 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A description will be given below of the best mode for carrying out the present invention.
A diaphragm damper according to the present invention is used in a high-pressure pump which pressurizes a fuel supplied from a fuel tank on the basis of a reciprocating movement of a plunger so as to pressure feed to an injector side.
In this kind of high-pressure pump, a fuel chamber is formed in a fuel inlet side, and the fuel is pressurized and discharged by repeating “suction stroke” which sucks the fuel from the fuel chamber to a pressurizing chamber when a plunger moves down, “metering stroke” which returns a part of the fuel in the pressurizing chamber to the fuel chamber when the plunger moves up, and “pressurizing stroke” which pressurizes the fuel when the plunger further moves up after a suction valve is closed.
The diaphragm damper according to the present invention is used for reducing pulsation which is generated in a fuel chamber of the high-pressure pump as mentioned above.
Further, the diaphragm damper according to the present invention is provided with the following structures as shown in FIGS. 1 to 3 .
More specifically, a high-pressure gas is sealed into a high-pressure chamber 11 formed by two discoid metal diaphragms 1 and 1 which are bonded to each other in their outer peripheral portions 10 .
Further, a rubber-like elastic member 2 is arranged within the high-pressure chamber 11 .
A material of the rubber-like elastic member 2 preferably employs a rubber-like elastic material such as a nitrile rubber (NBR), a hydrogen additive nitrile rubber (HNBR), an acrylic rubber (ACM), a silicone rubber (VMQ), a fluorosilicone rubber (FVMQ), a fluorine-contained rubber (FKM), an ethylene propylene rubber (EPDM), a chloroprene rubber (CR), a chlorosulfonated polyethylene (CSM), a styrene butadiene rubber (SBR), a butyl rubber (IIR), and an urethane rubber (AU), which has a Shore hardness of Hs 50 or less.
The Shore hardness Hs is set to be equal to or less because a damping function of the metal diaphragms 1 and 1 is not inhibited.
According to the structure mentioned above, a space in which the fuel flows within the fuel chamber is not inhibited without changing the conventional attaching structure of the metal diaphragms 1 and 1 , and it is possible to optionally set an amount of volume change caused by a resonance frequency and a pressure, so that it is possible to optimize the diaphragm damper performance.
Further, the metal diaphragms 1 and 1 are obtained by folding outer peripheral edges of two discoid members which are flat and are constructed by metal members into a curves shape and integrally bonding the outer peripheral edges to each other, and a discoid space chamber forming a high-pressure chamber 11 is formed in an inner portion of the metal diaphragms 1 and 1 .
A welding means or a caulking means is appropriately selected and used for integrally bonding.
The rubber-like elastic member 2 is constructed by discoid sheet portions 25 and 26 which are provided so as to respectively come into contact with two discoid metal diaphragms 1 and 1 , and a plurality of projections 251 and 261 which are circumferentially arranged between the sheet portions 25 and 26 .
Further, the rubber-projections 251 and 261 are integrally formed with the sheet portions 25 and 26 as is apparent from FIG. 2 , and are structured such as to extend from the one sheet portions 25 and 26 toward surfaces of the other sheet portions 25 and 26 .
More specifically, as shown in FIG. 3 , three rubber projections 261 are arranged on the one surface of the sheet portion 26 so as to be circumferentially uniform (at intervals of 120 degree). In the same manner, three rubber projections 261 having the same shape are arranged on the one surface of the other sheet portion 25 so as to be circumferentially uniform (at intervals of 120 degree) in the same manner.
In the present embodiment, three rubber projections 251 and 261 are respectively arranged on the one surfaces of the sheet portions 25 and 26 uniformly, that is, six rubber projections are totally provided, as shown by a broken line in FIG. 1 , however, at least two rubber projections may be respectively provided, totally four rubber projections may be provided.
Further, the diaphragm damper is finished by adhering a surface where the rubber projections 251 and 261 of the sheet portions 25 and 26 are not provided, to each of the inner surfaces of the metal diaphragms 1 and 1 by an adhesive agent, thereafter assembling them in such a manner that the rubber projections 251 and 261 of the sheet portions 25 and 26 are deviated from each other at 60 degree, and integrating the outer peripheral portions 10 of two discoid metal diaphragms 1 and 1 by welding.
According to the structure mentioned above, a space in which the fuel flows within the fuel chamber is not inhibited without changing the conventional attaching structure of the metal diaphragms 1 and 1 , and it is possible to optionally set an amount of volume change caused by a resonance frequency and a pressure, so that it is possible to optimize the diaphragm damper performance.
Further, since a plurality of rubber projections 251 and 261 are structured such as to be uniformly arranged on the circumference which is less deformed in the outer peripheral side of the metal diaphragms 1 and 1 , it is possible to effectively damp the resonance of the metal diaphragms without inhibiting the deformation of the center portion which is most deformed in the metal diaphragms 1 and 1 .
Further, since the rubber projections 251 and 261 are structured such as to extend alternately from the one sheet portions 25 and 26 toward the surfaces of the other sheet portions 25 and 26 , as shown in FIG. 2 , the balance of the rubber-like elastic members 2 and 2 is good, and it is possible to effectively damp the resonance of the metal diaphragms 1 and 1 .
Further, as shown in the drawing, leading ends of the rubber projections 251 and 261 are formed into a circular arc shape in their cross section.
As a result, a good following property to the deformation of the metal diaphragms 1 and 1 can be obtained, and it is possible to effectively damp the resonance of the metal diaphragms 1 and 1 .
Next, a description will be given of the other diaphragm damper according to the present invention on the basis of FIGS. 4 to 7 .
A different point from the diaphragm damper described previously exists in a point that the rubber-like elastic member 2 is provided in the center portion of the metal diaphragms 1 and 1 .
The rubber-like elastic member 2 is formed into a columnar shape, and is arranged in a center portion 112 of the high-pressure chamber 11 so as to be concentric with the metal diaphragms 1 and 1 .
Further, both end portions in an axial direction of the columnar rubber-like elastic member 2 are in contact with each of two metal diaphragms 1 and 1 .
Further, it is effective to adhere the columnar rubber-like elastic member 2 to the metal diaphragms for holding the rubber-like elastic member 2 to the center portion 112 of the high-pressure chamber 11 .
Further, the columnar rubber-like elastic member 2 may be formed into a cylindrical shape obtained by boring a center portion of the rubber-like elastic member 2 . In the case of the cylindrical shape mentioned above, the rubber-like elastic member 2 is more easily deformed. As a result, the damper function of the metal diaphragms 1 and 1 is not inhibited.
Next, a description will be given of a second aspect of the diaphragm damper according to the present invention on the basis of FIGS. 7 and 8 .
A different point from the aspect described above exists in a point that the rubber-like elastic member 2 is provided with a plurality of positioning leg portions 21 and 21 which come into contact with the outer peripheral side 12 of the high-pressure chamber 11 , and a point that the metal diaphragms 1 and 1 are formed a repeated pattern of annular concave portions 13 and 13 and annular convex portions 14 and 14 which are formed into concentric circles.
Three positioning leg portions 21 are formed so that three positioning leg portions are uniformly arranged from the outer peripheral surface of the columnar member 21 which is positioned at the center.
Further, outer peripheral end portions of the positioning leg portions 21 and 21 are formed into a columnar projection shape.
According to the structure mentioned above, since it is possible to inhibit the rubber-like elastic member 2 from moving within the high-pressure chamber 11 , it is possible to more stably damp the resonance of the metal diaphragms 1 and 1 .
Further, since the metal diaphragms 1 and 1 are formed the repeated pattern of the annular concave portions 13 and 13 and the annular convex portions 14 and 14 which are formed into the concentric circles, it is possible to obtain a more secure pulsation absorbing action of the diaphragm damper.
Next, a description will be given of a third aspect of the rubber-like elastic member 2 which is used in the diaphragm damper according to the present invention on the basis of FIG. 9 .
A different point from the second aspect described previously exists in a point that end portions of a plurality of positioning leg portions 21 and 21 are integrated with a ring-shaped portion 22 which comes into contact with the outer peripheral side 12 of the high-pressure chamber 11 .
According to the structure mentioned above, since it is possible to further enhance the damping of the resonance of the metal diaphragms 1 and 1 , and it is possible to more securely inhibit the rubber-like elastic member 2 from moving within the high-pressure chamber 11 , it is possible to more stably damp the resonance of the metal diaphragms 1 and 1 .
Next, a description will be given of a fourth aspect of the rubber-like elastic member 2 which is used in the diaphragm damper according to the present invention on the basis of FIG. 10 .
A different point from the third aspect described previously exists in a point that the rubber-like elastic member 2 is constructed only by the ring-shaped portion 22 according to the third aspect.
According to the structure mentioned above, since it is possible to further hold down a capacity which the rubber-like elastic member 2 occupies within the high-pressure chamber 11 , and it is possible to inhibit the rubber-like elastic member 2 from moving within the high-pressure chamber 11 , it is possible to more stably damp the resonance of the metal diaphragms 1 and 1 .
Next, a description will be given of a fifth aspect of the rubber-like elastic member 2 which is used in the diaphragm damper according to the present invention on the basis of FIG. 11 .
The rubber-like elastic member 2 is constructed by two discoid portions 23 and 23 which respectively come into contact with two metal diaphragms 1 and 1 with wide areas, and a connection portion 24 which connects two discoid portions 23 and 23 to each other in their center portions.
Further, the rubber-like elastic member 2 is stored in such a manner that whole surfaces of two discoid portions 23 and 23 are respectively in contact with two metal diaphragms 1 and 1 , as shown in FIG. 12 .
According to the structure mentioned above, since the rubber-like elastic member 2 is in contact with the metal diaphragms 1 and 1 with the wider range, it is possible t more securely damp the resonance of the metal diaphragms 1 and 1 .
Further, it goes without saying that the present invention is not limited to the modes for carrying out the invention mentioned above, but can employ the other various structures without deviating from the scope of the present invention.
INDUSTRIAL APPLICABILITY
The diaphragm damper according to the present invention is useful as the diaphragm damper which is used for reducing the pulsation generated in the high-pressure pump employed in the engine.
|
The objective of the present invention is to provide a diaphragm damper with which the amount of volume change due to the resonance frequency and pressure can be set freely and the performance of the diaphragm damper can be optimized, without changing the attachment structure for a conventional metal diaphragm and without obstructing the space where fuel flows in a fuel chamber. To this end, this diaphragm damper, wherein a high-pressure gas is enclosed in a high-pressure chamber formed by two disk-shaped metal diaphragms the outer circumferential portions of which have been joined together, is constructed such that rubber-like elastic members are arranged within the high-pressure chamber.
| 5
|
PRIORITY
This application claims priority from copending U.S. provisional patent application Ser. No. 60/074,920, filed Feb. 17, 1998, entitled “APPARATUS AND METHOD FOR TRANSMITTING DOCUMENTS BETWEEN A SERVER COMPUTER AND A CLIENT COMPUTER”, the disclosure of which is incorporated herein, in its entirety, by reference.
FIELD OF THE INVENTION
This invention generally relates to data transmission networks and, more particularly, to transmitting data between a client computer and a server computer.
BACKGROUND OF THE INVENTION
The World Wide Web is a collection of server computers connected to the Internet that utilize the Hypertext Transfer Protocol (“HTTP”). HTTP is a known application protocol that provides users with access to documents (e.g., web pages) written in a standard mark-up page description language-known as Hypertext Markup Language (“HTML”). HTTP is used to transmit HTML web pages between a remote computer (e.g., a server) and a local computer in a form that is understandable to browser software (e.g., Netscape Navigator™, available from Netscape Communications Corporation of Mountain View, Calif.) executing on the local computer. A local computer (“client computer”) “accesses” a web page by downloading the HTML code that makes up the web page. Once downloaded, the browser software interprets the HTML within the page, and displays a graphical representation of the page (defined by the HTML code) upon a client-side display device.
Like most software, browser software and server software typically are tested prior to distribution. Currently, browser and server software often are tested by manually downloading many web pages onto a client computer in a repetitive fashion. It is not uncommon for a single page to be downloaded several hundred times for such testing purposes. In a similar manner, computer graphical subsystems (e.g., the INTENSE 3D® graphics accelerator, available from Intergraph Corporation of Huntsville, Ala.) commonly are tested by manually and repetitively downloading graphics intensive web pages. Both testing processes require that a person manually download each of the required pages, however, thus increasing the ultimate cost of the product being tested.
SUMMARY OF THE INVENTION
In accordance with one aspect of the invention, an apparatus for transmitting a set of documents from a server computer to a client computer utilizes a document list of document identifiers for automatically and repetitively transmitting selected documents from the server computer to the client computer. To that end, the apparatus first receives a first download request from the client computer. Once the request is received, then the document list is accessed to identify the identifier of a first document in the document list. Once identified, the first document and a controller are transmitted to the client computer. The controller controls the client computer to transmit a second download request to the server computer after a predetermined condition is satisfied. In some embodiments, the predetermined condition is the passing of a predetermined amount of time and the controller is a tag within the first document.
In accordance with other aspects of the invention, in response to receipt of the second download request, the server again accesses the document list to identify the identifier of a second document in the document list. Once identified, the second document is transmitted to the client computer. In preferred embodiments, the document list is stored in memory of the server computer, and includes a plurality of sublists that are directed to documents having at least one preselected attribute (e.g., the existence of graphical images in the document). In additional embodiments, an information displayer also is transmitted to the client computer after the identifier of the first document is identified. The information displayer controls the client computer to display information relating to each of the documents received by the client computer.
In accordance with another aspect of the invention, the document is a World Wide Web page and the server is a World Wide Web server. In such case, the identifier is a uniform resource locator.
In accordance with still another aspect of the invention, an apparatus and method of transmitting a set of documents from a server to a client computer utilizes a selector that, in response to receipt of a download request message, selects one of the set of documents based upon information not in the download request. For example, the download request message may include a request to download the selector itself, or it may be a message that merely requests that the selector provide transmit any document (i.e., one of the documents in the set of documents). Accordingly, in preferred embodiments, the download message includes no address information identifying the selected document to be transmitted.
In still other aspects of the invention, the apparatus is a computer program product for use on a computer system. The computer program product includes a computer usable medium having computer readable program code thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and advantages of the invention will be appreciated more fully from the following further description thereof with reference to the accompanying drawings wherein:
FIG. 1 schematically shows a commonly used network arrangement in which a client computer system may communicate with a network site via the Internet.
FIG. 2 shows a preferred embodiment of the invention in which a control script maintains the state of a document list.
FIG. 3 shows a preferred process utilized by a server computer for automatically uploading web pages to the client computer.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 schematically shows a commonly used network arrangement in which a (local) client computer system 100 may communicate with a network site via the Internet 101 . When utilized with a preferred embodiment of the invention, the network site is a World Wide Web site (“web site 102 ”) on a server computer system 104 that may be accessed by browser software 106 on the client computer system 100 . The web site 102 preferably includes server software, and one or more web pages that may be downloaded by the browser 106 onto the client computer 100 .
In accordance with a preferred embodiment of the invention, selected web pages at the web site 102 are serially and automatically downloaded onto the client computer 100 . To that end, the HTML code.of each of the selected web pages first is modified to include a controller such as, for example, a “META-REFRESH” tag (see below). As discussed in greater detail below, the controller causes the client computer 100 to issue a subsequent download request to the server 104 for another network document (i.e., a web page). Once modified to include the controller, the uniform resource locator (“URU”) of each such modified web page is added to a document list 108 . FIG. 2 shows one embodiment of such a document list 108 having “N” web pages. Each of the web pages identified in the document list 108 is transmitted to the client computer 100 by means of a control script 110 (i.e., a software program on the server computer 104 ). As discussed in greater detail below, the control script 110 preferably utilizes a session variable 112 to determine the order in which each of the selected web pages in the document list 108 are to be transmitted to the client computer 100 .
FIG. 3 shows a preferred process utilized by the server computer 104 for automatically uploading web pages from the server computer 104 to the client computer 100 . It should be noted that the entire apparatus for performing such process preferably is located on the server computer 104 . Accordingly, the client computer 100 requires no specialized software or other apparatus to perform the process. In alternative embodiments, the apparatus may be located remotely from the server computer 104 .
The process begins at step 300 in which it is determined if a download request from the client computer 100 is received by the server computer 104 . For reasons discussed in detail below, the download request preferably is a request to download the control script 110 . Although not downloaded, the control script 110 performs a number of functions (noted below) upon receipt of the download request.
The first download request from the client computer 100 may be initiated in accord with many methods. For example, in preferred embodiments, the client computer 100 may download a home web page (from the server computer 104 ) having a graphical user interface (“GUI”) for initiating the request. The GUI may include a button having indicia such as “LAUNCH TEST” that, when selected, designates the control script 110 as the target web page to be downloaded. Once selected, a series of configuration menus may be displayed. In preferred embodiments, a “WEB PAGE TYPE” configuration menu may enable a user to select one or more of several types of web pages to download. Among those types of web pages are those with certain types of detailed graphical indicia, or those with plain text. Additional types of web pages also may be those having portions within the HTML code that are written in certain languages (e.g., JAVASCRIPT or PERL), or those having multimedia applications. A user may select the type of web page to download based upon the product being tested. For example, if testing a graphics subsystem, web pages with detailed graphical indicia may be selected. Conversely, if testing a network connection, web pages with plain text may be selected.
Accordingly, the first download request preferably is generated by selecting the “LAUNCH TEST” button, or in response to a call produced by a controller (e.g., a META-REFRESH tag) within a displayed page. In other embodiments, the first download request may be generated by a JAVA applet or other program.
Once the request is received, the process continues to step 302 in which the control script 110 determines if the session variable 112 is pointing to the end of the document list 108 . In preferred embodiments, the session variable 112 is included in the Microsoft INFORMATION SERVER™ server software, version 3.0, available from Microsoft Corp of Redmond, Wash. The INFORMATION SERVER™ server software typically is utilized with the Microsoft NT™ operating system, also available from Microsoft Corp. The control script 110 is programmed to manipulate the session variable 112 to point to the URL of a web page (in the list 108 ) that is to be transmitted to the client computer 100 (i.e., the “current URL” or “current page”). Although a session variable 112 is discussed, however, it should be noted that other methods of determining the current URL in the document list 108 may be utilized. For example, the control script 110 may be written to include its own pointer. In other embodiments, the current URL may be maintained in a database or in a text file.
The control script 110 preferably is written in ACTIVE SERVER PAGE® language (“ASP”). In alternative embodiments, the control script 110 is written in PERL or JAVASCRIPT. Other known programming languages may be utilized in lieu of those mentioned.
The process ends if it is determined at step 302 that the end of the list 108 has been reached. Conversely, if it is determined at step 302 that the end of the list 108 has not been reached, then the process continues to step 304 in which the current page (i.e., the current page and its associated controller) is transmitted to the client computer 100 . Once the current page is transmitted, the process continues to step 306 in which the session variable 112 (i.e., the pointer) is incremented to the next URL in the list 108 . The process then loops back to step 300 in which the server computer 104 waits to receive another download request from the client computer 100 .
Preferred embodiments are not intended to be limited to a list as shown in FIG. 2 . Other methods of utilizing a set of documents in the described manner may be employed. For example, documents may be dynamically modified and added to the set of documents, and then transmitted to the client computer 100 .
As noted above, the HTML code of each web page to be transmitted to the client computer 100 is modified to include a controller, such as the META REFRESH tag, that causes the client computer 100 to transmit a subsequent download request to the server computer 104 after the web page is downloaded. Accordingly, each web page transmitted to the client computer 100 preferably is modified. Absent such modification, preferred embodiments will not operate as desired. For more information on the META REFRESH tag, as well as other HTML tags, see, for example, the “HTML 4.0 Specification W3C Working Draft, Sep. 17, 1997” at http://www.w3.org VWD-html40/html40.txt).
As is known in the art, the META REFRESH tag includes both a time variable and a target variable, and is located in the header portion of a web page. The time variable in each web page (preferably set by a preconfiguration utility) determines the total amount of time that the, web page is to be displayed by the client computer 100 . The target variable in each page (also preferably set by a configuration utility) designates the web page or other document that is to be called upon expiration of the total amount of time designated by the time variable. In preferred embodiments, the target variable is set to the URL of the control script 110 . As mentioned above, the control script 110 responds to a request from the client computer 100 at step 300 (FIG. 3) by transmitting the next web page in the document list 108 to the client computer 100 if the end of the document list 108 has not been reached.
The time variable in the META REFRESH tag maybe set according to the type of web page in which the tag is utilized. For example, the time variable may be set to a relatively long time if the web page includes extensive graphical indicia. Conversely, the time variable may be set to a relatively short time if the web page merely includes plain text and no extensive graphical indicia.
Of course, the browser software 106 on the client computer 100 must support the META REFRESH tag when such tag is used as a controller. Accordingly, in preferred embodiments, the browser software 106 may be either of INTERNET EXPLORER™, version 2.0 or higher, available from Microsoft Corp, or NETSCAPE NAVIGATOR™, version 2.0 or higher, available from Netscape Communications Corporation. Both noted browser programs are preferred since both support the META REFRESH tag (i.e., HTML specification 3 . 2 ).
In alternative embodiments, other types of controllers may be utilized in lieu of the META REFRESH tag. For example, a Java applet may be.utilized to perform the function of setting a time interval and initiating another request. The controller may be either a part of the HTML code of the transmitted web page, or an independent, freely operating program that may be executed by the browser 106 , operating system, or other software executing on the client computer 100 .
The document list 108 preferably is created by first determining which web pages are to be in the document list 108 for the client computer 100 , and then modifying the HTML code in such web pages to include the META REFRESH tag. Web pages are selected to be in the list 108 based upon the groups of web pages selected by the user in the WEB PAGE TYPE configuration menu. In alternative embodiments, a client computer 100 having appropriate access rights to the server computer 104 may upload a web page to the document list 108 . Such web page may be from any source such as, for example, another web server. Once uploaded to the server computer 104 , such web page first is modified by the control script 110 to include the META REFRESH tag, and then added to the document list 108 .
In other embodiments, an information displayer may be transmitted to the client computer 100 to display the results of the test in a results window on a display device coupled to the client computer 100 . Such test results may include the number of pages accessed by the client computer 100 , the time that each page is displayed by the display device, and the total amount of time that the test executed. The results window may be displayed when the “LAUNCH TEST” button is selected. The information in the results window may be updated any predetermined time interval such as, for example, every five seconds. In preferred embodiments, the information displayer is a web page that initially is transmitted to the client computer 100 with the home page. In a manner similar to the web pages being downloaded, the results window (web page) preferably includes a META REFRESH tag and thus, is periodically updated by the server 104 .
The server computer 104 may simultaneously perform the document transmission process as shown in FIG. 3 with a plurality of client computers (not shown). In such case, the control script 110 simultaneously performs the process shown in FIG. 3 for each session that is being conducted with each of the plurality of client computers. More particularly, the control script 110 creates a separate document list 108 for each client session, and then increments the session variable 112 for each list 108 , as necessary, to maintain the state of each session.
Preferred embodiments of the invention enable a client computer 100 to utilize two or more servers that each include a local control script 110 . In particular, each server may include a GUI that initiates the process shown in FIG. 3 . Once the end of the document list 108 on a first server computer 104 is reached, the document list 108 on a second server computer 104 may be accessed and traversed by the control script 110 that is local to the second server computer 104 . This may be accomplished by setting the target variable in the META REFRESH tag in the last web page in the first server document list 108 to the control script 110 on the second server computer 104 . In other embodiments, the target field in the META REFRESH tags of, transmitted web pages may be set to alternate between control scripts on different remote server computers 104 .
It should be noted that although preferred embodiments of the invention have been described in terms of the World Wide Web, other embodiments of the invention may be practiced with other types of networks. Accordingly, the description of various embodiments of the invention in terms of the World Wide Web is not intended to limit the scope of the invention.
Preferred embodiments of the invention may be implemented as a computer program product for use with a computer system. Such implementation may include a series of computer instructions fixed either on a tangible medium, such as a computer readable media (e.g., a diskette, CD-ROM, ROM, or fixed disk) or transmittable to a computer system, via a modem or other interface device, such as a communications adapter connected to a network over a medium. Medium may be either a tangible medium (e.g., optical or analog communications lines) or a medium implemented with wireless techniques (e.g., microwave, infrared or other transmission techniques). The series of computer instructions embodies all or part of the functionality previously described herein with respect to the system. Those skilled in the art should appreciate that such computer instructions can be written in a number of programming languages for use with many computer architectures or operating systems. Furthermore, such instructions may be stored in any memory device, such as semiconductor, magnetic, optical or other memory devices, and may be transmitted using any communications technology, such as optical, infrared, microwave, or other transmission technologies. It is expected that such a computer program product may be distributed as a removable media with accompanying printed or electronic documentation (e.g., shrink wrapped software), preloaded with a computer system (e.g., on system ROM or fixed disk), or distributed from a server or electronic bulletin board over the network (e.g., the Internet or World Wide Web).
Although various exemplary embodiments of the invention have been disclosed, it should be apparent to those skilled in the art that various changes and modifications can be made which will achieve some of the advantages of the invention without departing from the true scope of the invention. These and other obvious modifications are intended to be covered by the appended claims.
|
An apparatus for transmitting a set of documents from a server computer to a client computer utilizes a document list of document identifiers for automatically and repetitively transmitting selected documents from the server computer to the client computer. To that end, the apparatus first receives a first download request from the client computer. Once the request is received, then the document list is accessed to identify the identifier of a first document in the document list. Once identified, the first document and a controller are transmitted to the client computer. The controller controls the client computer to transmit a second download request to the server computer after a predetermined condition is satisfied. The predetermined condition may be the passing of a predetermined amount of time and the controller is a tag with in the first document.
| 7
|
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/190,391, filed 28 Aug. 2008, and entitled “Dual Locking Flow Control Valve,” which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to fluid pressure operated systems and devices, particularly those featuring at least partially fluid tight operation.
BACKGROUND OF THE INVENTION
[0003] A very popular valve in the automation industry is a 4-way directional control valve. This valve consists of a manifold with a set of flow control solenoids mounted onto the manifold. The solenoids shift a spool using a combination of air and electricity to redirect the flow of the air through the manifold. The spool and the bore within which it slides are often constructed of metal. The steel spool slides inside the metal bore to shift the direction of fluid, such as air, oil or water to different ports. This metal-on-metal seal has a tendency to leak after operating for a short period of time.
[0004] There remains a need for a valve that can solve this tendency to leak problem, either by being an add-on to the leaking valve, or by being integrated into the valve, which, in turn, will lead to increased safety and operating life. There is also a need for easy attachment and compact size.
SUMMARY OF THE INVENTION
[0005] The invention provides a dual locking (DL) valve that can be easily attached to a manifold to solve the leaking problem. This is advantageous in automated systems that must hold position without drifting over time or where parts must be held in place in the event of a drop in pressure and is also advantageous for use in leak testing systems. A second advantage is that no mounting holes or extra space is required for mounting the valve. The valve may mount directly to a 4-way valve manifold with two fasteners. A third advantage is no additional plumbing is required, i.e., all plumbing is internal. The DL valve also has a manual release so that during system repair or during an emergency stop, the potential energy of the trapped air can be released. A variety of options can also be added, including flow controls, adjustable pilot, sensor ports, auto release with metered exhaust, manual exhaust to atmosphere.
[0006] Additional advantages of the invention include:
1. The addition of the DL valve makes the entire valve assembly fluid tight on both the output ports, which eliminates drift due to leaky or worn spools. 2. The DL valve can be added without having to drill holes for mounting the valve, i.e., direct mount to the base manifold. 3. No added plumbing is required, so time and money are saved. 4. Fast and easy to attach the DL valve—saving time and money, i.e., the DL may be assembled in approximately two minutes. The DL may also be added after a machine has already been assembled. 5. A manual release allows the release of trapped air from both ports independently. 6. The flow control option controls the velocity of the pneumatic device, for use on single manifolds. 7. The adjustable pilot option, also for use on single manifolds, can be used to overcome differential pressure problems and set for quicker stopping. 8. An embodiment of the DL valve incorporates compatibility with the International Organization for Standardization (ISO) port interface specification ISO 15407-2 (with electrical connector) or 15407-1 (without electrical connector), directed to pneumatic fluid power, five-port directional control valves.
[0015] Generally, a valve according to the present invention includes a valve body having first, second, third and fourth reentrant bores formed therein. The valve body further includes a first cartridge bore in fluid communication with the first third reentrant bores and a second cartridge bore in fluid communication with the second and fourth reentrant bores. The cartridge bores preferably include a piston bore, an input counterbore, an output counterbore and a bearing sleeve counterbore. At least partially within each cartridge bore is a piston cartridge. Each piston cartridge includes a longitudinal piston rod, a first piston head secured to one end of the piston rod, and a second piston head secured to a second end of the piston rod. A poppet member is slidably disposed on the piston rod, biased in a poppet bias direction by a poppet bias spring. The valve body further includes a first fluid channel in fluid communication with the first reentrant bore and the second cartridge bore, preferably with its respective piston bore. Separated from the first fluid channel is a second fluid channel in fluid communication with the second reentrant bore and the first cartridge bore, preferably with its respective piston bore. A plurality of nonintersecting throughbores may be formed through said valve body. The plurality of nonintersecting throughbores may number three to five.
[0016] According to an embodiment of a valve according to the present invention, the valve body may be a unitary member. The valve body may be at least substantially parallelepiped in shape, including a front surface, back surface, top surface, bottom surface, left surface and right surface. A plurality of nonintersecting throughbores may be formed through the valve body, including through the bottom surface and the top surface.
[0017] According to an embodiment of a valve according to the present invention, the cartridge bores may extend through and include the left surface and the right surface. The first reentrant bore and the second reentrant bore may be formed into the valve body through the top surface. The third reentrant bore and the fourth reentrant bore may be formed into the valve body through the bottom surface.
[0018] According to an embodiment of a valve according to the present invention, the valve may further include a manual release mechanism including a manual release cover, a manual release gasket and first and second manual release plungers. The manual release cover includes a pilot channel formed therein and is coupled to the valve body to cover one end of the cartridge bores. The manual release gasket includes a first plunger aperture, a second plunger aperture and a gasket pilot hole formed therethrough, where the gasket is situated between a portion of the manual release cover and the valve body placing the gasket pilot hold in fluid communication with the pilot channel. The first manual release plunger extends through the manual release cover, through the first plunger aperture in the gasket and into the first piston bore so as to be contactable with the first piston cartridge. The second manual release plunger extends through the manual release cover, through the second plunger aperture in the gasket and into the second piston bore so as to be contactable with the second piston cartridge.
[0019] According to an embodiment of a valve according to the present invention, the valve may include a flow control mechanism. The flow control mechanism may include a mounting plate including a first adjusting aperture and a second adjusting aperture formed therethrough. A first threaded adjusting screw may extend through the first adjusting aperture into the first cartridge bore, preferably the output counterbore thereof, and a second threaded adjusting screw may extend through the second adjusting aperture into the second cartridge bore, preferably the output counterbore thereof. A first lock nut may be threaded onto the first adjusting screw, adapted to selectively prevent rotation of the first adjusting screw with respect to the mounting plate, and a second lock nut may be threaded onto the second adjusting screw, adapted to selectively prevent rotation of the second adjusting screw with respect to the mounting plate. The mounting plate is preferably coupled to the valve body to cover one end of the cartridge bores.
[0020] A system according to the present invention includes a fluid controlled actuator, a manifold in fluid communication with the fluid controlled actuator, first and second check valves in fluid communication with the manifold, and a fluid controlled solenoid assembly in fluid communication with the check valves. The fluid controlled actuator generally includes a first fluid chamber and a second fluid chamber. Such fluid controlled actuator, or fluid motor, may be a linear actuator comprising a plunger coupled to an actuating rod, where the plunger separates the first fluid chamber and the second fluid chamber. The manifold generally includes a first fluid port in fluid communication through a first fluid line with the first chamber of the fluid actuator and a second fluid port in fluid communication through a second fluid line with the second chamber. The manifold further includes a third fluid supply port. The first check valve includes a first check valve input, a first check valve output, and a first check valve pilot input, wherein the first check valve output is in fluid communication with the first fluid port on the manifold. The second check valve includes a second check valve input, a second check valve output, and a second check valve pilot input, wherein the second check valve output is in fluid communication with the second fluid port on the manifold. Also, the second check valve input is in fluid communication with the first check valve pilot input, and the second check valve pilot input is in fluid communication with the first check valve input. The fluid control solenoid assembly includes a fluid flow control spool that is moveable between a first position in which the fluid supply port is in fluid communication with the first check valve input, and a second position in which the fluid supply port is in fluid communication with the second check valve input.
[0021] According to one aspect of a system according to the present invention, when a supply fluid pressure in the fluid supply port is lost, the first check valve and the second check valve are closed.
[0022] According to one aspect of a system according to the present invention, when the fluid control solenoid assembly is in either of the first and second positions and when the supply fluid pressure is greater than either of the first fluid pressure or the second fluid pressure by a predetermined flow amount, respectively, both check valves are opened.
[0023] According to an aspect of a system according to the present invention, when the fluid control solenoid assembly is in the first position and when the supply fluid pressure is greater than the first fluid pressure, the supply fluid flows from the supply fluid port through the first check valve, through the first fluid line and into the first chamber, and a first exhaust fluid flows from the second chamber, through the second fluid line and through the second check valve.
[0024] According to an aspect of a system according to the present invention, when the fluid control solenoid assembly is in the second position and when the supply fluid pressure is greater than the second fluid pressure, the supply fluid flows from the supply fluid port through the second check valve, through the second fluid line and into the second chamber, and exhaust fluid flows from the first chamber, through the first fluid line and through the first check valve.
[0025] These and other features and advantages of the invention will become apparent from the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIGS. 1A , 1 B and 1 C form a schematic representation of a first embodiment of a system according to the present invention.
[0027] FIG. 1B is a cross-section view taken along line 1 B of FIG. 1A .
[0028] FIG. 1C is a cross-section view taken along line 1 C of FIG. 1A .
[0029] FIG. 2 is a front top right perspective view of a first embodiment of a valve according to the present invention.
[0030] FIG. 3 is a front bottom left perspective view of the embodiment of FIG. 2 .
[0031] FIG. 4A is a cross section partial assembly view taken along line 4 A- 4 A of FIG. 2 .
[0032] FIG. 4B is a right elevation, partial exploded view of the embodiment of FIG. 2 .
[0033] FIG. 5A is a cross section view of a second embodiment of a valve according to the present invention taken generally along a line similar to line 4 A- 4 A of FIG. 2 , but further including a flow control option.
[0034] FIG. 5B is a left elevation view of the embodiment of FIG. 5A .
[0035] FIG. 6A is a cross section view of a third embodiment of a valve according to the present invention taken generally along a line similar to line 4 A- 4 A of FIG. 2 , but further including a flow control option.
[0036] FIG. 6B is a left elevation view of the embodiment of FIG. 6A .
[0037] FIGS. 7A , 7 B and 7 C form a schematic representation of a first embodiment of a system according to the present invention.
[0038] FIG. 7B is a cross-section view taken along line 7 B- 7 B of FIG. 7A .
[0039] FIG. 7C is a cross-section view taken along line 7 C- 7 C of FIG. 7A .
[0040] FIG. 8 is a front top right perspective view of a known manifold.
[0041] FIG. 9 is a front top right perspective view of a fourth embodiment of a valve according to the present invention.
[0042] FIG. 10 is a front bottom left perspective view of the embodiment of FIG. 9 .
[0043] FIG. 11A is a partially exploded cross section view taken along line 11 A- 11 A of FIG. 9 .
[0044] FIG. 11B is an assembly view of a piston cartridge shown in FIG. 11A .
[0045] FIG. 12A is a bottom plan view of the embodiment of FIG. 9 .
[0046] FIG. 12B is a plan view of a gasket used with the embodiment of FIG. 9 .
[0047] FIG. 13 is a top plan view of a fifth embodiment of a valve according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0048] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
I. A System
[0049] Turning to the figures, FIGS. 1A , 1 B and 1 C provide an embodiment of a system 10 in which an embodiment of a dual locking valve according to the present invention may be used. Generally, air pressure from a supply source 12 , is directed through a manifold 20 and through an embodiment of a dual locking valve 100 , to controlling solenoids 16 . An electrical signal (not shown) sent to the solenoids 16 shifts a spool 18 contained therein, directing air pressure back through the dual locking valve 100 and out the manifold 20 to a working air cylinder 30 . A plunger 32 , located at least partially in the air cylinder 30 , applies force to an object (not shown), as is known.
[0050] The air cylinder 30 has a rod chamber 33 and a plunger chamber 35 . The rod chamber 33 is located between the plunger 32 and a rod end 34 of the cylinder 30 , and the plunger chamber 35 is located between the plunger 32 and the plunger end 36 of the cylinder 30 . In order for the plunger 32 to move towards the rod end 34 of the cylinder 30 , the rod chamber 33 of the air cylinder 30 must have an exhaust path to the atmosphere. This is accomplished by opening the piston cartridge 200 a opposite the pressurized piston cartridge 200 b.
[0051] As the piston 32 moves to extend the cylinder rod 38 , the air in the rod chamber 33 is pushed out. The exhaust air 13 travels back into the manifold 20 , through the valve 100 , through the solenoids 16 , back through the valve 100 , and out the manifold 20 to atmosphere.
[0052] In the event that the supply air pressure 11 is lost or a drop in that pressure occurs, the valve 100 will trap air on both sides of the air cylinder 30 , locking the plunger 32 in a safe, at least substantially static position.
II. Valve
[0053] Turning now to FIG. 2 and FIG. 3 , an embodiment 100 of a valve according to the present invention is shown. Generally, the valve 100 includes a valve body 102 , into which a plurality of reentrant bores 110 are formed, and through which a plurality of throughbores 120 may be formed. A first reentrant bore 112 and a second reentrant bore 114 may be formed in a spaced relationship into the valve body 102 . A third reentrant bore 116 and a fourth reentrant bore 118 may also be formed in a spaced relationship into the valve body 102 . The first and second reentrant bores 112 , 114 may be formed into the same surface of the valve body 102 , such as a top surface 104 thereof. The third and forth reentrant bores 116 , 118 may be formed into the same surface of the valve body 102 , such as a bottom surface 106 thereof. The top surface 104 and the bottom surface 106 may be substantially planar surfaces that may be at least substantially parallel to each other. Another reentrant bore that may be provided is a locating, or registration, bore 119 . The registration bore 119 may also be formed into the top surface 104 .
[0054] The throughbores 120 provided may serve a variety of purposes. For instance, a first pair of mounting throughbores 122 may be provided. A second pair of control throughbores 124 may provide direct flowthrough to enable control of the solenoid 16 . A third pair of exhaust throughbores 126 may be provided. A supply air throughbore 128 and an electrical connector throughbore 129 may also be provided. It is to be understood that some or all of the throughbores 120 may be utilized in any given embodiment. The throughbores 120 preferably extend completely through the thickness of the valve body 102 , such as between and including the top surface 104 and the bottom surface 106 .
[0055] Also with reference to FIG. 4A , disposed within the valve body 102 are a first cartridge bore 142 and a second cartridge bore 144 . The first cartridge bore 142 is in fluid communication with the first reentrant bore 112 and the third reentrant bore 116 , and the second cartridge bore 144 is in fluid communication with the second reentrant bore 114 and the fourth reentrant bore 118 . The cartridge bores 142 , 144 may be formed substantially orthogonal to their respective reentrant bores 112 , 116 and 114 , 118 .
[0056] Each cartridge bore 142 , 144 is preferably formed as a throughbore which may include one or more counterbores.
[0057] Within each cartridge bore is a piston cartridge 200 . The cartridges 200 are interchangeable, fluid tight, and function to hold air in the cylinder 30 in the event of a pressure loss or a change in pressure. The piston cartridge 200 generally includes a longitudinal piston rod 202 , a first piston head 210 , a second piston head 220 , and a poppet member 230 slidably disposed on the piston rod 202 and located generally between the first and second piston heads 210 , 220 . The substantially free sliding movement of the poppet member 230 generally, without pilot pressure, checks air in one direction and allows free flow in the opposite direction. The first piston head 210 is connected to a first end 204 of the piston rod 202 , and the second piston head 220 is connected to a second end 206 of the piston rod 202 , which may include a threaded engagement means 208 to cooperate with the second piston head 220 . The first piston head 210 is preferably formed with an annular piston seal groove 212 about its circumference, which accommodates placement of a first piston seal 214 , such as a grooved elastomeric O-ring. The first piston head 210 also preferably provides a first poppet stop surface 216 and a piston bias bore 218 adapted to accept a piston bias spring, such as an end cap spring 256 . The second piston head 220 is preferably formed with an annular piston seal groove 222 about its circumference, which accommodates placement of a second piston seal 224 , such as a grooved elastomeric O-ring. The second piston head 220 also preferably provides a second poppet stop surface 226 .
[0058] The poppet member 230 is slidably disposed on the piston rod 202 , the piston rod 202 preferably extending through the poppet member 230 . Situated between the poppet member 230 and the piston rod 202 , there may be a rod gasket or seal 203 such as an elastomeric O-ring that is disposed in an annular groove 205 formed about the piston rod 202 . Situated between the poppet member 230 and the first piston head 210 is a poppet bias spring 240 , which biases the poppet member 230 in a bias direction 242 , which is generally towards the second piston head 220 . The poppet member 230 itself may generally be formed as a frustoconical member extending between a first end 232 and a second end 234 , and further including an annular sealing flange 236 disposed thereabout. The annular sealing flange 236 includes a sealing surface 238 , which, when the piston cartridge 200 is assembled, generally faces towards the second piston head 220 . Disposed on and/or recessed into the sealing surface 238 is a poppet gasket 239 , which may be formed of an elastomeric material.
[0059] The piston cartridge 200 may generally be assembled by situating the rod gasket 203 in the annular groove 205 provided on the piston rod 202 . The poppet bias spring 240 may be placed on the rod 202 , resting against the first piston head 210 . The poppet member 230 may be slid onto the piston rod 202 and the second piston head 220 may be secured to the piston rod 202 . The piston seals 214 , 224 are placed around their respective piston heads 210 , 220 .
[0060] As indicated above, the cartridge bores 142 , 144 are provided with preferably at least one counterbore. For clarity in this section, only the first cartridge bore 142 will be described, with the understanding that the description also applies to the second cartridge bore 144 . The cartridge bore 142 includes a piston bore 142 a , an input counterbore 142 b , an output counterbore 142 c , and a bearing sleeve counterbore 142 d . The first, or input reentrant bore 112 intersects the cartridge bore 142 at the input counterbore 142 b and the third, or output reentrant bore 116 intersects the cartridge bore 142 at the output counterbore 142 c . The output counterbore 142 c provides a poppet seat, or sealing ledge 148 and further provides sufficient clearance for sliding movement of the poppet member 230 and desired fluid flow. To maintain the piston cartridge 200 in a preferred orientation, a bearing sleeve 250 may be used. The bearing sleeve 250 includes a piston aperture 252 , into which the first piston head 210 may be situated, the bearing sleeve 250 circumferentially contacting the first piston seal 214 . Disposed around the bearing sleeve 250 is preferably a bearing sleeve seal 254 , such as an elastomeric O-ring, which is adapted to sealingly engage the output counterbore 142 c provided in the cartridge bore 142 . The second piston head 220 is received into the piston bore 142 a.
[0061] In the first embodiment 100 , the piston cartridges 200 and bearing sleeves 250 are maintained in the valve body 102 by a piston cover 130 , which generally extends to cover one side of the cartridge bores 142 , 144 and is secured to the valve body 102 , such as by using a plurality of threaded fasteners 132 . On the opposite end of the cartridge bores 142 , 144 from the piston cover 130 , a manual release mechanism 150 may be provided. The manual release mechanism 150 includes a manual release cover 152 , a pair of manual release plungers 154 , and a manual release gasket 156 . The manual release plungers 154 are flanged posts that extend through the manual release cover 152 , sealed thereto by a manual release plunger gasket 158 , such as an elastomeric O-ring, through the gasket 156 to contact the second piston head 220 or second piston rod end 206 to enable manual override of the piston bias spring 256 . This allows the release of air that may be trapped in the air cylinder 30 .
[0062] The manual release cover 152 , the manual release gasket 156 and certain features of the valve body 102 provide pilot fluid crossover fluid paths. That is, it has been found desirable to place the first reentrant bore 112 in fluid communication with the second piston bore 144 a and the second reentrant bore 114 in fluid communication with the first piston bore 142 a . The first reentrant bore 112 is placed in fluid communication with the second piston bore 144 a through a first crossover fluid path 160 . The first crossover fluid path 160 is created partially by a first pilot input reentrant bore 162 formed into the valve body 102 , terminating in fluid communication with the first reentrant bore 112 . A first pilot channel 164 is formed in the valve body 102 thereby fluidly coupling the first pilot reentrant bore 162 , and thus the first reentrant bore 112 , to the second piston bore 144 a . The second reentrant bore 114 is placed in fluid communication with the first piston bore 142 a through a second crossover fluid path 165 . The second crossover fluid path 165 is created partially by a second pilot input reentrant bore 166 formed into the valve body 102 , terminating in fluid communication with the second reentrant bore 114 . A second pilot channel 168 is formed in the manual release cover 152 , separated from the first pilot channel 164 by the manual release gasket 156 . The second pilot channel 168 fluidly couples the second pilot reentrant bore 166 , and thus the second reentrant bore 114 , through a gasket pilot hole 169 , to the first piston bore 142 a.
III. Detailed Operation
[0063] Turning back to FIG. 1 , the operation of the system 10 in moving the plunger 32 in a single direction is described herein. It will be readily understood by a person of ordinary skill in the art that movement of the plunger 32 in the opposite direction would simply involve a shift in the solenoid spool 18 , and the operation would be identical, with each piston cartridge 200 swapping functionality with the other. Air pressure 11 from the supply source 12 , is connected to the supply port 22 on the manifold 20 . This port 22 is placed in fluid communication with the supply throughbore 128 on the valve 100 , thereby providing a direct flow path to the solenoids 16 . The solenoid 16 shifts the spool 18 with a combination of air pressure and an electrical signal, to direct the flow of the air pressure 11 to the first reentrant bore 112 , causing the poppet member 230 located in the first cartridge bore 142 to open due to a buildup of air pressure. The poppet member 230 is biased toward the poppet seat 148 by the poppet bias spring 240 , which allows the poppet member 230 to open when there is a 1-2 psi pressure difference across the poppet member 230 . With the poppet member 230 open, or spaced from the poppet seat 148 , the air moves through the first reentrant bore 112 , through the first cartridge bore 142 and into the third reentrant bore 116 . The third reentrant bore 116 is in fluid communication with a first control port 301 on the manifold 20 , which is in fluid communication with the plunger chamber 35 of the air cylinder 30 .
[0064] The air in the rod chamber 33 needs a passage to exhaust to atmosphere. This is accomplished by using the pressure side of the valve 100 to open the cartridge 200 on the exhaust side of the circuit. This is accomplished by using the crossover fluid paths 160 , 165 . Through one of these paths at a time, the air from a reentrant bore on the pressure side unseats the poppet member 230 in the exhaust cartridge 200 allowing air to flow from the fourth reentrant bore 118 , which is in fluid communication with a second control port 302 on the manifold 20 , to the second reentrant bore 114 . The open path allows air to escape from the rod chamber 33 of the cylinder 30 up to the solenoids 16 where there is an open flow through the solenoid 16 and back into the valve 100 through an exhaust throughbore 126 which is connected to the manifold 20 and which is exhausted to atmosphere out of one of the exhaust ports 325 therein.
[0065] The cartridges 200 fit into the valve body 102 , at least partially, but preferably entirely within the cartridge bores 142 , 144 . The cartridge 200 slides into the cartridge bore 142 , where the second piston seal 224 contacts the piston bore 142 a , the poppet member 230 is in the output counterbore 142 c and is biased toward the poppet seat 148 resulting in an air-tight seal on the poppet seat 148 . The bearing sleeve 250 and the bearing sleeve seal 254 slide into the output counterbore 142 c and rest on the bearing sleeve counterbore 142 d.
[0066] The end cap spring 256 is placed in the end of the first piston head 210 , which may be formed as an integral part of the piston rod 202 , to bias the entire cartridge 200 toward the poppet seat 148 . The entire procedure is repeated for the second cartridge 200 . When both cartridges are in place, the piston cover 130 is fastened in place with screws 132 . When the cover 130 is in place, the poppet members 230 are closed against the poppet seats 148 .
[0067] The solenoids 16 may likely require electrical signals to operate. Normally, the solenoids 16 are mounted directly to the manifold 20 , thereby allowing a direct connection between an electrical plug on the solenoids 16 and an electrical jack on the manifold 20 . When the valve 100 is placed between the manifold 20 and the solenoids 16 , however, the electrical signal to power the two solenoids may be carried by an electrical passthrough connector 170 on the valve 100 that plugs into a female connector on the manifold 20 and a male connector on the solenoids 16 . The air pressure required to shift the spool 18 in the solenoid assembly 16 , is supplied by the two control throughbores 124 in the valve body 102 .
[0068] The air passages between the DL valve and the manifold are sealed with a gasket ( 28 ). The groove to retain the gasket is machined into the DL block ( 2 ). The air passages between the solenoids ( 4 ) and the DL valve are sealed with a gasket attached to the solenoids ( 4 ).
[0069] The entire assembly comprising the solenoids 16 , the valve 100 and the manifold 20 may be held together with just two standoffs (not shown) that have a male thread on one end that threads into the manifold 20 and a female thread that connects to the solenoids 16 . The standoffs fit into the mounting throughbores 122 in the valve body 102 so that a standoff seal can seal air-tight in the standoff bore 122 . A small locating, or registration pin 172 helps to locate or align the connection between the manifold 20 and the valve 100 , and may cooperate with a registration bore 319 on the manifold 20 .
[0070] The two control throughbores 124 provided through the valve body 102 supply air from the manifold 20 to the two solenoids 16 that help to open and close air passages in conjunction with electronic signals to help shift the spool 18 from side to side.
IV. Valve Options
[0071] A. Flow Controls
[0072] One option is a flow control for both cartridges 200 to control cylinder speed by metering airflow from the air cylinder 30 . FIGS. 5A and 5B depict a second embodiment of a valve according to the present invention, where, instead of a simple piston plate 130 , a flow control mechanism 133 is provided in its place. An flow control adjusting screw 135 is added to the end of each cartridge that limits the movement of the poppet member 230 when the cartridge 200 is pressurized to the open position. A lock nut 137 may be used to lock the adjusting screw 135 in position. Metering out is the preferred method of controlling air cylinder speed. This also eliminates the need to add an extra valve to control the air cylinder speed.
[0073] B. Adjustable Pilots
[0074] An additional or alternative option gives the valve 100 the ability to adjust the air pressure required to shift the cartridges 200 and open the valve. The end cap spring 256 may not function correctly in cases where there is a large pressure difference between the cylinder advance and retract circuits. This can happen when the air cylinder 30 is in the vertical position with a large load on the end of the cylinder rod 38 . This will require a greater air pressure to lift the load than to lower the load. The small pressure required to lower the load may not be large enough to pilot the cartridge 200 open, so adjusting the spring pressure for a lower pressure operation will result in smoother operation.
[0075] Adjusting the spring pressure to a higher force will also make the air cylinder stop faster. In some cases due to system design, the exhaust pressure cannot escape fast enough, causing the cartridge 200 to stay open. When the pressure drops low enough where the end cap spring 256 can overcome the pilot pressure, the cartridge 200 will close. The spring force on the cartridge 200 is increased by turning an adjusting screw 138 clockwise. Increasing the force on the cartridge 200 will cause the cartridge 200 to close faster. A set screw 139 is supplied for each cartridge 200 in order to lock the respective adjusting screw 138 in place.
V. Cascaded Manifold System
[0076] Turning now to FIGS. 7A , 7 B and 7 C, a second system 17 according to the present invention is shown. It may be desirable to cascade two or more stackable manifolds 21 adjacent to each other. The system 17 operates the same as the first system 10 , the only exception being that a plurality of manifolds 21 for controlling a plurality of working loads, such as the cylinder 30 , are disposed adjacent each other. An example of such a manifold 21 is shown in FIG. 8 . Generally this type of manifold 21 has a plurality of lateral ports that are in fluid communication with at least substantially identical lateral ports of neighboring manifolds 21 . The lateral ports may include a supply port 22 , solenoid control ports 323 , and exhaust ports 325 . Also provided on the manifold 21 is a solenoid interface 320 . The solenoid interface 320 includes solenoid control ports 324 , exhaust ports 326 , a first circuit port 312 and a second circuit port 314 .
[0077] Like in the first system 10 , a flow control solenoid 16 would normally be placed directly adjacent the solenoid interface 320 . In this system 17 , however, a fourth embodiment 400 of a valve according to the present invention is placed between the manifold 21 and a flow control solenoid 16 . The fourth valve embodiment 400 is depicted in FIGS. 9 , 10 , 11 A, 11 B and 12 . Generally, the valve body 402 of this embodiment 400 is substantially the same as the valve body 102 of the first embodiment 100 . The primary difference between this embodiment 400 and the first embodiment 100 is that this embodiment 400 includes substantially planar right and left sides 408 , 409 . That is, the first embodiment 100 included a manual release mechanism 150 protruding from its right side 108 and a piston plate 130 or other optional features protruding from the left side 109 . Due to the nature of the stacking manifolds 21 , however, such protrusions are undesirable as they interfere with adding valves onto each adjacent manifold.
[0078] Accordingly, to render the sides 408 , 409 substantially planar, the fourth embodiment 400 incorporates a recessed crossover channel cover 452 on the right side 408 and a pair of recessed piston plates 430 on the left side 409 . The crossover channel cover 452 generally serves to cover one end of the cartridge bores 142 , 144 , as well as provide the fluid pilot channels 164 , 168 , generally in the same manner in which they are provided by the manual release cover 152 . The crossover channel cover 452 may be secured to the valve body 402 with countersunk threaded fasteners 453 . The recessed piston plates 430 generally serve the same purpose as the piston plate 130 , which is to provide a stationary abutment for the piston bias spring 256 and to at least partially contain the piston cartridge 200 in the cartridge bore 142 or 144 . The recessed piston plates 430 may be secured to the valve body 402 with countersunk threaded fasteners 432 .
[0079] FIG. 12A depicts a bottom plan view of the fourth embodiment 400 of a valve according to the present invention. The valve body 402 , like the valve body 102 of the first embodiment 100 , preferably includes a gasket groove 480 formed partially into the bottom surface 406 of the body 402 . Disposed at least partially in the gasket groove 480 is a preferably elastomeric gasket 482 as shown in FIG. 12B . Also, in FIG. 12A , it is to be noted that into the bottom surface 406 of the valve body 402 , the third reentrant bore 116 , the fourth reentrant bore 118 , the exhaust throughbores 126 , and the supply air throughbore 128 may be provided in a standardized interface orientation, such as that disclosed by the International Organization for Standardization (ISO) specification 15407-2 (or 15407-1), or an orientation compatible therewith. Such orientation may be utilized with any of the valve embodiments disclosed herein.
[0080] FIG. 13 depicts a fifth embodiment 500 of a valve according to the present invention. The fifth embodiment 500 generally comprises the fourth embodiment 400 , with the inclusion of a manual release mechanism 490 for each cartridge bore 142 , 144 . Each manual release mechanism 490 includes a reentrant release bore 491 extending through an outside surface of the valve body 402 and into one of the cartridge bores 142 or 144 . The release bore 491 preferably includes a first counterbore 492 into which a release bias spring 493 and a release plug 494 , the release bias spring 493 biasing the plug 494 away from the respective cartridge bore 142 or 144 . The release bore 491 also preferably includes a second counterbore 495 into which a release plug collar 496 is secured, such as by being press fit or threaded therein. In this arrangement, in normal operation, the release bias spring 493 acts within the first counterbore 492 to bias the release plug 494 against the release plug collar 496 , thereby preventing any leakage. However, when desirable to manually release air pressure from a cartridge bore 142 or 144 , the force of the release bias spring 493 may be overcome by exerting pressure against the release plug 494 from outside the valve body 402 , thereby forcing the release plug 494 away from the release plug collar 496 , thereby allowing air to escape from the cartridge bore 142 or 144 through the reentrant release bore 491 , around the release plug 494 and out to the atmosphere. Also, in FIG. 13 , it is to be noted that into the top surface 404 of the valve body 402 , the first reentrant bore 112 , the second reentrant bore 114 , the exhaust throughbores 126 , and the supply air throughbore 128 may be provided in a standardized orientation, such as that disclosed by the International Organization for Standardization (ISO) specification 15407-2 (or 15407-1). Such orientation may be utilized with any of the valve embodiments disclosed herein.
[0081] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. For instance, it will occur that various combinations of the features herein described may be accommodated. For instance, the manual release mechanism 150 of the first valve embodiment 100 may be adapted for use with the second valve embodiment 400 , instead of the recessed crossover channel cover 452 . Also, while the preferred embodiment has been generally described as a pneumatic linear actuator, it is to be understood that an embodiment of the present invention may utilize or be utilized with any fluid motor. Furthermore, while the preferred embodiment has been described in connection with air as the fluid, it is to be understood that a valve according to the present invention would also function with other fluids such as oil and water. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
|
A dual locking valve assembly includes two check valve elements in two cartridge bores. Each check valve element opens to permit forward flow of fluid under pressure in the cartridge bore from an input bore to an output bore. The check valve element closes to block back flow of fluid under pressure in the cartridge bore from the output bore towards the input bore. The back flow of fluid under pressure exerts a closing force upon the check valve element from within the output chamber. A counter force generating element, or pilot element, communicates with the valve element, to selectively open the valve, even in the presence of back flow pressure. The pilot element exists as a fluid crossover path from one cartridge bore to the other.
| 5
|
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a method for holding an adapting part on a tubular casing of a turbo-engine, and to a corresponding adapting part and holding system.
The present invention applies in particular, although not exclusively, to a suspension for a turbo-engine on a pylon of an aircraft, by means of which the turbo-engine can be attached entirely securely to the structure of the aircraft.
The term suspension designates, in general terms, all the various necessary parts for attaching the turbo-engine to the pylon, such as attachments, articulations, spindles, ball swivels, articulated rods, arms, hoops, fittings, etc., which are usually employed to that effect.
Description of the Related Art
As is known, the suspension of a turbo-engine below a wing of an aircraft is generally located and contained in specific suspension planes of the turbo-engine, which planes are mutually parallel and orthogonal to the longitudinal axis of the turbo-engine.
Thus, such a suspension may comprise:
on one hand, a front suspension bracket in a front suspension plane located at the level of a structural intermediate casing of the turbo-engine and connecting the latter to the attachment bracket of the pylon; and on the other hand, a rear suspension bracket in a rear suspension plane located at the level of the structural exhaust casing of the turbo-engine and connecting the latter to the attachment bracket of the pylon.
The front and rear suspension brackets are respectively attached to the intermediate casing and to the exhaust casing via the intermediary of simple or double articulated rods and clevises which are molded thereon.
It is further known that such a suspension comprises thrust uptake means in the form of struts which are inclined with respect to the axis of the turbo-engine. The thrust uptake struts connect an inner ring, in the front suspension plane, to an outer ring (or hoop) of the exhaust casing, in the rear suspension plane. The struts are fastened to the two rings by means of attachments. Each attachment consists of two simple or double clevises, of which one is secured to the end of the strut and the other is secured to the wall of the corresponding ring, a common spindle passing through these.
The purpose of the arrangement of the suspension is, in particular, to take up the forces which act in the three directions (roll, pitch and yaw) of an orthonormal reference frame connected to the aircraft, and the moments according to these three directions.
However, the bulkiness of the attachment devises molded onto the outer ring of the exhaust casing represents an important limiting factor when defining the lines of the nacelle surrounding the turbo-engine and causes problems for integrating the latter underneath the wing of an aircraft, in particular when trying to bring the turbo-engine as close as possible to the wings of the aircraft (for example in the case of increasing the bypass ratio of the engine for the same ground clearance).
Moreover, since attaching the pylon to the exhaust casing requires a structural exhaust casing, the latter has a large mass.
In addition, the considerable separation between the two suspension planes means that the thrust uptake struts must be long. In order to avoid any risk of buckling, the struts are dimensioned accordingly, which results in a large associated diameter and mass.
In order to compensate for these drawbacks, it is known for the rear attachment of the pylon to be on a structural inter-turbine casing of a turbo-engine. In particular, this rear attachment requires an intermediate structural outer ring which is bolted on the downstream flange of the inter-turbine casing via the intermediary of a single downstream flange of the intermediate ring. The thrust uptake struts are attached with the aid of a spreader which is connected to the rear suspension bracket by means of a pivot connection. This rear suspension bracket is, for its part, connected to the structural ring by struts. These are connected, on one hand, to the suspension bracket and, on the other hand, to the intermediate structural ring by means of molded attachment clevises. These clevises are arranged upstream of the downstream attachment flange of the inter-turbine casing and are thus arranged in a cantilever configuration with respect to the latter. It is then vital to reinforce the structure of the intermediate ring, either by increasing the thickness or with the aid of ribs, which makes the ring considerably heavier.
Moreover, attaching this intermediate outer ring to the only downstream flange of the inter-turbine casing subjects the flange to substantial forces, meaning that it too has to be strengthened, which once again leads to an increase in mass.
In addition, the downstream flange of the intermediate ring is attached to the downstream flange of the inter-turbine casing either by means of an axial bolted connection, obtained with the aid of bolts oriented axially (that is to say parallel to the axis of the turbo-engine), or by means of a radial bolted connection, obtained with the aid of bolts oriented radially (that is to say perpendicular to the axis of the turbo-engine).
In the case of an axial bolted connection of the flange of the intermediate ring, it is known to manage the manufacturing tolerances by providing peelable shims. However, such peelable shims are difficult and laborious to install since the manipulation thereof over the entire circumference of the intermediate ring is complex.
In the case of a radial bolted connection of the flange of the intermediate ring, where the bolts are subjected principally to shear loading, it is essential to use large-diameter bolts, which increases the mass associated with the intermediate ring. Moreover, in this latter case, it proves difficult to manage the expansion of the intermediate ring and of the inter-turbine casing.
It is an object of the present invention to remedy these drawbacks.
BRIEF SUMMARY OF THE INVENTION
To that end, according to the invention, the method for holding an adapting part on a tubular casing of a turbo-engine, said part being designed to partially cover said casing,
is noteworthy in that the following steps are carried out:
one of the axial ends of the adapting part is connected to a corresponding first axial end of said casing, so as to form an axially sliding connection in the extension of said axial end of the adapting part; and
the other axial end of the adapting part is attached to a corresponding second axial end of said casing, so as to form a rigid connection.
Moreover, the adapting part designed to be held on a casing of a turbo-engine according to the method set out is noteworthy in that it comprises:
in the extension of one of its axial ends, a first connecting means configured so as to engage with a first complementary connecting means associated with said casing, so as to form the sliding connection; and at its other axial end, a second connecting means configured so as to be secured to a second complementary connecting means associated with said casing, so as to form the rigid connection.
Thus, by virtue of the invention, the adapting part may be held, at its axial ends, on the casing of the turbo-engine by means of a rigid connection on one hand, and by means of a sliding connection on the other hand. It is thus possible, by means of the sliding connection, to absorb at least part of the expansion—in particular the axial expansion—of the adapting part and of the casing in question, when the turbo-engine is in operation. Management of the expansion is improved. Moreover, it is possible by means of the sliding connection to have radial centering of the adapting part which is more appropriate and more precise than with a flange-type rigid connection for which manufacturing tolerances are difficult to manage. The invention provides for larger contact surfaces by means of which the adapting part can be positioned radially.
It will be noted that the sliding connection may be arranged either upstream of said casing or downstream thereof.
Preferably, the first connecting means comprises at least one projecting tab, which is entirely circular or extends over a predetermined angular sector, preferably equal to 120°. Thus, no flange is used in order to form the sliding connection, which reduces the mass of the adapting part.
Moreover, the second connecting means is advantageously in the form of a flange, which is entirely circular or extends over a predetermined angular sector, preferably equal to 120°.
In addition, the adapting part may comprise a hoop portion of predetermined angular sector, preferably equal to 120°. In this case, the adapting part, limited to a given angular portion, is less massive than a full intermediate ring, of circular cross section, of the type described above. The mass added to the turbo-engine by the adapting part, and the associated bulkiness, are less than the mass and the bulkiness of such a full intermediate ring. Moreover, mounting the more compact adapting part on the turbo-engine is made substantially easier. It will also be noted that drawing the lines of a nacelle surrounding the turbo-engine is simpler, as is bringing the latter closer to the wings of an aircraft.
Furthermore, the present invention also relates to a system for holding, on a tubular casing of a turbo-engine, an adapting part of the type described hereinabove, which is noteworthy in that it comprises:
the first complementary means associated with said casing, which is configured so as to engage with the first connecting means of the adapting part, so as to form the sliding connection; and the second complementary means associated with said casing, which is configured so as to engage with the second connecting means of the adapting part, so as to form the rigid connection.
Preferably, the first complementary connecting means comprises a connecting member comprising at least one groove, which is entirely circular or extends over a predetermined angular sector, preferably equal to 120°.
Thus, the tab of the adapting part may be introduced into the groove of the connecting member so as to form the sliding connection. It is then much easier to mount and remove the adapting part, reducing the time required for carrying out these operations.
Moreover, the circumferential ends of the groove, of predetermined angular sector, may advantageously be closed in order to avoid any rotation of the adapting part with respect to the casing in question and in order to make the angular positioning of said adapting part easier.
According to one embodiment in accordance with the present invention, the connecting member is fitted on one end flange of said casing. In this case, the connecting member may either extend, in the radial direction, a flange of a casing adjacent to said casing in question, or form a separate and independent element of the turbo-engine.
As a variant, the connecting member may radially extend one upstream or downstream end flange of said casing.
Furthermore, the present invention also relates to a suspension for a turbo-engine on a pylon of an aircraft, comprising a front suspension bracket which is designed to be mounted on an intermediate casing of the turbo-engine and a rear suspension bracket designed to be mounted on an inter-turbine casing of the turbo-engine, and an adapting part of the type specified hereinabove, in order to connect the rear suspension bracket to the inter-turbine casing of the turbo-engine.
The present invention also relates to a turbo-engine attached to a pylon of an aircraft via the intermediary of a suspension comprising a front suspension bracket mounted on an intermediate casing of the turbo-engine and a rear suspension bracket mounted on an inter-turbine casing of the turbo-engine, which is noteworthy in that:
the suspension further comprises an adapting part of the type described hereinabove, in order to connect the rear suspension bracket to the inter-turbine casing of the turbo-engine; and in that it comprises a system for holding said adapting part as mentioned above.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The figures of the appended drawing will make it easy to understand how the invention may be embodied. In these figures, identical references designate similar elements.
FIG. 1 shows, very schematically and in profile, a turbo-engine attached to an attachment pylon of an aircraft via the intermediary of a suspension in accordance with the present invention.
FIG. 2 shows, in a schematic perspective view, an example of a suspension implementing an adapting part in accordance with the present invention.
FIG. 3 is a schematic axial section of the adapting part of FIG. 2 , once mounted on the inter-turbine casing of the turbo-engine.
FIG. 4 shows, in a schematic perspective view, the adapting part of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1 , a suspension 3 is provided for mounting and attaching a turbo-engine 1 , of longitudinal axis L-L, to a pylon 2 of an aircraft below the wings of the latter, so as to form an interface between the turbo-engine 1 and the pylon 2 .
Thus, the suspension 3 of the invention is positioned between the pylon 2 having a box-type attachment bracket (partially represented in FIG. 2 ) and intermediate 4 and inter-turbine 5 outer casings of the turbo-engine 1 .
Moreover, the suspension 3 is positioned and contained in two suspension planes P1 and P2 of the turbo-engine 1 , which are mutually parallel and orthogonal to the longitudinal axis L-L thereof.
With respect to an orthonormal reference frame XYZ (corresponding to that of the aircraft 1 with X being the roll axis, Y being the pitch axis and Z being the yaw axis), the longitudinal axis L-L of the turbo-engine 1 is parallel to X and the suspension planes, front P1 and rear P2, are contained in planes formed by the Y and Z axes.
The front suspension plane P1 is arranged level with the intermediate casing 4 downstream of the fan of the turbo-engine 1 and the rear suspension plane P2 is, for its part, located level with the frustoconical inter-turbine casing 5 , arranged between a high-pressure turbine casing 6 and a low-pressure turbine casing 7 .
The front suspension 3 A and the rear suspension 3 B—forming the overall suspension 3 —are represented by rectangles 3 A and 3 B ( FIG. 1 ) connecting the casings 4 and 5 corresponding to the attachment bracket of the pylon 2 .
As shown in FIG. 2 , the suspensions, front 3 A and rear 3 B, respectively comprise a front suspension bracket 8 , in the front suspension plane P1, and a rear suspension bracket 9 , in the rear suspension plane P2.
In particular, the front suspension bracket 8 comprises a fitting 10 and three articulated rods 11 A and 11 B. The upper portion 10 A of the fitting 10 defines a platform for receiving the attachment bracket of the pylon 2 in the front suspension plane P1.
The fitting 10 extends on either side of the engine axis L-L via two double clevises 12 into which are inserted, respectively, the ends of the lateral struts 11 A, so as to form an articulated connection having a common spindle 13 passing through the two lugs of each of the clevises 11 A and the ends of the corresponding struts 11 A.
The fitting 10 also comprises a central clevis 14 so as to form an articulated connection with the central strut 11 B with a common spindle 13 . The front suspension bracket 8 is designed to take up the forces taking up the torque of the turbo-engine 1 in particular via the intermediary of the central strut 11 B. In this case (torque uptake at the front), the forces acting in the formed rear suspension 3 B are reduced. Indeed, taking up the torque on the intermediate casing 4 at the front of the turbo-engine 1 —which has a larger radius than the inter-turbine casing 5 —allows a reduction of the torque uptake forces. Such an attachment configuration prevents any torque uptake at the rear of the turbo-engine 1 at the level of the rear suspension 3 B, such that the latter is subjected to less force.
Moreover, the rear suspension bracket 9 comprises a fitting 15 and two lateral articulated rods 16 . The upper portion 15 A of the fitting 15 forms a platform for receiving the attachment bracket of the pylon 2 in the rear suspension plane P2.
The fitting 15 extends on either side of the engine axis L-L via two double clevises 17 A into which are inserted, respectively, the ends of the lateral struts 16 , so as to form an articulated connection having a common spindle 18 passing through the two lugs of each of the lateral clevises 17 A and the ends of the corresponding struts 16 .
The fitting 15 also comprises a double central clevis 17 B so as to form an articulated connection with a single clevis of an adapting part 19 in accordance with the invention, as is set out hereinbelow.
Furthermore, as shown in FIG. 2 , once mounted on the turbo-engine 1 , the rear suspension bracket 9 is attached to the adapting part 19 designed to be fitted on the inter-turbine casing 5 , in the rear suspension plane P2.
As shown in FIGS. 2 and 4 , the adapting part 19 is formed of a frustoconical hoop portion 20 of angular sector α approximately equal to 120°. The hoop portion 20 has a longitudinal extent along the axis L-L which is substantially equal to that of the inter-turbine casing 5 .
The adapting part 19 further comprises a tab 21 which extends, in the upstream direction, the axial end of the hoop portion 20 . The upstream tab 21 , which is partially cylindrical, extends over the angular sector α. It is inclined with respect to a generatrix T-T of the frustoconical portion 20 .
The adapting part 19 also comprises a downstream flange 22 secured to the downstream end of the hoop portion 20 and designed to be connected to the downstream flange 5 B of the inter-turbine casing 5 (see FIG. 3 ). The downstream flange 22 , in the form of a collar portion, extends over the angular sector α. In other words, when it is attached to the corresponding flange 5 B of the inter-turbine casing 5 , the attachment is effected only over an angle portion.
Once the adapting part 19 is fitted on the inter-turbine casing 5 , the downstream flange 22 is in a plane orthogonal to the longitudinal axis L-L, such that it is inclined with respect to the generatrix T-T.
As shown in FIG. 3 , the high-pressure turbine casing 6 comprises, at its downstream end, a circular flange 6 A which extends axially via a connecting member 23 comprising a groove 24 which is circular in shape. The connecting member 23 extends over an angular sector equal to the angular sector α.
The groove 24 , delimited by two concentric ribs 23 A and 23 B, defines a receiving recess designed to accommodate the tab 21 of the adapting part 19 . The depth of the groove 24 is such that, once the adapting part 19 is fitted on the inter-turbine casing 5 , a clearance remains between the free end of the tab 21 and the bottom of the groove 24 .
Moreover, the circumferential ends of the groove 24 are closed, such that the angular extent of the groove 24 corresponds to that of the tab 21 . Thus, once the tab 21 is accommodated with adjustment in the groove 24 , it is possible to prevent any rotation of the adapting part 19 with respect to the inter-turbine casing 5 and high-pressure casing 6 . Closing the circumferential ends of the groove 24 also facilitates the angular positioning of the adapting part 19 .
As a variant, the tab of the adapting part could comprise a plurality of notches, defining sub-tabs, and the groove of the connecting member could comprise radial walls, defining sub-grooves designed to accommodate the corresponding sub-tabs. In another variant, the sub-tabs could be flat and the sub-grooves straight.
It will be noted that the connecting member 23 may comprise a shoulder 23 C which is annular or partially annular and against which the upstream flange 5 A of the inter-turbine casing 5 is designed to press, in order to facilitate the centering of the latter.
Furthermore, as shown in FIGS. 2 to 4 , orifices 25 are regularly distributed over the downstream flange 22 of the part 19 such that, for example, they may be bolted to the corresponding downstream flange 5 B of the inter-turbine casing 5 . Of course, other attachment means could equally be employed, such as for example rivets, so as to replace the bolts.
When it is assembled on the turbo-engine 1 , the adapting part 19 is first fitted on the inter-turbine casing 5 by inserting the tab 21 into the corresponding groove 24 of the connecting member 23 . Once the tab 21 is accommodated in the groove 24 , the downstream flange 22 is fixed, by bolting, to the downstream flange 5 B of the inter-turbine casing 5 and to the upstream flange 7 A of the low-pressure turbine casing 7 . The connecting member 23 and the upstream flange 5 A of the inter-turbine casing 5 then define a system for holding the adapting part 19 on the turbo-engine 1 .
Thus, once the adapting part 19 is fitted on the inter-turbine casing 5 , the tab 21 engages with the groove 24 so as to form, on the upstream side, an axially sliding connection. On the downstream side of the adapting part 19 , a rigid connection, obtained by bolting, is formed by assembling the flanges 22 , 5 B and 7 A, respectively in this order.
The differential expansion of the casings and of the adapting part is thus better managed, with at least part of the axial expansion being absorbed by the upstream sliding connection.
Moreover, the forces supplied by the rear suspension bracket 9 on the adapting part 19 are transmitted directly to the sliding and rigid connections arranged at the axial ends of the inter-turbine casing 5 .
Furthermore, as shown in FIG. 4 , the adapting part 19 also comprises three suspension clevises 26 and 27 , of which two are lateral double clevises 26 and one is a central single clevis 27 . It goes without saying that, as a variant, the number and shape of the clevises (single or double) could be different.
The suspension clevises 26 and 27 are arranged on that face of the hoop portion 20 which faces outwards.
Moreover, as shown in FIG. 2 , the lateral articulated rods 16 which are articulated on the rear suspension bracket 9 are designed to form an articulated connection with the corresponding lateral clevises 26 of the part 19 . The free ends of the articulated rods 16 are inserted between the two lugs of the lateral clevises 26 and a common spindle 28 passes through them, thus forming an articulated connection.
The double central clevis 17 B of the rear suspension bracket 9 receives the single clevis 27 of the adapting part 19 , such that a common spindle 29 passes through it and thus forms an articulated connection.
Furthermore, in the example shown, the hoop portion 20 comprises a plurality of rectangular cutouts 30 which are designed to lighten the adapting part 19 and to allow cables, equipment or any other element to pass through.
FIG. 2 also shows two thrust uptake struts 31 which are connected to the rear suspension bracket 9 via the intermediary of a spreader 32 .
It is to be noted that, when mounting the suspension 3 on the turbo-engine 1 , the adapting part 19 is preferably first attached to the inter-turbine casing 5 . The rear suspension bracket 9 is then mounted on the adapting part 19 which is positioned in this manner. The attachment bracket of the pylon 2 is finally bolted to the corresponding platform of the rear suspension bracket 9 .
Of course, the present invention is in no way limited to the exemplary embodiment described hereinabove.
Thus, in a first variant which is not illustrated, the connecting member may axially extend the upstream flange 5 A of the inter-turbine casing 5 (and not the downstream flange 6 A of the high-pressure turbine casing 6 ).
In a second variant which is not illustrated, the connecting member may be independent and distinct from the flanges 5 A and 6 A, such that it can be fitted and attached to these flanges 5 A and 6 A, for example when they are assembled by bolting with one another. In this case, the distinct connecting member may be fitted on the upstream face of the downstream flange 6 A of the high-pressure turbine casing 6 , or on the downstream face of the upstream flange 5 A of the inter-turbine casing 5 . In this variant, shear pins may also be provided on one of the flanges 5 A or 6 A in order to facilitate the positioning thereon (in particular the angular centering) of the connecting member.
Furthermore, the invention may equally apply to an adapting part and a tab of entirely circular shape.
It will finally be noted that the adapting part in accordance with the invention is not limited to use in a rear suspension of a turbo-engine of an aircraft.
|
An adapting part is designed to be held on a casing of a turbo-engine, partially covering the casing. The adapting part includes, in the extension of one of its axial ends, a first connector to engage with a first complementary connector associated with the casing to form a sliding connection. The adapting part also includes, at its other axial end, a second connector to be secured to a second complementary connector associated with the casing to form a rigid connection.
| 8
|
BACKGROUND OF THE INVENTION
The present invention relates generally to an explosive device useful for cutting tubing in oil and gas well drilling applications and a method for assembling the device. More particularly, the device comprises an explosive charge in a zirconia casing, an electrically activated means for detonating the explosive charge, and a housing for attaching the casing and detonation means to a drill string. The explosive charge is then lowered to a desired point in an oil or gas well and detonated by passing an electric charge down the drill string to the detonation means. The method of assembly comprises grounding the explosive charge and detonator at all times during assembly. This minimizes the possibility of detonation during assembly due to static electric charges or stray electric currents in the components of the device. Detonation of the explosive charge or detonation means during assembly could cause serious injury to a person assembling the device.
Conventional devices for cutting tubing in oil or gas wells have used either mechanical cutters or explosive charges to separate the tubing into two segments. Mechanical cutters are lowered into the well to the desired point, and generally include teeth or other cutting elements that rotate or otherwise move and cut through the tubing to separate it. Explosive-charge cutting devices, on the other hand, use a shaped explosive charge that is lowered to the desired point in the well and then detonated. The explosive charge is shaped so that it causes the tubing to separate at the desired point when it is detonated.
Conventional explosive-charge tubing cutters typically enclose the explosive charge in a casing which is attached to a drill string and includes a means for detonating the explosive charge that is activated by an electric current. The electric current is provided by an external circuit and controlled by an operator at the top of the well. The electric current is passed down the drill string by means of a cable to the tubing cutter when the explosive device is at the proper position to cut the tubing. The electric current causes the detonation means, usually a blasting cap, to detonate, which in turn causes the explosive charge to detonate. Ideally, the tubing cutter, except for the explosive charge and its casing, can then be retrieved from the well.
Many conventional explosive-charge tubing cutters use a steel or cast iron casing for the explosive charge. These metal casings have the disadvantage that when the explosive charge is detonated the casing breaks into large pieces. These pieces can then jam or plug parts of the drill string and may make retrieval of the drill string difficult by jamming between the well casing and the drill string.
SUMMARY OF THE INVENTION
The invention comprises an improved tubing cutter device and a method of assembling the device. The device is useful for cutting tubing and casing at a desired place in an oil and gas well during operations. More particularly, the device comprises an explosive charge in a zirconia ceramic casing, a means for detonating the explosive charge, and a housing attachable to a drill string for lowering the charge into a well and for transferring an electric charge that activates the means for detonating the charge. The method of assembly of an explosive device, such as a shaped charge, insures that the conductive elements of the explosive charge are always grounded during assembly so that the possibility of premature detonation is minimized.
The improved tubing cutter device is superior to conventional explosive tubing cutters because zirconia ceramic is tougher than conventional materials used for explosive casings. Further, the zirconia ceramic disintegrates into many fine sand-like particles when the device is detonated, and these particles do not jam or plug other parts of the drill string.
The method of assembly for shaped charges, including the tubing cutter device, can be critical because premature detonation can result in serious injury or death to a person assembling the device. The explosive charge is detonated by means of a small explosive such as a blasting cap which is detonated by an electric charge. During assembly any inadvertent electric charges can detonate the blasting cap or even the explosive charge. Stray electric charges may derive from static electricity or ungrounded circuits. The method of assembly of the invention minimizes this possibility by insuring that the explosive charge and blasting cap are grounded at all times. Conventional methods of assembling explosive tubing cutters do not necessarily provide a ground for the explosive charge and blasting cap at all times.
DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a cross-sectional view of the assembled tubing cutter, detonator, and firing head.
FIG. 2 depicts a detailed cross-sectional view of the firing head and detonator assembled together.
FIG. 3 depicts a schematic view of the bottom of the detonator including a blasting cap, a grounding wire, and a temporary grounding wire.
DETAILED DESCRIPTION OF THE INVENTION
The present invention includes a novel explosive device for cutting tubing in oil well drilling operations and a method of assembling an explosive device. Referring to FIG. 1, a schematic view of a tubing cutter assembly 10 in accordance with the present invention is depicted, partially in a vertical section. The assembly includes a tubing cutter 12 which is comprised of an explosive charge 14, a blasting cap 16, a firing head 18, and a detonator assembly 20.
Tubing cutter 12 comprises an upper housing 13 which is preferably made of steel and includes a threaded female aperture 15. The threaded female aperture 15 of upper housing 13 is screwed onto a threaded male end 17 of the firing head 18. The interior of the upper housing 13 is open and adapted to receive firing head 18, including detonator assembly 20. The bottom housing 19 of tubing cutter 12 is made from zirconia ceramic and includes a generally toroidal shaped charge 14. Shaped charge 14 will cut the tubing when the charge is detonated. Bottom housing 19 of tubing cutter 12 may be attached to the upper part of the tubing cutter in a conventional manner, such as through use of a suitable adhesive.
Zirconia (ZrO 2 ) ceramic has low thermal conductivity, chemical inertness to molten metals, and a modulus of elasticity comparable to steel. Table 1 includes various properties for zirconia.
TABLE 1______________________________________Mechanical Properties:Density (g/cm.sup.3) 5.58Vickers Hardness Hv (kg/mm.sup.2) 1,500Bending Strength (psi) 55,000Compressive Strength (psi) 285,000Youngs Modulus (×10.sup.6 psi) 27Poissons Ratio 0.30Fracture Toughness (MN/m.sup.1.5) 7.0Thermal Properties:Thermal Conductivity, 0.084cal cm/cm.sup.2 s deg CSpecific Heat, 0.066cal/g at 25° C.Maximum Service Temperature, °F. 350Surface Quality:As Sintered (RMS micro inches) 15-25Ground (RMS micro inches) 20-40Polished (RMS micro inches) 2-10______________________________________
Zirconia ceramic is preferred over steel or similar metals for the casing of the explosive charge because when the charge is detonated, the zirconia disintegrates into many fine sand-like particles. In contrast, a steel or cast iron casing does not disintegrate but instead forms large pieces when the explosive charge is detonated. It should be appreciated that these pieces of steel can damage other equipment in the oil or gas well and can also jam parts of the drill string.
Zirconia ceramic is preferred over conventional ceramic casings for the explosive charge because it is less prone to breakage than other ceramics for downhole operations. In particular, other ceramics which have been used for items such as tubing cutter charge housings, such as alumina ceramics, are relatively brittle and prone to breaking or cracking when being lowered into a well. For example, the fracture toughness for zirconia ceramic is 7.0 as shown in Table 1 while the comparable fracture toughness for alumina ceramics ranges from 3.2 to 4.1. The zirconia is believed to be approximately twice as resistant to fractures than the alumina ceramic. A zirconia ceramic material which has been found satisfactory for use for explosive charge casings is manufactured by Kyocera Feldmuehle, Inc., a corporation doing business at 100 Industrial Park Road, P. 0. Box 678, Mountain Home, N.C. 28758.
Referring to FIG. 2, therein is depicted, partially in vertical section, along with an exemplary thread protector/shorting plug for use in practicing a method of assembly in accordance with the present invention, a schematic view of the assembled firing head 18 and detonator 20. The firing head assembly 18 comprises a firing head housing 24; detonator assembly 20; a washer 22; o-rings 26, 28, 30, and 32; a nut and bolt 36; a washer 38, and a spring 40.
The firing head housing 24 includes a larger diameter end with a female threaded fitting, and a smaller diameter end with a male threaded fitting. The female threaded end will facilitate the securing of other components to the firing head, and the male threaded end will facilitate the coupling of the firing head to a tubing cutter such as depicted in FIG. 1. Firing head 18 is fitted with o-ring 26 which provides a seal between the firing head 18 and the tubing cutter 12 when the firing head/detonator assembly is threaded into the tubing cutter.
The detonator assembly 20 is coupled to firing head housing 24 such as through use of a threaded end and a nut 36. Detonator assembly 20 includes a spring 40 which is fitted into the recess 25 in the detonator where a blasting cap detonative charge 16 fits. The spring is electrically conductive. It should be appreciated that the spring and detonator form part of the firing circuit that transfers an electric charge to the detonation means or blasting cap. Specifically, detonator assembly 20 conducts electricity from the end that is inserted into the firing head to blasting cap 16.
The firing head is assembled by attaching the detonator assembly 20 to firing head housing 24. The assembly method of the present invention includes the establishing of a grounding electrical connection between the detonator and the firing head housing at the time of assembly. In the depicted embodiment, this is accomplished by placing a shorting plug 50 in firing head housing 24, such that it will electrically engage detonator assembly 20 and form a circuit between detonator assembly 20 and firing head housing 24 at the time detonator assembly 20 is coupled to housing 10. At the time of assembly, a temporary ground wire 46, as depicted in FIG. 3, will preferably be used to establish an electrical connection between spring 40 and the remainder of detonator assembly 20. The temporary electrical connection is maintained by any suitable temporary connector or tie, such as a twisted wire tie 48, which secures ground wire 46 to assembly 20. When the detonator assembly is secured to firing head housing 24, the upper end of this temporary grounding wire 46 may be placed in electrical contact with firing head housing 24, thereby establishing electrical continuity between all parts. When it is desired to run the tubing cutter, this temporary ground wire may be removed.
Thus, the assembly method of the present invention assures that an electrical connection is maintained between the firing head housing and the detonator during assembly, and therefore assures that static charges which could potentially actuate the detonator will not be established between the two components.
Many modifications and variations may be made in the techniques and structures described and illustrated herein without departing from the spirit and scope of the present invention. Accordingly, it should be readily understood that the embodiments described and illustrated herein are illustrative only and are not to be considered as limitations upon the present invention.
|
A tubing cutter apparatus includes a housing or casing member formed of a zirconia ceramic material. The zirconia ceramic material is located at least proximate an explosive charge section, such the detonation of the explosive charge will cause shattering the ceramic section. The tubing cutter may be assembled in a safe manner by establishing ground connections between separate portions of the apparatus. These ground connections established during assembly will prevent the buildup of static electrical charges, which could cause premature detonation of the cutter.
| 5
|
The present application is based on and claims the benefit of U.S. provisional patent application Ser. No. 60/547,966, filed Feb. 26, 2004, the content of which is hereby incorporated by reference in its entirety.
FIELD OF INVENTION
This invention relates to methods for generating T-cells with enhanced immunostimulatory capabilities for use in cell therapy treatment protocols.
BACKGROUND OF THE INVENTION
Cell therapy methods have been developed in order to enhance the host immune response to tumors, viruses and bacterial pathogens. Cell therapy methods often involve the ex-vivo activation and expansion of T-cells. Examples of these type of treatments include the use tumor infiltrating lymphocyte (TIL) cells (see U.S. Pat. No. 5,126,132 issued to Rosenberg), cytotoxic T-cells (see U.S. Pat. No. 6,255,073 issued to Cai, et al.; and U.S. Pat. No. 5,846,827 issued to Celis, et al.), expanded tumor draining lymph node cells (see U.S. Pat. No. 6,251,385 issued to Terman), and various other lymphocyte preparations (see U.S. Pat. No. 6,194,207 issued to Bell, et al.; U.S. Pat. No. 5,443,983 issued to Ochoa, et al.; U.S. Pat. No. 6,040,177 issued to Riddell, et al.; U.S. Pat. No. 5,766,920 issued to Babbitt, et al.).
For maximum effectiveness of T-cells in cell therapy protocols, the ex vivo activated T-cell population should be in a state that can maximally orchestrate an immune response to cancer, infectious diseases, or other disease states. For an effective T-cell response, the T-cells first must be activated. For activation, at least two signals are required to be delivered to the T-cells. The first signal is normally delivered through the T-cell receptor (TCR) on the T-cell surface. The TCR first signal is normally triggered upon interaction of the TCR with peptide antigens expressed in conjunction with an MHC complex on the surface of an antigen-presenting cell (APC). The second signal is normally delivered through co-stimulatory receptors on the surface of T-cells. Co-stimulatory receptors are generally triggered by corresponding ligands or cytokines expressed on the surface of APCs.
Due to the difficulty in maintaining large numbers of natural APC in cultures of T-cells being prepared for use in cell therapy protocols, alternative methods have been sought for ex-vivo activation of T-cells. One method is to by-pass the need for the peptide-MHC complex on natural APCs by instead stimulating the TCR (first signal) with polyclonal activators, such as immobilized or cross-linked anti-CD3 or anti-CD2 monoclonal antibodies (mAbs) or superantigens. The most investigated co-stimulatory agent (second signal) used in conjunction with anti-CD3 or anti-CD2 mAbs has been the use of immobilized or soluble anti-CD28 mAbs.
The combination of anti-CD3 mAb (first signal) and anti-CD28 mAb (second signal) immobilized on a solid support such as paramagnetic beads (see U.S. Pat. No. 6,352,694 issued to June, et al.) has been used to substitute for natural APCs in inducing ex-vivo T-cell activation in cell therapy protocols (Levine, Bernstein et al. 1997; Garlie, LeFever et al. 1999; Shibuya, Wei et al. 2000). While these methods are capable of achieving therapeutically useful T cell populations, the use of paramagnetic beads makes the ease of preparation of T-cells less than ideal. Problems include the high cost of the beads, the labor-intensive process for removing the beads prior to cell infusion, and the inability of the beads to activate CD8 T-cell subsets (Deeths, Kedl et al. 1999; Laux, Khoshnan et al. 2000). In addition, the T-cell populations resulting from this method, and other prior art T-cell stimulation methods, lack the type of robustness required for eliciting effective immune stimulation when infused into patients. As a consequence, no prior art cell therapy protocols have demonstrated significant efficacy in clinical settings.
This has motivated the search for more effective methods for activating T-cells for use in cell therapy protocols. One such method is the use of APC tumor cell lines that have been genetically modified to express receptors that bind mAbs. These modified APC can be loaded with anti-CD3 and anti-CD28 mAbs (Thomas, Maus et al. 2002) or additionally modified to express the ligand for 4-1BB (Maus, Thomas et al. 2002) and then used to activate T-cells for use in cell therapy protocols. It was found that these modified APCs resulted in more effective activation of T-cell populations than the use of CD3/CD28-coated paramagnetic beads. However, the use of genetically-manipulated tumor cell lines in cell therapy protocols raises safety concerns which limit the commercial application of this technique.
SUMMARY OF THE INVENTION
In this situation, biodegradable supports coated with a first material that is capable of cross-linking second materials with reactivity to moieties on the surface of T-cells are utilized. The coated biodegradable supports are then mixed with second material labeled T-cells. The signals delivered by the cross-linked second materials are enhanced by centrifugation of the mixture. The signals are further enhanced by the culture of the mixture at high cell densities.
The present invention also includes biodegradable devices that have a biodegradable support with one or more agents that are reactive to T-cell moieties. Such agents deliver signals to T-cells to enhance immunostimulatory or immunoregulatory capabilities.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
There is a need for improved T-cell stimulation methods capable of increasing the robustness of T-cells for use in cell therapy protocols that are more suitable for use in human therapy.
In order to improve the robustness of T-cells, it is also desirable that the improved stimulation methods as closely as possible mimic the stimulatory effects of natural APCs. The improvement in T-cell activation observed with the CD3/CD28-coated APC cell lines discussed above (Thomas, Maus et al. 2002); (Maus, Thomas et al. 2002), was attributed to the availability of ligands to co-stimulatory molecules naturally expressed on the APC cell line that worked in concert with the CD3/CD28 stimulation. These ligands included B7-H3, PD-L1, PD-L2 and IL-15.
Therefore, it is desired to have a method for improved T-cell stimulation capable of presenting a multiplicity of co-stimulatory ligands without the requirement for use of a tumor cell line.
Natural APCs, however, not only provide multiple simultaneous stimuli to T-cells, they provide different arrays of multiple stimuli at different times and/or stages in the T-cell response to T-cell stimulation. No prior art T-cell stimulation methods are capable of mimicking this natural process.
The ability to mimic this natural process would provide a means to control not only the expansion of T-cells, but also the differentiation of T-cells. In the process of T-cell differentiation into regulatory or effector cells, different signals are required at different times and/or stages in the T-cell response to APC stimulation. Thus, it would be desirable to be able to create ex-vivo conditions that mimic this natural process in order to provide a greater variety of differentiated cells for use in cell therapy, including cells which could either stimulate immunity or suppress immunity.
The maintenance of the high density cell cultures used in the present invention require special care, as the degradation of the biological supports causes a fall in the media pH and the higher cell densities result in rapid accumulation of metabolic waste products and consumption of nutrients in the culture medium. For these reasons, media changes are required at least daily and preferably at least twice daily after the cells obtain a cell density in excess of 1 million per ml.
Frequent media changes can remove endogenous cytokines that are important for the maintenance and growth of the T-cell cultures. Therefore, in preferred embodiments, the removed culture media is filtered through a dialysis membrane in order to remove metabolic waste products, but retain endogenous cytokines. The retained media is then supplemented with fresh nutrient media and returned to the mixed culture. This enables the cells to be exposed to fresh nutrient media without dilution of the endogenous cytokines.
As the T-cells grow and mature in the cultures, various arrays of second materials can be added to the cultures at any time as required and subsequently cross-linked by mixing with additional coated biodegradable supports. Alternatively, the second materials can be added to the biodegradable supports and the coated supports added at various times to the cultures. Centrifugation of the mixture each time after adding additional second materials and coated biodegradable supports provides added benefit. In preferred embodiments, the centrifigation step is conducted daily to coincide with the media dialysis step.
Biodegradable Spheres
Aliphatic polyesters, such as poly(lactic acid) (PLA), poly(glycolic acid) (PGA), copolymers of PLA and PGA (PLGA) or poly(carprolactone) (PCL), and polyanhydrides are preferred materials for use as biodegradable polymers for the supports. The polymers can be formulated as various shapes, such as films, strips, fibers, gels, nanospheres or microspheres, and then coated with a first material. Microspheres are a preferred formulation because they can be reproducibly manufactured into small microsphere particle sizes of 1 to 0.500 microns, preferably 1 to 10 microns and most preferably 1 to 5 microns. Microspheres of this size range are capable of direct injection into the body by conventional methods. It is preferred that the coated microspheres be formulated to degrade in culture media or physiological fluids within 14 days, more preferably within 7 days, and most preferably within 3 days. In other preferred methods, nanospheres are formulated. These devices are preferred in applications where very rapid degradation, for example 3 days or less is required.
One preferred first material for coating on the biodegradable microspheres is polyclonal goat (or sheep) anti-mouse polyclonal antibodies. By way of example, this preferred first material can be used to cross-link mouse-derived monoclonal antibodies, or fragments or genetically engineered derivatives thereof, that have specificity for T-cell surface moieties. Thus, for example, the mixing of goat anti-mouse coated microspheres (or nanospheres) with human T-cells labeled with mouse anti-human CD3 and mouse anti-human CD28 mAbs will cause the cross-linking of the mouse mAbs on the human T-cells through the binding of the goat anti-mouse polyclonal antibody with the mouse mAbs. The cross-linking of the mAbs causes the activation and proliferation of the T-cells. Many combinations of first materials and second materials can be used to accomplish the objective of cross-linking second agents attached to T-cell surface moieties in order to initiate signal transduction and activation of T-cells. Alternatively, the second materials can be added to the biodegradable supports prior to addition to the T-cells.
The coated biodegradable microspheres (or nanospheres) used in the present invention provide many advantages for preparation of T-cells for use in cell therapy protocols over prior art methods where mitogenic agents are immobilized on a solid surface, such as paramagnetic beads:
First, since the devices are biocompatible and naturally degrade into non-toxic substances, there is no need to institute a bead removal process.
Second, because the devices have a low density, they can be used with cells being subjected to a centrifugal force. Prior art devices, such as paramagnetic beads, cause damage to cells when subjected to centrifugation. The ability to centrifuge cells with the beads permits the use of centrifugal force to enhance the quality of signals provided to the T-cells by stimulatory ligands cross-linked on the surface of the T-cells and also provides a means to wash and otherwise process the T-cells for preparation for infusion.
Third, in one use of the present invention, rather than immobilizing T-cell stimulatory and co-stimulatory ligands to a solid surface to present signals to T-cells, the use of a coated biodegradable microspheres (or nanospheres) permits the ligands to be first applied to the T-cells and then the labeled T-cells to be mixed with the coated biodegradable microspheres (or nanospheres). In this manner, the coated microspheres (or nanospheres) act as a universal cross-linking agent.
Fourth, as a universal cross-linking agent, a multiplicity of stimulatory and co-stimulatory ligands can be applied to T-cells and be cross-linked by the coated beads and the composition of the multiplicity of stimulatory and co-stimulatory ligands to be cross-linked can be varied over time.
Fifth, the ability to vary the composition of the array of stimulatory and co-stimulatory signals provided to T-cells over time permits the practice of methods designed to mimic natural presentation of T-cell proliferation, differentiation and functional signals.
Sixth, the ability to mimic the natural signal presentation to T-cells permits the development of T-cells with a multitude of functional characteristics for use in cell therapy protocols.
Seventh, the ability to control the sequence and variety of signals delivered to T-cells over time permits a means to control the differentiation pathways of T-cells ex-vivo. This will permit experimentation with novel combinations and sequencing of signals delivered to T-cells. Such methods will lead to T-cell products with novel effector functions both stimulatory and suppressive for use in cell therapy protocols.
For the purposes of the present invention, all references to T-cells includes a population of cells with at least a portion of the cells containing T-cells. T-cells are cells which express TCR, including α/β and γ/δ TCRs. T-cells include all cells which express CD3, including T-cell subsets which also express CD4 and CD8. T-cells include both naïve and memory cells and effector cells such as CTL. T-cells also include regulatory cells such as Th1, Tc1, Th2, Tc2, Th3, Treg, and Tr1 cells. T-cells also include NKT-cells and similar unique classes of the T-cell lineage.
Increased Signal Transduction
One aspect the present invention provides methods for enhanced stimulation of a population of T-cells by the concentration of a mixture of first material coated biodegradable microspheres (or nanospheres) and second material labeled T-cells. In order to increase the efficacy of the signal transduced to the T-cells, it is important to both increase the quantity of second agents cross-linked and the quality of the cross-linking.
In order to assure the highest quantity of second materials that are associated with the corresponding surface moieties on the surface of the T-cells, the labeling of the T-cells should be conducted with excess second materials. In a preferred embodiment where mouse mAbs to human T-cell surface antigens are the second materials, the mAbs are preferably mixed with a T-cell suspension whereby the T-cells are at a concentration of 1×10 6 to 1×10 7 per ml and each mAb is at a concentration of 0.5 μl/ml to 10 μl/ml, preferably 1 μl/ml. The labeled T-cells should be mixed with the coated biodegradable spheres at a ratio of at least one sphere per cell, and preferably at a ratio of 3 spheres per cell.
In order to assure the highest quality of cross-linking, the labeled cells and the coated biodegradable spheres are preferably first mixed thoroughly and then concentrated together under centrifugal force. The centrifugation is preferably conducted every 3 days, more preferably at least once daily. It is also preferable that the T-cells be kept at 4° C. from the time new mAbs are added through the completion of the centrifugation. Keeping the cells at refrigeration temperature prevents the capping and shedding of the ligated T-cell surface receptors prior to being cross-linked.
Cell Culture Methods
It is preferable to maintain processive and sustained TCR signal transduction and co-simulation in order to provide the most robust T-cells for use in cell therapy protocols. For this reason, the methods of the present invention work best when the cultured T-cells are maintained at high cell densities, such as greater than 10 6 cells/ml, or more preferably greater than 10 7 cells/ml, or most preferably greater than 10 8 cells/ml. The high cell densities increase the cell:cell interaction and the interaction with the biodegradable spheres.
The increased cell:cell interaction has a beneficial effect that is separate from the cross-linking effect of the biodegradable spheres. The beneficial effect comes from the expression of stimulatory ligands which upregulate on the surface of T-cells in response to maximal activation conditions. These ligands interact with the corresponding receptors on other T-cells. For example, T-cells will express one or more of the following TNFR co-stimulatory ligands such as LIGHT, CD70, OX40L, 4-1BBL and CD30L after maximal activation.
Maintaining cells at high densities in culture with biodegradable spheres requires the frequent changing of the culture media. The high cell densities result in a high rate of build up of metabolic waste products and consumption of available nutrients. In addition, the hydrolysis of the biodegradable spheres causes the pH of the culture media to become acidic. Too rapid media replacement, however, can be detrimental to cultures where exogenous cytokines are not utilized. It is preferable not to use exogenous cytokines when processing cells for use in cell therapy protocols, as exogenous cytokines can be toxic when infused into humans and can make the cultured cells dependant upon the presence of the exogenous cytokines for viability. Therefore, the methods of the present invention include a dialysis step in the cell processing.
Dialysis of the culture medium with membrane pore size of 10,000 dalton or less will enable retention of endogenous cytokines while allowing passage of metabolic waste. In preferred embodiments, half the culture medium of a culture is removed daily and 90% passed through a dialysis filter. The media passed through the filter is discarded, while the retained media is brought up to the original volume with fresh culture media.
According to the method of the present invention, a process is described for producing T-cells with robustness and enhanced function for use in cell therapy protocols involving: (1) the labeling of a population of T-cells with one or more agents that have reactivity to cell surface moieties; (2) mixing of the population of labeled T-cells with coated biodegradable spheres capable of cross-linking the agents attached to cell surface moieties on the T-cells causing a signal to be transduced to the T-cells; (3) concentrating of the mixture by centrifugation; (4) continued culture of the T-cells at high cell density; and (5) removal of media from the cultures at least daily and the dialysis of the media for retention of endogenous cytokines and replacement with fresh media; and (6) repeat of the process as necessary with the same or different agents for labeling of the T-cells in order to generate both the quantities of T-cells necessary for infusion and the optimal function of the T-cells for clinical effect.
Choice of T-cell Ligating Targets
The ability to design more efficient and effective T-cell activation, expansion and differentiation methods will be a direct result of the selection and timing of application of second materials. Second materials are agents which are capable of ligating T-cell surface moieties and delivering a signal to the T-cell upon cross-linking. These materials are preferably monoclonal antibodies, or fractions or genetically manipulated versions thereof, such as fusion proteins. The selection of second materials will be as a result of understanding of the T-cell activation, expansion and differentiation process and the requirements for the type and duration of signals at any one time in the life of the responding T-cells.
It is known that at least two type of receptors need to be engaged for T-cell activation, the TCR and a co-stimulator (Chambers and Allison 1999). In response to natural APC engagement with antigenic peptide and co-stimulatory ligands, the contact site of the APC and T-cell forms an “immunological synapse”. The synapse assembles into topologically and spatially distinct regions. The initial TCR engagement occurs at the periphery of the synapse (Grakoui, Bromley et al. 1999) after which ligand engagement of co-simulating molecules such as CD28, CD2, CD48 and LFA-1 facilitates the sorting and re-arrangements of receptors at the synapse. The content of molecules at the synapse can be specifically enriched in a subset of proteins and can selectively exclude proteins. This selective movement of proteins is facilitated by structures known as “lipid rafts”.
Lipid raft membrane partitioning is known to be crucial for optimal TCR signal transduction (Moran and Miceli 1998; Janes, Ley et al. 1999) and co-stimulators to TCR signaling cause the synapse formation and the re-organization and clustering of lipid rafts at the synapse. These events provide a natural mechanism for integrating spatial and temporal information provided to T-cells from the environment.
Accordingly, knowledge of the types of receptors available at the synapse in response to defined stimuli can provide the information for deciding the various types of co-stimulators to utilize over a period of time. Lipid rafts function as platforms for the concentration and juxtaposition of TCR associated signal transducers and assembly of an organized TCR signaling complex. Thus, by a process of first providing a defined array of signals to a population of T-cells and next analyzing the proteins assembled in lipid rafts that were induced by the first array, a second array of possible signals can be determined. The process can be repeated with second array stimulators. After application of the second array, the process can be repeated with a third array and so on. At each step in the process, the response of the T-cells can be monitored in order to optimize for the desired function, such as proliferation, the types and quantities of selected cytokine production, the expression of effector molecules and other functional surface molecules.
For example, both CD2 and LFA-1 are raft associated proteins that can stimulate initial T-cell activation in the absence of CD28 engagement (Yashiro-Ohtani, Zhou et al. 2000). The engagement of these molecules is known to upregulate and increase avidity for receptors for ICAM-1 which could then be engaged in a second array. CD2/LFA-1 engagement are know to facilitate T-cell activation by increasing the number of TCRs engaged over time, whereas CD28 functions by increasing the potency of those TCRs that are engaged, thus lowering the number of TCRs that need to be engaged in order to effect a response (Bachmann, McKall-Faienza et al. 1997).
In preferred embodiments, a first array including CD3 and other co-stimulatory molecules selected from one or more of the following: CD2, CD28, CD48, LFA-1, CD43, CD45, CD4, CD8, CD7, GM1, LIGHT (HVEM fusion protein) is utilized. A second array including CD3 and one or more of the first array co-stimulators with the additional choices of the following inducible co-stimulatory ligands: CD27, OX40, 4-1BB and CD30.
Also in preferred embodiments, T-cell counter receptors to various adhesion molecules can be engaged during the process. Examples of adhesion molecules on T-cells are: CD44, CD31, CD18/CD11a (LFA-1), CD29, CD54 (ICAM-1), CD62L (L-selectin), and CD29/CD49d (VLA-4). Other suitable second array agents include non-cytokine agents which bind to cytokine receptors and deliver a signal when cross-linked. Examples of these type of agents are mAbs to cytokine receptors including: IL-2R, IL-4R, IL-10R, Type II IFNR1 and R2, Type I IFNR, IL-12Rbeta1 and beta2, IL-15R, TNFR1 and TNFR2, and IL-1R. Also any agents capable of binding to chemokine receptors on T-cells and delivering a signal when cross-linked, including those in the C—C and C—X—C categories. Examples of chemokine receptors associated with T-cell function include CCR1, CCR2, CCR3, CCR4, CCR5, and CXCR3
Example Methods
Examples of optimized processes for producing a T-cell population with enhanced ability to stimulate the immune system follow. All examples utilize goat anti-mouse coated biodegradable microspheres and T-cells labeled with mouse mAbs specific for T-cell surface antigens:
Example #1
Set-up (Day 0)
(1) collection of leukocytes by leukapheresis;
(2) purification of 10 8 CD4+ T-cells by positive selection;
(3) labeling of purified CD4+ cells with anti-CD3, anti-CD28 and anti-IL-12Rbeta2 mAbs;
(4) mixing the labeled cells with coated microspheres in gas permeable bags (3:1 sphere:cell);
(5) suspension of the mixture at a cell density of 1×106/ml in 100 ml;
(6) centrifugation of the mixture at 500×g for 8 min at 4° C.;
(7) gently resuspend and culture in humidified atmosphere at 37° C. with 5% CO 2 ;
Day 3
(8) remove 80 ml of culture media by syringe aspiration using a 0.45 micron filter so as not to remove any cells;
(9) pass 70 ml of the removed media through a dialysis filter of 6,000 dalton cut-off size;
(10) add 70 ml of fresh culture media to the retained 10 ml and add back to the culture bag;
(11) add 100 μg each of anti-CD3, anti-CD28, anti-IL-12Rbeta2 and anti-4-1BB mAbs to the culture bag;
(12) mix coated microspheres at a sphere:cell ratio of 1:1;
(13) centrifuge mixture at 500×g for 8 min at 4° C.;
(14) gently resuspend and culture in humidified atmosphere at 37° C. with 5% CO 2 ;
Day 4
(15) repeat steps 8-10
Day 5
(16) repeat steps 8-10
Day 6
(17) repeat steps 8-14
(18) after 12 h repeat steps 8-10
Day 7
(19) repeat steps 8-10
(20) after 12 h repeat steps 8-10
Day 8
(21) repeat steps 8-10
(22) after 12 h repeat steps 8-10
Day 9
(23) harvest T-cell population and formulate for infusion
Results
This method results in a population of T-cells with enhanced proliferation and production of IFN-gamma and TNF-alpha compared to cells activated with CD3/CD28-coated immunomagnetic beads alone. N=6
Fold
IFN-gamma
TNF-alpha
IL-4
Method
Expansion
ng/ml
ng/ml
pg/ml
Example #1
830 +/− 77
970 +/− 160
180 +/− 38
<20
3/28-beads +
80 +/− 20
3 +/− 2.2
0.5 +/− .2
80 +/− 16
IL-2
Example #2
Set-up (Day 0)
(4) collection of leukocytes by leukapheresis;
(5) purification of 10 8 CD4+ T-cells by positive selection;
(6) labeling of purified CD4+ cells with anti-CD3, anti-CD28 mAbs;
(4) mixing the labeled cells with coated microspheres in gas permeable bags (3:1 sphere:cell);
(5) suspension of the mixture at a cell density of 1×106/ml in 100 ml;
(6) centrifugation of the mixture at 500×g for 8 min at 4° C.;
(7) gently resuspend and culture in humidified atmosphere at 37° C. with 5% CO 2 ;
Day 3
(8) remove 80 ml of culture media by syringe aspiration using a 0.45 micron filter so as not to remove any cells;
(9) pass 70 ml of the removed media through a dialysis filter of 6,000 dalton cut-off size;
(15) add 70 ml of fresh culture media to the retained 10 ml and add back to the culture bag;
(16) add 100 μg each of anti-CD3, anti-CD28, mAbs to the culture bag;
(17) mix coated microspheres at a sphere:cell ratio of 1:1;
(18) centrifuge mixture at 500×g for 8 min at 4° C.;
(19) gently resuspend and culture in humidified atmosphere at 37° C. with 5% CO 2 ;
Day 4
(15) repeat steps 8-10
Day 5
(16) repeat steps 8-10
Day 6
(24) repeat steps 8-14
(25) after 12 h repeat steps 8-10
Day 7
(26) repeat steps 8-10
(27) after 12 h repeat steps 8-10
Day 8
(28) repeat steps 8-10
(29) after 12 h repeat steps 8-10
Day 9
(30) harvest T-cell population and formulate for infusion
Results This method results in a population of T-cells with enhanced proliferation and production of IFN-gamma and TNF-alpha compared to cells activated with CD3/CD28-coated immunomagnetic beads alone, as well as enhanced expression of CD40L. N=6
Fold
IFN-gamma
TNF-alpha
CD40L
Method
Expansion
ng/ml
ng/ml
%
Example #2
630 +/− 77
90 +/− 16.7
8.8 +/− 1.3
78.5 +/− 10
3/28-beads +
80 +/− 20
3 +/− 2.2
0.5 +/− .2
15 +/− 6
IL-2
Example #3
Set-up (Day 0)
(7) collection of leukocytes by leukapheresis;
(8) purification of 10 8 CD4+ T-cells by positive selection;
(9) labeling of purified CD4+ cells with anti-CD3, anti-CD28 and anti-HVEM mAbs;
(4) mixing the labeled cells with coated microspheres in gas permeable bags (3:1 sphere:cell);
(5) suspension of the mixture at a cell density of 1×106/ml in 100 ml;
(6) centrifugation of the mixture at 500×g for 8 min at 4° C.;
(7) gently resuspend and culture in humidified atmosphere at 37° C. with 5% CO 2 ;
Day 3
(8) remove 80 ml of culture media by syringe aspiration using a 0.45 micron filter so as not to remove any cells;
(9) pass 70 ml of the removed media through a dialysis filter of 6,000 dalton cut-off size;
(20) add 70 ml of fresh culture media to the retained 10 ml and add back to the culture bag;
(21) add 100 μg each of anti-CD3, anti-CD28, anti-CD27 and anti-4-1BB mAbs to the culture bag;
(22) mix coated microspheres at a sphere:cell ratio of 1:1;
(23) centrifuge mixture at 500×g for 8 min at 4° C.;
(24) gently resuspend and culture in humidified atmosphere at 37° C. with 5% CO 2 ;
Day 4
(15) repeat steps 8-10
Day 5
(16) repeat steps 8-10
Day 6
(31) repeat steps 8-14
(32) after 12 h repeat steps 8-10
Day 7
(33) repeat steps 8-10
(34) after 12 h repeat steps 8-10
Day 8
(35) repeat steps 8-10
(36) after 12 h repeat steps 8-10
Day 9
(37) repeat steps 8-10;
(38) after 12 h repeat steps 8-10;
(39) add 100 μg each of anti-CD3, anti-CD28, and HVEM-Fc to the culture bag;
(40) mix coated microspheres at a sphere:cell ratio of 1:1;
(41) centrifuge mixture at 500×g for 8 min at 4° C.;
(42) gently resuspend and culture in humidified atmosphere at 37° C. with 5% CO 2 ;
Day 10
(43) repeat steps 8-10;
(44) after 12 h repeat steps 8-10;
Day 11
(45) harvest T-cell population and formulate for infusion.
Results
This method results in a population of T-cells with enhanced proliferation and production of IFN-gamma LIGHT and FasL compared to cells activated with CD3/CD28-coated immunomagnetic beads alone. N=6
Fold
IFN-gamma
FasL
Method
Expansion
ng/ml
LIGHT (%)
%
Example
290 +/− 21
44 +/− 6.2
38.4 +/− 3.3
61.4 +/− 10
#3
3/28-
80 +/− 20
3 +/− 2.2
6.1 +/− 5
4 +/− 1.3
beads +
IL-2
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.
CITED REFERENCES
Bachmann, M. F., K. McKall-Faienza, et al. (1997). “Distinct roles for LFA-1 and CD28 during activation of naive T cells: adhesion versus costimulation.” Immunity 7(4): 549-57.
Chambers, C. A. and J. P. Allison (1999). “Costimulatory regulation of T cell function.” Curr Opin Cell Biol 11(2): 203-10.
Deeths, M. J., R. M. Kedl, et al. (1999). “CD8+ T cells become nonresponsive (anergic) following activation in the presence of costimulation.” J Immunol 163(1): 102-10.
Garlie, N. K., A. V. LeFever, et al. (1999). “T cells coactivated with immobilized anti-CD3 and anti-CD28 as potential immunotherapy for cancer.” J Immunother 22(4): 336-45.
Grakoui, A., S. K. Bromley, et al. (1999). “The immunological synapse: a molecular machine controlling T cell activation.” Science 285(5425): 221-7.
Janes, P. W., S. C. Ley, et al. (1999). “Aggregation of lipid rafts accompanies signaling via the T cell antigen receptor.” J Cell Biol 147(2): 447-61.
Laux, I., A. Khoshnan, et al. (2000). “Response differences between human CD4(+) and CD8(+) T-cells during CD28 costimulation: implications for immune cell-based therapies and studies related to the expansion of double-positive T-cells during aging.” Clin Immunol 96(3): 187-97.
Levine, B. L., W. B. Bernstein, et al. (1997). “Effects of CD28 costimulation on long-term proliferation of CD4+ T cells in the absence of exogenous feeder cells.” J Immunol 159(12): 5921-30.
Maus, M. V., A. K. Thomas, et al. (2002). “Ex vivo expansion of polyclonal and antigen-specific cytotoxic T lymphocytes by artificial APCs expressing ligands for the T-cell receptor, CD28 and 4-1BB.” Nat Biotechnol 20(2): 143-8.
Moran, M. and M. C. Miceli (1998). “Engagement of GPI-linked CD48 contributes to TCR signals and cytoskeletal reorganization: a role for lipid rafts in T cell activation.” Immunity 9(6): 787-96.
Shibuya, T. Y., W. Z. Wei, et al. (2000). “Anti-CD3/anti-CD28 bead stimulation overcomes CD3 unresponsiveness in patients with head and neck squamous cell carcinoma.” Arch Otolaryngol Head Neck Surg 126(4): 473-9.
Thomas, A. K., M. V. Maus, et al. (2002). “A cell-based artificial antigen-presenting cell coated with anti-CD3 and CD28 antibodies enables rapid expansion and long-term growth of CD4 T lymphocytes.” Clin Immunol 105(3): 259-72.
Yashiro-Ohtani, Y., X. Y. Zhou, et al. (2000). “Non-CD28 costimulatory molecules present in T cell rafts induce T cell costimulation by enhancing the association of TCR with rafts.” J Immunol 164(3): 1251-9.
|
T-cells are generated with enhanced immunostimulatory capabilities for use in self therapy treatment protocols, by utilizing a biodegradable device with a biodegradable support that has one or more agents that are reactive to T-cell surface moieties. The biodegradable devices are mixed with the T-cells sufficiently so that the one or more agents cross-link with the T-cells' surface moieties and deliver a signal to the T-cells to enhance immunostimulatory capabilities.
| 2
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of the co-pending application of the same inventors, filed Aug. 30, 1985, under Ser. No. 771,276, and titled "Method and Apparatus for Cleaning Tower Basins", now U.S. Pat. No. 4,683,067, issued July 28, 1987.
INFORMATION DISCLOSURE STATEMENT
In refrigeration and other cooling equipment, it is common to utilize a cooling tower, wherein water is used as a heat exchange fluid to circulate through the cooling equipment, then to convey the heat to the cooling tower where heat is removed. In these cooling towers, there is conventionally a basin from which water is removed to flow to the cooling equipment, the water coming from the cooling equipment and being sprayed into the top of the cooling tower. Atmospheric air normally passes through the cooling tower, either naturally or forced by fans, to cool the water as the water passes through the tower.
It will be understood that, in the conventional cooling tower, various sediments build up in the basin. These sediments of course include contaminants that naturally occur in the cooling water, and also include contaminants picked up in the cooling system, and in the pipes connecting the cooling tower with the cooling system. Additionally, it will be understood that contaminants from the tower itself tend to collect in the water.
An additional source of contaminants that appears to be overlooked by many of the cleaning systems is the atmosphere itself. Since a cooling tower is normally situated in the open air, and generally on the top of a building, it will be recognized that sand and other air-borne materials will pass into the tower, and be carried into the tower basin. In an urban area, which is of course the area of greatest usage of cooling towers, the air tends to be rather highly contaminated so there is normally a relatively rapid buildup of sediment in the tower basin. Especially when there is construction in the vicinity, it will be recognized that there will be a very large amount of dust that may include sand, clay and soot, and various petroleum products and the like that will tend to bind these contaminants together.
The result of the above discussed contaminants is that the basin of a cooling tower will accumulate a large quantity of sludge in a relatively short time.
There have been some efforts at providing a cleaning system for cooling tower basins, but these have included such systems as shown in U.S. Pat. No. 4,362,628 to Kennedy et al. wherein a conventional pump is used to remove material from a tower basin, water being filtered and returned to the tower basin. Obviously, such a system could not handle the heavy and abrasive sludge that is actually found in a tower basin. U.S. Pat. Nos. 4,389,351 and 4,427,553 disclose perforated headers disposed within the tower basin, the object being simply to pump the material from the tower basin, with periodic backflush flow. Makeup water is added which both renews the water level and dilutes the remaining tower water. Again, these systems could not handle the sludge actually found in tower basins.
One of the conventional means for maintaining a cooling tower is referred to as a "bleed". This comprises means for sensing highly contaminated water, and means for draining a portion of the basin water. The conventional makeup water valve will then replace the drained water. It will therefore be understood that the highly contaminated water is diluted with fresh water, thereby reducing the total concentration of contaminants. Clearly, this system will not remove the sludge from the bottom of the tower, basin.
The prior art means for truly cleaning the tower basin has involved shutting down the tower and draining the basin, and followed by the arduous task of manually shovelling the material from the tower basin. Such a procedure has numerous disavantages, including the fact that the entire cooling system must be shut down. Also, it will be understood that the tower basin is normally coated with an anti-corrosive material, and the scraping of shovels on the basin tends to scratch or remove the anti-corrosive coating. Also, in many instances it is virtually impossible to shut down the cooling system since it may be used for such critical things as medical facilities, computer facilities and the like.
It will be understood that a few tower basins may be so situated that the sludge and debris needs to be elevated for removal from the basin. Since a siphon typically requires that the net motion be down, the usual siphon, and the apparatus disclosed in the above identified co-pending application, would be unuseable for such towers.
SUMMARY OF THE INVENTION
This invention relates generally to a method and apparatus for cleaning cooling tower basins and the like, and is more particularly concerned with a highly efficient cleaning system, using a siphon for conveyance of the refuse, and which is further useable below grade.
The present invention provides a method for removing the sludge from the bottom of a tower basin wherein water flow is established, and suction is applied to the bottom of the basin to remove the sludge therefrom. The material removed is strained to allow the water to be passed into the conventional sewer system, while damaging sludge is retained in a filter means.
In one embodiment of the invention, a siphon action is established, and the siphon action is passed through a cleaning tool having a cleaning head disposed below the basin water level. Sludge from the basin is passed through the cleaning tool, into the siphon, and the sludge is collected in a filter means while water passes therethrough to be disposed of in conventional manner. It is contemplated that the present invention may be embodied in a single, portable tool for use with various cooling towers, or may be embodied in a permanent installation for cleaning a single tower, or a gang of towers.
In one embodiment of the invention, receiving means is provided, with pump means for removing refuse from the receiving means. The siphon supplies the receiving means; and, in this embodiment, the basin to be cleaned may be below grade from the discharge of the siphon.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will become apparent from consideration of the following specification when taken in conjunction with the accompanying drawings in which:
FIG. 1 is a somewhat schematic illustration showing a tower cleaning apparatus made in accordance with the present invention;
FIG. 2 is a schematic illustration showing a permanent installation for practicing the present invention;
FIG. 3 is a side elevational view showing apparatus made in accordance with the present invention in conjunction with a tower to be cleaned;
FIG. 4 is a view similar to FIG. 3 but showing a modified form of the invention for use when the tower basin is below grade;
FIG. 5 is an enlarged cross-sectional view showing one form of receiver for use in the arrangement of FIG. 4;
FIG. 6 is a view similar to FIG. 5 but showing another form of receiver; and,
FIGS. 7 and 8 are illustrations of two nozzles for use with the cleaning apparatus of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Referring now more particularly to the drawings and to those embodiments of the invention here chosen by way of illustration, FIG. 1 shows the general system embodying the present invention. It will be recognized that FIG. 1 is substantially the same as FIG. 1 in the above identified co-pending application. The earlier filed co-pending application sets forth the structure and operation in detail, and the disclosure in that application is incorporated herein by reference. The details will therefore not be repeated except as needed for an understanding of the present additions and modifications.
FIG. 1 generally discloses a cooling tower 10 having a basin with sludge and the like 11 below the water line within the basin. The cleaning apparatus of the present invention is generally designated at 12 and includes a vertical pipe 14 extending down from a manifold 15. The manifold 15 has connected thereto a hose 16 which is connected through a valve 18 to the cleaning tool 19.
The lower end of the vertical pipe 14 is formed into a trap 20, the trap 20 then leading through a valve 21 to a filter 22.
It has been found that the sludge in cooling towers may harbor disease-causing organisms. Because of this fact, a person intimately contacting the refuse may be in danger of contracting such disease. It will be understood that the basin 10 conventionally contains a sufficient quantity of a biocide that the water itself cannot harbor such organisms; however, the sludge in the tower basin is sufficiently cohesive that the biocide-containing water cannot treat the sludge. Further, because of the efficient technique of the present invention in removing the sludge, the sludge may not be adequately contacted by water even during removal to remove the hazard of the dangerous organisms.
With the above in mind, the present invention may optionally include biocide injecting means generally designated at 24. The injection means comprises a tank or other source of a biocide designated at 25. The material is removed from the tank 25 by a pump 26, the pump 26 being preferably a metering pump. The pump 26 delivers material through a check valve 28 to a point in the system just before the filter 22.
While any readily available biocide may be utilized with the present system, it will be understood that ordinary bleach, sodium hypochlorite, is very effective since it is a source of free chlorine. Also, the biocide can be injected just before the filter 22, and the turbulence through the filter screens and the filter bag will sufficiently mix the biocide with the sludge and other material to provide adequate treatment of all the material. The waste water and the collected sludge will then be reasonably safe for handling and disposal.
It will be remembered that, in operation of the system of the present invention, one may wish to close the valve 18 and temporarily remove the cleaning tool 19 from below the water. Since the system utilizes a siphon action, entry of air into the system can break the siphon and require the start-up procedure again. In the earlier filed copending application it was mentioned that the valve 18 can be closed, and the wet filter bag will collapse and act as a flap valve. It has further been discovered that the trap 20 is a very simple and effective means for preventing entry of air into the system, and use of the trap 20 does not require any additional manual operation.
While a specific rigid member or the like may be used to form the trap 20, it will also be seen that the flexible hose forming the vertical pipe 14 can be allowed to drape into the form of a trap so that no additional pieces are required.
Looking next at FIG. 2 of the drawings, it will be noted that a plurality of cooling towers 10a and 10b is shown, each tower having a valve 30 adjacent thereto, the valves 30 being equivalent to the valve 18 in the system of FIG. 1. A vertical pipe 31, then, leads down to a pipe 32. The pipe 32 contains a valve 34 which is equivalent to the valve 21 in FIG. 1. From the valve 34, a pipe 35 leads into a trap 36, then to a filter 38. If the biocide injection is to be used in the embodiment of FIG. 2, it would preferably be connected just before the filter 38.
The operation of the embodiment of FIG. 2 is the same as was discussed in the earlier, copending application, except for the trap 36. The only difference is therefore that the trap 36 will provide a reasonably sure means to prevent entry of air into the system when all the valves 30 are closed with consequent temporary cessation of the siphon action. It is believed that the system will be easily understood without further discussion.
Looking next at FIG. 3 of the drawings, it will be noted that this is substantially the same system as is shown in FIG. 1 of the drawings, and the parts carry the same reference numerals. In this figure it will be noted that the filtering apparatus generally designated at 22 is within a container 40, the container 40 being provided with wheels 41 and 42. This structure, fully described in the parent application, places the connection for the pipe 14 above the level 44 on which the apparatus rests. Because of this arrangement, the flexible hose comprising the pipe 14 can bend down, then up, to form the trap 20.
Once again, the operation will be well understood from the foregoing brief statement in conjunction with the disclosure in the parent application, the trap 20 being the only difference.
Attention is next directed to FIG. 4 of the drawings which discloses another embodiment of the present invention. The important difference in the embodiment of FIG. 4 is that the apparatus can operate below grade, contrary to the usual operation of a siphon.
In FIG. 4, the cooling tower is generally designated at 50, and the tower has a basin 51 here shown as resting on a level surface 52. It sometimes happens that the apparatus of the present invention cannot be placed on the same level 52, or slightly below as is usual. The result is that the siphon action that is required for the operation must pick up on the lower level 52 and discharge at a higher level such as the level 54.
The apparatus shown in FIG. 4 includes the cleaning tool 55 with a valve 56 at the tool 55. The valve 56 connects to a flexible hose 58 which extends upwardly to connect to the manifold 59. From the manifold 59, a larger hose 60 extends down. Thus, the hose 58, manifold 59 and larger hose 60 make up the siphon previously described and used in the present invention. It should be noted, however, that the embodiment of the invention shown in FIG. 4 may use only the hose itself rather than the separate container as the manifold 59.
The hose 60 discharges into a receiver 61, and a connecting hose 62 leads from the receiver 61, through a trap 64, to the filter apparatus 65.
Within the receiver 61, there is mounted a pump which will be discussed below. Those skilled in the art will understand that most pumps are unable to move the sludge with its contained debris. To be able to move the material with a high content of solids, a sewage pump or a trash pump may be utilized. Both are centrifugal pumps having very open vanes, typically only two vanes, in order to be able to handle the maximum amount of solids.
The discharge from the receiver is connected directly to the connector pipe 62; and, both the pipe 60 and the pipe 62 are sealed with respect to the receiver 61 so that the interior of the receiver 61 is hermetically sealed.
With the above description in mind, the operation should be understandable. The beginning of the operation is the same as with other embodiments of the invention in that water is admitted into the system to fill the down-side of the siphon. In the system of FIG. 4, one will fill the pipe 60, and the manifold 59 if used. With the nozzle of the cleaning tool 55 under the water in the basin 51, water will be allowed to flow from the pipe 60 and the pump will be operated. Material will therefore move from the tower basin, up the hose 58, and down the hose 60, and be deposited into the receiver 61. With the pump in operation, the material will be urged through the connector pipe 62 and into the filter housing 65.
The system shown in FIG. 4 of the drawings can be operated with at least two different arrangements for the receiver 61. One version is shown in FIG. 5 of the drawings, and an alternate version is shown in FIG. 6.
The less expensive embodiment of the invention is that shown in FIG. 5, and this version is preferable for that reason. It will be seen that a sewage pump 66 is mounted within the receiver 61, the pump 66 being supported a short distance above the bottom of the receiver 61. The inlet hose 60 extends into the receiver 61 just sufficiently to allow the material to flow from the hose 60 into the receiver 61. The connector hose 62, then, is connected directly to the discharge of the pump 66 for removing materials from the receiver 61.
Those skilled in the art will realize that a sewage pump is typically low power, perhaps around one-half horsepower, or less than 400 watts. The sewage pump is not capable of suction-lift of material, but simply pushes material from the discharge. As a result it will be seen that the sludge is fed to the pump 66 by gravity, and the pump 66 then urges the sludge out of the receiver through the connector hose 62.
Though a sewage pump is not designed to lift material through suction, it will be obvious that there is some small amount of suction at the intake side of the pump. This small amount of suction will be reflected through the pipe 60 and will effectively increase the siphon action. It is therefore the combination of the siphon that has previously been discussed, and the additional lowering of the pressure by the pump 66, that allows the siphon of the present invention to operate below grade.
It will be understood that the sewage pump 66 can handle a large quantity of solids because of its open vane construction. Nevertheless, very large and heavy objects such as large rocks, large pieces of metal and the like will cause some damage to the pump. Further, the pump can be clogged by, for example, large sheets of material such as plastic sheeting frequently used in contruction. To prevent all these problems, the pump 66 is supported somewhat above the bottom of the receiver 61, thereby providing a settling action. Very heavy objects, once on the bottom, will not rise and go into the pump 66.
In combination with the settling area, the pump 66 is enclosed by a wire mesh surround 68. Since the pump 66 is designed to handle solids, and will pump the majority of debris found in cooling tower basins, the mesh should be quite large, to exclude only exceptionally large debris and to exclude sheet material. A mesh of 11/4 inches has been used successfully, though other mesh sizes may be used.
Turning now to FIG. 6 of the drawings it will be seen that the receiver 61 has the pipe 60 entering the receiver 61, and extending nearly to the bottom. The exit 62 from the receiver is just at the top, requiring that the receiver be filled to sustain flow.
The mesh surround within the receiver 61, in this embodiment, is arranged to receive material immediately from the pipe 60. Again the mesh surround 69 is an open mesh to stop only exceptionally large solids and sheet material.
The connector pipe 62 leads to the intake side of a pump known as a "trash pump". This pump is capable of considerable suction lift, though it is still an open vane, centrifugal pump. Again, the bottom of the receiver 61 acts as a settling area, and the mesh surround 69 receives sheet material and the like to protect the pump 70 from damage or clogging.
While the trash pump 70 is capable of suction lift, even of relatively heavy material, it will be understood that the present invention still utilizes the siphon as previously described for the primary material moving force. The trash pump 70 pumps well when fed with liquid, but would require a lot of time and energy to bring the material initially to the pump. Thus, the siphon comprising hoses 58 and 60, and the manifold 59 when used, is primed as previously described. Operation of the pump 70 will of course lower the pressure within the receiver 61, hence in the pipe 60, to continue, and to enhance, operation of the siphon allowing the siphon to lift material from below grade.
Turning next to FIGS. 7 and 8 of the drawings, two specific nozzles for use with the present invention are shown. The feature common to both nozzles is that inlets are provided on all sides of the nozzles. It will be obvious from the above description that the nozzle must be moved through the sludge in the tower basin. Such motion will necessarily cause some agitation and tend to suspend some particles in the water. The preferred nozzle has suction in all directions to take in adjacent water with the contaminants.
FIG. 7 is a cross-sectional view of a nozzle of the type that may be used in the open floor of a basin. It will be seen that the body 75 has a connection 76 for the cleaning tool 19, and a transverse slit 78 will take in the bulk of the sludge from the bottom of the basin.
As the nozzle moves through the sludge, suction will be provided at the front by at least one hole 79 and at the rear by at least one hole 80. Similarly, the sides are provided with holes such as the hole 81 and the top has at least one hole 82. Realizing that rather high suction is being applied to the body 75, it will be understood that contaminants in the area of the nozzle will be pulled into the nozzle.
FIG. 8 illustrates a nozzle 85 which is tubular, the cleaning tool 19 being connected at the end 86, here shown as broken away. The nozzle shown in FIG. 8 is sufficiently elongated that it can reach into interstices and other generally inaccessible places in a tower basin. The open end 88 of the nozzle 85 will primarily receive the sludge to be removed while the plurality of holes 89 generally cover the nozzle 85 to provide suction in all directions. Operation is then substantially the same as the nozzle shown in FIG. 7, and no further description is thought to be necessary.
From the foregoing description it will be understood that the present invention provides an improved tower basin cleaning system. When, during a cleaning operation, the nozzle of the cleaning tool 19 needs to be removed from the water, the operator can simply close the valve 18 and lift the tool from the water. The trap 20 will contain a quantity of liquid to prevent the passage of air into the system so that, when the valve 18 is opened, the siphon action will immediately resume.
When it is felt that the sludge in the tower basin may be contaminated, or any time the operator prefers the additional safety margin, the biocide injector 24 can be used to kill harmful organisms.
The nozzles having a plurality of secondary inlets provide good removal of the sludge, which is the primary problem, and further remove water having contaminants temporarily entrained therein. Thus, the nozzles herein disclosed provide improved cleaning of the system.
Finally, though the majority of tower basins are above grade so that a simple siphon action can be used to operate the system, a few tower basins are either literally below ground level, or are so situated that the discharge end of the pipe 14 cannot be placed lower than the intake end of the tool 19. For these tower basins, the receiver 61 can be used. Operation of the open vane pump 66 or 70 creates enough suction that, in conjunction with the siphon of the present invention, the sludge can actually be elevated and discharged on a higher level.
It will of course be realized by those skilled in the art that the particular embodiments of the invention here presented are by way of illustration only, and are meant to be in no way restrictive; therefore, numerous changes and modifications may be made, and the full use of equivalents resorted to, without departing from the spirit or scope of the invention as outlined in the appended claims.
|
A method and apparatus for cleaning cooling tower basins. The apparatus includes a cleaning tool carrying a nozzle for picking up sludge within the basin, and a siphon for providing continuous suction on the cleaning tool. The pipe making up the siphon is formed into a trap to prevent entry of air into the system on temporary cessation of siphon action. The down side of the siphon may empty into a receiving tank; and, a pump can remove material from the receiving tank and lower the pressure to enhance operation of the siphon. With such enhancement, the siphon can lift material from a basin and discharge the material on a level above the level of the water in the basin. The nozzle has openings in all faces to suck in adjacent water and pick up contaminants suspended in the water adjacent to the nozzle.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based on and claims priority to U.S. Provisional Application No. 611469204, filed Mar. 30, 2011, herein incorporated by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] This invention was made in part with Government support. The Government may have certain rights in this invention.
FIELD OF THE INVENTION
[0003] This invention pertains to copoly(imide oxetane)s having low adhesion surface properties and to oligomers useful to make such copoly(imide oxetane)s. The oxetane oligomers contain fluorocarbon moieties that enable the copoly(imide oxetane)s to achieve the low adhesion surface properties with relatively low oxetane content. The invention also pertains to processes for making the copoly(imide oxetane)s and anisotropic coatings and articles of manufacture from them.
BACKGROUND OF THE INVENTION
[0004] Marine biofouling, membrane fouling, insect adhesion on aircraft surfaces, microbial contamination of sterile environments, and surface particle contamination all present unique challenges. An array of mitigations strategies has been pursued to address these problems.
[0005] Passive strategies for minimizing fouling or contamination of surfaces are beneficial especially in environments where active mitigation of the fouling or contamination is impractical or impossible. For instance, lunar dust compromised seals, clogged filters, abraded visors and space suit surfaces, and was a significant health concern during the Apollo missions. Accordingly, passive mitigation utilizing materials with an intrinsic resistance to surface contamination would be advantageous for such applications. One passive mitigation strategy is modification of a material's surface energy either chemically or topographically or both.
[0006] Any surface material needs to meet the requirements of its application. High performance polymeric materials have been developed to address various requirements for mechanical, thermal, and optical properties. Modification of the chemical constituency of these polymeric materials can alter their properties. Thus, modification of high performance polymeric materials is often hampered due to degradation of the desired characteristic properties. Modifying a polymeric material to influence surface characteristics is problematic as addition of sufficient modifier to the bulk chemical composition to achieve the desired surface modification could also result in the diminution of other important performance properties of the polymeric material. If the modifier is well dispersed within the polymer matrix, a majority of the modifier will be located in the interior of the polymeric structure where it will not contribute to the structure's surface properties. This is especially problematic if the modifier is expensive, provides no other performance enhancement or diminishes bulk properties of the polymeric material.
[0007] Polymeric materials with low adhesion surface properties have been demonstrated to be effective in a wide variety of applications. Low surface energy polymeric materials, i.e., those exhibiting a high water contact angle, have been used to reduce marine biofouling, water and ice adhesion, and biofilm formation: to improve oxidation, corrosion and stain resistance; to minimize dust adhesion; and to modify the performance of microfluidic systems and biomedical devices. The ability to selectively modify the surface energy of high performance polymeric materials without sacrificing their superior mechanical, thermal and optical properties is of significant utility.
[0008] A number of approaches have been suggested to yield polymeric materials with low surface energy. One of the most well known polymeric materials having low surface energy are fluorinated, aliphatic polymers such as those available under the trade name TEFLON® fluoropolymers. The presence of both aliphatic carbon species and fluorine atoms contributes to the low surface energy of this class of materials. These polymeric materials have an approximate homogeneous composition, do not use a controlled modification, and thus cannot be tailored for the introduction of further surface features. Moreover, they do not adhere well to substrates and are difficult to process. Generally the polymer is provided as a powder to be coated and sintered onto the substrate. Another approach is to vapor deposit highly fluorinated carbonaceous materials to various substrates.
[0009] Another approach to provide low surface energy polymeric materials is to incorporate surface modifying agents into the materials. These surface modifying agents are thermodynamically driven to migrate to the surface of the polymeric material preferentially due to more favorable interactions at the air interface compared to the polymeric matrix.
[0010] Omnova Solutions Inc. offers a family of hydroxyl terminated oxetane-derived oligomers under the trade name POLYFOX® fluorochemicals and have found commercial application in polymeric systems. Fluorine-containing oxetane derivatives have been used extensively as surface modification agents for modification of urethanes. See, for instance, Malik, et al.. United States patent application publication No. US 2004/0087759. Medsker, in U.S. Pat. No. 7,022,801 and Thomas, et al., in United States patent application publication No. 2003/0092862, disclose the use of fluoro-containing oxetane polymers to impart wetting, flow or leveling properties to a variety of coatings while producing little foam.
[0011] Wynne, U.S. Pat. No. 7,396,590 and Wynne, et al., in U.S. Pat. No. 7,771,793 disclose making polymeric articles or coatings that have a surface phase having an activity of interest. They disclose preparing a surface active telechelic that includes both a surface active segmer which favors migration to the surface of a bulk polymer and one or more functional segmers which provide an activity of interest (e.g., biocide, bioactive, UV protective, hydrophobic, hydrophylie, etc.). The telechelics disclosed include those made using fluorine-containing oxetanes.
[0012] Weinert, et al, in U.S. Pat. No. 6,972.317 disclose monofunctional polyfluorooxetane oligomers and polymers that can be reacted with cyclic ethers or functionalized with a functional end group such as an acrylate, a methacrylate, an allylic, an amine, etc., for use in radiation curable or thermal curable coating compositions. They believe that the fluorinated side groups of the fluorooxetanes are disproportionately present at the interfaces between the coating and substrate and between the coating and the atmosphere.
[0013] Polyimides are known for their thermal stability, fire resistance, good chemical resistance and excellent mechanical properties. Polyimides have good mechanical elongation and tensile strength and good adherence properties to many substrates. Some polyimides exhibit high optical clarity. Polyimides have found application as coatings, insulating films in the electronic industry, fibers and articles of manufacture including for demanding applications such as bushings, bearings in jet engines, or other constructive parts.
[0014] Accordingly, a need exists for a low surface energy polymeric material that has the mechanical, thermal, chemical and optical properties associated with polyimides.
SUMMARY
[0015] In accordance with this invention copoly(imide oxetane) materials are provided that can possess the mechanical, thermal, chemical and optical properties associated with polyimides and exhibit a low energy surface. By this invention, copoly(imide oxetane)s are prepared using a minor amount of an amino terminated fluorinated oxetane-derived oligomer. Sufficient fluorine-containing segments of the copoly(imide oxetane)s migrate to the exterior surface of the polymeric material to afford low surface energies. In preferred copoly(imide oxetane) coatings and articles of manufacture, the surface is saturated with fluoro-groups even at very low, e.g., below about 0.5 mass percent oxetane oligomer in the copoly(imide oxetane). Although greater amounts of oxetane oligomer could be used, often virtually no further improvement in surface hydrophobicity is observed. Hence it is possible with the copoly(imide oxetane)s of this invention to tailor the surface properties while still maintaining the physical properties of the polyimide. The copoly(imide oxetane)s of this invention can enhance the viability of polyimides for many applications and may be acceptable where homopolyimide materials have been unacceptable.
[0016] In the way of an overview, the copoly(imide oxetane)s of this invention are characterized as containing divalent radicals of an oligomer derived from a fluorine-containing oxetane, preferably oxetanes containing a perfluorinated carbon on a substituent on the beta carbon of the oxetane. The oxetane oligomer content of the copolymer is often less than about 10 or 15, preferably less than about I, mass percent of the copolymer. In some preferred aspects, the oxetane oligomer content of the copolymer is between 0.001 and 0.1, mass percent of the copolymer. Often the water contact angle is greater than about 85°, preferably greater than about 90°. If desired, concentrations higher than 15 mass percent oxetane oligomer may be used to make the copoly(imide oxetane). Although at these high levels of oxetane content physical properties of the copolymer such as glass transition temperature, tensile strength and abrasion resistance will be inferior to the corresponding polyimide; however, the copoly(amic acid oxetane) and copoly(imide oxetane) will have low surface energy and in some instances, the copolymer may be soluble in polar organic solvents such as N,N-dimethylacetamide, acetone, and tetrahydrofuran or combinations thereof.
[0017] One aspect of the invention pertains to oligomers represented by the formula:
[0000] (E) y R 1 —C(O)—O-J-C(O)—R 1 (E) y
[0000] wherein:
J is [CH 2 —CR 2 R 3 —CH 2 O] m or [(CH 2 —CR 2 R 3 —CH 2 —O) p —(R 6 —O) q —(CH 2 —CR 2 R 3 —CH 2 —O) r ] wherein R 6 is a substituted or unsubstituted aliphatic or aromatic moiety of 2 to 16 carbons, preferably CR 7 CH 2 — wherein R 7 is H or methyl; E is —NO 2 or —NH 2 , and preferably each E is either —NO 2 or —NH 2 ; y is 1 or 2, and preferably each y is 1: R 1 is an aliphatic or aromatic hydrocarbon moiety of 1 to 10 carbon atoms, preferably R 1 is a divalent phenyl group; R 2 is —H, —F, or alkyl of 1 to 6 carbon atoms, and preferably is an alkyl of 1 to 3 carbon atoms, and most often methyl; R 3 is —F, —R 4 H (n−a) F a , —R 5 —O—R 4 H (n−a) F a , or —O—R 4 H (n−a) F a , wherein R 4 is an alkyl or ether moiety of 1 to 30 carbons, R 5 is an alkyl moiety of 1 to 30 carbons, a is an integer of 3 to n, and n is twice the number of carbon atoms in the alkyl moiety plus 1; and m is between about 4 and 500, preferably between about 6 and 100, p is between about 4 and 150, q is between about 1 and 150, preferably between about 4 and 150.
Preferably the omega carbon of R 4 has three fluoride substituents. Preferably, R 5 is —CH 2 —O—C(R′) 2 —CF 3 , wherein R′ is —H or —F.
[0025] Preferred oligomers of this invention are represented by the formula:
[0000] (E) y R 1 —C(O)—O-Q p -(R 6 ) q -C(O)—R 1 (E) y
[0000] wherein:
E, y, R 6 , p, q, r and R 1 are as defined above; and Q is derived from the oligomerization of oxetane monomer wherein at least 40 mole percent of the oxetane monomer is substituted at the beta carbon with at least one substituent containing at least one perfluorinated carbon atom.
[0029] The substituted oxetane monomer from which Q is derived can be represented by the formula:
[0000]
[0000] wherein:
R 3 is —F, —R 4 H (n−a) F a , —R 5 —O—R 4 H (n−a) F a , and —O—R 4 H (n−a) F a , wherein R 4 is an alkyl or ether moiety of 1 to 30 carbons, and preferably is an alkyl of 1 to 3 carbon atoms, and most often methyl, R 5 is an alkyl moiety of 1 to 30 carbons, a is an integer of 3 to n, and n is twice the number of carbon atoms in the alkyl moiety plus 1.
[0031] Another aspect of this invention pertains to polyamic acids that can be imidized to make copoly(irnide oxetane)s having the structure represented by:
[0000] -(G-A)-(D-A)-
[0000] wherein:
G is represented by the formula
[0000] —NH—R—C(O)—O-J-C(O)—R 1 —HN—
wherein:
R 1 and J are as defined above;
A is represented by the formula
[0000]
wherein:
L is a hydrocarbyl-containing moiety of 2 to 100 carbon atoms optionally containing divalent radicals selected from the group consisting of oxygen, silyl, sulfur, carbonyl, sulfonyl, phosphonyl, perfluoro, tertiary amino, and imido;
D is represented by the formula
[0000] —NH-Z-NH—
wherein:
Z is a hydrocarbyl-containing moiety of 1 to 100 carbon atoms optionally containing divalent radicals selected from the group consisting of oxygen, sulfur, silyl, carbonyl, sulfonyl, phosphonyl, perfluoro, tertiary amino, and imido.
[0041] Another aspect of this invention pertains to copoly(imide oxetane)s containing the oxetane oligomers of this invention. The copoly(imide oxetane)s are prepared by using the oxetane oligomers of this invention wherein E is —NH 2 , and generally the copoly(imide oxetane) contains less than about 10, say, 0.001 to 5, preferably, 0.001 to 0,1, mass percent of the oxetane oligomer. The copoly(imide oxetane)s of this invention can be represented by the structure:
[0000] -(G-M)-(D-M)-
[0000] wherein:
G is represented by the formula
[0000] ═N—R 1 —C(O)—O-J-C(O)—R 1 —N═
wherein:
R 1 , and J are as defined above;
M is represented by the formula
[0000] (—C(O)) 2 -L-(C(O)—) 2
wherein:
L is as defined above;
D is represented by the formula
[0000] ═N—Z—N═
wherein:
Z is defined as above.
The copoly(imide oxetane) may be a block co-polymer or a random co-polymer.
[0051] A yet further aspect of this invention pertains to coatings having an outer surface and a bonding surface that comprise the copoly(imide oxetane)s of this invention. The coatings are characterized as having an anisotropic distribution of fluorine atoms over its thickness with a higher concentration at the outer surface. Preferred coatings have a water contact angle of at least 90° at the outer surface. The coating may be on any suitable surface including metal, ceramic, glass, wood, paper, fibers, textiles, membranes, or polymer surfaces. The coatings can be prepared by applying on a substrate a solution containing a copoly(amic acid oxetane) of this invention in a volatile solvent for the copoly(amic acid oxetane) to form a copoly(amic acid oxetane)-containing coating, and then subjecting the copoly(amic acid oxetane)-containing coating to drying and imidization conditions to form the anisotropic copoly(imide oxetane)-containing coating. In some aspects, the copoly(imide oxetane) of this invention may he soluble in a low boiling solvent in an imide form, thus allowing for it to be cast directly on an article and then solvent evaporated to form the coating.
[0052] Another aspect of this invention pertains to articles of manufacture having an outer surface on a polymeric matrix comprising the copoly(imide oxetane) of this invention wherein the article of manufacture has a higher concentration of fluorine atoms at its outer surface than that used to make the polymeric matrix. The article may be made by casting, molding, extruding or other suitable process. For example, the article of manufacture may be made by forming a polymeric matrix containing the copoly(amic acid oxetane) of this invention into the shape of the article of manufacture and subjecting the article of manufacture to imidization conditions to form the article of manufacture. The polymeric matrix may be in a slurry or solvent when formed into the sought shape or may be in the form of a substantially dry particulate, e.g., having a major dimension of between about 20 and 2000 microns. The particulate polymeric matrix may be formed into the sought shape under pressure and subjected to imidization conditions to form the copoly(imide oxetane)-containing article of manufacture.
[0053] An aspect of this invention pertains to making coatings and articles of manufacture by contacting a polyamic acid coating or article of manufacture with a diamine oligomer of this invention or a copoly(amic acid oxetane) of this invention at its exterior surface and then subjecting the coating or article of manufacture to imidization conditions. The polyamie acid coating or article of manufacture need not contain fluorine, yet upon imidization, the fluorine-containing oxetane oligomer or copoly(imide oxetane) becomes integral with the material of the coating or article of manufacture without gross phase segregation.
[0054] An additional aspect of the invention pertains to processes for making copoly(amic acid oxetane)s and copoly(imide oxetane)s comprising:
a. reacting an oxetane oligomer of the formula
[0000] H—O-J-H
wherein J is as defined above, with an acyl reagent of the formula O 2 N—R 1 C(O)X. wherein R 1 is aliphatic or aromatic hydrocarbon moiety of 1 to 10 carbon atoms and X is selected from the group consisting of bromide, chloride and iodide, —H, —OH, and —OR 8 , wherein R 8 is alkyl of 1 to 3 carbon atoms, under nucleophilic reaction conditions, to provide nitro-terminated oligomer; b. hydrogenating the nitro-terminated oligomer under hydrogenation conditions including the presence of hydrogenation catalyst to convert nitro moieties to amine moieties and provide diamine-terminated oligomer; c. reacting the diamine-terminated oligomer with at least one of
(i) dianhydride of the formula
[0000] O(C(O)) 2 -L-(C(O)) 2 O (I)
wherein I, is as defined above; preferably in the presence of one or more diamines of the formula
[0000] —NH-Z-NH— (II)
wherein: Z is as defined above, and (ii) anhydride-terminated prepolymer of (I) and (II) preferably having a weight average molecular weight of between about 1000 and 500,000 g/mol, under condensation polymerization conditions, to provide the polyamic acid; and d. subjecting the polyamic acid to imidization conditions, preferably either a thermal ring closure including a temperature of at least about 120° C., say, between 150° C. to 400° C., to provide the polyimide, or a chemical ring closure in the presence of dehydrating and ring-closing catalyst such as one or more of pyridine, triethylamine, acetic anhydride or the like at a temperature in the range of range of about −20° C. to 200° C.
[0064] A yet further aspect of this invention comprises a polymer composite, which may be in the form of a coating or article of manufacture, said composite comprising copolymer containing fluoro-containing oxetane oligomer and a particulate filler to provide a water contact angle of at least 100°. Examples of copolymers include, but are not limited to, block and random copolymers such as polyester/polyoxetane copolymers such as from ethylene terephthalate, propylene terephthalate, trimethylene terephthalate and butylene terephthalate; acrylic copolymers such as copoly(acrylate oxetane), copoly(methacrylate oxetane); copoly(urethane oxetane); copoly(amide oxetane) such as from butyrolactam, caprolactam, lauryl lactam, and polyamides from the reaction of adipic acid or sebacic acid with a diamine such as hexamethylene diamine; copoly(imide oxetane); copoly(siloxane oxetane); copoly(urea oxetane); copoly(ether oxetane) such as copolymers with polyether ether ketone; copoly(sulfone oxetane); and copoly(sulfide oxetane). The preferred copoly(imide oxetane)s are those of this invention. The particulate fillers may be composed of metal, metal oxides and metal sulfides. Preferably the particulate fillers have a major dimension of less than about 5 microns, more preferably less than about 0.5 micron, and sometimes less than about 0.05 micron. Examples of particulate fillers include, but are not limited to, oxides such as silica, alumina, titania, yttria, zirconia, molybdenum oxide, iron oxide, metals and metal alloys such as gold, silver, copper, germanium, platinum, iron and cobalt/platinum; semiconductors such a lead sulfide, cadmium sulfide, CdSe, CdTe; sulfides such as molybdenum sulfide and cesium sulfide; phosphates such as aluminum phosphate; clays such as montmorillonite, vermiculite, hectorite; carbonates such as calcium carbonate; carbon allotropes such as carbon black or carbon nanotubes, finely ground rubber, and molecular sieves. The amount of filler can vary depending upon particle size and inherent surface energy. In general, the composites contain from about 0.1 to 40, say, 0.5 to 20, mass percent particulate filler based upon the mass of the composite. In preferred aspects of this invention, the composite possesses a water contact angle of at least about 120°.
DETAILED DESCRIPTION
[0065] Definitions and Procedures
[0066] Water contact angle as used herein is the angle that deionized water contacts the surface of the polymer. A PTA 1000B contact angle goniometer available from First Ten Angstroms, Inc., Portsmouth, Va, United States can be used to measure the water contact angle using an 8 microliter drop.
[0067] Polyimides
[0068] Polyimides are typically prepared by the reaction between a diamine and a dianhydride under condensation polymerization conditions although it is possible to prepare polyimides by other reactions such as that of a dianhydride and a diisocyanate or a diester of the dianhydride with a diamine. The copoly(imide oxetane)s of this invention use as all or a portion of the diamine component a diamine which is a derivative of a fluorine-containing oxetane oligomer, herein called a FOX diamine.
[0069] The FOX diamine preferably constitutes a minor portion by mass of the diamine components used in the synthesis, often less than about 20, preferably less than about 10, and most times between about 0.02 to 0.5, mass percent of the total diamine where the properties of the polyimide are sought. Generally, the amount of FOX diamine is sufficient to provide a water contact angle of at least 85°, preferably at least 90°.
[0070] The FOX diamine can be represented by the structure:
[0000] —N—R 1 —C(O)—O-J-C(O)—R 1 —N—
[0000] as discussed above. One or more FOX diamines can be contained in the copoly(imide oxetane)s of this invention.
[0071] The optional diamine may be one or more aliphatic or aromatic diamines and includes diamines containing other hetero atoms. One or more other diamines may he used. Examples of diamines include aliphatic diamines such as trimethylenediamine, tetramethylenediamine, pentamethylenediamine, hexamethylenediamine, 2,2,4-trimethylhexamethylenediamine, 2,4,4-trimethylhexamethylenediamine, octamethylenediamine and nonamethylenediamine; and an alicyclic diamine such as bis(4-aminocyclohexyl)methane and bis(4-amino-3-methylcyclohexyl)methane; aromatic diamines, for example, phenylenediamine, diaminotoluene, 2,4-diaminomesitylene, 3,5-diethyl-2,6-diaminotoluene, xylylenediamine (in particular, metaxylylenediamine, paraxylylenediamine), bis(2-aminoethyl)benzene, biphenylenediamine, a diamine having a biphenyl backbone (e.g., 4,4′-diamino-3,3′-ethylbiphenyl), a diamine having adiphenyl alkane backbone [e.g., diaminodiphenylmethane, bis(4-amino-3-ethylphenyl)methane, bis(4-amino-3-methylphenyl)methane, 3,3′-dichloro-4,4′-diaminodiphenylmethane, 2,2′-bis(4-aminophenyl)propane], bis(4-aminophenyl)ketone, bis(4-aminophenyl)sulfone, or 1,4-naphthalenediamine, and an N-substituted aromatic diamine thereof; alicyclic diamine such as 1,3-cyclopentanediamine, 1,4-cyclohexanediamine, and bis(4-amino-3-methylcyclohexyl)methane; an aliphatic amine, such as trimethylenediamine, tetramethylenediamine, penamethylenediamine, hexamethylenediamine, 2,2,4-trimethylhexamethylenediamine, 2,4,4-trimethylhexamethylenediamine, and octamethylenediamine, and an N-substituted aliphatic diamine thereof; and ether diamines such as poly(alkylene ether)diamines including poly(ethylene ether)diamine, poly(propylene ether)diamine, poly(tetramethylene ether)diamine; random or block copolymers of ethylene oxide and propylene oxide including propylene oxide and poly(propylene oxide) terminated poly(ethylene ether)diamine, 4,4′-oxydianiline; and aminated random or block copolymers of tetrahydrofuran with minor amounts of a second monomer such as ethylene oxide, propylene oxide, methyl tetrahydrofuran, bis[4-(3-aminophenoxy)phenyl]methane, bis[4-(4-aminophenoxy)phenyl]methane, 1,1-bis[4-(3-aminophenoxy)phenynethane, 1,1-bis[4-(4-aminophenoxy)pheny]ethane, 1,2-bis[4-(3-aminophenoxy)phenyl]ethane, 1,2-bis[4-(4-aminophenoxy)phenyl]ethane, 2,2-bis[4-(3-aminophenoxy)phenyl]propane, 2,2-bis[4-(4-aminophenoxy)phenyl]propane, 2,2-bis[4-(3-aminophenoxy)phenyl]butane, 2,2-bis[4-(4-aminophenoxy)phenyl]butane, 2,2-bis[4-(3-aminophenoxy)phenyl]-1,1,1,3,3,3-hexafluoropropane, 2,2-bis[4-(4-aminophenoxy)phenyl]-1,1,1,3,3,3-hexafluoropropane, 4,4′-bis(3-aminophenoxy)biphenyl, 4,4′-bis(4-aminophenoxy)biphenyl, bis[4-(3-aminophenoxy)phenyl] ketone, bis[4-(4-aminophenoxy)phenyl] ketone, bis[4-(3-aminophenoxy)phenyl] sulfide, bis[4-(4-aminophenoxy)phenyl]sulfide, bis[4-(3-aminophenoxy)phenyl] sulfone and bis[4-(4-aminophenoxy)phenyl] sulfone.
[0072] Any suitable dianhydride or dianhydride combination can be used to make the copoly(imide oxetane) and one or more dianhydrides can be used. Aliphatic and aromatic dianhydrides can find application in making the copoly(imide oxetane)s of this invention. Examples of useful dianhydrides of the present invention include pyromellitic dianhydride (PMDA); 3,3′,4,4′-biphenyl tetracarboxylic dianhydride (RPDA); 3,3′,4,4′-benzophenone tetracarboxylic dianhydride (BTDA); 4,4′-oxydiphthalic anhydride (ODPA); 3,3′,4,4′-diphenylsulfone tetracarboxylic dianhydride (DSDA); 4,4′-(4,4′-isopropylidenecliphenoxy)bis(phthalic anhydride) (BPADA); 2,3,6,7-naphthalene tetracarboxylic dianhydride; 1,2,5,6-naphthalene tetracarboxylic dianhydride; 1,4,5,8-naphthalene tetracarboxylic dianhydride; 2,6-dichloronaphthalene-1,4,5,8-tetras-arboxylic dianhydride; 2,7-dichloronaphthalene-1,4,5,8-tetracarboxylic dianhydride; 2,3.3%4 1 -biphenyl tetracarboxylic dianhydride; 2,2′,3,3′-biphenyl tetracarboxylic dianhydride; 2,3,3′,4′-benzophenone tetracarboxylic dianhydride; 2,2′,3,3′-benzophenone tetracarboxylic dianhydride; 2,2-bis(3,4-dicarboxyphenyepropane dianhydride; 1,1-bis(2,3-dicarboxyphenyl)ethane dianhydride; 1,1-bis(3,4-dicarboxyphenyl)ethane dianhydride; bis(2,3-dicarboxyphenyl)methane dianhydride; bis(3,4-dicarboxyphenyl)methane dianhydride; 4,4′-(hexafluoroisopropylidene)diphthalic anhydride (6FDA); bis(3,4-dicarboxyphenyl)sulfoxide dianhydride; tetrahydrofuran-2,3,4,5-tetracarboxylic dianhydride; pyrazine-2,3,5,6-tetracarboxylic dianhydride; thiophene-2,3,4,5-tetracarboxylic dianhydride; phenanthrene-1,8,9,10-tetracarboxylic dianhydride; perylene-3,4,9,10-tetracarboxylic dianhydride; bis-1,3-isobenzofurandione; bis(3,4-dicarboxyphenyl)thioether dianhydride; bicyclo[2.2.2]oct-7-ene-2,3,5,6-tetracarboxylicdianhydride; 2-(3′,4′-dicarboxyphenyl)5,6-dicarboxybenzimidazole dianhydride; 2-(3′,4′-dicarboxyphenyl)5,6-dicarboxybenzoxazole dianhydride; 2-(3′,4′-dicarboxyphenyl)5,6-dicarboxybenzothiazole dianhydride; bis(3,4-dicarboxyphenyl)2,5-oxadiazole 1,3,4-dianhydride; 2,5-(3′,4′-dicarboxydiphenylether) 1,3,4-oxadiazole dianhydride; butane-1,2,3,4-tetracarboxylic dianhydride; pentane-1,2,4,5-tetracarboxylic dianhydride; cyclobutane tetracarboxylic dianhydride; cyclopentane-1,2,3,4-tetracarboxylic dianhydride; cyclohexane-1,2,4,5 tetracarboxylic dianhydride; cyclohexane-2,3,5,6-tetracarboxylic dianhydride; 3-ethyl cyclohexane-3-(1,2)5,6-tetracarboxylic dianhydride; 1-methyl-3-ethyl cyclohexane-3-(1,2)5,6-tetracarboxylic dianhydride; 1-ethyl cyclohexane-1-(1,2),3,4-tetracarboxylic dianhydride; 1-propylcyclohexane-1-(2,3),3,4-tetracarboxylic dianhydride; 1,3-dipropylcyclohexane-1-(2,3),3-(2,3)-tetracarboxylic dianhydride; dicyclohexyl-3,4,3′,4′-tetracarboxylic dianhydride; 4,4′-bisphenol A dianhydride; 1,2,3,4-cyclobutanetetracarboxylic acid dianhydride; bicyclo[2.2.2]oct-7-ene-2,3,5,6-tetracarboxyliedianhydride; hydroquinonediphthalic anhydride; ethyleneglycol bis(trimellitic anhydride); 9,9-bis-(trifluoromethyl)xanthenetetracarboxylic dianhydride (6FCDA); 9-phenyl-9-(trifluoromethyl)xanthenetetracarboxylic dianhydride (3FCDA); 9,9-diphenyl-2,3,6,7-xanthenetetracarboxylic dianhydride (PPXDA); 9,9-diphenyl-2,3,6,7-tetramethylxanthene (TMPPX); 9,9-diphenyl-2,3,6,7-xanthenetetracarboxylic bis(p-anisidylimide); 9,9-diphenyl-2,3,6,7-xanthenetetracarboxylic bis(butylimide); 9,9-diphenyl-2,3,6,7-xanthenetetracarboxylic bis(p-tolylimide); 9-phenyl-9-methyl-2,3,6,7-xanthenetetracarboxylic dianhydride (MPXDA); 9-phenyl-9-methyl-2,3,6,7-xanthenetetracarboxylic bis(propylimide); 9-phenyl-9-methyl-2,3,6,7-xanthenetetracarboxylic bis(p-tolylimide); 9,9-dimethyl-2,3,6,7-xanthenetetracarboxylic dianhydride (MMXDA); 9,9-dimethyl-2,3,6,7-xanthenetetracarboxylic bis(propylimide); 9,9-dimethyl-2,3,6,7-xanthenetetracarboxylic bis(tolylimide); 9-ethyl-9-methyl-2,3,6,7-xanthenetetracarboxlylic dianhydride (EMXDA);); 9,9-diethyl-2,3,6,7-xanthenetetracarboxylic dianhydride (EEXDA); etc. Many of the above mentioned dianhydrides (if not all) can also be used in their ‘tetra-acid form’ (or as mono, di, tri, or tetra esters of the tetra acid), or as their diester acid halides (chlorides). In some embodiments of the present invention however, the dianhydride form is generally preferred because it is generally more reactive than the acid or the ester.
[0073] Typically the reaction is conducted in the presence of one or more organic solvents for the dianydride and diamine. Exemplary solvents include N,N-dimethylformamide, N,N-dimethylacetamide, N,N-diethylacetamide, N,N-dimethylmethoxyacetamide, N-methyl-2-pyrrolidone, 1,3-dimethyl-2-imidazolidinone, N-methylcaprolactam, 1,2-dimethoxyethane, bis(2-methoxyethyl) ether, 1,2-bis(2-methoxyethoxy)ethane, bis[2-(2-methoxyethoxy)ethyl] ether, tetrahydrofuran, 1,3-dioxane, 1,4-dioxane, pyridine, picoline, dimethylsulfoxide, dimethylsulfone, tetramethylurea and hexamethylphosphoramide. The reaction temperature is normally between about 15° C. and 75° C., preferably less than about 50° C. The reaction can be carried out under any pressure and ambient pressure is satisfactory. The reaction is typically conducted under any dry inert atmosphere such as nitrogen, helium, and argon. The reaction time depends upon the reactive nature of the reactants, solvent and reaction temperature. The reaction is usually continued for sufficient time to complete formation of a copoly(amic acid oxetane) which is usually from about 0.1 to 50 hours, say, about 2 to 30 hours. The copoly(amic acid oxetane) can be thermally imidized, resulting in the evolution of water, by heating, e.g. at a temperature of at least about 120° C., and often from about 150° C. to 400° C., or chemically imidized.
[0074] FOX Diamines
[0075] The FOX diamines used in making the copoly(imide oxetane)s of this invention can be represented by the structure
[0000] NH 2 —R 1 —C(O)—O-J-C(O)—R 1 NH 2
[0000] where J, R 1 , R 2 , R 3 and m are as defined above.
[0076] One source of FOX diamines uses fluorine-containing oxetane oligomers where the oligomers are functionalized to provide the diamine. The functionalization may proceed by any suitable process. A particularly advantageous process is to react hydroxyl-terminated oligomer with an acyl reagent containing a nitro substituent under nucleophilic reaction conditions to provide a di-nitro functionalized oligomer. The di-nitro functionalized oligomer can be readily hydrogenated under hydrogenation conditions, especially mild hydrogenation conditions, to provide the FOX diamine.
[0077] The hydroxyl-terminated fluorine containing oxetane oligomers can be represented by the structure:
[0000] H—O-J-H
[0000] where J is as defined above. Examples of the oligomers include, but are not limited to, oligomers made from one or more of 3-(2,2,2-trifluoroethoxymethyl)-3-(2,2,3,3,4,4,4-heptafluorobutoxymethyl)-oxetane, 3-(2,2,2-trifluoroethoxymethyl)-3-(3,3,4,4,5,5,6,6,7,7,8,8,8-trifluorooctyloxymethyl)oxetane, 3-(2,2,3,3,4,4,4-heptafluoro-butoxymethyl)-3-(2,2,3,3,4,4,5,5,6,6,7,7,8,8,8-pentadecafluorooctyloxymethyl)oxetane, 3-(2,2,2-trifluoroethoxymethyl)-3-(3,3,4,4,5,5,6,6,7,7,8,8,9,9,10,10,10-heptadecafluoro-decyloxymethyl)oxetane and 3-(2,2,3,3,4,4,4-heptafluorobutoxymethyl)-343,3,4,4,5,5,-6,6,7,7,8,8,9,9,10,10,11,11,12,12,12-heneicosafluorodedecyloxymethyl)oxetane, and block oligomers with diols and hydroxyl-terminated oligomers such as ethylene glycol, propylene glycol, 1,3-propanediol, butanediol, poly(alkylene ethers) including polyethylene ether), poly(propylene ether), poly(tetramethylene ether); random or block copolymers of ethylene oxide and propylene oxide including propylene oxide and poly(propylene oxide), random or block copolymers of tetrahydrofuran with minor amounts of a second monomer such as ethylene oxide, propylene oxide, methyl tetrahydrofuran, bis[4-(3-hydroxyphenoxy)phenylmethane, bis[4-(4-hydroxyphenoxy)phenyl]methane, 1,1-bis(4-(3-hydroxyphenoxy)phenyl]ethane, 1,1-bis[4-(4-hydroxyphenoxy)phenyl]ethane, 1,2-bis[4-(3-hydroxyphenoxy)phenyl]ethane, 1,2-bis[4-(4-hydroxyphenoxy)phenyl]ethane, 2,2-bis[4-(3-hydroxyphenoxy)phenyl]propane, 2,2-bis[4-(4-hydroxyphenoxy)phenyl]propane, 2,2-bis[4-(3-hydroxyphenoxy)phenyl]butane, 2,2-bis[4-(4-hydroxyphenoxy)phenyl]butane, 2,2-bis[4-(3-hydroxyphenoxy)phenyl]-1,1,1,3,3,3-hexafluoropropane, 2,2-bis[4-(4-hydroxyphenoxy)phenyl]-1,1,1,3,3,3-hexafluoropropane, 4,4′-bis(3-hydroyphenoxy)biphenyl, 4,4′-bis(4-hydroxyphenoxy)biphenyl, bis[4-(3-hydroxyphenoxy)phenyl] ketone, bis[4-(4-hydroxyphenoxy)phenyl]ketone, bis[4-(3-hydroxyphenoxy)phenyl]sulfide, bis[4-(4-hydroxyphenoxy)phenyl]sulfide, bis[4-(3-hydroxyphenoxy)phenyl]sulfone and bis[4-(4-hydroxyphenoxy)phenyl]sulfone.
[0078] The nucleophilic reaction conditions to convert a hydroxyl-terminated oxetane oligomer to a di-nitro functionalized oligomer can vary widely and optimal conditions will depend upon the acyl reagent used. The acyl reagent is generally present in a stoichiometric excess of that required for the nucleophilic reaction with both hydroxyls of the oligomer, say, a mole ratio of acyl reagent to hydroxyl on the oligomer of between about 1.1:1 to 10:1, and most often between about 1.5:1 to 5:1. Typically the reactions are conducted in the presence of one or more organic solvents for the oligomer and a base. The solvent and the base may be the same or different. Advantageously the base is an organic amine. The base is preferably present in an amount in excess of that required to neutralize the co-product of the nucleophilic reaction. Often the mole ratio of base to acyl reagent is at least about 2:1, and more frequently in the range of about 5:1 to 50:1, The reaction temperature is normally between about 10° C. and 120° C., preferably about 30° C. to 80° C. Preferably the reaction menstruum is under stirring and the acyl reagent is gradually added to avoid undue exotherms. The reaction can be carried out under any pressure and ambient pressure is satisfactory. The reaction is typically conducted under any dry inert atmosphere such as nitrogen, helium, and argon. The reaction time depends upon the reactive nature of the reactants, solvent and reaction temperature. Usually the reaction is complete in about 0.01 to 20 hours.
[0079] Exemplary bases that can serve as solvents include trimethylamine, triethylamine, tripropylamine, tributylamine, N,N-dimethylformamide, N,N-dimethylacetamide, N,N-diethylacetamide, N,N-dimethylmethoxyacetamide. Other solvents include ethanol, n-propanol, isobutanol, butanol, hexanol, cyclohexanol, cyclohexane, hexane, benzene, toluene, xylene, methylene chloride, ethylene dichloride, N-methyl-2-pyrrolidone, 1,3-dimethyl-2-imidazolidinone, N-methylcaprolactam, 3-methylphenol, 1,2-dimethoxyethane, bis(2-methoxyethyl) ether, 1,2-bis(2-methoxyethoxy)ethane, bis[2-(2-methoxyethoxy)ethyl]ether, tetrahydrofuran, 1,3-dioxane, 1,4-dioxane, pyridine, picoline, dimethylsulfoxide, dimethylsulfone, tetramethylurea and hexamethylphosphoramide.
[0080] The acyl reagent is preferably an acyl halide such as a bromide, chloride or iodide with chlorides being most preferred. Examples of nitro-substituted acyl reagents include, without limitation, 3-nitrobenzaldehyde, 3, nitrobenzoic acid, methyl 3-nitrobenzoate, 3-nitrobenzoyl chloride, 4-nitrobenzoyl chloride, 3-nitrobenzoyl bromide, 4-nitrobenzoyl bromide, 3-nitrobenzoyl iodide, 4-nitrobenzoyl iodide, nitroacetyl bromide, nitroacetyl chloride, nitroacetyl iodide, nitropropionyl chloride, nitrobutyryl chloride, nitrovaleryl chloride, nitrocaproyl chloride, and isomers and lower alkyl and halo-substituted compounds thereof.
[0081] The dinitro-functionalized oligomer is then subjected to hydrogenation to convert the nitro groups to amino groups. As the nitro groups are readily hydrogenated to amino groups, mild hydrogenations conditions can be used to prevent undue hydrogenation of other moieties in the oligomer. The hydrogenation is typically conducted in a solvent which may be the same or different from the solvent used in the nitro functionalization of the oligomers. Often, alkanol solvents are preferred. The hydrogenation is conducted in the presence of a catalytically effective amount of hydrogenation catalyst. Hydrogenation catalysts include platinum catalysts, such as, for example, platinum/carbon catalysts (Pt/C) or PtO 2 ; palladium catalysts, such as, for example, Pd/C; rhodium catalysts, such as, for example, Rh/C, Rh/Al 2 O 3 or Rh 2 O 3 ; nickel catalysts, nickel/molybdenum catalysts such as, for example, Raney nickel; or iridium catalysts, and mixtures thereof Special preference is given to Pd/C or REV. Frequently the reaction menstruum is maintained under mixing such as stirring or agitation when conducted in a batch process. The hydrogenation temperature is usually in the range of about 10° C. to 120° C., preferably about 20° C. to 80° C. Hydrogen is provided at a pressure of between about 100 and 5000 kPa gauge, preferably between about 150 and 1000 kPa gauge. The duration of the reaction in batch mode is generally in the range of about 0.5 to 40 hours. In continuous processes, the reaction menstruum passes through a fixed catalyst bed, often at a liquid hourly space velocity of between about 0.5 and 10 hr −1 .
EXAMPLES
[0082] The following examples are to further illustrate the invention and are not in limitation thereof All parts and percentages are by mass unless otherwise stated or clear from their context.
Example 1
Synthesis of Dinitro-Terminated Oxetane Oligomer
[0083] This example uses a hydroxyl-terminated oxetane available as POLYFOX™ PF-6320, 3-(2,2,2-trifluoroethoxymethyl)-3-(2,2,3,3,4,4,4-heptafluorobutoxymethyl)-oxetane oligomer having an approximate molecular weight of 3400 g/mole. To a glass flask blanketed with nitrogen which contains about 150 milliliters of toluene are charged 60.32 grams of the oligomer. Triethyl amine (14.52 grams) is added and the solution is stirred for about 10 minutes and heated to about 50° C. A previously prepared solution of 10.4 grams of p-nitrobenzoyl chloride dissolved in 150 milliliters of toluene is added to the oligomer-containing solution drop wise over a period of about 30 minutes. The solution is then stirred under reflux for about 16 hours, then cooled to room temperature. The solution is then filtered, washed twice (250 milliliters) with an aqueous solution of 5 mass percent sodium bicarbonate and then once with 250 milliliters of deionized, distilled water. Thereafter the solution is dried over magnesium sulfate. The liquor is then rotary evaporated to yield a viscous, honey-colored oil. The oil is vacuumed dried. The dried sample contains the dinitro-terminated oxetane oligomer.
Example 2
Synthesis of Diamine-Terminated Oxetane Oligomer
[0084] A 100 milliliter, mechanically stirred, glass reaction vessel is charged with 8.8 grams of the dinitro-terminated oxetane oligomer of Example 1, 0.445 grams of palladium on carbon hydrogenation catalyst available from Aldrich Chemical Co. having a metal loading of 5 mass percent, and 40 milliliters of anhydrous ethanol. The resulting solution is degassed and subsequently backfilled with hydrogen to 200 kPa gauge. The solution is maintained under agitation for 16 hours at ambient temperature. After removing hydrogen, the solution is filtered through diatomaceous earth (CELITE™ available from Celite Corporation, Goleta, Calif., United States) followed by rotary evaporation and vacuum drying. The dried sample contains the diamine of the oxetane oligomer.
Example 3
Synthesis of Copoly(Imide Oxetane)
[0085] A series of copoly(imide oxetane)s are prepared using the following general procedure:
1. The diamine-terminated oxetane oligomer is dissolved in N,N-dimethylacetamide to provide an oligomer solution. 2. The other diamine, 4,4′-oxydianiline, is added to a stirred, glass reaction flask and dissolved in N,N-dimethylacetamide. 3. An amount of the oligomer solution is added to the flask to provide a sought mass ratio of the oxetane oligomer to the diamine. 4. The solution in the flask is stirred for about 10 minutes and then dianhydride, 3,3′,4,4′-bisphenyltetracarboxylic dianhydride, is added to the flask. The amount of dianhydride added provides a molar ratio of dianydride to total diamine of about 1.0:0.95. Sufficient N,N-dimethylacetamide is added to provide a 20 mass percent solids solution. 5. The solution is stirred at ambient temperature (about 22° C.) for about 16 hours under an inert gas atmosphere.
[0091] The solution contains copoly(amic acid oxetane). Table 1 summarizes the polymers made.
Example 4
Imidization to Copoly(Imide Oxetane)
[0092] Imidization of the polymer material is done using the following general procedure. Samples of each solution made in Example 3 are centrifuged to remove gas bubbles. A film is cast from each sample using a doctor blade to an approximate thickness of about 500 to 750 microns on glass and each film is placed in a forced air drying chamber at room temperature for about 24 to 48 hours to remove solvent and provide a tack-free surface. Some of the films are then thermally imidized under nitrogen using a cure cycle with stages at 150° C., 175° C., 200° C. and 250° C. with a minimum hold of 40 minutes at each stage.
[0093] Some of the copoly(amic acid oxetane) solutions are chemically imidized by reaction with acetic anhydride and pyridine. In this procedure, 33.02 grams of a 10 mass percent solids copoly(amic acid oxetane) and N,N-dimethylacetamide solution are poured into a 100 milliliter 3-necked round bottomed flask. Then 3.9 milliliters of pyridine and 3.3 milliliters of acetic anhydride are added to the flask and the reaction mixture is mechanically stirred overnight at ambient temperature under an inert atmosphere. After about 16 hours the reaction mixture is poured into a blender containing water resulting in precipitation of the chemically imidized copoly(imide oxetane) product. The copoly(imide oxetane) is filtered, stirred in hot water for several hours, filtered again and allowed to dry.
Example 5
Evaluation of Copoly(Imide Oxetane)
[0094] The cast and imidized coatings are evaluated for various characteristics and performance properties.
[0095] Modulus of the coatings is determined using a Sintech 2W test frame with a crosshead speed of 5.08 millimeters per minute and analyzed using Testworks 8.0 software (both available from MTS Systems Corporation, Eden Prairie, Minn., United States). See Table I.
[0096] A ThermoFisher™ ESCA lab 250 X-ray photoelectron spectrometer (available from Thermofisher Scientific, Waltham, Mass., United States) is used for XPS analysis.
[0097] A FTA 1000B contact angle goniometer available from First Ten Angstroms, Inc., Portsmouth, Va., United States is used to measure the water contact angle with an 8 microliter drop being used. See Table I.
[0098] Dust adhesion is evaluated by adhering a 6 millimeter diameter sample of the cast film on the end of a sonication device. The surface is coated with an approximate monolayer of particles having a particle diameter of less than about 30 microns. The sonication device uses a series of sonication steps of increasing magnitude.
[0099] With respect to dust adhesion, the copoly(imide oxetane)-containing films exhibit improved surface clearance and potentially lower adhesion values than the homopolymer.
[0100] The XPS surface analysis indicates that the fluorine population of the exterior (air-facing) surface of the coating films reaches a plateau at a low fluorine-containing oxetane moiety content in the copoly(imide oxetane) material. The data are presented in Table 1. For sake of comparison, the fluorine atomic concentration of the oxetane oligomer is about 29 atomic percent The interior surface (glass-facing surface) has a fluorine population higher than that of the bulk, but less than that of the exterior surface (air-facing surface) which is also reported in Table 1. The XPS analysis thus confirms an unexpected migration of the fluorine-containing oxetane moieties in the copoly(imide oxetane) to the surface, and further indicates that only a very small amount of the oxetane oligomer is required to provide sought low surface energies. Although the presence of the oxetane oligomer does not unduly adversely affect the mechanical properties of the copoly(imide oxetane) at somewhat higher levels, the ability to achieve the low surface energies with very small amounts of the oxetane oligomer would not detract from the desirable bulk properties of the copoly(imide oxetane) material.
[0000]
TABLE 1
Diamine
Elonga-
Exterior
Glass
oxetane
Modu-
Break
tion at
Water
Surface
Surface
oligomer,
lus,
Stress,
Break,
Contact
Fluorine,
Fluorine,
mass %
MPa
MPa
%
Angle, °
Atomic %
Atomic %
0
3590
141
10.1
81
5
2
0.01
3560
142
8.3
93
0.1
3570
142
9.2
95
14
5
0.2
3510
139
11.5
95
14
0.4
3450
138
7.5
94
20
0.5
3350
142
5.5
94
16
9
0.8
3460
138
11.2
94
17
1.0
3440
141
8.7
98
19
8
2.0
3380
138
8.7
94
17
5.0
3140
126
9.7
95
18
4
|
Copoly(imide oxetane) materials are disclosed that can exhibit a low surface energy while possessing the mechanical, thermal, chemical and optical properties associated with polyimides. The copoly(imide oxetane)s are prepared using a minor amount of fluorinated oxetane-derived oligomer with sufficient fluorine-containing segments of the copoly(imide oxetane)s that migrate to the exterior surface of the polymeric material to yield low surface energies. Thus the coatings and articles of manufacture made with the copoly(imide oxetane)s of this invention are characterized as having an anisotropic fluorine composition. The low surface energies can be achieved with very low content of fluorinated oxetane-derived oligomer. The copolymers of this invention can enhance the viability of polyimides for many applications and may be acceptable where homopolyimide materials have been unacceptable.
| 2
|
PRIOR ART STATEMENT
Japanese Utility Model Publication No. 41523/1974, Patent Publication No. 24726/1976, Laid-open Utility Model Application No. 33302/1975 and pending Utility Model Application No. 84541/1973, assigned to the applicant, all relate to an electromagnetic or solenoid pump which may be operated with the drive circuit of the invention. U.S. Pat. No. 3,606,595 is a counterpart of Japanese Utility Model Publication No. 41523/1974. U.S. Pat. No. 3,514,228 discloses an electromagnetic pump having a solenoid coil which is fed from a half wave rectifier connected with an a.c. source. U.S. Pat. No. 3,502,026 shows an electromagnetic pump unit including a rectifier, but which is not directed to a flow rate control. Other related art includes U.S. Pat. Nos. 4,045,714, 2,907,929, 3,562,598, 3,942,078 and 3,582,716.
BACKGROUND OF THE INVENTION
The invention relates to a drive circuit for a solenoid pump of a type controlling a small flow and in which a solenoid coil is energized intermittently to cause a reciprocatory motion of a piston to achieve a fluid supply.
Delivery and control of a fuel flow to a room heater usually takes place either through the use of a solenoid pump or through the combined use of a fluid head to deliver the fuel and a flow control valve which controls the flow rate. In the former arrangement, a pulse from an oscillator may be fed to the solenoid pump for control purpose, but a control circuit required to control the flow rate is complex. In the latter, the flow control valve of mechanical type must be equipped with an orifice of a greatly reduced size in order to permit a control over a small flow rate, presenting difficulties in its manufacture and maintenance of the required precision.
To accommodate for this situation, there is provided a drive circuit for a solenoid pump which is simple in arrangement and which permits a facilitated flow control. Such an arrangement is illustrated in FIG. 1, where an a.c. source A.C. is shown connected with one end of a series combination of a rectifier SR1 and resistor R1, the other end of which is connected with one end of a solenoid coil 1 of a solenoid pump. The other end of the coil 1 is connected with a thyristor SCR1, which is in turn connected with the other terminal of the a.c. source. A capacitor C1 is connected in shunt with the series combination of coil 1 and SCR1. The gate of thyristor SCR1 is connected with a shunt resistor R4, the other end of which is connected with the other terminal of the source. The gate is also connected with a trigger circuit which comprises a variable resistor VR1, capacitor C2 and trigger diode TD. A diode SR2 is connected through current adjusting resistors R2 and R3 with the trigger circuit, and prevents a reverse flow of the charge on the capacitor C2 to the source. A zener diode ZD1 is connected at its one end with the junction between the resistors R2, R3 and with the other terminal of the source at its other end, and functions to supply a constant voltage to the trigger circuit. A capacitor C3 may be connected in shunt with the Zener diode for maintaining the constant voltage. If desired, the resistor R1 may be formed by a variable resistor.
In operation, the alternating current from the source is rectified by rectifier SR1 into a d.c. current, which is passed through the resistor R1 to the capacitor C1. The capacitor C1 may be charged to the peak value of the a.c. source in a time interval T CM which is determined by the resistance of resistor R1 and the capacitance of capacitor C1. Such time interval may be several a.c. cycles. In the trigger circuit, the capacitor C2 is charged until the voltage thereacross reaches a threshold voltage of the trigger diode TD, whereupon it conducts to cause the capacitor C2 to discharge through the resistor R4, thereby developing a trigger pulse which is applied to the gate of the thyristor SCR1. This trigger pulse occurs repeatedly with a period Ttr which depends on the breakdown voltage of the Zener diode, resistance of resistors R3, VR1, capacitance of capacitor C2 and the threshold voltage of the trigger diode TD. Thus, the period Ttr can be varied by the adjustment of the variable resistor VR1.
In response to the trigger pulse, the thyristor SCR1 conducts, whereby the capacitor C1 discharges through the solenoid 1. When the current flows through the solenoid, the charge on the capacitor C1 is discharged and the current ceases to flow through the solenoid 1 during the negative half cycle of the source, rendering the thyristor SCR1 non-conductive. By choosing the time intervals such that T CM <Ttr, the solenoid 1 can be energized by a discharge current of the capacitor C1 after it has been charged to the peak value of the source if the number of energizations per minute of the solenoid or the interval Ttr is adjusted by means of the variable resistor VR1.
The conventional drive circuit described above is simple in arrangement and provides a desired operating characteristic while reducing the number of parts required. It is to be noted that when operated with a commercial frequency, the solenoid pump will achieve a discharge performance which is generally greater than is desired. In order to reduce the frequency, an oscillator employing a pair of thyristors is often provided which is d.c. operated by conversion from the source of a commercial frequency. As compared with such an arrangement, it will be seen that the described circuit requires a single thyristor and hence a single trigger circuit, thus simplifying the circuit arrangement and avoiding the need for the provision of a high capacity d.c. source. The flow rate can be controlled by changing the period of the trigger pulse, which is conveniently accomplished by adjusting the variable resistor VR1.
FIG. 2a shows the mechanical construction of an exemplary solenoid pump. Specifically it includes a hollow core 8 carrying a valve body 9 and disposed slidably inside the solenoid 1 so as to be excited by the latter. The pump also includes a pair of permanent magnets 4, 5 disposed in axial alignment with the core in opposing relationship with the opposite magnetic poles thereof, and a pair of springs 6, 7 disposed between the respective magnets and the valve body. A check valve 10 is included in the inlet passage of the pump. The pump is shown in longitudinal section in FIG. 2a, while FIGS. 2b and 2c show schematically the pump when the solenoid 1 is energized and deenergized, respectively. When the solenoid 1 is energized, the core 8 is magnetized to the polarity shown, and experiences an attraction by the magnet 4 and a repulsion by the magnet 5, thus moving upward as shown in FIG. 2b. When the solenoid 1 is deenergized, the core 8 tends to maintain its position shown in FIG. 2b, but the spring 6 urges it downwardly toward the magnet, until it reaches a neutral position shown in FIG. 2c where the resilience of the springs 6, 7 is balanced. When the solenoid coil 1 is energized again, the core assumes the position shown in FIG. 2b.
In the conventional drive circuit, the series connection of the solenoid coil 1 across the source AC allows an alternating current from the source to flow through the solenoid in addition to the discharge current of the capacitor C1 when the thyristor SCR1 conducts, causing a change in the energy supplied to the solenoid and hence the fluid discharge per unit time of the pump in response to fluctuations in the source voltage. Additional disadvantages relate to a varying value of the drive current applied to the solenoid 1 as the capacitance of the capacitor C1 changes with temperature fluctuation or as a result of aging effect and/or the resistance of solenoid 1 changes.
SUMMARY OF THE INVENTION
It is an object of the invention to avoid the described disadvantages of the prior art by providing a drive circuit for solenoid pump which permits an adjustment of the drive rate over an increased extent by controlling the period of oscillation of a trigger circuit through the detection of a drive current passing through the solenoid, which facilitates the circuit design and which avoids a variation in the discharge from the pump with a fluctuation of the source voltage.
In accordance with the invention, the above object is accomplished by providing detecting resistor connected in series with a solenoid drive circuit for detecting a discharge current from a capacitor which is passed through the solenoid. The voltage developed across the detecting resistor charges a second capacitor. When the voltage across the second capacitor reaches a given threshold value, the trigger circuit renders a thyristor contained in the drive circuit conductive, whereby a discharge current from the capacitor is supplied to the solenoid. As a result, if a fluctuation in the source voltage causes a corresponding change in the capacitor discharge current, the voltage developed across the second capacitor varies in a corresponding manner to change the time required for the voltage thereacross to reach the threshold value. In this manner, the period of oscillation of the trigger circuit is controlled in accordance with the magnitude of the capacitor discharge current, with consequence that the drive energy per unit time is controlled to a uniform value to maintain a uniform discharge from the pump.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram of a conventional drive circuit for a solenoid pump;
FIG. 2a is a longitudinal section of an exemplary solenoid pump;
FIGS. 2b and 2c are schematic illustrations of the operation of the pump shown in FIG. 2a;
FIGS. 3 to 5 are circuit diagrams of several embodiments of the invention;
FIG. 6a graphically shows the relationship between the drive period of the pump and the solenoid drive current; and
FIG. 6b graphically shows the exponential change of the voltage with time of the capacitor (C4) in FIGS. 3 and 4.
DESCRIPTION OF EMBODIMENTS
Referring to FIG. 3, there is shown a circuit diagram of one embodiment of the invention. In this Figure, elements corresponding to those shown in FIG. 1 are designated by like reference characters as before. A rectifier SR3 is connected in shunt with a series combination of the solenoid 1 and a detecting resistor R8, and represents one element in the charging circuit of capacitor C1, which is charged by a d.c. current as supplied from an a.c. supply A.C. through a series combination of resistor R1 and rectifier SR1 and supplies it to the solenoid 1 as a drive current when the thyristor SCR1 conducts. Specifically, when the thyristor SCR1 conducts, the discharge path including capacitor C1, thyristor SCR1, detecting resistor R8, and solenoid 1 is closed, whereby the capacitor C1 supplies a drive current to the solenoid 1. At this time, a voltage is developed across the detecting resistor R8 in accordance with the magnitude of the drive current. A programmable unijunction transistor PUT which may be referred to as N-gate thyristor is connected between resistors R3 and R4, and forms a main switching element of the trigger circuit. A gating circuit of PUT is formed by resistors R6, R7 and field effect transistor FET1. A detecting circuit comprises the detecting circuit R8 and a capacitor C4 which is connected between the source and gate of the field effect transistor FET1, with a series combination of a rectifier SR4 and resistor R9 being connected in series between the gate of the field effect transistor and the junction between the solenoid 1 and the detecting resistor R8, and with a variable resistor VR being connected in shunt with the capacitor C4. The arrangement is such that the detecting circuit integrates the drive current passing through the solenoid 1 with a charging time constant determined by the values of capacitor C4 and resistor R9 and a discharge time constant determined by the values of capacitor C4 and variable resistor VR, with the integrated voltage being applied to the gate of the field effect transistor FET1.
In the embodiment described above, when the power is initially turned on, the field effect transistor FET1 conducts with zero bias, and the oscillation frequency of the trigger circuit is determined by the time constant of capacitor C2 and resistor R3. After a given time interval, the potential at the anode of PUT rises above the gate potential to render PUT conductive, whereby a voltage is developed across resistor R4 to be applied to the gate of thyristor SCR1 in the discharge circuit. Consequently, a given magnitude of discharge current, which has been stored in the capacitor C1, is passed through the solenoid 1. After the discharge of the capacitor C1, thyristor SCR1 is turned off at the time when the source voltage reverses in polarity and current zero occurs. Subsequently, the capacitor C1 begins to charge. The drive current flowing through the solenoid 1 is detected by the detecting circuit, with a voltage depending on the magnitude of the drive current charging and discharging the capacitor C4 and being applied to the gate of the field effect transistor FET1, thus controlling the period of oscillation of the trigger circuit.
Describing the operation more specifically, the capacitor C1 is charged from the source through a series combination of resistor R1 and rectifier SR1. The current flow which occurs when the thyristor SCR1 conducts is detected as a voltage developed across the detecting resistor R8. This voltage is more negative than the negative terminal of the source and is integrated by a charging time constant circuit formed by capacitor C4 and resistor R9 and a discharge time constant circuit formed by capacitor C4 and variable resistor VR, with the integrated voltage being applied to the gate of the field effect transistor FET1. The latter conducts when the voltage across the capacitor C4 which is applied to its gate reaches a threshold value.
The trigger circuit includes PUT, to the anode of which is applied a constant voltage across the Zener diode ZD1 after a time delay determined by the time constant of capacitor C2 and resistor R3 both connected with this electrode. When the applied voltage is higher than the potential at the junction between the resistors R6 and R7 which forms a voltage divider for the gate of the transistor, the latter is rendered conductive, developing a voltage across the resistor R4. In response to this voltage, the thyristor SCR1 is rendered conductive.
However, it is to be noted that the gating circuit of PUT comprises the voltage divider R6, R7 and the field effect transistor FET1 connected in series therewith, so that if the field effect transistor is non-conductive, the voltage applied to the gate of the PUT is equal to the Zener voltage applied to the anode, thus precluding the conduction of PUT. In other words, PUT is rendered conductive only when the field effect transistor FET1 conducts to reduce the potential at the junction between the resistors R6, R7 below the Zener voltage applied to the anode. The conduction of the field effect transistor FET1 is controlled by the detecting circuit which supplies a threshold voltage to the gate in accordance with the magnitude of the drive current passing through the solenoid 1 and after a given time interval. For example, if the current flow through the solenoid 1 increases to increase the negative voltage level to which the capacitor C4 is charged. Since this voltage must be discharged through the variable resistor VR before the voltage to reach the threshold value of the field effect transistor FET1, an increased time delay is provided until the next occurrence of a pulse. In this manner, the period of oscillation of the trigger circuit is controlled in accordance with the magnitude of the drive current through the solenoid 1, thus achieving a uniform drive energy supplied to the solenoid pump per unit time.
Referring to FIG. 4, there is shown another embodiment of the invention. In this instance, the field effect transistor FET1 shown in FIG. 3 is replaced by a transistor Tr1. In this embodiment, when the power is turned on, a base current is introduced through the variable resistor VR to render the transistor conductive. The oscillation frequency at the begining of the operation is determined by the time constant of capacitor C2 and resistor R3 in the same manner as mentioned above in connection with the previous embodiment. A modification is indicated by broken lines in which resistors R1 and R2 are short-circuited and the cathode of the rectifier SR3 is connected with the junction between the solenoid 1 and resistor R8.
FIG. 5 shows a possible modification in which the placement of capacitor C1 and solenoid 1 are reversed from the previous arrangements.
FIG. 6a graphically shows an ideal drive relationship between the drive current (I) and the drive period (f). While there is offset N which depends on the pump response, it will be seen that the curve shown in FIG. 6a is similar to a discharge characteristic of a capacitor (C4) and variable resistor (VR) circuit, which is the exponential voltage (V) time (t) response shown in FIG. 6b. Consequently, the compensation corresponds to a change in the current value, so that the circuit arrangement may operate satisfactorily without Zener diode ZD2 which is provided to control the voltage to which the capacitor C1 is charged, for selected values of pump drive period. As shown in FIG. 4, an approximately linear operation is provided with a trnasistor (Tr1) over a reduced range of current values, so that for practical purposes, the use of the transistor Tr1 achieves substantially a similar result as the embodiment shown in FIG. 3.
From the foregoing description, it will be understood that the invention controls the period of oscillation of the trigger circuit in accordance with the magnitude of a discharge current which is supplied to the solenoid of a solenoid pump, thus maintaining a stabilized discharge of the pump in the presence of a fluctuation in a source voltage, a change in the resistance of the solenoid or a change in the capacitance of the capacitor which supplies its discharge current to the solenoid.
|
An electrical energy stored in a capacitor is discharged to the solenoid of a solenoid pump through a thyristor as the latter is controlled to conduct, thereby producing a reciprocating movement of the piston of the pump. The value of the drive current passing through the solenoid is detected by a detection circuit, and a signal which depends on the magnitude of the drive current is applied to the trigger circuit of the thyristor. The period of oscillation of the trigger circuit which controls the conduction of the thyristor is controlled by the signal, whereby a uniform drive energy per unit time to the solenoid pump is assured.
| 7
|
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.